WHAT EXACTLY IS ROLLING?

The majority of steel products start their life by being converted from the

ingot or continuous cast form by a process of rolling. To the steel supplied in the

ingot form, the preliminary treatment, given is reduced in its section by

rolling. Rolling consists of passing a metal between two rolls which grip the sheet

and so reduced it in size, and after each pass the rolls are brought closer together

and the metal passed through until required reduction in its section has been

attained.
 FACTS TO REMEMBER :
1. Volume entering ==== Volume leaving
A1×F1 ==== A2×F2

2. Speed increased develops between ‘A’ and ‘C’ on roll surfa-

ce. Therefore, since roll surface travels at constant speed,

there must be slippage between roll and steel. Theoretically,

this slippage of the roll on the steel is forward between ‘A’

and ‘B’, and backward between ‘B’ and ‘C’. ‘B’ is the

neutral point.

3. Increase in the speed can be explained by starting that the

longitudinal pull in the direction of the ‘BP’ is the result of

many tangential pulls at the roll surface introduced immedia-

ly at the point of contact with the steel at ‘A’ until the bar

leaves at ‘C’. These tangential forces are equal to the force of

friction.

4. Therefore, as the pressure of the rolls increases, friction incre-

ses. Tangential pulls and subsequent longitudinal pull along ‘CP’

increases, and the bar leaves faster. Thus the increased speed

compensates for the decreases area of the bar.

 CONTENTS

TOR STEEL SECTION

 WIRE ROD SECTION

MS WIRE SECTION

QUALITY CONTROL

MAINTAINENCE SECTION

UTILITY
TOR STEEL SECTION
MANUFACTURING OF TOR STEEL

PROCESS FLOW CHART

RAW
FEEDING TO 16” MILL
MATERIAL
FURNACE STAND
AS BILLET

10” MILL
CONTINEOUS CONTINEOUS
STAND
STAND-2 STAND -1

CONTINEOUS
COILER QUALITY
STAND-3
CONTROL

DISPATCH
DISPATCH IN WIRE ROD,
TWISTING
MARKET TMT TORR
 SALENT FEATURES OF HOT ROLLING

• Metal is fed to the rolls when it is above its recrystallisation

temperature.

• Coefficient or friction between the rolls and the stock is com-

pearatively lower.

• Theoretical analysis can be easily carried out extensively de-

veloped theory is available.

• Experimental measurements can be easily carried out in cold rolling.

• Heavy reduction is not possible.

• Hardness increases. Excessive cold working generates cracks.

Ductility of the metal reduces. Cold rolling increases the tensile
strength and yield strength of steel.

• Roll radius is smaller.

• The cold rolled surface is smooth and oxide-free.

PRODUCTION PLANNING

&

CONTROL
This is the first application undertaken in the process of production. It plans

the production and accordingly it controls its physical aspects. This department

deals with the planning in par with the customer’s requirement with the

minimum wastage. It works according on the party’s order, in which grade they

want:

O- ORDINARY 0.15% C.

D- DRAWING 0.12% C.

DD- DEEP DRAWING 0.10% C.

EDD- EXTRA DEEP DRAWING 0.08% C.

The other parameters demanded by the party may be its width, hardness, quality

(tonnage) and last of all for the purpose they want to use the coil or sheet, whether

for cycle chains, link plates, compressor cell, stamping, auto parts etc.

We generally prefer H.R (hot rolled) coils of mild steel with thickness ranging

from 1.6 to 6.0 mm. the width of the H.R coils may be upto 1550 mm. the HR

coils comes from either Tata/Bokaro/Imported. Tata is the main source of

among them.
 PPC issue coil cards which consists of cutting of HR coil at HR slitter,

slitting of CR coils, keeping in view side trimming for scrap from which it has

come from.

PPC keeps the record of the coil during every stage of its processing i.e.

from HR slitting to the dispatch. It keeps record of the previously processed

coil & the running coil.

WIRE ROD
 PROCESS:
Hot rolled carbon steel billets are ordered . These billets are of cross-section

100mm^2*5.5m , 125mm^2* 5.5m . This raw material is used to produce MS wire

,
Wire rod ,Torr of different dimensions. Billet is fed into furnace known as Pre

heated furnace. In this furnace billet is heated to a temperature which is 0.6 of

melting point temperature . The fuels which can be used for firing furnace are

FO( furnace oil) , LDO( light diesel oil), RFO (residual fuel oil). The furnace is

well explained in utility. When billet get heated injector unit push the billet so that

it come out of the furnace. The temperature of the furnace is around 1100 *c to

1150 *c. This billet is than passed through rollers powered by heavy AC motors.

