Bharat Heavy Electrical Limited, Haridwar

Training Report in
Turbine Section & Central Foundry & Forging
Plant

SUBMITTED BY:
RAVI PRAKASH SINGH
B.Tech -FINAL YEAR(2007-08)
MECHANICAL ENGINEERING
ROLL NO-0404340029
B.I.E.T-JHANSI
TRANING PERIOD-(9th June - 8th July 2006)

SUBMITTED TO:
Mr.ALOK SHUKLA
SENIOR MANAGER
TURBINE GOVERNING SECTION
BHARAT HEAVY ELECTRICAL LIMITED
HARIDWAR
BUNDELKHAND INSTITUTE OF
ENGINEERING &
TECHNOLOGY,JHANSI
TRANING REPORT IN
TURBINE SECTION

SUBMITTED BY:
RAVI PRAKASH SINGH
B.Tech -FINAL YEAR(2007-08)
MECHANICAL ENGINEERING
ROLL NO-0404340029
B.I.E.T-JHANSI
TRANING PERIOD-(9th June - 8th July 2006)

SUBMITTED TO:
Dr.V K BHATT
Prof & HEAD OF DEPARTMENT
 MECHANICAL ENGINEERING DEPARTMENT
B.I.E.T-JHANSI
ACKNOWLEDGEMENT

Before we get into detail of the report,I feel the heartfelt

responsibility to mention my acknowledgement to several people to whom I
owe the success of my venture of training and writing this report.
I am grateful to Mr.ALOK SHUKLA Sr.MANAGER(TURBINE
GOVERNING SECTION) who allowed me to undergo vocational summer
training and guided me during training period at BHARAT HEAVY
ELECTRICAL LIMITED,HARIDWAR which holds the rank amongst
the top Public Sectors in india , exhibiting excellent performance with safest
and most friendly enviornment, fulfilling all kinds of standards respective to
its name,reputation and fame.
I would like to give special thank to all the staff of BHEL TURBINE
SECTION for their great and remarkable contribution, support and guidance
during training period.Their constant effort made this training really a
learning experience. The well planned schedule and structure helped me in
understanding the systems and equipments easily and effectively.

Ravi Prakash Singh

24th Dec 2007
 CONTENT

1. BHELAN OVERVIEW

2. HEEPAN OVERVIEW

3. TURBINES & AUXILLIARY BLOCK

4. HYDRO TURBINE

5. STEAM TURBINE

6. GAS TURBINE

7. MANUFACTURING PROCESS

8. BLADE SHOP

9.BROAD SPECIFICATION OF MAJOR MACHINES TOOLS &

MACHINES - CNC MACHINE TOOLS

10. NON CNC MACHINE TOOLS

 1.BHEL AN OVERVIEW

BHEL is the largest engineering and manufacturing enterprise in India

in the energy related infrastructure sector today. BHEL was established more
than 40 years ago when its first plant was setup in Bhopal ushering in the
indigenous Heavy Electrical Equipment Industry in India a dream which has
been more than realized with a well recognized track record of performance
it has been earning profits continuously since 1971-72 and achieved a sales
turnover of Rs. 6347 crore with a pre-tax profit of Rs. 294 crore in 2000-01.

BHEL caters to core sectors of the Indian Economy viz., Power

Generation's & Transmission, Industry, Transportation, Telecommunication,
Renewable Energy, Defense, etc. The wide network of BHEL's 14
manufacturing division, four power Sector regional centres, over 150 project
sites, eight service centres and 18 regional offices, enables the Company to
promptly serve its customers and provide them with suitable products,
systems and services efficiently and at competitive prices. BHEL has
already attained ISO 9000 certification for quality management, and ISO
14001 certification for environment management.
POWER GENERATION

Power generation sector comprises thermal, gas, hydro and nuclear

power plant business as of 31.03.2001, BHEL supplied sets account for
nearly 64737 MW or 65% of the total installed capacity of 99,146 MW in
the country, as against nil till 1969-70.

