REPORT

INDUSTRIAL TRAINING

Done by:
CIBIN PAUL JYAOEEE011
BESTO BOSE JYAOEEE013
FRANCY JOHNSON JYAOEEE020
KRISHNAKUMAR JYAOEEE029
ANAND PAUL N.T. JYAOEEE058
 ACKNOWLEDGEMENT

We wish to express our sincere gratitude to Mr. JAYAKRISHNAN (A &

HRD) for providing us an opportunity to do our internship project work in
“STEEL INDUSTRIAL LIMITED FORGING (SFIL).”

We also wish to express our gratitude to the officials and other staff
members of Steel Industrial Limited Forging (SFIL) who rendered their
help during the period of our internship work.

We sincerely thank our Management, Principal Dr. K. K. Babu and Head

of the Department (EEE) Mr. Ratnan P. for encouragement in carrying out
this internship project.

PAGE 1
 CONTENT
1 CHAPTER 1

INTRODUCTION

COMPANY PROFILE

QUALITY STANDARDS

2 CHAPTER 2

ORIENTATION

PRODUCTION DEPARTMENT

ORANIZATION DEPARTMENT

DIESHOP

FORGESHOP

HEAT TREATMENT OPERATIONS

TESTING/INSPECTION FACILITIES

QUALITY CONTROL DEPARTMENT

MATAINANCE DEPARTMENT

MATERIALS DEPARTMENT

TECHANICAL DEPARTMENT

3 CHAPTER 3

LEARNING EXPERIENCE

PAGE 2
 CHAPTER 1

INTRODUCTION

Steel and Industrial Forgings Ltd (SIFL) is a public sector undertaking

(PSU) fully owned by Government of Kerala situated in Athani in Trissur,
Kerala state of India. The company was in corporate in 1983 and started
commercial production in1986. It is an AS9100C and ISO9001:2008
certified company. Untiring efforts of three decades has saddled SIFL
firmly in the Forging Industry of India and abroad with best ratings for its
products and services. Forgings with exquisite designs and shapes, flawless
forms and contours, broadband and spectra of metals like ALLOY STEEL,
SUPER ALLOYS, ALUMINIUM and TITANIUM. All in wide range of
Weights and unmatched quality have made SIFL the most sought after
forging company in the country for critical components. The main products
of SIFL are: Complex and high precision aerospace forgings, specialized
forgings for defence, heavy forgings or commercial vehicles, Indian
Railways and other components for automobiles etc.

COMPANY PROFILE

Steel &Industrial Forgings Limited (SIFL) is an AS9100 C certified, Public

Sector undertaking fully owned by Government of Kerala. Incorporated in
1983 and Started commercial production in 1986, SIFL Rapidly forged
ahead to become a name to reckon with. We are masters in Titanium and
Special alloy forgings.
Untiring efforts of two decades has saddled SIFL firmly in the forging
industry of India and abroad with best rating for its products and services.
Forgings with exquisite designs and shapes, flawless forms and contours,
broadbands and spectra of metals like alloy steel, super alloys, aluminium
and titanium.
All in wide range of weights and unmatched quality have made SIFL the
most sought after forging company in the country for critical components.
SIFL’s diverse product mix caters to a wide range of sectors. This include
complex and high precision aerospace forging, specialized forgings for

PAGE 3
defence, heavy forgings for commercial vehicles, railways and other
components for automobiles etc.

QUALITY STANDARDS

An AS 9100 C certified organisation, our strength and prime aim is strict

adherence to quality standards. At SIFL, we believe that our success
depends entirely on delivering the quality customer demands. Our policy is
to always attain and wherever possible exceed the standards expected by
our valued customers. This is achieved by continuous improvement
programme in process discipline, manufacturing methods and Quality
Systems. Our success is in regular interactions with National Laboratories,
premier forging institutes and of course, long term association with our
prestigious customers. SIFL cater to a wide range of Industries in Defence,
Automobile, Heavy engineering, Aero Space, Railways, Earthmoving
Equipment, Agriculture etc. They draw strength from our team of
experienced professionals and workforce committed to quality and timely
delivery. The support from prestigious public and private sector together
with guidance from Government of Kerala makes us one among the best
performing State Public Sector Units in Kerala.

SIFL continued with landmark development, during the last quarter

also. The company has been recommended for AS91 00 certification. The
remarkable products developed includes seven items for Arjun M ark-Il,
main battle tank being developed by CVRDE for INDIAN ARMY. This
includes, Integral axle arms which are indigenized for the first time in the
country and are of very complex in design another technological feat which
was successfully completed is the development of stainless steel valve body
(S41 O) for BHEL, Trichy. This is the heaviest forging done by SIFL so far
and weighs 850KG/piece. The company has become a partner in the
prestigious Brahmos missile development program by obtaining an order
from M/s Brahmos Aerospace Ltd, Hyderabad. This involves
indigenization of forgings in Titanium, Aluminium and Stainless Steel
Alloys.

