summer internship project work on

HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. LTD.

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1. COMPANY OVERVIEW:

FIGURE 1: SWAJIT ENGINEERING PVT. LTD

It is a pleasure to introduce SWAJIT, as a leading 'Customized solution provider

for Industrial chains. Swajit Engineering Pvt. Ltd. is based at Aurangabad (M.S),

India. Swajit has evolved in as the leading Conveyor chain manufacturer,

Conveyor chain supplier & Conveyor chain exporter of all type of Roller conveyor

chains and any types of Link, Pin and Bush mechanism for Material handling

systems. Also SWAJIT manufacturing 2", 2.5", 3" & 3.5" Simplex, Duplex &

Triplex transmission chains.

Since the inception in 1992;Swajit is equipped with latest technology

comprising ‘state-of-art-plant’ with all Infrastructure facilities & processes,

advanced metallurgical laboratory to manufacture all types Conveyor chains and

Slats of finest quality.

Swajit has a dedicated and technically qualified team of experienced Engineers &

Metallurgists for fulfilling precisely the customer’s needs on the continuous basis.

We have developed an expertise to provide a wide range of Conveyor chains and

its components for diversified industry segments like Sugar, Cement, Automobile,

Steel, Solvent, Boiler& Thermal power plant, Co-generation, Bakeries, Asphalt,

Breweries, Chemical & Fertilizers, Bottling, Food Processing, Agriculture,

Mining, Paper and Allied Industries.

Excellent Quality is Swajit’s inherent strength and in a journey of two decades

organization has strongly emerged as the unchallenged leaders in the ever-growing

Indian Market and we are now looking beyond the boundaries to increase our

business in the Global market. Organization has attained this niche position by

creating the best products to exceed customer expectations, creating everlasting

Customer Satisfaction with trust and service to generate repeated orders. Swajit

adhere to global business practices and also an ISO 9001: 2008 company certified

by TUV NORD (Germany).


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Organization has a list of valued clients and look forward to add your distinguished

name into it, hence requesting you to solicit your enquiries. Swajit assures

excellent solutions to specify your specified requirements supported by timely

delivery. They are looking forward to build a technically proven & mutually

beneficial relationship in future.

(A leading Conveyor Chain Manufacturer, Supplier & Exporter of all type of

Roller conveyor chains, Transmission chains & Slates since 1992)


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2. OBJECTIVES

To study production planning and control practices used during Heat

Treatment processes at Swajit.

To study the shop floor management during handling heat treatment

operations at swajit.

To check the strength, hardness and wear resistance of material.

(Bulk hardening, surface hardening)

To check toughness of the material. (Tempering, recrystallization annealing)


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3. INTRODUCTION TO SWAJIT PLANT

Since the inception in 1992;Swajit is equipped with latest technology

comprising ‘state-of-art-plant’ with all Infrastructure facilities & processes,

advanced metallurgical laboratory to manufacture all types Conveyor chains

and Slats of finest quality. Swajit has a dedicated and technically qualified

team of experienced Engineers & Metallurgists for fulfilling precisely the

customer’s needs on the continuous basis. We have developed an expertise

to provide a wide range of Conveyor chains and its components for

diversified industry segments like Sugar, Cement, Automobile, Steel,

Solvent, Boiler & Thermal power plant, Co-generation, Bakeries, Asphalt,

Breweries, Chemical & Fertilizers, Bottling, Food Processing, Agriculture,

Mining, Paper and Allied Industries.

Overseas Market

01. Philippines

02. Mauritius

03. Malaysia

04. Uganda

05. Kenya

06. Tanzania

07. Zambia

08. Indonesia

09. Rwanda

10. Ethiopia

11. Spain

12. Jamaica

13. Sudan

14. Nepal

15. Vietnam

http://www.swajit.com/index.php/overseas-market


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FAQs

Product range?

- Pitch 75 to 400 mm.

- Breaking Load 10 to 250 ton.

Delivery time?

- 8 to 10 weeks.

MISSION

1. Providing products as complete solutions.

2. To become a leading name in global market by Best performance.

3. To become the first choice for the established trade.

4. Be Accountable for Human resource development, occupational &

Customer’s health & safety.

VISION

1. To establish as a brand associated with quality and consistency in

Manufacturing all kind of chains in Asia & Europe by 2020.

2. Perfect Implementation of Occupational Health and Safety

Management System (OHSAS).

