Summer Trning Report

8/2/2019 Summer Trning Report

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A PROJECT ON

Manufacturing Process of Wire & Wire Ropes

IN

WIRE AND WIRE ROPES DIVISION

TATI SILWAI, RANCHI

Submitted by:

Kunal SinghUNIVERSITY Roll No.-09103007027

HALDIA INSTITUTE OF TECHNOLOGY,HALDIA, W.B.

Acknowledgement


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The satisfaction and euphoria that accompany the successful completion of the work would

be incomplete unless I mention the people, as an expression of gratitude, who made it

possible and whose constant guidance and encouragement served as a beacon of light and

crowned my efforts with success. This report would have been impossible but for the support

and guidance that we receive from various people at different stages of the project.

Our sincere thanks to Mr.Arvindkumar, HOD of HRD department Usha Martin Industries

Ltd. Whose excellent guidance, encouragement and patience has made possible the

successful completion of project. We are also thankful to all the staffs who shared their

experience and knowledge with us despite of there so busy schedule.

Last but not the least we extend my sincere thanks to the entire team for providing me their

time and active co-operation and all who have helped me directly or indirectly in this project.

Contents

INTRODUCTION


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USHA MARTIN COMPANY PROFILEWIRE & WIRE ROPE DIVISIONRAW MATERIALOUTLINE OF MANUFACTURING PROCESS

oPATENTINGoPICKLINGoWIRE HEAT TREATMENToLE-FOUR FURNACEoDSW FURNACEoWIRE MILLoROPERYoDISPATCH

CONCLUSIONBIBLIOGRAPHY

Preface


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As a student of B.tech in Mechanical Engineering,I had come to this industry for

having experience of manufacturing processes implanted here,i.e. manufacturing of wires and

wire ropes.

This industry uses steel rods of various dia.(15mm to 35mm) As its raw material which is

being processed to make wires and wire ropes that are used in constructional purposes such

as making bridges structures, lifts, and for support in cranes, etc.

The steel used for manufacturing is been transformed into its fine pearlitic state and then been

drawn into wires of required diameters.

Rope making consists of two specific processes namely preparation of strands from wires, in

which wires are twisted about themselves, and then making ropes by twisting of these strandshelically about a core which is generally made of jute or steel. Ropes have a specific

specification which tells about number of stands and number of wires in each strand. For

example: A 6x36 rope means it has 6 strands, each containing 36 wires.

Ive discussed about what I learnt here i.e.detailed manufacturing processes used here in forth

coming pages.


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Usha martin company profile

Vision

In our chosen business, we shall retain market leadership in India and shall be globallycompetitive through customer orientation and excellence in quality, innovation and

technology.

Looking back: a brief history

1960the company was incorporated as UshaMartin Black(wires ropes limited) having its

wire rope plant at Ranchi. The name was changed to UshaMartin Black limited in 1979 and

further changed to Usha martin industries limited(UMIL) in 1983.

1965UMIL promoted UshaIsmal limited(UIL) in collaboration with CCL Systems limitedof UK for the manufacture of fittings and accessories, equipment for pre-stressed concrete

system, wire ropes & wire ropes splicing equipment at Ranchi. UIL merged with UMIL in

1990 and became adivision of the company.

1971UMIL promoted UshaAlloy Steel Limited(UASL) for the manufacture of billets at

Jamshedpur. UASL merged with UMIL in 1988.

1975UASL acquired an on-going rolling mill at Agra.

1975UMIL set up its Machinery Division at Bangalore for the manufacture of wire

drawing and allied machine in technical collaboration with Marshall Richards Barco

Limited(MRB) of UK.

1979in order to obtain steady supply of wire rods for its wire rope plant, UASL set up a

Wire Rod Rolling Mill at Jamshedpur.

1987UMIL, along with Bihar state Electronics Development Corporation, promoted

UshaBeltron Ltd. (UBL)in collaboration with AEG KABEL of Germany for the manufacture

of jelly Filled Telephone Cables.

1997UMIL merged with UBL w.e.f 1st

October 1997

2000Acquisition of speciality wire rope manufacturing plant in UK BruntonShaw

2000Commissioning of 25 MW thermal power plant for captive consumption.

2001Commissioning of 2nd

SMS to enhance capacity and produce quality specialty steel.

