Industrial Training Report on Fabrication (Tractors India Limited)

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Report On Short Term Industrial Training On Fabrication In Tractors India Limited, EPS,

Kharagpur

Date : 8th October, 2014 To 22nd October, 2014

Prepared By

Rajib Ghorui, Roll 12889

Tapas Pal, Roll 12882

Ranjit Nandi, Roll 12863

Prasenjit Mandal, Roll 12862

Central Calcutta Polytechnic, Department Of Mechanical Engineering

Under The Guidance Of

Mr. Tapan Kumar Das

TIL, EPS, Kharagpur

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1. Introduction

As a part of the curriculum, and for the partial fulfilment of the industry knowledge we underwent an industrial training at the department of Fabrication of Tractors India Limited, EPS, Kharagpur from 8th October to 22nd October 2014

Tractors India Limited, EPS, Kharagpur is a vast variety disciplines. The primary engineering divisions that the industry possess are Nesting, Cutting, Material Preparation, Fabrication, Machining, BIF Fitting, Component Fitting, Dressing & Grinding, Final Inspection, Shot Blasting, Primer Painting, Finish Painting & Assembly.

Fabrication was the department in which we were placed for the industrial training. This department is concerned with design & manufacture of Counter weight, Inner BOOM, Outer BOOM, Chasis etc. These equipment have vast application & demand in the market.

Under the guidance of Mr. T.K. Das, We got the opportunity to have exposure to the works carried out in this department of the industry, hence learn a good deal from them. During the period of industrial training, we made a counter weight.

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2. Assignments completed during training

Here is listed the primary tasks assigned and completed during the period of training. Brief discussions on each of the assignments will follow under the remaining sub-sections in below.

i.) Systematic Study Of Drawing ii.) Material Selection As Per Drawing iii.) Marking/Nesting Of Platesiv.) Cutting Process Of MS Plates

1.) CNC Plasma Cutting2.) OXY Acetylene Cutting3.) Band Saw Cutting

v.) Practical Training Of Component Fabrication1.) Super Counter Weight Of PIXEF Crane

vi.) Overall View Of Welding Symbols, Welder Qualification & Welding Process Qualifications

vii.) Basic Idea Of Welding Defects And Non Destructive Testviii.) Basic Requirement Of Safety Inside Shop Floor.

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Fabrication Process

Drawing Study The drawing is the main part of any mechanical based industry. So we have to study the drawings carefully. If we don’t study it carefully, the work will become faulty to perform. There will be more problem in dimension and shape.

Material Selection As Per Drawing There are many types of material used in the plant such as E250A, E350C, Sailma, etc. So we have to select the proper material in use. It is a vital matter in a particular plant so that the work will be more efficient. We should have proper authority to select that.

Nesting It is also a main part which is performed before cutting of a selected material, used in CNC cutting machine. It is mainly done by an expert. By the proper nesting we can reduce the loss of material. Some other task like marking (i.e. For bending, drilling etc.) Have to be done at this time.

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Cutting Process Of MS Plates

CNC Plasma Cutting

Plasma cutting is a process that is used to cut steel and other metals of different thicknesses (or sometimes other materials) using a plasma torch. In this process, an inert gas (in some units, compressed air) is blown at high speed out of a nozzle; at the same time an electrical arc is formed through that gas from the nozzle to the surface being cut, turning some of that gas to plasma. The plasma is hot enough to melt the metal being cut and moves fast enough to blow molten metal away from the cut.

Oxy Acetylene Cutting

In oxy-fuel cutting, a torch is used to heat metal to its kindling temperature. A stream of oxygen is then trained on the metal, burning it into a metal oxide that flows out of the kerf as slag. Sometime called a "Gas Axe".

Torches that do not mix fuel with oxygen (combining, instead, atmospheric air) are not considered oxy-fuel torches and can typically be identified by a single tank (Oxy-fuel cutting requires two isolated supplies, fuel and oxygen). Most metals cannot be melted with a single-tank torch. As such, single-tank torches are typically used only for soldering and brazing, rather than welding.

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Band Saw Cutting

A Band Saw is a power tool which uses a blade consisting of a continuous band of metal with teeth along one edge to cut various workpieces. The band usually rides on two wheels rotating in the same plane, although some bandsaws may have three or four wheels. Bandsawing produces uniform cutting action as a result of an evenly distributed tooth load. Bandsaws are used for woodworking, metalworking, or for cutting a variety of other materials. They are particularly useful for cutting irregular or curved shapes, but can make straight cuts. The minimum radius of a curve that can be cut on a particular saw is determined by the width of the band and its kerf.

Material Preparation After cutting the operation is to be done is material preparation for send to the next step which is welding. The operations are drilling, tapping, grinding, reaming etc.

Welding The art of joining metals by heating and then pressing together is a very old one. However the latter developments and advancements in this field have given to a number of altogether different processes and techniques for welding of metals. there are many types of welding which are used in industries such as

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i.) Forge welding,

ii.) Electric arc (metal arc, carbon arc, argon arc, etc.),

iii.) Gas flame (oxy-acetylene, water gas welding, etc.)

iv.) Gas plus electric arc welding (atomic hydrogen welding)

v.) Electrical resistance (resistance and electro-slag)

vi.) Thermit welding

vii.) Energy ray (electron beam and laser welding)

viii.) Mechanical energy (friction and ultrasonic welding).