BHEL has proven turnkey capabilities for executing power projects

from concept to commissioning, it possesses the technology and capability
to produce thermal sets with super critical parameters up to 1000 MW unit
rating and gas turbine generator sets of up to 240 MW unit rating. Co-
generation and combined-cycle plants have been introduced to achieve
higher plant efficiencies. to make efficient use of the high-ash-content coal
available in India, BHEL supplies circulating fluidized bed combustion
boilers to both thermal and combined cycle power plants.

The company manufactures 235 MW nuclear turbine generator sets

and has commenced production of 500 MW nuclear turbine generator sets.
 2.HEEP: AN OVERVIEW

Over the years, Bharat Heavy Electricals Limited has emerged as

world class Engineering and Industrial giant, the best of its kind in entire
South East Asia. Its business profile cuts across various sectors of
Engineering/Power utilities and Industry. The Company today enjoys
national and international presence featuring in the "Fortune International-
500" and is ranked among the top 12 companies in the world, manufacturing
power generation equipment. BHEL has now 14 Manufacturing Divisions, 8
Service Centres and 4 Power Sectors Regional Centres besides a large
number of project sites spread over India and abroad.

HEEP: FACILITIES AND INFRASTRUCTURE

Modernization and regular up gradation / up gradation of facilities and

other infrastructure is a continuous endeavor at HEEP, BHEL. After initial
setting up of the plant during the year 1964-72, in collaboration with the
Soviet Union, the plant facilities and infrastructures have since been
continuously upgraded under various investment projects viz, Stamping Unit
Project, LSTG Project, Motor Project, Governing Components Project, TG
Facilities Modernization, TG Facilities Augmentation, Quality Facilities
Augmentation, EDP projects, Gas Turbine Project, Facilities have also been
added and establishments have been created for new projects in Defense and
Aviation Project. Additionally, R &D facilities have also been created under
Generators Research Institute, Pollution Control Research Institute, HTL
modernization and other such scheme

Today the Plant has unique manufacturing and testing facilities,

computerized numerically controlled machine-tools, Blade shop, heavy duty
lathes, milling machines, boring machines, machining centers and many
more. The Over Speed Vacuum Balancing Tunnel created for rotors up to
1300 MW (32T, 6.9 M dia bladed rotor, 6 rpm up to 4500 rpm) is one of
the 8 of its kind in the entire world.

The total spectrum of sophisticated, unique and other facilities at HEEP,

Hardwar are the state-of-the-art in manufacturing processes and can be
utilized for a variety of products' manufacture.
 3.TURBINE AND AUXILIARY BLOCK-III

GENERAL

Block-III manufactures Steam Turbines, Hydro Turbines, Gas Turbines and

Turbines Blades. Special Toolings for all products are also manufactured in
the Tool Room located in the same block. Equipment layout plan is as per
Drawing appended in Section III. Details of facilities are given in Section II.

The Block consists of four Bays, namely, Bay-I and II of size 36x378 metres
and 36x400 metres respectively and Bay-III and IV of size 24x402 metres
and 24x381 metres respectively. The Block is equipped with the facilities of
EOT Cranes, compressed air, Steam, Overspeed Balancing Tunnel,
indicating stands for steam turbine, rotors, one Test stand for testing 210
MW steam turbines Russian Design, one Test Stand for Hydro Turbine
Guide Apparatus and two separate Test Stands for the testing of Governing
Assemblies of Steam and Hydro Turbines.
 4.HYDRO TURBINES

For manufacturing of Hydro Turbines, Bay-I has the following sections:

Circular Components Machining Section This section is equipped with

a number of large/ heavy size Horizontal and Vertical Boring Machines,
Drilling Machines, Centre Lathes, Marking Table and Assembly Bed. The
major components machined in this section are Spiral Casing with Stay
Ring, Spherical and Disc Valve bodies and Rotors.

Runner and Servo Motor Housing Machining Section This section is

equipped with NC/CNC and conventional machines comprising Heavy and
Medium size vertical and Horizontal Boring Machines, Centre Lathes,
Grinding machines and Drilling Machines, Marking Table, Assembly Bed,
Assembly Stands for Steam Turbine and Gas Turbine assemblies and
Wooden Platform for overturning heavy components. Hydro Turbine
Runners, Servomotors, cylinders, Labyrinth Ring, Regulating Ring, Stay
Ring, Turbine Cover, Lower Ring, Kaplan Turbine Runner Body and Blades
are machined here.