IN these rollers 16” mill consist of 3 stands, the material of rollers of 1st stand is of

EN-9 material, 2nd and 3rd stand is of Cast Iron (chilled roll). 10” mill also consist

of 3 stands, the material of 1st stand is of EN-31 and all remaining stands are of

chilled roll. After that comes the tern of continuous mill where , 2 stands are of

12mm , two of 10mm and two of 8mm. Billets pass through these stands and get

deformed into shape desired . If we want to have wire rod of 10mm then it can be
done by diverting its path
 MS WIRE SECTION

PROCESS:
After getting wire rod from rolling mill wire of size varying from size 1-3mm is

produced . This wire of desired diameter can be obtained by passing it trough a

machine called Dry Wire Drawing Machine. In this machine wire can be feed

through payoff unit when it is of smaller diameter or by any other method. Then

this wire is coiled on drums after passing through die box . After passing through

five such drums its diameter get reduced to the desired size because of

continuous removal of material in the die box with the help of die. At the end

this wire is coiled on the spoolers .

Straight Line Wire Drawing Machine : Straight Line Wire Drawing

Machines were developed for straight or deflection free drawing of wire to

provide better drawability lower frictional contact and lower operator

interference. Theoretically there is no limit as far as the wire material or wire

diameter is concerned to be drawn on these machines. ASSOMAC has pioneered

to indigenously develop the Straght-Line Wire Drawing Machine Technology in

India. Presently the range available is capstan diameter 900mm, 750mm,

600mm, 550mm, 500mm, 460mm, 400mm and 300mm for inlet wire diameter

16mm down to 0.5mm. Line speeds upto 22 Mtrs / Sec. These heavy Straiht Line

Wire Drawing Machines provide remarkable drawing performance for Low,

Medium and High Carbon Steel Wire, Stainless Steel Wire and special Alloy

Steel Wire and Non-Ferrous Alloy Steel Wire.This machine has a sensor roller
between the drum and the next die such that the wire passes in contact with this

roller. These rollers have sensors to detect the position of the arm and maintain

tension on the wire by regulating speed of the drums. The drums of this machine

are inclined to the vertical axis to effect fill on the drums. Principally this

machine is best suited for thick wires.

This type of Straight Line Wire Drawing Machine has the drums in vertical axis

without any incline the wire transfer happens through two fixed pulleys and on

moving pulley mounted on a dancing arm. This dancing arm is either spring

loaded or pneumatic loaded with sensor .There is a constant length of wire on the

drum and the wire from drawing drum is transferred to the next die through the

fixed pulleys and the dancer pulley in the inclined plane.This machine is

particularly suitable for Wires below 4 mm diameter and necessarily required for

wire sizes below1.5mm.

Rotating Die Boxes : Die Boxes are meant for improved performance, die life

and wire quality. The complete range of rotating die boxes, which cover a wide

range of sizes and applications are mounted on machine.

Wire Machine Accessories :

1. Wire Pointing Machines : Wire Pointing Machines are suitable for

pointing different types of materials like Mild Steel, High Carbon

Steel, Aluminium, Copper, etc. The pointing rolls are made of High

carbon alloy steel materials hardened tempered and ground finished.

Both hand driven as well as power driven. The machine is mounted

on 4 wheels, thereby making it mobile and useful to serve several

drawing machines. The machine is of a Swiveling Type with 12mm-

0.8mm thickness of wires.

2. Butt Welding Machines : Butt Welding Machines include accurate

welding pressure and a stronger welding strength. high quality of

transformer primary and secondary materials provide long and

trouble free service life.

 QUALITY CONTROL

Quality control means examining the quality of product made. Every section of

production is consulted by quality control deptt.for the benefit of good quality of

the product. This department ensures whether the product is to be dispatched or

needs to be reprocessed.This department is backed by an advanced testing

laboratory for physical metallurgical and chemical tests.Vickers hardness tester for

testing the hardness of the wire . The lab is equipped with Spectrometer for

determining chemical /metallurgical composition .

Recognizing the fact of having the stringent Quality Control System in place ,

Bhushan Power has been accredited by an ISO9001: 2000 certificate by DNV.

 PACKING AND DISPATCH

This is the last deptt. Of the manufacturing plant. After the coil has been

processed i.e. it has been rolled annealed and slitted in CRS section as per the
party’s requirement, it is then packed in packing section.

The packing is done by to party’s requirement. The packing is done either by

Hessian ( 0% moisture ) + polythene ( generally for C/T product ) or by Hessian

only. After the coil is wounded with Hessian or polythene, it then secured tightly

by packing patti. Then the coil according to its size is then weighed in weighing

machine.

The slitted coils are then shifted to godown and the coil status is given to the

excise deptt. After that marketing deptt. Issues dispatch order to packing and then

the coil is loaded into trucks to be delivered to the concerned party.