2003UshaBeltron Ltd. Changed its name to Usha Martin Ltd.(UML). UML created Fine

Cord plastic coated Fine Wires, household wire, polymer coated wire Fine Ropes & Bright

Bars manufacturing facilities in Tatisilway Ranchi.


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Company profile

UML is the 2nd largest wire & rope manufacturer in the world and has the largestvariety in South East Asia.

It is multiproduct, diversified engineering conglomerate with 10 production units inIndia, 1 in Thailand, 1 in UK and 1 in Dubai.

It is savingvaluable foreign exchange by exporting its product to 42 countries likeUSA, Africa and Middle East, conforming to the strictest product qualities standards.

It got the ISO 9000 Certification by BVQI in 1994. ICICI(BCB) did the business process re-engineering in1996 and line system was

setup to enhance performance.

With the modern concepts like TPM, value engineering, QC, suggestion scheme,customer satisfaction and human resource development, UML is trying to reach

unparalleled heights.

UML is serving through a leading daily PrabhatKhabar, KGVK, Usha MartinTechnical Institute.


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Steel Division

A backward integration initiative, the Usha Alloy and Steel Division(UASD) at Jamshedpur

is one of the largest amongst secondary steel manufacturers of specialty steel long products in

India. With ISO 9002 certified facilities, UASD has pioneered the unique process of steel

making through mini blast furnace-arc furnace route, which ensures superior quality of steel

at a lower cost. UASD serves a range of industries like automobile, general engineering,

fasteners, railways, defence and power.

Machinery Division

The ISO 9001 unit was set up in 1974 at Bangalore to manufacture wire drawing and allied

machines. Over the years the division has added a wide range of Wire, Wire rope & cable

machinery to its product range and is now the leader in this field in India. The division started

with technical collaboration with M/S Marshall Richards Barco of UKand subsequently hascollaborated with internationally reputed firms like de-Angelli Industries SPA, Italy,

StorebergerMaschinenfabrik, Germany, Hi-Draw Machinery ltd, UK and

RedaelliTechnaMeccanica, Italy. A facility in Ranchi has also been created for manufacturing

machines required for wire drawing and stranding applications.

UshaIsmal Division

This unit, having manufacturing unit in Ranchi (Eastern India), is the leader in the field of

pre-stressing equipment and accessories and also executes pre-stressing job on turnkey basis


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Raw Material Handling

Raw Material Use and Handling

More efficient utilization of raw materials will reduce losses and unnecessary wastegeneration ensures that employee:-

Use supplies only for their intended purpose Use only the amount necessary Keep frequently used hazardous materials near the site of use to minimise

spills/accidents

Provide transfer method which prevent spills and quality problems Pipelines for intermediate transfer Gravity spigot or pump to dispense bulk liquid material A spout and funnel for transferring liquids to different containers. Proper connection/disconnection of hoses and lines Control access to hazardous raw materials Designate central personnel to distribute materials.

Material Handling Equipment

Were engaged in manufacturing and exporting material handling equipment used for

industrial purpose.

Patenting of Steel wire

The Patenting of Steel wires is a Heat-Treating process known for some time an applied

generally, which consists of an Austeniting(Annealing) phase and an isothermal

Quenching(holding) phase. Austeniting is carried out at a temp. of about 900C and

Isothermal Quenching at temp. of about 500C.


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For the practical realization of the two phases of the Patenting process various solutions are

known. In the Austeniting phase of Patenting, the Steel Wire(generally several parallel

guided Steel Wires) is heated to the required temp. by means of direct or indirect heating.

Furnaces of different pullover systems are used for the indirect heating. This heating method

has the common drawback that, due to the relatively low heat efficiency, the Steel Wire iswarmed up slowly to the required temp. so that the either Pullover speed must be kept low or

the linear measurement of the furnace must be increased. Direct heating is disadvantageous

with respect to productivity, and indirect heating because of the cost of investment.a further

drawback of the known method is that the scaling of Steel Wire can be reduced but not

stopped, even with the application of an intricate firing system and a protective atmosphere.