Guide Vanes and Shaft Machining Section This section is equipped with
Heavy duty Lathe machines upto 16 metres bed, CNC turning machines,
Horizontal Boring Machine, Heavy planer, Deep Drilling Machine, Boring
Machines, marking Table, Marking Machines and Assembly Beds. Turbine
shafts, Guide Vanes, Journals and Rotors of Spherical and Disc Valves are
machined here. Rotors of Steam Turbines are also machined in this section.

Assembly Section In this section, assembly and testing of Guide

Apparatus, Disc Valve, Spherical Valves, Servo motor shaft and combined
Boring of coupling holes are done.

Preservation and Packing Section Final preservation and packing of all

the Hydro Turbine components / assemblies is done here.

Small components Machining Section This is equipped with Planetary

Grinding Machine, Cylindrical Grinding Machines, small size Lathes,
Planers, Vertical and Horizontal Boring Machines. Small components like
Bushes, Levers, Flanges etc. and governing assemblies and machines here.
Governing Elements Assembly and Test Stand Section This section is
equipped with facilities like oil Pumping Unit, Pressur Receiver.

5.STEAM TURBINES

The facilities and parts manufactured in the various sections of Steam

Turbine manufacture are as follows:

Turbine casing Machining Section It is equipped with large size Planer,

Drilling, Horizontal Boring, Vertical Boring, CNC Horizontal and Vertical
Boring machines etc. Fabrication works like casings, Pedestals etc. are
received from Fabrication Block-II.

Rotor Machining Section It is equipped with large size machining tools

like Turning Lathe, CNC Lathes, Horizontal Boring Machines, special
purpose Fir tree Groove Milling Machine etc. Some rotor forgings are
imported from Russia and Germany and some are indigenously
manufactured at CFFP, BHEL, Hardwar.

Rotor Assembly Section This is equipped with Indicating Stand, Small

size Grinding, Milling, Drilling, machines, Press and other devices for fitting
Rotors and Discs. Machined Rotor, Discs and Blades are assembled here.
Balancing and over speeding of Rotor is done on the dynamic balancing
machine.

Turbine casing Assembly Section Machined casings are assembled and

hydraulically tested by Reciprocating Pumps at two times the operating
pressure.

Test Station - Test station for testing of 210 MW USSR Steam Turbine at no
load is equipped with condensers, Ejector, Oil Pumps, Oil containers Steam
Connections etc, required for testing. Overspeed testing is done for
emergency Governor. Assembly Test Stands for different modules of
Siemens design are equipped with accessory devices.

Painting Preservation and Packing Section All the parts are painted,
preserved and packed here for final dispatch.

Bearings and Miscellaneous Parts Machining Section This section is

equipped with small and medium size basic machine tools, e.g., lathes,
Milling M/c, Horizontal Borer, Vertical Borer, drilling M/c etc. for
manufacture of bearings and other miscellaneous parts of turbine.

ROTOR ASSEMBLY OF V94.3A STEAM

TURBINE
Sealing and Diaphragm Machining Section It is equipped with medium
size Vertical Boring, Horizontal Boring, Planning, Drilling Machines etc.
wherein castings of sealing Housings, Liner housings, Forgings of Rotor
Discs, castings and fabricated Diaphragms and components are machined. It
is also equipped with CNC machining center.

Precision Horizontal Boring, Plano-Milling machines etc, are for

manufacture of Governing Casting, Servo Casings and other medium parts
of governing and Main Turbine assemblies.

Governing Machining Section This section is equipped with medium size

and small size lathes, medium CNC lathe, Milling, Grinding, Drilling,
Slotting and Honing Machines. Governing assembly parts are machined
here.

