Bhushan Training Report

8/10/2019 Bhushan Training Report

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TRAINING REPORT

OF

SIX WEEKS INDUSTRIAL TRAINING, UNDERTAKEN

AT

BHUSHAN POWER AND STEEL

SUBMITTED IN PARTIAL FULFILLMENT OF THE DEGREE

OF

BACHELOR OF TECHNOLOGY

IN

DEPARTMENT OF MECHANICAL ENGINEERING

Submitted By: Under the Guidance of:

Name: Shivanshu Gupta Name: GIAN SABLOK

College Roll No.: UM-11910 Designation: DGM


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PREFACE

Training is a part and parse of professional course in engineering. Classroom study is not

enough to develop a professional mind and person. Exposure to industrial environmentis necessary to make one a good engineer. In industrial environment one comes in

contact with real practice and problems of industrial. One can see things practically

which one has studied in classroom.

This training report describes about the various departments in which I have worked and

tried to become familiar with the practical working of the machines and tried to gain

knowledge.

I went through all the departments located in steel plant. Being in the industry premises

I had an added advantage to look at the production function also. It was not possible forme to get detailed knowledge of all the function even then I tried to grasp a few

important functions and observed others.

I am greatly thankful to the cooperative behavior of executives and the workers of the

Bhushan Power and Steel Co. Ltd., Chandigarh.


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COMPANY PROFILE

BHUSHAN-The Beginning

Brij Bhushan Singal, the prime mover, a visionary entrepreneur founded the Bhushan

group than 20 years ago in Chandigarh.

Making a moderate start with manufacture of hinges rail track fasteners in early 70s

with a capital less than a lakh of rupees, the group has continuously grown by

modernizing, expanding and integrating its fascilities/ operations.

Joined by his young and dynamic sons Sanjay & Neeraj in the 80s and taking

advantage of the liberalized environment in the steel sector, Brij Bhushan Singal has

propelled the group to the success earning it a permanent place among the large

players of the steel industry, with a turnover of Rs. 2200 crore, cash profit of over

Rs. 180 crore and net worth of Rs. 500 crore

BHUSHAN POWER & STEEL LIMITED

Bhushan power & steel limited, is an ISO 9002 certified company of erstwhile

Bhushan Group, is a merged entity of Bhushan Power & steel Limited, Bhushan

Mettalic Limited & Dcor Steel Limited having turnover of more than INR 2000 Crores

(USD 460 Million) is a leading manufacturer of Flat, Round and value added productsin steel. Bhushan Power & Steel Limited has by continuation up-gradation of

technology, redesigning structures, integrating & synergizing operatios made a

special place in production of various value added products in secondary Steel

segment among the steel producers in India. From production of special steel for

vehicles and white goods segment to high class steel for Exports, Bhushan has made

its mark. Bhushan Power & Steel Limited is having 7 World Class & state of art plant

at Chandigarh, Derabassi, Kolkata & Orissa in India. A completely integrated plant is

commissioned under Phase-I in Orissa and Phase-II is all set for take off. At all of

these plants, technology and equipments are procured from world-renownedCompanies like Luirgi from Germany, ABB limited, SMS Demag, Siemens etc. Bhushan

is selling its value added range of products in Secondary Steel through a large

distribution network in India ( comprising more than 25 Sales offices ) and Abroad.

Among our major and valued customers in India are Hero Honda, Honda Scooters,

Yamaha Motorcycles, JBM, BPL, HMT, GNA Group, Hero Cycles, Avon Cycles, Atlas

Cycles, Delton Cables etc. Bhushans products are being exported to China,

Singapore, Malaysia, Hong Kong, Indonesia, Philliphines, Dubai, Oman, Saudi

Arabia, South Africa, Thailand, Korea, Mayanmar, Srilanka, Nepal, Bangladesh,

Vietnam etc. and a host of African countries.


