Internship presentation at Fabrimax Engg Pvt Ltd

Presented byAbhishek Gawande A-04Palash Thuturkar A-50

VII semester B.E. (Mech), 2013-14

Under the supervision of Dr D J Tidke

Department of Mechanical Engineering G.H. Raisoni College of Engineering, Nagpur

(An autonomous Institute under UGC act 1956 & affiliated to RTMNU, Nagpur)

Industry Internship Presentation

CONTENTSCompany IntroductionOrganization ChartFabrication process flow chartQuality standards for fabricationProcesses & EquipmentsPost-Weld InspectionCase StudyReferences

COMPANY INTRODUCTION

Company Details:-

Company Name:- Fabrimax Engineering Pvt Ltd.

Company Address:- J 20/21 MIDC Hingna, Nagpur

Established on :- 5th August 2005

Managing Director:- Mr. Pavan Chokhani

Contact Person:- Ms Madhuri Mahalle

Duration of Internship:- 24 weeks

Starting Date:- 15 June

Timings :- 10:00 AM to 3:00 PM

The different products manufactured in the company are as follows:-

Steel tower for Wind mill

Structural items

General structure

Vertical lift gates

Pipe fabrication

Light to heavy fabrication & erection of structural

steel.

Quality PolicyTo produce items of high standard using best quality

material to give customer satisfaction at the highest level.

To update techniques to deliver quality goods in time as per specification of the customer.

To develop human resources through communication training and participation at all levels.

To achieve productivity through efficiency (do things rightly) and effectiveness (doing right things) safeguarding environment and conserve natural resources.

QUALITY STANDARDS FOR FABRICATION

Raw Material

All raw materials shall be purchased according to the grades specified in

the drawings.

It shall be well and cleanly rolled to the dimensions, sections and masses

as specified.

The finished material shall be reasonably free from surface flaws,

laminations, rough/jagged and imperfect edges and all other harmful

defects. Minor surface defects may be removed by surface grinding

provided the thickness shall not reduce locally more than 4% below the

minimum specified thickness.

Ultrasonic testing is mandatory for all plates having thickness more than

22mm.

QUALITY STANDARDS FOR FABRICATIONMarking

Marking shall be done by skilled fitter and before cutting and same should

be cross checked by shop supervisor or other fitter.

Cutting

Where ever possible use Pug Machine or Shearing for plate cutting.

Dress up cutting edges for burr removal. Gas cut notches shall be filled by

welding and merge properly.

The edges shall be smooth ground, straight and square.

Fitting

Fitting shall be done by skilled fitter and should be cross checked by shop

supervisor or other fitter.

Due care shall be taken for proper edge preparation required for welding.

Shrinkage allowance shall be considered.

ProcessesCNC cutting:-Use to cut the plates of desired

shape and size Machine is highly suitable for

Y and V shapes that bevel with only one pass and help to cut in different shapes either with dry plasma or oxy-gas

This machine has advanced 5 axis robotic compound movement control technology that decreases manufacturing time

Three Roller BendingA Roll bender is a mechanical jig

having three rollers used to form a metal bar into a circular arc.

The rollers freely rotate about three parallel axes, which are arranged with uniform horizontal spacing.

Two outer rollers, usually immobile, cradle the bottom of the material while the inner roller, whose position is adjustable, presses on the topside of the material.

Submerged Metal Arc WeldingIt requires a non-

continuously fed consumable solid or tubular (flux cored) electrode.

The molten weld and the arc zone are protected from atmospheric contamination by being "submerged" under a blanket of granular fusible flux consisting of lime, silica, manganese oxide, calcium fluoride, and other compounds.

When molten, the flux becomes conductive, and provides a current path between the electrode and the work.

This thick layer of flux completely covers the molten metal thus preventing spatter and sparks as well as suppressing the intense ultraviolet radiation and fumes that are a part of the SMAW process.

Grit BlastingEquipment includes a

Impeller or Compressor, Hoses and Nozzles connected with their pressure control.

The Grit used are sized by the size of screening mesh. Finer sized are usable for polishing while coarser usable for grinding and surface removing.

Grit blasting is a process by which abrasive particles are made to impinge on a component to clean or modify its surface properties.

Methods of propelling the particles also vary and include entrainment in compressed air, liquid or vapor streams, and mechanical projection methods .

Grit blasting is used to remove sand and scale in the fettling of castings, and for dressing of stampings and billets, etc. It is often used to prepare surfaces after welding to improve the adhesion of coatings .

The impact of the grit on the metal surface puts the surface layer into compression, and this effect can be beneficial, for example, in reducing stress corrosion cracking in aluminum alloys.

Post-weld Inspection It is very difficult to produce a perfect welded joint

free from any defect. So, it is very important to detect the weld defects and

to accept or reject the final component depending on its application.

To detect such defects without damaging the weld, several techniques are employed, known as non-destructive testing (NDT).

Non Destructive test includes:-DP test RT testUT test

A liquid penetrant is applied at the surface of the specimen. The penetrant is drawn by the surface flaws due to capillary action and this is subsequently revealed by a developer, in addition with visual inspection.

Principle

Radiography Testing

Top view of developed film

X-ray film

The part is placed between the radiation source and a piece of film. The part will stop some of the radiation. Thicker and more dense area will stop more of the radiation.

= more exposure

= less exposure

The film darkness (density) will vary with the amount of radiation reaching the film through the test object.

•High frequency sound waves are introduced into a material for the detection of surface flaws in the material.•When there are discontinuities ,such as cracks, porosity etc in the sound path ,then part of the sound will be reflected from the discontinuities surface.•Reflected sound waves signal received by the transducer is then transformed back into an electric signal & its intensity is shown on the display unit.

f

Ultrasonic Testing

CASE STUDY

Automatic Ultrasonic Weld Inspection

•Nondestructive examinations such as ultrasonic testing (UT) are normally carried out on all main structure welds of the tower. •This is a bit tedious process where the scanning head is moved along each weld by an operator. •Robotic automation provides the capability to handle the UT sensor with greater precision.• Also it allows the scanning head to travel accurately along the welds which is not possible with manual scanning. •The interface is simple and the robot’s accurate speeds provide excellent data feedback for the monitoring of the weld which ultimately results in maintaining high quality standards.

•The device which is used for automatic inspection of welds is placed far away from operators view.•Remote control is available on robots to allow for setup, operation, programming, and monitoring the weld.

•Remote access through the device is achieved through standard PC office tools such as a Web browser, which lowers the cost of monitoring and control. • Optional viewing cameras can also be installed for viewing the actual robot system.•This system eliminates the issues that a manual test includes and ensuring quality does not impose a limit in the production times, thereby increasing the production rate.

Case Study

Humidity plays important role during painting process.

Humidity more than 90% is not desirable for painting process.

Thus painting process stops during the rainy season due more percentage of humidity.

Usage of dehumidifier could be beneficial during rainy season for decreasing the humidity of air.

Dehumidifier WorkingA fan draws in humid

air and carries it through a refrigerated evaporator

The air is cooled well below its dew point

The water condenses on the cold surface of the evaporator and drips into a water container or is led directly to a drain.

Then the cold dry air continues through a hot condenser which heats it up and returns it to the room to pick up new humidity. This procedure is continued until the desired condition is achieved.

REFERENCESWebsite http://nptel.iitm.ac.in/www.efunda.comhttp://en.wikipedia.org/wiki/Indiahttp://www.howstuffworks.com/ Book Manufacturing Technology by Hajra choudrySheet metal working by Robert cook

THANK YOU