Diaphragm and Governing Assembly Section It is equipped with

deflection testing equipment for Diaphragms, Dynamic Balancing Machine
for balancing Impeller of Centrifugal Oil Pumps and small fittings and
assembly equipment. Governing test stand is equipped with the facilities like
Oil Pumping Unit, Pressure Receiver, Servomotor, overspeed testing of
Emergency Governor etc.

Light machine shop In addition to normal conventional machine tools it

is equipped with CNC Lathes, CNC Milling, CNC Vertical Boring, Precision
Milling, planetary grinding machines etc. for manufacture of small and
medium precision components of governing and other turbine parts.
 6.GAS TURBINE

All the components of Gas Turbine are machined and assembled using the
facilities available for manufacturing of steam and hydro turbines except the
following facilities which are procured exclusively for the manufacturing of
Gas Turbine and are installed in the areas specified for gas turbine
manufacturing.

Hydraulic Lifting Platform

This facility is used for assembly and disassembly of G.T. Rotor. This is a
hydraulically operated platform which travels upto 10 M height to facilitate
access to different stages of Rotor. This is installed in Bay-I assembly area.

CNC Creep Feed Grinding M/c.

This is installed in Gas Turbine machining area Bay-II Extn. This M/c grinds
the hearth serration on rotor disc faces. Hirth serrations are radial grooves
teeth on both the faces of rotor discs. Torque is transmitted trough these
serrations, which are very accurately ground.

External Broaching Machine

This machine is installed in GT machining area and is used to make groove

on the outer dia of rotor discs for the fitting of moving blades on the discs.

CNC Facing Lathe

This machine is installed in GT machining area and is used basically for

facing rotor disc but can turn other components also.

CNC Turning Lathe

This machine is installed in Bay-I Heavy Machine Shop and is used to turn
Tie Rods of Gas Turbine, which have very high length / diameter ratio. Tie-
Rod is a very long bolt (length approx. 10 meter & dia 350-mm) which is
used to assembly and holds the gas turbine rotor discs to form a composite
turbine rotor.
GAS TURBINE
Wax Melting Equipment

This is low temp. electric furnace installed in Gas Turbine blading area in
Bay-II. It is used to mix and melt Wax and Colaphonium, which is required
to arrest the blade movement during the blade tip machining of stator blade
rings.

Gas Turbine Test Bed

This test bed is installed near the Gas Turbine Machining area in Bay-II.
This facility is used to finally assemble the gas turbine. Combustion
chambers are not assembled here, which are assembled with main assembly
at the site.

Combustion Chamber Assembly Platform

This facility is a 3 Tier Platform installed in Bay-I assembly area and is used
for assembly of Combustion Chambers of Gas Turbine.
 7.MANUFACTURING PROCESS

HYDRO TURBINES

The major processes involved in various Hydro Turbine Sections are as

follows:

Marking and checking of blanks manual as well as with special marking

M/c.

Machining on Horizontal Boring, Vertical Boring, Lathes etc. as the case

may be on CNC /Conventional Machines. Intermediate assembly operation
is carried out on the respective assembly beds provided.

The sub-assemblies are further assembled for hydraulic/functional testing.

Hydraulic testing is done using a power driven triple piston horizontal
hydraulic pump, which can generate a pressure of 200 Kg/Cm2. It can also
be carried out using a power pack.

On Governing elements / assembly and test stand, the components / sub-

assemblies / assemblies are tested up to a hydraulic pressure of 200 Kg / c
m2 using the piston pump. Oil testing upto 40 Kg / c m 2 is carried out with
oil pumping unit, which is permanently installed on this bed.

STEAM TURBINE

Processes carried out in various sections of steam turbine manufacture are

based on the following main phases.

Machine section Castings, Forgings, welded structures and other blanks

are delivered to this section. The manufacturing process is based on the use
of high efficiency carbide tipped tools, high speed and high feed machining
techniques with maximum utilization of machine tool capacity and quick
acting jigs and fixtures.

Assembly Section Casings and governing assemblies are hydraulically

tested for leakage on special test Bed. Assembled unit of governing and
steam distribution systems is tested on Governing Test Bed. General
Assembly and testing of Steam Turbine is carried out on the main Test Bed
in Bay-II.
 OVERSPEED & BALANCING TUNNEL

Painting, Preservation and Packing After testing the turbine, it is

disassembled and inspected. Then the parts are painted, conserved and
packed for final dispatch.