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MISSION & VALUE

Our Mission is to achieve clear identiy and leadership globally in Steel production and

distribution by integration of complete chain of production starting from captive ironore to end user Steel Products.

Our revolution in Steel production has helped us to carve a niche unique only to

market leader. Every year passes by with new value additions and more accolades

from our customers- Locally and Globally. In pursuing our mission, we at BHUSHAN

POWER & STEEL LIMITED are guided by following values

QUALITY

To be the best in quality. We aim and achieve excellence.

TECHNOLOGY

State of art technology and product enrichment by continuous Research and

Development

CUSTOMER FRIENDLY

Our products are world class and more and more clients are appreciating and using

our products. We also undertake customized products with values addition and

enhancement.

CORPORATE GOVERNANCE

We comply with all applicable laws and regulation. We believe in maintain clean

environment and conservation of natural resources. We contribute towards

betterment of our staff and provide them with best of facilities.

ENVIROMENT PROTECTION AND PRACTICE

We are adopting and implementing pollution control measures as a matter of policy.

OUR COMMITMENTS

To improve the quality of our products and complete integration of various

stages of production.

To be conscious towards quality and pricing of our products. We strive by

continuous research and development to make our products world class,

having distinct identity and uniqueness.

To run the company profitably year after year.

To workforce motivated, skilled and well looked after.


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PRODUCTS

Cable Tapes- These Tubes are widely used for Power and Industrial boilers,

Transformers, Super heaters, Automobiles and Bicycles, Railway Electrification,

Furniture and General Engineering Applications etc.

GP Coils-These Tubes are widely used for Power and Industrial boilers, Transformers,

Super heaters, Automobiles and Bicycles, Railway Electrification, Furniture and General

Engineering Applications etc.

Steel Coils- These Tubes are widely used for Power and Industrial boilers, Transformers,

Super heaters, Automobiles and Bicycles, Railway Electrification, Furniture and General

Engineering Applications etc.

GP Coils Sheets- Applications: Galvanised Coils and Sheets are used to make Boxes,

Containers, Ducting, Cooler Body, etc.

Corrugated Sheets- corrugated sheets are extensively used for Industrial sheds,

housing, temporary structures etc.

Cold Rolled Sheets-Cold Rolled Sheets are used in the manufacture of Automobiles,

White Goods, Panels, Furniture, Transformers, Oil barrels and drums and general

engineering products.

Narrow CR Coils- Narrow Cold Rolled Coils are used in the manufacture of Automobiles,

Precision Tubes, Cable Tapes, White Goods, Electrical Panels, Furniture, Transformers,

Oil barrels and drums and general engineering products.

Black Pipe- Black pipe is used for transportation of air, gas, fabrication of structure,

automobiles, cycles and general furniture industries. Varnished pipes are used for

general engineering industries.

Precision Tubes- These Tubes are widely used for Power and Industrial boilers,

Transformers, Super heaters, Automobiles and Bicycles, Railway Electrification,

Furniture and General Engineering Applications etc.


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Pig Iron-A product in solid (lumpy) form obtained upon solidification of hot metal in

pig casting machine. Pig Iron is used for production of cast iron casting and steel

Wire Rod and Bar Mill- With the introduction of most technologically advancedspecial and alloy steel long product rolling complex for manufacture of value added

bars and coils, a new dimension has been added in BPSL's long history in the steel

business.

The Long Product Rolling Complex consists of a most modern 0.5 million tpa

multiproduct Wire Rod and Bar Mill (18 pass Horizontal & Vertical Continuous Mill)

supplied by Danieli Morgardshammar, Italy and KOCKS, Germany (4 pass mill).