MAINTAINANCE
The function of this section is maintenance and repair of the damage and worn out

rollers and other components. Bhushan Steels And Power Limited has a well

furnished maintenance section wherein necessary repairs are carried out. The

section has the following machines.

• THE LATHE MACHINE:

Lathe machine is called mother of industry. The fact is that lathe in big factories

where turning is not necessary is also used for repair works. The parts of rollers

are roughly finished by lathe, the good finishing is obtained by grinding machine.

• THE CENTRE LATHE :

The important machine parts of centre lathe are:

1) BED: the lathe bed forms the base of the machine. The head

stock and tail stock are located on either end of the bed and

carriage rest over the lathe bed and slides on it. The quality of

beds must be :
  It should be sufficiently rigid to prevent deflection under cutting
pressure.
 It must be massive with sufficient depth and width to absorb
vibrations.
 It must resist the twisting stress set up due to resultant of two
forces.
 The bed should be seasoned naturally.

2) THE HEAD STOCK:

The head stock is secured permanently on the inner ways at the left end of the

lathe bed, and it provide mechanical means of rotation the work at the multiple

speeds. The speed depends upon:

a) Type of material to be cut.

b) Type of cutting tool material used.

c) Type of finish desired

d) Type of cutting fluid used.

e) The diameter of work.

f) Type of operation.

g) The rigidity and conditions of machine.

 3) TAIL STOCK OR LOOSE HEADSTOCK:

Tailstock is located on the inner ways on the right hand end of the bed. It has two

main uses:

 It supports the other end of work.

 It holds a tool for performing like drilling, reaming, tapping etc.

 Sometimes graduated spindles and micrometer dials on

hand wheels for accurate length setting are incorporated on tail

stock.

4) CARRIAGE:

The carriage of a lathe has several parts serves to support. The following are the

main points:

a) Saddle

b) Cross slide

c) Compound slide

d) Tool post
 • SHAPER: edit it

Universal Cylinder Grinder:

In the C.R division of BHUSHAN INDUSTRIES, the rolling process is very

much

employed, the basic principle of rolling are two rollers. The roller can wear or tear

after some time or for some new machine rollers are required with a better surface

finish. Therefore the grinding machine is used.

The principle parts of a plain cylindrical grinders are:

1) BED (Base)

It is the main casting of the machine which rests on the floor. It supports the

other parts on it. On the top of the base are carefully machined ways for the
sliding

table of the grinder to slide on it. At the rear of the machine is a column attached

to the base. On the top of this column is provided a cross slide for the movement
of the wheel head on it perpendicular to the bed ways.

2) Table: The machine consists of two tables:

• Sliding Table: it is mounted at the front and top of the

base. It may be moved longitudinally by hand or power to more the workpieces

centre. It provides the necessary reciprocal motion to the table.

• Swivel table: it is mounted on the top of the sliding table and it is

pivoted at its center. For cylindrical grinding swivel table center line and sliding

table center line can be swiveled through an angle of +6.

a) Head stock: it is mounted on the left end of the swivel

table. The work driving motor is incorporated in the head

stock. Some jobs must be held on a face plate; others are

held between two chucks or in a special fixture mounted

on the spindle of headstock. Most work pieces are ground

cylindrically held between centers. The driving plate is

mounted on spindle nose. A balanced dog is fastened to

headstock end of the workpiece, which is mounted

between centers, and engages a pin in the drive plate

revolves about the head stock dead center and gives the

job its rotary motion.

b) Tail stock: The tail stock is mounted on the right end

of swivel table. It is used for holding workpieces on

centers, one dead centre being placed in the nose of the

head stock spindle, whereas other being supported on the

tail stock spindle.

c) Wheel Head: wheel head is mounted on the slide at the

top and rear ( back side ) of the base. It carries a straight

disc type grinding wheel mounted on a spindle which is

mounted on or driven by a belt from a separate electric

motor. The wheel head may be moved on the horizontal

plane but in universal grinder it is permanently fixed.

d) Steady past: Long pieces of the work often required an

additional support other than centers against heavy

pressure of grinding wheel. This supports is called steady

rest.

MATERIAL HANDLING
 INTRODUCTION:

As this plant use billets of heavy weight , something should be used to unload or

load these billets from trucks . These billets are feed in the furnace . Also the wire

rods produced in hot rolling mill need to be transported to wire drawing unit .

Heavy rollers are moved from one place to the other with the help of overhead

cranes. In the course of production materials are moved and transferred by means

of hoisting and conveying machines and mechanisms are an integral part of the

production.