PAGE 4
 CHAPTER 2

ORIENTATION

On the first day of our industrial training we had to complete many

formalities regarding the training that we are going to undertake. We were
directed to meet the Human Resource Department. There we did some
paper works regarding our personal data. After that we proceed to their
work shop for training.

PRODUCTION DEPARTMENT

Production systems place very important role in achieving organizational

excellence. A number of organization world-wide have achieved and
sustained excellence by effective production management. Effective
production management involves understanding of the characteristics of
various types of production systems, identification of the dynamics of
different phase of the management process, realizing the potential of
different analytical tools, visualizing the impact of various uncertain
situations and developing the ability to react under various scenarios to
achieve consistently excellent business result. These organization achieved
superior quality, higher productivity, perfect delivery performance, customer
satisfaction and enterprise excellence all with lower cost. Production is the
basic activity of all industrial unit.
All other activities revolves around this activity. The production
department consist of two divisions: the forge shop and the material
preparation division.

FUNCTIONS

. Planning daily production according to annual target.

. Monitoring actual production and checking any deviation.

PAGE 5
PROCEDURE FOR PRODUCTION

1. Planning and control.

2. Monthly and weekly plans are communicated to the production head by
planning. Based on the plans, the production head will communicate to the
shift in-charge about daily plan. Jobs are then allocated and recorded in
forge shop job and cum shift wise production report.
3. Setup verification is done before starting the work order and is recorded.
After the approval of setup, bulk production is started. Corrective actions
are initiated for process non-conformances.
4. Analysis of setup NCs is done daily for implementing corrective actions.
Shift in-charge monitors the process and the inspections are carried out by
QA. Root card come work order is issued and is updated by the shift in-
charge for the required process and the work order is updated and moved
along with the material till the completion of all process which is referred
for traceability.
5. If any rejection is found in the process, the same will be updated in NC
register and the root card and the material is identified with rejection tag for
deposition action.
6. Components are offered to QA for final inspection. After production, die
should be cleaned and handed over to the die shop.

DIE DESIGN & DEVELOPMENT

SIFL’s design & engineering capabilities are ably backed by a well- equipped
Die Shop, set up along modern lines with Double Spindle Copy Milling
Machines, Electrical Die Sinking Machine, CNC Die Sinking Machine, CNC
Turning Centre, Radial Drilling machines, Heavy Duty Plano miller, Lathes,
Tool & cutter grinders, etc. The design and development of the die holds the
key to blemish-free forgings.
At SIFL, we design both single-impression and multi-impression dies. The
design, of course, is related to the forging drawings. And the decision on the
type of die to be used, is based on the specific requirement of each case. The
care that goes into the design of each die, also goes into the selection of raw
materials and the sequence of operation that follows. To facilitate
uninterrupted operations, SIFL is equipped with standby Power Generators.

PAGE 6
To keep pace with hi-tech developments, SIFL has equipped itself with
CAD, CAM facilities like DELCAM for three dimensional modelling of
Product, Die & Tool design etc. thereby minimizing the development cycle
time. All these qualities have helped SIFL grow quickly into a premier
forging unit, capable of producing forgings with close dimensional
tolerances.

DIE SHOP

The die shop is a section where dies are manufactured for forging
components as per the design submitted by the client. Huge die block made
of forged steel are imported from Germany. Then dovetail are cut on it at an
angle of 10 degree for the purpose of inserting the key and holding it firmly
in the ram of the press during forging process. Holes are drilled on the block
and rods are inserted for the purpose of lifting it using a crane for carrying it
from one site to another. The material of die is DIN-271 4. In die shop the
different software used for the drawing are Solid work, unigraphics, Master
cam etc. The die history cards are used to record each and every work details
done for a die. A template is prepared for each drawing of the components to
be forged and a mould of it is made in plaster of pairs for checking the
accuracy.

FORGE SHOP

A forge shop is a place where the forging of the required products is done.
Forging is a manufacturing process involving the shaping of metal using
localized compressive forces. The blows are delivered with a hammer or a
die. Forging is often classified according to the temperature at which it is
performed: cold forging, warm forging, or hot forging.
Forging can produce a piece that is stronger than an equivalent cast or
machined part. As the metal is shaped during the forging process, its internal
grain deforms to follow the general shape of the part. As a result, the grain is
continuous throughout the part, giving rise to a piece with improved strength
characteristics. Additionally, forgings can target a lower total cost when
compared to a casting or fabrication. When you consider all the costs that are
involved in a product’s lifecycle from procurement to lead time to rework,
then factor in the costs of scrap, downtime and further quality issues, the

PAGE 7
long-term benefits of forgings can outweigh the short-term cost-savings that
castings or fabrications might offer.