The state of the art Wire Rod & Bar Mill, one of the most modern plants of this typein the world, will produce:

Straight Bars

Bar in Coil form

Wire rods

Mill Product Range-

Product * Size Range

Round Bars 16mm to 90 mm

Round Corner Square 16 mm to 75 mm

Hexagonal Bars 16 to 50 mm

Wire Rods 5mm to 22 mm

Bar in Coil 16 mm to 60 mm

Finished Product Bundle Characteristics

SL LENGTH WEIGHT MAX DIA. END CUTS

(Meters) Kg mm Cold Shear Metallic Saw & Abrasive Cut

1 6 2000 300

2 12 4000 300


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Wire Rod Coil Characteristics

Item Outside Dia Inside dia No & Type of ties Weight

1 Approx. mm Approx mm No - type Kg

2 1250 900 4-flat knot 2100,2400,3000

1MANUFACTURING OF TUBES ON PRECISION TUBE MILL

1.1 PROCEDURE-

JIB CRANE

UNCOILER SECTION

TIG WELDER

ACCUMULATOR

FORMING SECTION

WELDING ZONE

COOLING ZONE

SIZING ZONE

ALPHA CUT OFF

RUN OUT TABLE

JIB CRANE-

A jib crane is a type of crane where a horizontal member (jibor boom), supporting a

moveable hoist, is fixed to a wall or to a floor-mounted pillar. Jib cranes are used in

industrial premises and on military vehicles. The jib may swing through an arc, to give

additional lateral movement, or be fixed. Similar cranes, often known simply as hoists,

were fitted on the top floor of warehouse buildings to enable goods to be lifted to all

floors.


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UNCOILER SECTION-

The slitted coil is loaded on the uncoiler with the help of JIB CRANE which can weigh a

load of 5 H.P. motor which puts the slitted coil in the support of uncoiler. The support

can be enlarged or shortened in dia according to inner dia of coil There are two big

wheels in the uncoiler to support the slitted coil from the side. The wheels can be

rotated due to bearing on wheel shaft. There are two types of uncoiler, one which can

be stopped by hydraulic mechanism and other in which brakes or speed can be lowered

by the applying force on the roll by tightening it, on the moving shaft. The uncoiler can

be rotated if one coil ends. In hydraulic mechanism both supporting and rotating of

uncoiler is automatic.

It is the facility to uncoil the coil to make it stable by equipping the drum of widened

coil inside diameter and applying the back tension during the line operation.

The frame is of welding structure type and the top frame is supported by slewing

bearing on the bottom frame while it is revolving by Slewing Ring Gear and pinion.

The drum has 4-segment structure of toggle link system, which is possible to reduce

and to enlarge.

The main shaft is of Tube Type and the load goes up and down inside to enlarge and

reduce the segment and hydraulic cylinder is connected to the back of the load


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supply to the mill can be eliminated by the addition of a strip accumulator and a coil

joining machine. This coil accumulator has the special device called the internal pinch

roll simultaneously carrying out the revolution and rotation inside of the machine to

reduce the damage to the strip and the noise so the proper tension is always applied to

the strip and as no pushing force is applied, it is saved in a stable condition.

The Accumulator's Role

A strip accumulator provides a continuous line of strip to a tube mill from a supply of

non-continuous coils of strip. It does this by accumulating or temporarily storing strip in

a manner that permits the strip to be withdrawn to a mill line from the accumulator,

while strip is simultaneously added to the accumulator at a higher speed.

FORMING SECTION-

After accumulator it comes forming section, in it the coil is formed to take circular

shape. They are three to four in number forming rolls, placed next to each other. The
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WELDING ZONE(HIGH FREQUENCY WELDER)

There are two types of welder:

C.F.I(Current fed welder)

V.F.I.(Voltage fed welder)

In High Frequency Welded (HFW) pipe production process, hot rolled steel coils are fed

with a high capacity accumulator in order to achieve continuous welding. Coil edges are

milled using carbide cutters in order to assure a high quality weld. Coils are then

formed by cold forming method using a set of cage rolls and fin passes, and then joined

using high frequency currents using induction or alternatively conduction methods.