3. Improving employee skills, involvement & Quality of Life (QOL).

VALUES

1. Ethical Business Practices.

2. Excellent Services.

3. Continuous Customer Focus.

4. Technology Enhancement.

http://www.swajit.com/index.php/faqs


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Customer Segments:-

Type of chain

1 Automobile

1. Slat conveyor chain

2 Boiler and Thermal Power plant

1. Ash handling chain

2. Coal Handling chain

3. Gate chain

4. Travelling Grate chain

3 Cement Industry

1. Drag & Flow conveyor chain

2. Paul retarder & retarder chain

3. Bucket Elevator chain

4. Pan Conveyor chain

5. Reclaimerstaker chain

6. Deep bucket conveyor chain

7. Enemas conveyor chain

4 Chemical and Fertilizer 1. Conveyor chain for coal feeding

2. Feeder breaker chain for Collieries

3. Bucket elevator chain for Fertilizer

5 Solvent Industry

1. Bucket elevator chain

2. Drag chain

3. Extractor chain

6 Steel Industry

1. Cooling bed conveyor chain

2. Transfer bed conveyor chain

3. Conveyor chain for cold draw bench

4. Mandrill insert chain


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5. Shell pusher chain

6. All types of conveyor chain

7 Sugar Industry

1. Baggase carrier chain

2. Block type & inter carrier chain

3. Cane carrier chain

4. Feeder table chain

5. Sugar elevator chain

6. Sugar bag staker chain

7. Slates and fabricated rake

8 Other Applications

1. Agriculture

2. Food Processing

3. Bakeries

4. Home Appliances

5. Paper mill

6. Amusement park

FIG.3.1 VARIOUS CONVAYER CHAINS


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4. HEAT TREATMENT

Heat treatment is an operation or combination of operations involving

heating at a specific rate, soaking at a temperature for a period of time and

cooling at some specified rate. The aim is to obtain a desired microstructure

to achieve certain predetermined properties (physical, mechanical, magnetic

or electrical).

Fundamentals Fe-C equilibrium diagram. Isothermal and continuous cooling

transformation diagrams for plain carbon and alloy steels. Microstructure

and mechanical properties of pearlite, bainite and martensite. Austenitic

grain size. Hardenability, its measurement and control.

Processes Annealing, normalizing and hardening of steels, quenching media,

tempering, Homogenization. Dimensional and compositional changes during

heat treatment. Residual stresses and decarburisation.

Surface Hardening Case carburising, nitriding, carbonitriding, induction and flame hardening

processes.

Special Grade Steels Stainless steels, high speed tool steels, maraging steels, high strength low

alloy steels.

Cast irons White, gray and spheroidal graphitic cast irons

Nonferrous Metals Annealing of cold worked metals. Recovery, recrystallisation and grain

growth. Heat treatment of aluminum, copper, magnesium, titanium and

nickel alloys. Temper designations for aluminum and magnesium alloys.

Controlled Atmospheres

Oxidizing, reducing and neutral atmospheres.


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4.1 Hardening

Hardening is performed to impart strength and hardness to alloys by heating

up to a certain temperature, depending on the material, and cooling it

rapidly. Steel is heated up to austenitic region and held there until its carbon

is dissolved, and then cooled rapidly, the carbon does not get sufficient time

to escape and get dissipated in the lattice structure. This helps in locking the

dislocation movements when stresses are applied.

Quenching is performed to cool hot metal rapidly by immersing it in brine

(salt water), water, oil, molten salt, air or gas. Quenching sets up residual

stresses in the workpiece and sometimes results in cracks. Residual stresses

are removed by another process called annealing.

4.2 Annealing

Annealing is performed to reduce hardness, remove residual stresses,

improve toughness, restore ductility, and to alter various mechanical,

electrical or magnetic properties of material trough refinement of grains.

Cooling rate is very slow around 10oC per hour. Process is carried out in a

controlled atmosphere of inert gas to avoid oxidation. Partial annealing is

incomplete annealing and there is partial phase transformation however in

sub-critical annealing there is no phase transformation. Used to achieve

ductility in work hardened steels.

4.3 Normalizing

The process is similar to annealing and is carried out to avoid excessive

softness in the material. The material is heated above austenitic phase and

then cooled in air. This gives relatively faster cooing and hence enhance

hardness and less ductility.