A forging process involve different process,

. Drawn out: length increases, cross-section decreases
. Upset: length decreases, cross-section increases
. Squeezed in closed compression dies: produces multidirectional flow

DROP FORGING

Drop forging is a forging process where a hammer is raised and then

‘dropped’ onto the work piece to deform it according to the shape of the die.
There are two types of drop forging: open-die drop forging and closed-die
drop forging. As the names imply, the difference is in the shape of the die,
with the former not fully enclosing the work piece while the latter does.

OPEN-DIE FORGING

Open-die forging is also known as smith forging in open-die forging, a

hammer strikes and deforms the work piece, which is placed on a stationary
anvil. Open-die forging gets its name from the fact that the dies (the surfaces
that are in contact with the workpiece) do not enclose the workpiece,
allowing it to flow except where created by the dies. The operator therefore
needs to orient and position the workpiece to get the desired shape. The dies
are usually flat in shape, but some have a specially shaped surface for
specialized operations. For example, a die may have a round, concave, or
convex surface or be a tool to form holes or be a cut-off tool. Open-die
forgings can be worked into shapes which include discs, hubs, blocks, shafts
(including step shafts or with flanges), sleeves, cylinders, flats, hexes,
rounds, plate, and some custom shapes. Open-die forging lends itself to short
runs and is appropriate for art smiting and custom work. In some cases, open-
die forging may be employed to rough-shape ingots to prepare them for
subsequent operations. Open-die forging may also orient the grain to increase
strength in the required direction.

PAGE 8
FORGING & HEAT TREATMENT FACILITIES

The billets for forging are heated in oil fired or electric furnaces, closely
controlling the temperature to reduce the scale formation and overheating so
that the metallurgical properties are ensured in the final product. In addition,
in-process inspection is carried out at all stages and 100% inspection for
visual defects after forging. The accepted forgings are duly heat treated to
ensure its mechanical properties. By providing heat treatment services in-
house, SIFL is able to maintain greater control over heat treating process.
The facility comprise batch furnaces both oil fired & electrical, continuous
electrical heating furnaces, solution treatment etc. to carry out annealing,
normalizing, hardening, tempering, iso-thermal annealing, solution treatment
etc or other operations as specified by our customer. Close temperature
control and process monitoring with the help of temperature recorders
ensures uniform properties duly supported by evaluation of metallurgical
properties through representative test pieces.

HEAT TREATMENT OPERATIONS

The common heat treatment operations that are carried out in the heat
treatment department are:

QUENCHING is the rapid cooling of a workpiece to obtain certain material

properties. A type of heat treating, quenching prevents undesired low-
temperature processes, such as phase transformations, from occurring. It
does this by reducing the window of time during which these undesired
reactions are both thermodynamically favorable, and kinetically accessible;
for instance, quenching can reduce the crystal grain size of both metallic and
plastic materials, increasing their hardness.
In metallurgy, quenching is most commonly used to harden steel by
introducing marten site, in which case the steel must be rapidly cooled
through its eutectoid point, the temperature at which austenite becomes
unstable. In steel alloyed with metals such as nickel and manganese, the
eutectoid temperature becomes much lower, but the kinetic barriers to phase
transformation remain the same. This allows quenching to start at a lower
temperature, making the process much easier. High speed steel also has
added tungsten, which serves to raise kinetic barriers and give the illusion

PAGE 9
that the material has been cooled more rapidly than it really has. Even cooling
such alloys slowly in air has most of the desired effects of quenching.

ANNEALING is a heat treatment that alters the physical and sometimes

chemical properties of a material to increase its ductility and reduce its
hardness, making it more workable. It involves heating a material to above
its recrystallization temperature, maintaining a suitable temperature, and then
cooling.
In annealing, atoms migrate in the crystal lattice and the number of
dislocations decreases, leading to the change in ductility and hardness. In the
cases of copper, steel, silver, and brass, this process is performed by heating
the material (generally until glowing) for a while and then slowly letting it
cool to room temperature in still air. Copper, silver and brass can be cooled
slowly in air, or quickly by quenching in water, unlike ferrous metals, such
as steel, which must be cooled slowly to anneal. In this fashion, the metal is
softened and prepared for further work—such as shaping, stamping, or
forming.