The coil edges, which reach welding temperature through the resistance shown by steel

to the applied electrical current, are butted together and welded. This method does

not use any filler material for the weld to take place. Immediately subsequent to

welding, internal and external burrs are removed in order to achieve a uniform surface.


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COOLING ZONE-

In cooling section, the tube after being weld and extra metal removed by the tool , is

fed into a cooling tank in which the tube is completely dipped into the coolant, so that

the temperature raised by the welding of the tube is lowered down and at the same

time tool hardness also increased.


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SIZING SECTION-

The sizing the tube is fed into sizing rolls from where the tube gets its final size. It

consists of four sizing rolls and three truck head roll in which tubes are given final size.

In truck head other attachments are fitted to get sectioned tubes. The right size tubing

limits fluid-friction losses that cause pressure drop, heat generation and, in case ofsuction lines, pump-damaging cavitations.

A tube that is too small raises fluid velocity, which has many detrimental effects. In

suction lines, it leads to cavitation that starves and damages pumps. In pressure lines, it

causes excessive friction losses and turbulence, both resulting in high pressure drops and

heat generation. High heat, in turn, accelerates wear in moving parts and ages seals and

hoses. The end results are shorter component life and wasted energy and, therefore,

low levels of efficiency.

On the other hand, tubing thats too large unnecessarily increases costs. It can also

consume valuable real estate that makes it more difficult to fit tubing into confined

spaces and restricts engineers in configuring adjacent equipment and components. And

oversized tubing can simply be harder and more time consuming to install. It also weighs

more than necessary, and that hurts fuel consumption on mobile equipment. Matching

tubing to an application involves selecting the right material and determining optimum

OD and wall thickness.
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ALPHA CUT OFF-

After passed through sizing rolls the tube passes through the cutting machine in which

alpha shaped cutter is used On another mill simple plain cutter is used which is placedon the trolley. The trolley moves to and motion by rack and worm gear attached at

bottom of the trolley. The limit switches control the trolley travel. The tube is cut off

by the cutter in which cutting action is controlled by air pressure cylinder.

In an alpha cutting, there is an encoder behind the truck head rolls whose number of

rpm is counted to know how much length of tube is passed off from it and required

length to cut off is fed into the computer. The alpha cutter travel is controlled by the

limit switches. The cutting stroke and return stroke happens when the clutch engages

with flywheel return stroke when it disengages from flywheel after brakes are applied

to stop the alpha cutter at rest. It is the facility to automatically cut the pipe to havethe desirable length according to the instruction from D.D.S system.

The carriage of the cut off machine travels on the rail of the top of the bed and

the drive is cut off by pinion and the rack passing through A.C servo motor and the

gear box.

The travelling wheel and the supplementary wheel to prevent conduction are

assembled in the carriage of the cut off machine.

The clamp operates up and down by the hydraulic cylinder and it is designed for

simple disassembling and easy repair by manufacturing the clamp assembly on the top

to complement the existing repair problem.


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The ascent and descent of the saw minimizes the wearing of the saw and bug

generation by applying the hydraulic valve system to perform the operation of quick

forward movement - quick cut off - slow cut off - quick return.


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RUN OUT TABLE-

The tube after being cut out as per demand is collected at the run out table. For

inspection if there is defect in the tube such as welding defect due to joining of strip end

on the TIG welder or the tube which is drilled to see the weld on the TIG welder.


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TOOL ROOM

VARIOUS MACHINES

SHAPER MACHINE

MILLING MACHINE

LATHE MACHINE

HOBBING MACHINE

SHAPER MACHINE-

A shaper is a type of machine tool that useslinear relative motion between the work piece

and a single point cutting tool tomachine a linear tool path. Its cut is analogous to that of

alathe,except that it is (archetypally) linear instead ofhelical.(Adding axes of motion

can yield helical tool paths, as also done inhelical planing.) A shaper is analogous to a

planer,but smaller, and with the cutter riding a ram that moves above a stationary work

piece, rather than the entire work piece moving beneath the cutter. The ram is moved

back and forth typically by acrank inside the column;hydraulically actuated shapers also

exist.