In this process, austenite is decomposed in ferrite and carbide at relatively

lower temperature and fine pearlite is produced. Normalizing is less

expensive than annealing. In normalization variation in properties of

different sections of apart is achieved. The selection of heat treatment

operations is strongly influenced by the carbon content in the steel. Heat

treatments on phase diagram of steel.


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4.4 Tempering

Martensite is very hard and brittle. Tempering is applied to hardened steel

to reduce brittleness, increase ductility, and toughness and relieve stresses in

martensite structure. In this process, the steel is heated to lower critical

temperature keeping it there for about one hour and then cooled slowly at

prescribed rate. This process increases ductility and toughness but also

reduces hardness, strength and wear resistance marginally. Increase in

tempering temperature lowers the hardness.

4.5 Surface Hardening

Heat treatment methods in general change the properties of entire material.

Hardening improves wear resistance of material but lowers impact resistance

and fatigue life. Therefore sometimes there is requirement of surface

hardening Two methods are used, first is heating and cooling to get required

phase, and second is thermo-chemical treatment. Induction heating Flame

hardening High frequency resistance heating Laser beam hardening Electron

beam hardening Carburizing Nitriding Cyanding.

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FIG.4.1 HEAT TREATMENT FURNACE


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FIG.4.2 ROTARY FURNACE


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5. HARDNESS TESTING

5.1What is Hardness?

Hardness is the property of a material that enables it to resist plastic

deformation, usually by penetration. However, the term hardness may

also refer to resistance to bending, scratching, abrasion or cutting.

5.2 Measurement of Hardness:

Hardness is not an intrinsic material property dictated by precise

definitions in terms of fundamental units of mass, length and time. A

hardness property value is the result of a defined measurement

procedure.

Hardness of materials has probably long been assessed by resistance

to scratching or cutting. An example would be material B scratches

material C, but not material A. Alternatively, material A scratches

material B slightly and scratches material C heavily. Relative hardness

of minerals can be assessed by reference to the Moh's Scale that ranks

the ability of materials to resist scratching by another material. Similar

methods of relative hardness assessment are still commonly used

today. An example is the file test where a file tempered to a desired

hardness is rubbed on the test material surface. If the file slides

without biting or marking the surface, the test material would be

considered harder than the file.

If the file bites or marks the surface, the test material would be

considered softer than the file. The above relative hardness tests are

limited in practical use and do not provide accurate numeric data or

scales particularly for modern day metals and materials. The usual

method to achieve a hardness value is to measure the depth or area of

an indentation left by an indenter of a specific shape, with a specific

force applied for a specific time. There are three principal standard

test methods for expressing the relationship between hardness and the

size of the impression, these being Brinell, Vickers, and Rockwell.

For practical and calibration reasons, each of these methods is divided

into a range of scales, defined by a combination of applied load and

indenter geometry


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5.3 Hardness Test Methods:

Rockwell Hardness Test

Rockwell Superficial Hardness Test

Brinell Hardness Test

Vickers Hardness Test

Microhardness Test

Moh's Hardness Test

Scleroscope and other hardness test methodS


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Rockwell Hardness Test

The Rockwell hardness test method consists of indenting the test material

with a diamond cone or hardened steel ball indenter. The indenter is forced

into the test material under a preliminary minor load F0 usually 10 kgf.

When equilibrium has been reached, an indicating device, which follows the

movements of the indenter and so responds to changes in depth of

penetration of the indenter is set to a datum position. While the preliminary

minor load is still applied an additional major load is applied with resulting

increase in penetration. When equilibrium has again been reach, the

additional major load is removed but the preliminary minor load is still

maintained. Removal of the additional major load allows a partial recovery,

so reducing the depth of penetration. The permanent increase in depth of

penetration, resulting from the application and removal of the additional

major load is used to calculate the Rockwell hardness number.

HR = E - e

e = permanent increase in depth of penetration due to major load F1

measured in units of 0.002 mm.

E = a constant depending on form of indenter: 100 units for diamond

indenter, 130 units for steel ball indenter.

HR = Rockwell hardness number.

D = diameter of steel ball.


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FIG.5.1 ROCKWELL HARDNESS TESTING MACHINE


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The Brinell Hardness Test

The Brinell hardness test method consists of indenting the test material with

a 10 mm diameter hardened steel or carbide ball subjected to a load of 3000

kg. For softer materials the load can be reduced to 1500 kg or 500 kg to

avoid excessive indentation. The full load is normally applied for 10 to 15

seconds in the case of iron and steel and for at least 30 seconds in the case of

other metals. The diameter of the indentation left in the test material is

measured with a low powered microscope. The Brinell harness number is

calculated by dividing the load applied by the surface area of the indentation.