But in this industry mainly electric arc welding (MIG, TIG, MAG and SAW) which is described below is used.

MIG

Full form of MIG is metal inert gas welding. In this process the carbon dioxide and argon gas. It involves welding of metals using a consumable metal electrode in an inert gas atmosphere. The arc is struck between the metal electrode and the work piece. The electrode is in the form of a continuous wire which is fed into the arc, by an adjustable speed electric motor, at the same speed at which it is melted and deposited in the weld. The inert gases like argon, helium, carbon dioxide or a mixture of these gases are used for providing the inert gas shield.

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TIG

Tungsten inert gas welding is basically an arc welding process in which the arc is struck between a non-consumable tungsten electrode and the base metal. The inert gas used in this process is same as metal arc welding.

SAW

It is basically an arc welding process in which the arc is struck between a non-consumable tungsten electrode and the base metal. The process derives its name from the fact that the arc remains submerged inside a layer of a granular and fusible flux.

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Welding Symbols

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Welding Defects

There are many types of welding defects found in welding. The common factors in which the defects happens are a) The environment a weld has to encounter in service. b) The type of loading a weld has to undergo. c) The type and size of defect. d) The type of service the welded part is to render e) The pattern of stresses a weld has to face. Common Causes Behind Welding Defects

a) Lack of welding skills in the welder. b) Use of poor quality welding consumables. c) Unfavourable characteristics of the parent metal. d) Faulty welding techniques and procedures. e) Poor cleanliness. f) Low welding temperature g) Humid atmosphere around the weldment. The Common Defects Are

a) Inclusions b) Cracks c) Distortion d) Poor Penetration e) Inadequate Fusion f) Undercut g) Porosity h) Overlapping i) Spatter j) Faulty Profile And Weld Size.

Dressing

In dressing the grinding operation is done to get a surface which is able to use in the UT test. In this process the sharp edges of the welded material are to be removed for surface finish and good looking. The burrs which are made by welding are also to be removed in dressing.

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Inspection

We have used three types of inspection to sure about the products dimension, proper welding, crack on the plate, etc. Dimension faults are mainly solved by measuring with a proper scale by a well-educated inspector. There are generally two types of inspection on welding are made. They are destructive test and nondestructive test. UT and DP are nondestructive test. The testing materials used in DP test is shown in the picture.

Machining (If Required)

When a complicated shape is not achieved by other process then the machining process required. . There are two machine in the machine shop of the plant. They are mainly based on milling and boring. The machine in main view are showed below. The machine is made by the companies “JUARISTI” & “TOS KURIM”. The machine are operated on CNC programming. They have three movement in their ram and the auto universal milling head of the machines have angular movement and the machines have three table which have rotational as well as reciprocating movement. The main difference in between two machine is the ram of JUARISTI is programmable in each 1degree where TOS KURIM’s ram is programmable in each 2.5 degree.

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Shot Blasting

Shotblasting is a method used to clean, strengthen (peen) or polish metal. Shot blasting is used in almost every industry that uses metal, including aerospace, automotive, construction, foundry, shipbuilding, rail, and many others. There are two technologies used: wheelblasting or airblasting.

Painting

Paint is a term used to describe a number of substances that consist of a pigment suspended in a liquid or paste vehicle such as oil or water. With a brush, a roller, or a spray gun, paint is applied in a thin coat to various surfaces such as wood, metal, or stone. Although its primary purpose is to protect the surface to which it is applied, paint also provides decoration.

Assembly

Assembly process is a very important process. After Painting the materials are taken to assembly department. Assembly process is done in two wayi) Sub Assembly ii) Main Assembly

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Basic Requirements Of Safety

1.) Job should be handle safely while using crane

2.) Hammering never be done on the Oxy-Acetylene cylinder, it may cause accidents

3.) Workshop should be cleaned properly

4.) Chain & Belts are to be checked before use

5.) Sharp corner can cut chain. So lower sheet or rubber can be used to save chain from damage

6.) Factory inspection to be done

7.) Electric safety should be taken properly

8.) Every worker should be trained about safety

9.) You are responsible for your own safety and for the safety to others

10.) All accidents are preventable

11.) Do not take short cuts, always follow the rules

12.) If you are not trained, don’t do it

13.) Use the right tools & equipment & use them in the right way

14.) Assess the risks before you approach your work

15.) Never wear loose clothes or slippery footwear

16.) Do not indulge in horseplay while at work

17.) Practice good house keeping

18.) Always Wear PPEs

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Acknowledgements

We would like to thank Mr. T.K. Das, our guide for the project, for providing us with the opportunities of studying, learning and gaining practical experience in various fields during the period of training. His invaluable suggestions not only helped us to reach the successful completion of the tasks assigned, but also made us learn a lot.

We would like to give special thanks to Mr. T.K. Das for helping us throughout with his wise suggestions, innovative ideas and whole-hearted help.

Finally we would like to thank Mr. Sandip Kr Bhattacharya, Mr. Rajib Sarkar and our institute, Central Calcutta Polytechnic, for giving us the opportunity to have a precious and rewarding experience of training in the prestigious industry of Tractors India Limited.

Regards

Rajib Ghorui

Date: 22nd October 2014 Tapas Pal

Ranjit Nandi

Prasenjit Mandal

Central Calcutta Polytechnic