Small shapers have been successfully made to operate by hand power. As size increases,

the mass of the machine and its power requirements increase, and it becomes necessary to

use a motor or other supply of mechanical power. This motor drives a mechanical

arrangement (using a pinion gear, bull gear, and crank, or a chain over sprockets) or a

hydraulic motor that supplies the necessary movement via hydraulic cylinders.

A shaper operates by moving a hardened cutting tool backwards and forwards across thework piece. On the return stroke of the ram the tool is lifted clear of the work piece,

reducing the cutting action to one direction only.

The work piece mounts on a rigid, box-shaped table in front of the machine. The height of

the table can be adjusted to suit this work piece, and the table can traverse sideways

underneath the reciprocating tool, which is mounted on the ram. Table motion may be

controlled manually, but is usually advanced by automatic feed mechanism acting on the

feed screw. The ram slides back and forth above the work. At the front end of the ram is a

vertical tool slide that may be adjusted to either side of the vertical plane along the stroke

axis. This tool-slide holds the clapper box and tool post, from which the tool can be
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positioned to cut a straight, flat surface on the top of the work piece. The tool-slide

permits feeding the tool downwards to deepen a cut. This adjustability, coupled with the

use of specialized cutters and tool holders, enable the operator to cut internal and

external gear tooth profiles, splines, dovetails, and keyways.

The ram is adjustable for stroke and, due to the geometry of the linkage, it moves fasteron the return (non-cutting) stroke than on the forward, cutting stroke. This action is via a

slotted link or Whitworthlink.

MILLING MACHINE-

A milling machine is amachine tool used tomachinesolidmaterials.Milling machines are

often classed in two basic forms, horizontal and vertical, which refer to the orientation of

the mainspindle.Both types range in size from small, bench-mounted devices to room-

sized machines. Unlike adrill press,which holds the work piece stationary as the drill

moves axially to penetrate the material, milling machines also move the work piece radially

against the rotatingmilling cutter,which cuts on its sides as well as its tip. Work piece and

cutter movement are precisely controlled to less than 0.001 in (0.025 mm), usually by
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means of precision ground slides andleadscrews or analogous technology. Milling machines

may be manually operated, mechanically automated, or digitally automated viacomputer

numerical control.

Milling machines can perform a vast number of operations, from simple (e.g., slot and

keyway cutting, planing, drilling) to complex (e.g., contouring, die sinking).Cutting fluid isoften pumped to the cutting site to cool and lubricate the cut and to wash away the

resultingswarf.

Mill orientation-

Vertical milling machine. 1: milling cutter 2: spindle 3: top slide or over arm 4: column 5:

table 6: Y-axis slide 7: knee 8: base

In the vertical mill the spindle axis is vertically oriented.Milling cutters are held in the

spindle and rotate on its axis. The spindle can generally be extended (or the table can be

raised/lowered, giving the same effect), allowing plunge cuts and drilling. There are two

subcategories of vertical mills: the bed mill and the turret mill.

A turret mill has a stationary spindle and the table is moved both perpendicular and parallel

to the spindle axis to accomplish cutting. The most common example of this type is the

Bridgeport, described below. Turret mills often have a quill which allows the milling cutter

to be raised and lowered in a manner similar to a drill press. This type of machine provides

two methods of cutting in the vertical (Z) direction: by raising or lowering the quill, and by

moving the knee.

In the bed mill, however, the table moves only perpendicular to the spindle's axis, while the

spindle itself moves parallel to its own axis.

Turret mills are generally considered by some to be more versatile of the two designs.

However, turret mills are only practical as long as the machine remains relatively small. As

machine size increases, moving the knee up and down requires considerable effort and it

also becomes difficult to reach the quill feed handle (if equipped). Therefore, larger milling

machines are usually of the bed type.