GAS TURBINE

The major processes involved in manufacturing Gas Turbine in various

sections of Bk-III are as

Machining

Castings, Forgings, welded structures and other blanks are received from
concerned agencies in the respective sections. These are machined keeping
in view optimum utilization of machine tools and toolings. Special jigs and
fixtures are made available to facilitate accurate and faster machining.
Proper regime and tool grades have been established to machine the
materials like inconel, which have poor machinablity.

Main Assembly

Final assembly is done on test bed. Parts are assembled to make sub-
assemblies. These sub-assemblies are again machined as per technological
and design requirements and are made ready for final assembly. After
assembly and insulation assembled Gas Turbine is sent to site.

Rotor Assembly

The rotor is assembled on Hydraulic Lifting Platform and sent to main

assembly, where after checking clearances, it is sent for machining. After
balancing, turbine side of rotor is disassembled, inner casing is fitted and
rotor reassembled. This work is also carried out on Hydraulic Lifting
Platform. Finally rotor is sent for assembly on test bed.

Combustion Chamber Assembly

This assembly is carried out on 3 tier platform installed for this purpose in
Bay-I assembly. After machining of all components, ceramic tiles are fitted
in flame tube. Burner and piping etc. is fitted in dome and combustion
chamber is finally assembled. It is directly sent to site after insulation.
 8.BLADE SHOP

Introduction:

Major part of Turbine Blade Machining Shop is located in Bay-IV of Block-

III. In this shop various types of Steam Turbine and Gas Turbine
Compressor blades are machined from bar stock, drawn profile, precision
and envelope forgings. It is a batch production shop comprising of various
kinds of CNC Machines and Machining Centers, besides various special
purpose and general purpose machines. The layout of equipments is as per
technological sequence of the manufacturing process. Blade shop
implements various On Line Quality Control Techniques through Run
Charts and Control charts. This shop is divided into four distinct areas.
Details of facilities are given in various schedules of Section-II.

Manufacturing Facilities:

Plain Milling Section

It prepares accurate reference surfaces on the blade blanks by milling and

grinding operation. It also manufactures the brazed type blades by induction
brazing of drawn profile and suitably machined spacers. This section carries
out banking by Band Saws, rhomboid grinding on Duplex grinding
machines and thickness grinding on Surface grinders.

Copy Milling Section

The Semi blanks prepared from plain milling section are further machined
by copy Milling Machines / CNC machines (CNC Heller and BSK Bed
type Klopp, BFH / BEK Knee type Machines) for concave and convex aero-
dynamic profile forms, (HTC-600, BFK Machines) for expansion angles,
Compound taper grinding of radial plane is carried out by Surface grinders.
It comprises of T-root machining centers for machining of T-root.

LP Section

This area deals with all types of free standing and forged blades for steam
Turbine Compressor. The freestanding blades are cerrobend casted in boxes
to hold the blade with respect to the profile. These blades roots are
subsequently machined on NTH, MPA-80A and T30 Machining Centers.
There is a five station 360o circular copy milling machine for machining the
profile of envelope forged blades / stocks for Steam Turbine and Gas
Turbine Blades. It also has 3D copy Milling and CNC Machines with
digitizing features for Tip-thinning, Fitted milling. The inlet edge of the last
stage of Low pressure Turbine Moving blades are hardened on a Special
Purpose Flame Hardening equipment.

Polishing Section

Blade Contours are ground and polished to achieve the desired surface finish
and other aerofoil requirements.

There are also other small sections e.g. Fitting Section, Tool and Cutter
Grinding, Toolings Repair Section in Blade Shop.

Inspection Device

3 D Coordinate Measuring Machines for taper and rhomboid checking.

Moment weighing Equipment

Real time Frequency analyzer for checking frequency of free standing

blades.

Contour plotter for plotting of blade profile with various magnifications.

Fir- tree root inspection device.