Direct heating is carried out for example by passing current through Steel Wire and utilizing

the arising Joulean Heat. With this method, the supply of current inside the wires causes

troubles. One of the known solutions utilises a mechanical contact arrangement, the drawback

of which is that is not reliable enough and therefore current supply is unstable. With another

known solution, current supply is provided through a metal bath. In this case the disadvantage

is the the wires are immersed into a lead bath by interrupting there path (e.g. by means of

rolls), therefore threading of the wire is difficult when starting, even with the above

mentioned direct heating methods, the scaling of steel wires causes troubles. The further

processing of the steel wires is possible only after descaling, requiring considerable

expenditures and time. The descaling is generally carried out by means of strong acids. The

application of acids is associated with accidents on the one hand and is detrimental to health

on the other hand (acid fumes). The other, isothermal quenching phase of the patenting

process is generally carried out by immersing the wire into a lead or salt bath of suitable

temperature. For the immersion deflecting (depressing) elements, e.g. rolls or rollers are used.These elements are however not reliable enough and render the operation of the equipment

too complicated. Another drawback of this solution is that the bath gets overheated at the

entrance point of the wire, therefore required quenching is not ensured and the wire quality is

thereby deteriorated. In order to eliminate the above difficulty, the bath is generally circulated

by means of special pumps. These pumps render the equipment more intricate and expensive

and at the same time, they easily break down due to adverse operating conditions.

Pickling

Pickling is a metal surface treatment used to remove impurities, such as stains, inorganic

contaminants, rust or scale, from ferrous metals, copper and aluminium alloys. A solution

called pickle liquor, which contains strong acids is used to remove the surface impurities. It is

commonly used to descale or clean steel in various steel making processes.


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Process

Many hot working processes and other processes that occur at high temperatures leave a

discolouring oxide layer or scale on the surface. In order to remove the scale the workpice is

dipped into a vat of pickle liquor. The primary acid used is HCl, although H2SO4 was

previously more common. HCl is more expensive than H2SO4, but it pickles much faster

while minimising base metal loss.

The acid used here for pickling is HCl. Acid cleaning has limitations in that it is difficult to

handle because of its corrosiveness, and is not applicable to all steels. Hydrogen

embrittlement becomes a problem for some alloys and high carbon steels. The hydrogen from

the acid reacts with the surface and makes it brittle and causes cracks.

Because of acids reactants to treatable steels, acid concentration and solution temperatures

must be kept under control to assure desired pickling rates.

Wire Heat Treatment

Wire after being drawn in wire mills and after passing the require quality checks are here for

heat treatment is done to achieve the necessary ductility of wires. These are required for the

further processing operation and the basic aim here is to change martensite structure which is

verybrittle, to a fine pearlite structure which is more ductile. So wires are treated in the


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furnace which maintained at austenitic temperature and quenched in the lead bath then they

undergo for the chemical process in the furnace section itself.

Two types of furnace are used here:-

Le-four furnace DSW furnace

The basic flowcharts and processes used there are shown in following pages.

Le-four Furnace

Le is a German word which means the. Hence this word Le with four means the four

zones of this furnace. The furnace is 15.57m in length and is gas fired. The gas used is LPG.


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Here the size of wire being treated ranges from 1.2mm to 5mm. the wires undergoes

following stages.

pp

Le-four Furnace:

Pay offthe wires are located here for carrying out process.

Pay off

furnace

Lead bath

Sand bath

Water cooling

Acid bath

Water wash

Phosphate bath

Dryer

Borax bath

Dryer

Take up

Flux bath

Dryer

Zinc tank

Lime bath

Take up


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Furnacethe wire is passed through the furnace where heating takes place. There are four

zones in the furnace with different as shown.

heating zone zone 1 104010C Slightly air rich

zone 2 103010C

Soaking zone zone 3 98010C Slightly gas rich

zone 4 98010C gas rich

Lead baththe wire after being heated is quenched to 550C.

Sand baththe wire is then passed through the sand bath, here the additional is wiped off

from the surface by sand.

Water coolingthe wires after passing from sand bath is further cooled and the sand is

washed off by water.

Acid bathwire are treated with HCl to remove oxide layer and outer contamination and the

wire is cleaned.

Water washthe wire is further washed off from acid.

Flux baththe wire is dipped in flux which acts as primer.

Dryerwire is dried her

Zinc tankthe wire is given a zinc coating to prevent it from corrosion.