Also of note is a lighter machine, called a mill-drill. It is quite popular with hobbyists, due

to its small size and lower price. A mill-drill is similar to a small drill press but equipped

with an X-Y table. These are frequently of lower quality than other types of machines.

Horizontal milling machine. 1: base 2: column 3: knee 4 & 5: table (x-axis slide is integral)

6: over arm 7: arbor (attached to spindle)

A horizontal mill has the same sort ofxytable, but the cutters are mounted on a

horizontal arbor (seeArbor milling)across the table. Many horizontal mills also feature abuilt-in rotary table that allows milling at various angles; this feature is called a universal
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table. While end mills and the other types of tools available to a vertical mill may be used

in a horizontal mill, their real advantage lies in arbor-mounted cutters, called side and

face mills, which have a cross section rather like a circular saw, but are generally wider

and smaller in diameter. Because the cutters have good support from the arbor and have a

larger cross-sectional area than an end mill, quite heavy cuts can be taken enabling rapid

material removal rates. These are used to mill grooves and slots. Plain mills are used to

shape flat surfaces. Several cutters may be ganged together on the arbor to mill a complex

shape of slots and planes. Special cutters can also cut grooves, bevels, radii, or indeed any

section desired. These specialty cutters tend to be expensive. Simplex mills have one

spindle, and duplex mills have two. It is also easier tocut gears on a horizontal mill. Some

horizontal milling machines are equipped with a power-take-off provision on the table.

This allows the table feed to be synchronized to a rotary fixture, enabling the milling of

spiral features such ashypoid gears.
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LATHE MACHINE-

A lathe is amachine tool which rotates the work piece on itsaxis to perform various

operations such ascutting,sanding,knurling,drilling,ordeformation with tools that are

applied to the work piece to create an object which hassymmetry about anaxis of

rotation.

Lathes are used inwoodturning,metalworking,metal spinning,Thermal spraying/ parts

reclamation, and glass-working. Lathes can be used to shapepottery,the best-known

design being thepotter's wheel.Most suitably equipped metalworking lathes can also be

used to produce mostsolids of revolution, plane surfaces and screw threads or helices.

Ornamental lathes can produce three-dimensional solids of incredible complexity. The

material can be held in place by either one or two centers, at least one of which can be

moved horizontally to accommodate varying material lengths. Other work-holding methods

include clamping the work about the axis of rotation using a chuck or collet, or to afaceplate, using clamps or dogs.

Examples of objects that can be produced on a lathe includecandlestick holders,gun

barrels,cue sticks,table legs,bowls,baseball bats,musical instruments (especially

woodwind instruments),crankshafts,andcamshafts.

Parts of a wood lathe-

A lathe may or may not have a stand (or legs), which sits on the floor and elevates the

lathe bed to a working height. Some lathes are small and sit on a workbench or table,and do not have a stand.

Almost all lathes have a bed, which is (almost always) a horizontal beam (althoughCNC

lathes commonly have an inclined or vertical beam for a bed to ensure thatswarf,or

chips, falls free of the bed). Woodturning lathes specialized for turning large bowls often

have no bed or tail stock, merely a free-standing headstock and a cantilevered tool rest.

At one end of the bed (almost always the left, as the operator faces the lathe) is a

headstock. The headstock contains high-precision spinning bearings. Rotating within thebearings is a horizontal axle, with an axis parallel to the bed, called thespindle.Spindles

are often hollow, and have exterior threads and/or an interiorMorse taper on the

"inboard" (i.e., facing to the right / towards the bed) by which work-holding accessories

may be mounted to the spindle. Spindles may also have exterior threads and/or an

interior taper at their "outboard" (i.e., facing away from the bed) end, and/or may have