TEMPERING is a process of heat treating, which is used to increase the

toughness of iron-based alloys. Tempering is usually performed after
hardening, to reduce some of the excess hardness, and is done by heating the
metal to some temperature below the critical point for a certain period of
time, then allowing it to cool in still air. The exact temperature determines
the amount of hardness removed, and depends on both the specific
composition of the alloy and on the desired properties in the finished product.
For instance, very hard tools are often tempered at low temperatures, while
springs are tempered to much higher temperatures.

NORMALISING involves heating the steel to about 40 degree Celsius

above its upper critical limit. The steel ¡s then held at this temperature for a
period of time and is then cooled in air. It is described that the temperature
of the steel shall be maintained for a period more than 2 minutes per mm of
section thickness and shall not exceed the upper critical temperature by more
than 50 degree Celsius air is the coolant that is used in normalizing process.

PAGE 10
TESTING/INSPECTION FACILITIES

Surface conditioning is done by shot blasting/grinding and final inspection

is carried out once again to ensure quality requirements. Non-conformities
are taken care of by timely corrective and preventive action. Calibration of
electrical furnaces of SIFL are done by NABL accredited laboratories like
HAL, STIC, CUSAT etc.
SIFL has set up a system of total quality control consisting of an array of
state-of-the-art specialty equipment’s where your products go through a
series of rigorous tests, the destructive test including tensile, jominy and
impact testing, wet analysis, carbon-sulphur determination, insitu
metallography(where microstructure can be observed without destroying
the job) and non-destructive tests using Spectrometer, Microscope,
Magnaflux crack detection, Die Penetrant, Ultrasonic flaw detection etc.
We are now equipped with a new digital ultrasonic flaw detector which has
got a range of 5mm to 5m in steel. Setting and control of quality standards
at all stages right from the receipt of raw material to the finished product
through quality plan makes us deliver superior quality forgings with close
dimensional tolerances and metallurgical properties.

MACHINING UNIT

SIFL has taken a step forward by setting up an exclusive facility for

carrying out precision machining and Testing of Complex parts. A full-
fledged sophisticated facility has been set up as a separate division at
Shornur for carrying out precision machining of forged and other intricate
parts. A fully integrated Precision Machine Shop equipped with state-of-art
CNC machines comprising CNC Horizontal Lathe, CNC Vertical
Machining Centre, CNC vertical Turret Lather, CNC gear Hobbing
machine etc, duly supported by in house CNC programming/modelling,
Design/Fabrication of Jigs & Fixtures, dedicated Inspection and Test
facility.

PAGE 11
QUALITY CONTROL DEPARTMENT

Quality control department has a responsibility to control and maintain the

quality of billets and to grade it according to BIS standards and reporting it
to production department. The department has full-fledged laboratory to do
this task. During refining the samples are analysed the products of the
company are every time subjected to the most stringent and
uncompromising test. Being holder of a good licence, company is
authorised to issue certificate conforming BIS specifications.

FUNCTIONS

. Inspect raw materials available.

. Test the quality of scrap.
. Checking the quality of billets.
. Checking the quality and size of rolled items.
. Analyse the heat.

QUALITY OF INPUTS

In fact, SIFL’s ISO 9001:2008 quality system covers the whole ground
. Acceptance plan and testing of 100% raw material supplies.
. Setting and control of quality standards for forging as per quality plan.
. Corrective and preventive actions are implemented promptly for
minimizing defects to a zero level.
. Certification of facilities by IBR, EIL, IRS and other inspection agencies.
. In-depth testing and research, based on specific customer requirements.
. Continuous vendor evaluation.
. Strict implementation of established processes.
. Calibration and maintenance of testing, measuring and thermal control
equipments.
. Constant and continuous consultation with customers and suppliers on all
technical aspects.
. Maintenance of high vendor rating with customers.

PAGE 12
MAINTENANCE DEPARTMENT

After Quality Control Department we went to visit Maintenance

department. The term ‘maintenance’ means to keep the equipment in
operational condition or repair it to its operational mode. Main objective of
the maintenance is to have increased availability of production systems,
with increased safety and optimized cost. Maintenance management
involves managing the functions of maintenance. The responsibility of
maintenance department is to keep the entire shift always ready for action.
For the smooth and effective functioning of company, it is necessary to
maintain the system properly. The motto is to minimize the downtime, keep
the machineries in good condition, and maximizes the utilization of
equipments and to achieve required level of quality. Maintenance
organization structure can be considered as being made up three necessary
and independent components.
. Resources.
. Administration.
. Work Planning and Control System.
The manager is responsible for the safe maintenance, repair or replacement
of plant equipment and systems, to ensure maximum production quality and
quality, while supporting the policies, goals and objectives of the company.