Lime baththe wire after galvanising is given lime bath which holds the zinc coating.

Take upthe wire finally reaches here and is taken on bobbins.

DSW furnace

It is also German word (d=Dutch s=stash w=work)


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DSW Furnace:

Pay offthe wires are located here for carrying out process.

Pay off

Furnace

Lead bath

Sand bath

Water cooling

Acid bath

Water wash

Flux bath

dryer

Zinc bath

Lime bath

Take up


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Furnacethe wire is passed through the furnace where heating takes place. There are four

zones in the furnace with different as shown.

Lead baththe wire after being heated is quenched to 550C.

Sand baththe wire is then passed through the sand bath, here the additional is wiped offfrom the surface by sand.

Water coolingthe wires after passing from sand bath is further cooled and the sand is

washed off by water.

Acid bathwire are treated with HCl to remove oxide layer and outer contamination and the

wire is cleaned.

Water washthe wire is further washed off from acid.

Flux baththe wire is dipped in flux which acts as primer.

Dryerwire is dried her

Zinc tankthe wire is given a zinc coating to prevent it from corrosion.

Lime baththe wire after galvanising is given lime bath which holds the zinc coating.

Take upthe wire finally reaches here and is taken on bobbins.

INSPECTION


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The wires after patenting are then inspected again. All the quality checks are performed to see

that whether the wires are meeting the required standards or not. If the wires are meeting the

required standards then they are either send for scrap or further rework if the wire pass the

quality checks then they are send for further drawing (to the ropery).

Wire Mill


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This section dealswith treatment of wire for required properties and then wire

drawing for its required cross section area.

At Usha Martin, it is practiced a total productive maintenance philosophy in all activities to

achieve zero breakage, zero accident and zero defect. Dedicated product development and

quality improvement teams have been formed to work closely with customers to continuously

fine tune our products and upgrade our quality norms, thus resulting in reduced production

loss, reduced rejection rates and productivity improvement at the customers end.

The stepwise checks performed to ensure stringent quality standards right from raw material

stage to wire rod supply are as follows:

Raw material Stage

The primary raw materials- iron ore, coke, and limestone are selected after meticulous

chemical and fractional size analysis. Further, reputed independent agencies periodicallyscreen and select the best quality vendors.

Mini blast furnace

Operations of MBF are controlled by a state of the art PLC driven control system thus

insuring a hot metal output that is consistent and repeatable in its properties. The furnace

utilises a low silicon hot metal for steel making. Typical hot metal chemistry is as follows:-

%C=4.3

%Mn=0.20

%Si=0.80

%S=0.07

%P=0.12

Steel melting shop

The MBFarc furnace process route insures steel with minimal tramp elements and low

gaseous content. Close monitoring at electric arc furnace at, ladle furnace and vacuumdegassing station controls the chemistry. It is further verified through there fully equipped

testing facilities that includes sophisticated instruments like optical emission spectrometer &

carbon sulphur analyser. Some specific techniques followed at the steel melting shop for

clean steel are:

Continuous Ar purging in ladle. Cored wire injection in ladle. Vacuum degassing treatment for special grades as required.

Some of the characteristics of high quality steel produced are:


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o Low tramp level (Cr+Ni+Cu=0.10% max.).o Low gaseous content (N70 PPM max.).o Low S (0.025% max.) and low P (0.025% max.).o Clean steel by modified inclusion morphology.

Casting

During casting, the hot metal stream is protected from atmospheric contamination by a ladle

shroud and a bellow shroud or submerged entry nozzle as applicable. An electromagnetic

stirrer in the mould and proper lubrication including uses of superior quality granulated

fluxes insure a defect free as cast billet surface. Few highlights of this process are:-

o Electromagnetic stirrer in the mould.o Intensive secondary cooling.o Equiaxed grain structure at billet core.o Superior surface finish of billets.

Further to prevent segregation and remnant defects, the first and last billets of any any casting

sequence are discarded.

Rolling

Before rolling, all billets are fully inspected and suitably dressed before charging into a

walking beam reheating furnace. The walking beam furnace is designed for a uniform heating

to achieve extra low decarburization level. The wire rod mill is a fully automated unit with

facilities like no twist single line rolling for better surface finish. It is also equipped withfacilities for thermo mechanical rolling. Following are the highlights of rolling:-

o Minimal decarburisation level (1% of wire roll max).o Standard testing done in process.o Options available for slow cooling, related cooling and fast cooling.o Facility for thermo mechanical rolling.o Front and tail cutting of billet at various stages of rolling.