Magna spray crack detection equipment.

MANUFACTURING PROCESS

The manufacturing process of turbine blades primarily depends on the type

of blade e.g. Bar type, Brazed type, Free standing (Forged type), Gas
Turbine Compressor blades. The bar type and brazed type blades are also
known as drum stage glades. The manufacturing technology of each of these
blades along with recommended machine tools / equipment is furnished
below.
 9.BROAD SPECIFICATION OF

MAJOR/IMPORTANT MACHINE TOOLS & MACHINES

A: CNC MACHINE TOOLS

CNC HORIZONTAL BORERS:

1. Item Description : CNC Horz. Borer

Model : RAPID 6C

Supplier : WOTN, GERMANY

CNC Control System : FANUC 12M

Spindle Dia. : 200mm

Table : 4000 x 4000 mm

Max. Load on Table : 100 T

Travers : X=20000, Y=5000, X=1400mm

Ram traverse : W = 1000 mm

Ram size : 400 x 400 mm

Power Rating : 90 KW

Weight of the m/c : 111 T

ATC Capacity : 60 Nos.

Plan No. : 1-227 (Block-I)

2. Item Description : CNC Stub Borer

Model : DW 1800

Supplier : HEYLIGENSTAEDT, GERMANY

CNC LATHE FOR ROTOR MACHINING

CNC Control System : SINUMERIK 7T

 Boring Dai : 625 2500 mm

Table : 4000 x 4000 mm

Headstock Travel : 4000 mm

Spindle Speed : 0.5 90 RPM (in 4 Steps)

Power Rating : 63 KW

Max. Load Capacity : 100 T

Weight of the m/c : 72 T

Plan No. : 27-420 (Block-III)

3. Item Description : CNC Horz. Borer (2 Nos.)

Model : W200 HB NC

Supplier : SKODA, CZECH

CNC Control System : SINUMERIK 850 M

Spindle Dia. : 200 mm

Traverse : X=12500,

Y=5000,

Z=2000mm

CNC LATHES

4. Items Description : CNC Centre Lathe

Model : D-1800 NYF

Supplier : HOESCH MFD, GERMANY

CNC Control System : SINUMERIK 3T

Centre Distance : 8000 mm

 Swing Over Carriage : 1800 mm

Swing Over Bed : 2400 mm

Spindle Speed : 0 125 RPM

Power Rating : 92 KW

Weight of the Job : 110 TON

Weight of the m/c : 124 TON

Plan No. : 2-394 (Block-III)

5. Item Description : CNC Centre Lathe

Mode : D-2300 NYFS-1

Supplier : HOESCH MFC, GERMANY

CNC Control System : SINUMERIK 7T

Centre Distance : 18000 mm

Swing Over Carriage : 2300 mm

Swing Over Bed : 2900 mm

Spindle Speed : 5 125 RPM

Power Rating : 110 KW

Weight of the job : 320 TON

Weight of the m/c : 216 TON

Plan No. : 2-360 (Block-III)

6. Item Description : CNC Centre Lathe

Model : KV2-1100 CNC

Supplier : RANVENSBURG, GERMANY

 CNC Control System : SINUMERIK 820 T

Centre Distance : 12000 mm

Centre Height : 900 mm

Swing Over Carriage : 1100 mm

Swing Over Bed : 1400 mm

Max. Turning Length : 12000 mm

Spindle Speed : 2-600 RPM

Longitudinal Cutting Feed (Z-Axis) : 1-5000 mm / min.

Transfer Cutting Feed (X-Axis) : 1-5000 mm/min.