The major material handling equipment used in this plant are:

• SLINGS:

Slings are the length of ropes or chains connected to form a loop or provide with

business-end tools which are used for binding, fastening the material and
suspending it from a hoisting mechanism and insure quick, convenient, reliable

and safe securing of the load.

Slings of hemp and synthetic ropes are employed for slinging the items having a

smooth machined surface, of not more than 1.5 tones in weight ( ground and

polished wooden items, light weight materials ). Such slings are recommended to

be used with thimbles only avoiding application of metal business-end tools since

they quickly abrade the ropes.

Slings built up of steel ropes are strong and durable, fail gradually so that it is

easy to determine the degree of their failure but they are prone to damage at sharp

bends and against sharp edges. In repeated loading the ropes are multiply bent,

the wires break and the ropes are rejected.

At present use is made of the following types of slings: rope slings, chain slings,

multi-purpose rope slings, multi-purpose chain slings. By the number of legs,

slings are divided into one-leg slings, two leg slings, three leg slings, four leg

slings and multi-purpose ones. The number of slings legs which are used suspend

the load is selected depending on the weight, dimensions and configuration of the

items.
 • OVERHEAD BRIDGE CRANES:

Overhead bridge cranes are the most widely spread type of cranes in ferrous

metallurgy. They are different in their purpose, load capacity and design. A

traveling electric crane comprises a crane bridge having a traveling mechanism, a

trolley with a hoisting mechanism and control cab. The cranes travel along the

workshop or work site over cranes tracks. Depending on the crane purpose the

hoisting mechanism is provided with various lifting attachments; hook, load

beams, tongs mechanical grips electromagnet or clamshell. As distinct from a

hook crane, the clamshell crane trolley carries alongside with a traveling

mechanism two similar mechanisms; one for lifting the clamshell and other for its

locking.
UTILITY
 Ac Electric Generator

There is an electric generator installed in this plant which

supplies the plant with electricity in case of power failure. This

helps in the safe and continual running of the plant.

Make : Stamford generators Ltd.

Type : H.C. 634W2

Year of manufacturing : 1996

Frequency : 50 Htz.

Ambient temp. : 40°C

NO. of phases : 3
 ACKNOWLEDGEMENT

The six week industrial training program is perhaps the most

important and

integral part of our curriculum. The reason as to why these six weeks are more

than just a sabbatical from college are self evident.

The training provides an ample opportunity to obtain genuine and first hand

industrial experience and to augment theoretical knowledge through actual

implementation and observation. The trainee works in office environs of some of

the premiere industrial establishments of our country. Naturally the work culture

leaves an indelible mark and a powerful impression also giving an ample

opportunity to interact with professional in their respective streams.

Training at Bhushan steels has not only been beneficial in the technical aspects,

but has also contributed immensely and actively towards growth in the personal

capacity, organized and aware individual.

I would like to pay my sincere thanks and gratitude to principal of our college. I

would also like to thanks all lecturers of the mechanical deptt. For their

unconditional support and motivation. I am just truly indebted to them. Without

their support my training would not have been a success.

I am thankful to GENERAL MANAGER allowing us to do

our training in his reputed organization. I am thankful to Mr. Anuj, our training in

charge for his constant motivation and guidance and for the years of industrial

experience that he has so readily shared with us. His visit to the factory were

looked forward to each one of us. Our training would not have been a success

without his unconditional and never ending support

Finally, I am thankful to the engineers and production managers working in their

respective dept. who contributed major in making the environment a better place

to work in.
 INTRODUCTION TO THE PLANT

In India, “Bhushan steel & Power Ltd.” Has emerged as one of the leading

giants in the manufacturing of steel rolled products. Bhushan Steel has shown its

mettle in this field of steel making. In a very short time it has captured new
heights

in this field . The Bhushan Group has revolutionized the Indian steel industries

with its plants well spread in India & abroad. This group was started way back in

1970’s.

My training was confirmed to Bhushan Steels hot rolling division , Plot No. 3.

Here, in this plant, complete process of hot rolling of steel is carried out. In this

plant Assomac machines are eye catching automatic wire drawing machine i.e.

technology has manifested itself in Bhushan Steel plant. It is an integrated steel

plant and plays very important role in Indian economy.This plant is not only

equipped with giant Pre-heated furnace and Lathes but with qualified and capable

staff people working. They are really co-operative and eager to share their
knowledge.

IMPORTANT LANDMARKS: (H.R. DIVISON)

(An ISO-9001:2000 Certified Unit)

• Plant became operational: December, 1996

• Plant turn over: 10,000M tones/month

• Customers: Maruti Udyog Ltd.

Hero Honda Motors Ltd.

Bajaj Autos.

Gabriel India Ltd.

Tata Motors.

Swaraj Mazda,

& many more