Final inspection

Besides the standard tests for wire rods like tensile, hardness, microstructure etc. a fully

developed infrastructure exists for conducting final inspection tests as per customer

specifications and international norms. Following are the inspections conducted:-

o Dimension checking.o Hot upset and cold upset tests.o Tensile tests.o Rockwell / Brinell hardness testing.o Hardenability testing.

Wire Drawing


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Wire drawing is a metal working process used to reduce the cross section of a wire by pulling

the wire through single or series of drawing die(s). There are many applications for wire

drawing, including electrical wiring cables, tension loaded structural components, springs,

paper clips, spokes for wheels and stringed musical instruments. Although similar in process,

wire drawing is different from extrusion, because in drawing the wire is pulled, rather thanpushed, through the die. Drawing is usually performed at room temperature, thus classified as

cold working process, but it may be performed at elevated temperatures for large wires to

reduce forces. More recently drawing has been used with molten glass to produce high

quality optical fibres.

Process

The wire drawing process is quite simple in concept. The wire is prepared by shrinking the

beginning of it, by hammering, filing, rolling or swaging, so that it will fit through the die.

The wire is then pulled through the die. As the wire is pulled through the die, its volumeremains the same, so as the diameter decreases, the length increases. Usually the wire will

require more than one draw, through successively smaller dies, to reach the desire size.

The process of wire drawing improves material properties due to cold working. The areal

reductions of small wires are 15-25% and larger wires are 20-45%. Very fine wires are

usually drawn in bundles. In a bundle, the wires are separated by a metal with similar

properties, but with lower chemical resistance so that it can be removed after drawing. If the

reduction in dia. is greater than 50% the process may require annealing between the processes

of drawing the wire through the dies. Commercial wire drawing usually starts with a coil of

hot rolled 9mm in dia. wire. The surface is then first treated to remove scales, then fed into asingle block or continuous wire drawing machine. Single block wire drawing machines

include means for holding the dies accurately in position and for drawing the wire steadily

through the holes. The usual design consists of a cast iron bench or table having a bracket

standing up to hold the die, the coil of wire being stored upon another drum or swift which

lies behind the die and reels off the wire as fast as required. The wire drum or block is

provided with means for rapidly coupling or uncoupling it to its vertical shaft, so that the

motion of the wire may be stopped or started instantly. The block is also tapered, so that the

coil of wire may be easily slipped off upwards when finished before the wire can be attached

to the block, asufficient length of it must be pulled through the die, this is affected by a pair

of gripping pincers on the end of a chain which is wound around a revolving drum, so

drawing the wire until enough can be coiled two or three times on the block, where the end is

secured by a small screw clamp or vice. When the wire is on the block it is set in motion and

the wire is drawn steadily through the dies. It is very important that the block rotate evenly

and that it runs true and pulls the wire at constant velocity, otherwise snatching occurs

which will weaken or even break the wire. The speeds at which wire is drawn vary greatly,

according to material and amount of reduction. Continuous wire drawing machines differ

from the single block machines in having a series of dies through which a wire passes in a

continuous manner. The difficulty of feeding between each die is solved by introducing a

block between each die. The speeds of the block are increased successively so that the

elongation is taken up and any slip compensated for. One of these machines may contain 3 to


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12 dies. The operation of threading the wire through all the dies and around the blocks is

termed stringing up.

Besides this, wire drawing machines are also classified on basis of state of lubricant used for

cooling the die and also for defect free drawing product, when drawing is in progress as:

Dry drawing machines Wet drawing machines

In dry drawing machines dry lubricants are used which may be a Ca or Na based soap

powder. Ca based lubricant are specially used for heavy reduction in wire diameter and low

speed for 1-4 ton dies, for cooling of the dies the machine use water, further these dry

drawing machines are classified into following categories:-

BOB (block over block) type. OTO (over take up over) type. Path finder type. Composite (BOB+OTO) type.