Main Spindle Drive Motor : 95.5 KW DC

Max. Feed Force Z/X Axis : 45000 N

No. of Tool carriers : 3

Plan No. : 1-120 (Block-III)

CNC MILLING MACHINES

7. Item Description : CNC Horz. Milling M/c (6 Nos.)

Model : BFH-15

Supplier : BATLIBOI, INDIA

CNC Control System : SINUMERIK 810 M

Table : 1500 x 400 mm

Traverse : X=1170 mm

Y=420 mm

Z=420 mm

Spindle Speed : 45 to 2000 RPM

 Power Rating : 11 KW

Max. Load Capacity : 630 Kg

Weight of the m/c : 4200 Kg

Plan No. : 2-449, 2-453, 2-454, 2-459, 2-460 (Block-

IIITBM)

8. Item Description : Universal Milling M/cs (2Nos.)

Model : BFK-15

Supplier : BATLIBOI, INDIA

CNC Control System : SINUMERIK 810 M

Table : 1500 x 400 mm

Traverse : X=1170 mm

Y=420 mm

Z=420 mm

Spindle Speed : 45-2000 RPM

Power Rating : 11 KW

Max. Load Capacity : 630 Kg

Weight of the m/c : 4200 Kg

Plan No. : 2-463, 2-466 (Block-III: TBM)

9. Item Description : CNC Bed Type Milling M/c

Model : FSQ 80 CNC

Supplier : TOSKURIM, CZECH

CNC Control System SINUMERIK 810 M

 Table : 3000 x 800 mm

TEE SLOT 28H7

Traverse : X= 3000 mm

Y= 870 mm

Z= 850 mm

Spindle Speed Range : H 2500 RPM

Spindle Drive Power : 18 KW continuous

22 KW intermittent

Spindle Head Size : 620 x 500 incldg ram

543 x 420 encldg ram

ATC Capacity : 24 Nos.

Table Load : 2500 Kg

Plan No. : 2-484 (Block-III)

CNC MACHINING CENTRES

10. Item Description : SPL. Purpose 6 Station T-Root

Machining Centre (2nos.)

Supplier : MIH, JAPAN

CNC Control System : FANUC 7M

Indexing Table : 1900 mm dia

Indexing Position : 6 Nos.

Plan No. : 2-356, 2-41 (Block-III: TBM)

11. Item Description : SPL Purpose FIR Tree Root M/cing
Cenre

Model : NTH 200

Supplier : RIGID, SWITZERLAND

CNC Control System : SINUMERIK 7M

Table : 1400 x 1400 mm

Traverse : X= 1950 mm

Y= 900 mm

Z= 600 mm

Spindle Speed : 30600 RPM

No of Spindle : 4

Power Rating : 22 KW

Plan No. 2-354 (Block-III TBM)

CNC VERTICAL BORERS

12. Item Description : CNC Vertical Borer

Model : TMD 40 / 50

Supplier : OSAKA MACHINES, JAPAN

CNC Control System : FANUC 6TB, 3TC

Table dia : 4000 mm

Turning dia : 5000 mm

Turning Height : 4200 mm

Spindle Speed : 0.23-30 RPM

No. of Ram : 2
 OTHER SPECIAL PURPOSE CNC MACHINES

13. CNC SURFACE BROACHING M/C

Make : Marbaix Lapointe, UK

Model : Champion 32 /10, 300

CNC System : SINUMERIC 850 M

Broaching capacity (pulling force) : 320 KN

Broaching slide stroke : 10.3 mm

Broaching slide width : 1500 mm

Max tool length (continuous /row) : 9650 mm

Broaching Speed (cutting stroke) : 1-25 M/min

Broaching Speed (return stroke) : 60 M/min

Drive power rating : 135 KW

Broaching slide movement : Electro-mechanical

Maximum noise level : < 80 Dbs

Max. dia of the disc (mountable) : 2300 mm

Max. weight of the job : 3000 Kgs

Indexing & rotating tables : 1500 mm, 1000 mm

Indexing accuracy : +/- 3 Arc sec.

Plan No. : 2-485

14. CREEP FEED GRINDING M/C

Make : ELB CHLIFE, GERMANY

Model : ELTAC SFR 200 CNC

CNC System : SINUMERIC 3 GG

Work-piece diameter : 200 2000 mm

 CNC BROACHING MACHINE

Work height : 2400 mm

Rotary & indexing table dia. : 2050 mm

Indexing accuracy : +/- 1 ARC SEC

Max. load capacity : 20000 KG

Y-axis (grinding head movement)

Vert. Traverse : 750 mm

Z- axis (grinding head support)

Movement on cross rail)

Horizontal traverse : 2400 mm

Traverse feed rate : 02 1200 mm /min

Grinding head main support

Drive motor : 34 KW

Grinding wheel max. Dia. : 500 mm

Max. Width : 100 mm

Bore : 203.2 mm

Surface speed : 16-35 M/Sec.

