NAME : AMIT KARMAKAR

COURSE : B.TECH (MECHANICAL)

SECTION : M2006B42
REG NO. :11007860
COLLEGE : LOVELY PROFESSIONAL UNIVERSITY




In
GAGAN FERROTECH LIMITED,
DURGAPUR(WB)



TYPES OF RAW MATERIALS
1. BILLETS
2. INGOTS


INGOTS :
TRAPEZOIDAL SHAPE STRUCTURE
MANUFACTURED BY CASTING FROM IRON ORE
COLOR CODE IS ALLOTTED TO MINIMIZE THE
ERROR
THREE TYPES OF CROSS-SECTIONAL DIMENSION
34 X 44 inches
32 X 42 inches
4 X 5 inches
50-60 INCHES INGOT LENGTH IS USED IN TMT
PRODUCTION


BILLETS :
ALMOST SIMILAR TO INGOTS BUT HAVE BETTER
SURFACE FINISH
LESS CHANCE OF BLOW HOLES BEING PRESENT
THE FINAL PRODUCT HAS BETTER FINISH WHEN
COMPARED TO INGOTS
NO STANDARD COLOR CODING REQUIRED


COLOR CODING OF INGOTS :
COLOR CODING IS DONE IN BASIS OF PRESENCE OF
PERCENTAGE OF CARBON IN INGOTS
Below .18 white paint
.18 to .20 blue paint
.21 to .23 green paint
.24 to .26 yellow paint
.27 to .30 orange paint
Above .30 red paint
PARAMETERS Fe 415
Fe500
Fe550
Fe415D
Fe500D
CARBON(MAX)

.30 .30 .30 .25 .25
SULPHUR(MAX) 0.060 0.055 0.055 0.045 0.040
PHOSPHORUS(MAX) 0.060 0.055 0.055 0.045 0.040
SULPHUR AND
PHOSPHORUS(MAX)
0.110 0.105 0.100 0.085 0.075
CE(MAX) 0.42 0.42 0.42 0.42 0.42
Manganese (Mn) improves hardenability, ductility and
wear resistance
Nickel (Ni) increases strength, impact strength and
toughness, impart corrosion resistance in combination with
other elements.
Copper (Cu) improves corrosion resistance
Chromium (Cr) improves hardenability, strength and
wear resistance, sharply increases corrosion resistance at high
concentrations
Silicon (Si) improves strength, elasticity, acid resistance
etc.......
Tests involved on ingots and billets are
Carbon percentage
Sulphur percentage
Phosphorus percentage
Coal gas is used to produce heat energy in
the Furnaces
Peak temperature goes up to 1200C
Billets are being heated for 4 hours
There are total 8 burners in the furnace
Burners are so adjusted that uniform
temperature is attained
Three processes involved in Furnace i.e.
Feeding, Heating and ejection.


FEEDING :
Feeding mechanism consists of worm gear
arrangements
HEATING :
Preheating zone, intermediate heating zone
and final heating zone
FURNACE EXIT :
Red hot billets are exited by Authorized
personnel in proper time and lead to Rolling
mills


There are three mills present in the line

ROUGHING MILLS


INTERMEDIATE MILLS


FINISHING MILLS
ROUGHING MILL:
First mill amongst three mills
Gear ratio used is1:6 to provide sufficient
torque to rolls
Three sets of roller present vertically
In Roughing mill very small elongation and
gradually decreasing diameter is attained



After Roughing mill billets moves to next
Rolling mill that is Intermediate Rolling Mill
But before entering the Intermediate Rolling
mill billets needs to accelerate its velocity.
Pinch rolls are used to accelerate billets with
the help of a motor of 50HP.
After Pinch rolls there is a set of CUTTER or
SHEARER with a cone shaped guide ways to
cut the ends of the rods for the better
entering to the Intermediate rolls.
INTERMEDIATE ROLLS:
The purpose of the Intermediate mill is to
attain considerable elongation and to prepare
the rod to enter in the Finishing mill
Before entering to the Finishing Mill two Pinch
rolls and a shearer are used.
FINISHING MILL:
Precision Rolls are used to get nearly accurate
dimensions
Also facilitates the brand imprint

This quenching process is called Thermex
Technology.
TMT bars are made to pass through specially
designed pipes carrying nozzles and pressure
gauges
Water is sprayed through the nozzle to
change the temperature of the rods abruptly
Velocity of the water and pressure of the
water results the hardening of the rods
After the TMT treatment the rods are made to
fall on the Cooling bed.
Before falling on the Cooling bed, the speeds
of the bars are reduced by using a speed
breaker
After complete cooling on the cooling bed,
the TMT rods are sent for the Inspection and
Dispatch



Thank You