The diameter of the impression is the average of two readings at right angles

and the use of a Brinell hardness number table can simplify the

determination of the Brinell hardness. A well-structured Brinell hardness

number reveals the test conditions, and looks like this, "75 HB 10/500/30"

which means that a Brinell Hardness of 75 was obtained using a 10mm

diameter hardened steel with a 500 kilogram load applied for a period of 30

seconds. On tests of extremely hard metals a tungsten carbide ball is

substituted for the steel ball. Compared to the other hardness test methods,

the Brinell ball makes the deepest and widest indentation, so the test

averages the hardness over a wider amount of material, which will more

accurately account for multiple grain structures and any irregularities in the

uniformity of the material. This method is the best for achieving the bulk or

macro-hardness of a material, particularly those materials with

heterogeneous structures.

FIG.5.2 BRINELL HARDNESS TESTING MACHINE


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A Brinell hardness result measures the permanent width of indentation

produced by a carbide indenter applied to a test specimen at a given load, for

a given length of time. Typically, an indentation is made with a Brinell

hardness testing machine and then measured for indentation diameter in a

second step with a specially designed Brinell microscope or optical system.

The resulting measurement is converted to a Brinell value using the Brinell

formula or a conversion chart based on the formula. Most typically, a Brinell

test will use 3000 kgf load with a 10mm ball. If the sample material is

aluminum, the test is most frequently performed with a 500 kgf load and

10mm ball.

Brinell test loads can range from 3000 kgf down to 1 kgf. Ball

indenter diameters can range from 10mm to 1mm. Generally, the lower

loads and ball diameters are used for convenience in “combination” testers,

like Rockwell units, that have a small load capacity. The test standard

specifies a time of 10 to 15 seconds, although shorter times can be used if it

is known that the shorter time does not affect the result. There are other

conditions that must be met for testing on a round specimen, spacing of

indentations, minimum thickness of test specimens, etc.

Test Method Illustration

D = Ball diameter

d = impression diameter

F = load

HB = Brinell result


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6. VARIOUS DEPARTMENTS OF SWAJIT ENGINEERING

1. PRODUCT DEVELOPMENT

1. Preparations of design drawings.

2. Laying down standards and acceptable norms.

3. Assemble and make new design in development shop.

4. Testing of new design prototype or design verification.

5. Modify old products to suit new market norms.

2. INDUSTRIAL ENGINEERING

1. Planning related to manufacturing methods.

2. Set up manufacturing facilities.

3. Selection of machines, technologies and process based upon the product and

design requirements.

4. Designing and ensuring availability of tools, jigs and fixtures.

5. Industrial engineering, fixing time standards, computation of manpower and

capacity requirements.


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3. LOGISTICS

1. Receipt and processing of orders placed by sales division.

2. Scheduling - involving assignment of priorities based on urgency and

material availability.

3. Procurement and administration of raw materials.

4. Overall co-ordination between marketing, client, excise etc.

5. Management of stores.

6. Dispatch of complete consignments.

4. MANUFACTURING

1. Pre manufacturing – manufacture of components and brazing of parts.

2. Assembly of manufactured and bought out components.

PRE-ASSEMBLY

This consist of various processes such as riveting, spot welding,

soldering through which various in-house and bought out parts are

assembled to form subgroups which are fed to the main product assembly

line after testing.

ASSEMBLY

The final product is assembled in the well laid out and balanced lines.

The product is thoroughly tested and packed before dispatch.


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5. QUALITY ASSURANCE

1. Inspection of incoming materials.

2. Inspection during stages of manufacturing and assembly processes.

3. Verification of standards of finished goods.

4. Routine testing after the products is ready.

5. Verify compliance with client requirements.

6. COMMERCIAL

1. Source customers.

2. Studies the requirements of the customers.

3. Collaborates with the technical and manufacturing sections.

4. Markets product made by factories.

5. Product cost calculation

6. Cost accounting & control

7. Planning and budgeting

8. Financial accounting

9. Inputs for company’s balance sheets.


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7. MAINTENANCE

Maintenance has been defined as a combination of any action carried

out to retain any item or to restore to it an acceptable condition. This action

may be some major adjustment, repair work, replacement of same part or

periodic check up or inspection, periodic lubrication, over hauling of parts,

sub assembly or equipment as whole.