Plan No. : 2-49

 10.NON-CNC MACHINE TOOLS

PRECISION HEAVY DUTY LATHE

Manufacturer: Karamatorsk Heavy Machine Tool Works (USSR); Model KS-1614

Specifications

1. Maximum Swing 2000mm

2. Maximum Diameter of work piece over the Saddle 1500 mm
3. Maximum Distance between Centres 8000mm
4. Diameter of Spindle bore 80 mm
5. Maximum Taper when machining by the method of Combined Feeds 0.15 mm
6. Maximum Length between Centres when machining by the method of 1200 mm
Combined Freeds
7. Maximum Weight of work piece 20000 kg
8. Maximum Length of Machine over the Saddle 8000 kg
9. Maximum Summary Effort of Cutting 10,000 kg
10. Limit Dimension of Thread Cut:

BALANCING MACHINE

Manufacturer: SCHENK (West Germany)

Model: Dj 90

Specifications

1. Weight of rotor 10,000 to 80,000

kg
2. Minimum weight without considerable loss of measuring sensitivity, 5000 kg
provided the berings can accommodate such small rotors.
3. Maximum weight for one bearing pedestal 45,000 kg
4. Height of rotor axis above machine bed 1600 mm
5. Rotor diameter (free swing over machine bed) not considering the funnel 4000 mm
6. Diameter of journal Max. 540 mm
7. Diameter of journal, with special sleeve bearing cups made from high Max. 600 mm
grade material.
8. Minimum distance between bearings for less than 10 tons rotor 1500 mm
9. Minimum distance between bearings for more than 10 tons rotor 1900 mm
10. Maximum distance between coupling plague and center of the scond 13500 mm
bearing pedestals
11. Rotational Speeds Min. 800 rpm
(a) For rotors from 5 to 10 tons Max. 4000 rpm
Min. 700 rpm
 (b) For rotors from 10 to 20 tons Max. 3600 rpm
Min. 600 rpm
(c) For rotors from 20 to 80 tons Max. 3600 rpm
12. Maximum test speed and overspeeds
(a) For rotors upto 50 tons 4500 rpm
(b) For rotors upto 50 to 80 tons 3600 rpm
13. Maximum centrifugal force admissible on each bearing pedestals for short 50,000 Kg
period of time
14. Balancing accuracy to be obtained depending on Selling Weight 0.3 to 3 micron

SPECIAL DRILLING & BORING MACHINE

Manufacturer: Machine Tool Works, Ryazan (USSR)

Model: PT 182 H5

SPECIFICATIONS:

1. Swing over bed 800 mm

2. Drilling dia 40-80 mm
3. Boring dia 80-250 mm
4. Swing of job in rest Max 300 mm
Min 110 mm
5. Swing of job in Max. 300
Headstock chuck Min. 110 mm
6. Maximum length of job 3000 mm
7. Maximum weight of job 2000 Kg
8. Number of spindles Headstock 1
Stemstock 1
9. Spindle location Horizontal
10. Distance to spindle axis: From bed wasy 400 mm
From floor 1100 mm
11. Head stock Spindle speed Max 750 r.p.m.
Min. 71. r.p.m.

CASTING

CASTING

Casting is a manufacturing process by which a liquid material is usually poured into a

mold, which contains a hollow cavity of the desired shape, and then allowed to solidify.
The solidified part is also known as a casting, which is ejected or broken out of the mold
to complete the process. Casting materials are usually metals or various cold setting
materials that cure after mixing two or more components together; examples are epoxy,
concrete, plaster and clay.
Casting is most often used for making complex shapes that would be otherwise difficult
or uneconomical to make by other methods.
Casting is a 6000 year old process. The oldest surviving casting is a copper frog from
3200 BC.