Functions
. Breakdown maintenance
. Calibration
. Preventive maintenance
. Machine Capability test

Breakdown Maintenance

There is a section which undertakes the job of maintaining, repairing the

parts of machinery where breakdown or disasters had happened. This
section is helpful to maintain such problems by them temporarily and thus
the production function will conduct smoothly without delays. The
department authority gets intimation who then attends the status of the
particular equipment in maintenance register. The site is inspected, and the

PAGE 13
logbooks are updated. The problems are recorded in machine history book
and monthly review is performed.

Calibration

Thermocouples are identified and calibrated once in three months. Non-

conforming thermocouples are disposed. Furnaces are calibrated by using
calibrated thermocouples. They are maintained at 1 000c. Certificate is
issued after calculation.

Preventive Maintenance

Maintenance of furnaces:

Furnaces are provided with thermocouples after ensuring the validity of

thermocouples. Furnaces are maintained at a temperature of 1 COt. The
performance is checked and they are handled over for production process.
The furnaces are inspected once in 30 days.
e.g.: lining failure, coil failure.
Equipments other than furnace: the 1 CT and 6T hammer and compressors
involves replacement/modification, the necessary spares are made
available. If unavailable, the parts are sketched. Before assembly of new
spares are made available. If unavailable, the parts are sketched. Before
assembly of new spares, components are verified with sketches. Records
are maintained for 3 years.

MATERIALS DEPARTMENT

Material input is very important as excess material as inventory causes costs

to the company and shortage of material results into stoppage of conversion
process and subsequently shortage of finished goods leading to customer
dissatisfaction. Management of material is crucial in a just Time Company.
Production process needs very strong material management support to gear
up to face challenges of current market. Material management provides
information about availability of new products and services in the market
which leads to cost efficient changes in the process.

PAGE 14
FUNCTIONS

. Material planning and control

. Procurements
. Handling
. Storage and preservation
. Inventory control
. Vendor development
. Vendor rating
. Waste control

FINISHING AND DISPATCH

At finishing and dispatch the forged job ¡s being blasted to get a finished
appearance. The polishing of the rough surface of the job after forging is
done shot blasting. Shot blasting device is a closed chamber equipment with
2 doors. This is because only one side of get shot blasted at a time and it takes
about 25 minutes. Flash is removed from the shot blasted job. Flash is an
excess of metal formed in the centre of the job which is to create a cushion
effect between the dies. Most of the customers require the flash to be
removed but some don’t want the flash to be removed. This may be because
the finished dimension after machining which the customers do separately
outside may be less. Punching of is also done here. Material code, company
name, material name code, heat number, die number are punched here.

TECHNICAL DEPARTMENT

As the name implies it is here where the designing and cad drawings of the
job is made. Technical department check the functioning and working
processes on each job. They are the once who decide what all works has to
be done on each material so that the desired output is formed. They decide
what sort of specifications are required for creating each product. Designing
is mainly done here. Customer gives a drawing of what output they require,
what specification and what characteristics they require. Technical team
analyse this and create a report whether they can make this or not. If yes they
create cad drawing regarding the same with allowances and tolerance since
they know the output capabilities of the machines available in the firm. They

PAGE 15
also create the codes for cutting and machining process in CNC and
machining equipment in the die shop. The type of die required and
specifications are calculated in technical department. The shape in the die
can be available by changing the cad diagram they made into 3D mode.
Software mainly used in SIFL for this purposes are:
. AUTO CAD
. SOLID WORKS
. CATIA
Mainly used metals in SIFL are steel, aluminium, and titanium. Density of
steel is 7.84 glcm, density of titanium is 405g/cm and density of aluminium
is 2.6 — 2.8g/cm. software help in forging drawing, blocker and finisher
drawing and specification, where to put inserts, when to use trimming tool.
For shaping proof machining is done in CAD.
Weight of the job is calculated as:
W=V*D
Where V=volume, D=density

PAGE 16
 CHAPTER 3

LEARNING EXPERIENCE

The in-plant training at Steel and industrial Forgings Limited has enhanced
our knowledge about the technical concepts of manufacturing and provided
exposure and predictability of subject in the industry. It gave us an
understanding as to how an organization operates and an idea as to how the
hierarchical structure of an organization is and helped us to understand the
chain of command and authority. The study was a significant endeavor in
analyzing overall functions of various departments within the organization.
It has provided us with valuable insight into the technical aspects of
manufacturing and the amount of hard work put ¡n by the managers,
engineers and workers in manufacturing a component.

PAGE 17