Wet drawing machines use Drasol as lubricant, which is a powder dissolved in water. Wet

drawing machines are different from there dry counter parts in respect that the wire to be

drawn becomes wet before entering to the dye, which doesnt occur in dry drawing machines.

Fig.: a typical wire drawing machine, showing a no. of blocks

Ropery


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Ropes are industrial components that are made from Strands which are further made from

wires. It function is almost similar to that of Gears for transmitting power to lift heavy

components with an additional property of shock absorbent. This is the section of this plant

where wire comes from furnace after being properly drawn, heat treated and proper quality

inspection.

CLASSIFICATION

STRANDS

When wires are wound helically around a core (king wire), it forms a strand. Different form

of strands is:-

Cross lead. Equal lead.

ROPES

When strand are wound around a core, it forms a rope. Ropes are classified according to the

type of core used as:-

Steel core ropes. Jute core ropes. Fibre core ropes.

MACHINERY USED FOR ROPE MAKING

The machines used for rope making work on similar principal of wounding a number of

strands around a core helically. Bobbins are loaded into cradles of the machine. The strands

after being wound are again loaded to bobbins with help of capstan which is governed by a

typical gear system.

TYPES OF MACHINERY USED IN ROPERY

Tubular stranding machine.

Sun and planetary machine. Buncher machine.

Tubular Stranding Machine

This strander is for manufacturing high carbon and low carbon steels wires. This type of

machine is having a tube like shape which is free to rotate around its longitudinal axis with

help of motors, belt drives and also a heavy gear train. Cradles are located on the axis of the

tube and the tubes surface is provided a number of holes for loading the bobbins on cradles.

There is also a face plate which remains stationary during the rope making and carries anumber of holes on it to let the strands pass through it. Its function is to maintain the wires of


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the rope in correct order before convergence on cone. Cone lies centrally on the face plate it

converges the wire to be twisted helically. Lubricants are used continuously near the cone to

reduce the friction between strands when they become loose. Lubricants used here are

bituminous and petroleum.

Fig: a Tubular stranding machine

Sun and planetary machine

Fig.: cradle of a sun & planetary machine

As by its name, this machine resembles with sun & planrtary system. The bobbins carrying

strands are loaded into cradles which are located on a heavy ring like structure, free to rotate

about its transverse axis. The core is a strand loaded saperately & unwoundes along the axis

of rotation of cradle. As the machine starts, the core gets continiously unwound and the

cradle rotates about its axis such that the strands in the cradle get hellicaly wound around the

core. Similar to tubular stranding machine, here also lubricant is provided at the wounding

section of the machine, to avoid friction between strands if by some means they get loose.

Buncher machine


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fig.: different parts of a Buncher machine

This particular machine is used for particularly making rope of thin wires. However all the

principals used here is the same as in preveous ones. The difference in operation of this

machine from previous ones is that, thin wires are used in place of srands and no lubricant is

used here.

Dispatch


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Here is despatch section the wires, strands, ropes undergo final inspection, after the final

inspection if goods are found to be meeting the required standard then they are sent for

disposal purpose.

After the ropes, strands and wires are given their final touches they are packed properly and

then sent to their respective customers via roadways, rail and air as required.

Conclusion


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Usha martin has taken giant strides in manufacturing of world class ropes strands and wires it

is hence forth became the second largest company in the world in terms of manufacturing ,

seeing and closuring the manufacturing processes one can appreciate the efficiency of

company.

All the manufacturing sections are well maintained and properly organised however there is

still scope of improvement and should be prepared to adopt to the highly volatile market

condition.

Bibliography


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WEBSITES CONSULTED:-

www.google.co.in

www.wikipedia.com

www.encyclopedia.com

www.ushamartin.com

www.encarta.com

BOOKS REFERED

Material science and engineering by W.F. Smith.

Production technology by R.K Jain.
http://www.google.co.in/http://www.google.co.in/http://www.wikipedia.com/http://www.wikipedia.com/http://www.encyclopedia.com/http://www.encyclopedia.com/http://www.ushamartin.com/http://www.ushamartin.com/http://www.encarta.com/http://www.encarta.com/http://www.encarta.com/http://www.ushamartin.com/http://www.encyclopedia.com/http://www.wikipedia.com/http://www.google.co.in/

Summer Trning Report

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