In other words Maintenance may be defined as an application of an

assembly of man and machine to keep the plant running at maximum

efficiency and profitability to keep it in maximum availability of plant and

conserve the life of plant and equipment.


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7. QUALITY INSPECTION AND QUALITY REPORTS

In Swajit first preference is always given to the quality though it might come

at higher cost but no chance is taken against the quality. Metal sheet and bars

are the primary raw material used in production department. When these

material arrive from source those are given to vendor to slash them into

required size. These materials are then inspected at arrival area of

department, for their dimensions and other quality parameters. Then those

are moved to storage areas present near each punching press.

While carrying out production process, at the beginning of each production

cycle few samples are produced and given for quality check if they are

passed then only further production is carried out, else necessary action is

taken with help of tool maintenance department.

7.1 QUALITY TESTS

In case of material treatment 2 types of tests are performed to check quality

of those.

1.Grinding test 2. Hardness test

For contacts quality test are performed using microscopic check for its shape

and vernier caliper is used to measure the dimensions.


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7.2 QUALITY REPORTS

Report is prepared by quality assurance department. Inspector from this

department draws samples of each product by predetermined method and

inspect its quality. If any defects are observed in quality of those samples

then that person prepares I – report and submits that report to concerned

department.

The concerned department to which report is issued prepares second report.

This department inspects the entire lot, from which those samples were

collected which got rejected. For each department there is 2% tolerance level

allowed, if the no of rejection from that entire lot are exceeding that limit of

2% then the concerned department is required to prepare second report. This

report contains details of the incident and justification for the same.


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Fig:7.1 ISO certification of Swajit Engineering


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8. DISPOSAL OF SCRAP

The scrap generated while production process is required to be disposed

using some proper guidelines. This generated scrap is categorized mainly

into hazardous waste, ferrous scrap and non ferrous scrap. While disposing

hazardous wastes like grinding dust, araldite waste etc. along with these

waste form 3 and form 12 are attached which helps in identify that its

hazardous waste and proper procedure is followed while it`s disposal. In

case of non-ferrous scrap, this scrap is sold to vendor from which that raw

material was bought. Being a non-ferrous material it is very expensive and

hence waste of such material also gives good value. In case of both i.e.

disposal of hazardous and non-ferrous waste records are maintained. These

records contains amount or quantity of waste (weight), packed in which

container (plastic, metal, any other), originator, vendor details etc.

While in case of ferrous scrap, being non hazardous and also not having

much re-sell value record of such is not maintained and is directly sold to

vendors.


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9. CONCLUSION

Production planning and control practices used in Heat treatment department

are very efficient. Capacity utilization is very effective and efficient.

Production targets are met on regular basis. Also the number of defects or

numbers of rejections are very less, even less than 4.2% of total production.

Shop floor management system implemented in Heat treatment department

is very effective. It has helped in establishing proper chain of command and

proper channel for communication. It also helps in understanding, what all

activities are taking place on floor at that movement and also helps in

keeping track of various performance parameters like additional cost, quality

issues, safety etc.

With help of FOCUS ( ERP software) and scientific techniques of inventory

management, HT and Production department are able to keep low levels of

inventory while also achieving high inventory turnover.


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10. RECOMMENDATIONS

1) Conventional instrument should be replaced by the Digital instrument.

That will give more accuracy and minimize errors.

E.g. Digital Vernier caliper should be used.

2) Quality inspection should be carried out after every stages of during Heat

treatment operations.

3) Inspection record of daily as well as monthly production should be

maintain as per the ISO standards.


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11. Bibliography

https://en.wikipediya.org

https://en.swajit.com

www.iso.org/iso/about/iso_members.htm

www.thermotreatedwood.com

www.anvilfire.com/FAQs/Heattreating.htm

www.osti.gov/servlets/purl/836878/

www.can-eng.com/HeatTreatment

https://en.wikipediya.org/

https://en.swajit.com/

http://www.iso.org/iso/about/iso_members.htm

http://www.thermotreatedwood.com/

http://www.anvilfire.com/FAQs/Heattreating.htm

http://www.osti.gov/servlets/purl/836878/

http://www.can-eng.com/HeatTreatment

summer internship project work on

Documents

swajit engineering

swajit plant

swajit manufacturing

types conveyor chains

type of roller conveyor

heat treatment processes

wide range of conveyor

industrial chains