a hand-wheel or other accessory mechanism on their outboard end. Spindles are

powered, and impart motion to the work piece.
http://en.wikipedia.org/wiki/Machine_toolhttp://en.wikipedia.org/wiki/Axis_of_rotationhttp://en.wikipedia.org/wiki/Cuttinghttp://en.wikipedia.org/wiki/Sandinghttp://en.wikipedia.org/wiki/Knurlinghttp://en.wikipedia.org/wiki/Drillinghttp://en.wikipedia.org/wiki/Deformation_(engineering)http://en.wikipedia.org/wiki/Rotational_symmetryhttp://en.wikipedia.org/wiki/Axis_of_rotationhttp://en.wikipedia.org/wiki/Axis_of_rotationhttp://en.wikipedia.org/wiki/Woodturninghttp://en.wikipedia.org/wiki/Metalworkinghttp://en.wikipedia.org/wiki/Metal_spinninghttp://en.wikipedia.org/wiki/Thermal_sprayinghttp://en.wikipedia.org/wiki/Potteryhttp://en.wikipedia.org/wiki/Potter%27s_wheelhttp://en.wikipedia.org/wiki/Solid_of_revolutionhttp://en.wikipedia.org/wiki/Candlestickhttp://en.wikipedia.org/wiki/Gun_barrelhttp://en.wikipedia.org/wiki/Gun_barrelhttp://en.wikipedia.org/wiki/Cue_stickhttp://en.wikipedia.org/wiki/Furniture#Tablehttp://en.wikipedia.org/wiki/Bowl_(vessel)http://en.wikipedia.org/wiki/Baseball_bathttp://en.wikipedia.org/wiki/Woodwindhttp://en.wikipedia.org/wiki/Crankshafthttp://en.wikipedia.org/wiki/Camshafthttp://en.wikipedia.org/wiki/CNChttp://en.wikipedia.org/wiki/Swarfhttp://en.wikipedia.org/wiki/Spindle_(tool)http://en.wikipedia.org/wiki/Morse_taperhttp://en.wikipedia.org/wiki/Morse_taperhttp://en.wikipedia.org/wiki/Spindle_(tool)http://en.wikipedia.org/wiki/Swarfhttp://en.wikipedia.org/wiki/CNChttp://en.wikipedia.org/wiki/Camshafthttp://en.wikipedia.org/wiki/Crankshafthttp://en.wikipedia.org/wiki/Woodwindhttp://en.wikipedia.org/wiki/Baseball_bathttp://en.wikipedia.org/wiki/Bowl_(vessel)http://en.wikipedia.org/wiki/Furniture#Tablehttp://en.wikipedia.org/wiki/Cue_stickhttp://en.wikipedia.org/wiki/Gun_barrelhttp://en.wikipedia.org/wiki/Gun_barrelhttp://en.wikipedia.org/wiki/Candlestickhttp://en.wikipedia.org/wiki/Solid_of_revolutionhttp://en.wikipedia.org/wiki/Potter%27s_wheelhttp://en.wikipedia.org/wiki/Potteryhttp://en.wikipedia.org/wiki/Thermal_sprayinghttp://en.wikipedia.org/wiki/Metal_spinninghttp://en.wikipedia.org/wiki/Metalworkinghttp://en.wikipedia.org/wiki/Woodturninghttp://en.wikipedia.org/wiki/Axis_of_rotationhttp://en.wikipedia.org/wiki/Axis_of_rotationhttp://en.wikipedia.org/wiki/Rotational_symmetryhttp://en.wikipedia.org/wiki/Deformation_(engineering)http://en.wikipedia.org/wiki/Drillinghttp://en.wikipedia.org/wiki/Knurlinghttp://en.wikipedia.org/wiki/Sandinghttp://en.wikipedia.org/wiki/Cuttinghttp://en.wikipedia.org/wiki/Axis_of_rotationhttp://en.wikipedia.org/wiki/Machine_tool


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HOBBING MACHINE-

Hobbing is amachining process for makinggears,splines,andsprockets on a hobbing

machine,which is a special type ofmilling machine.The teeth or splines are progressively

cut into the work piece by a series of cuts made by acutting tool called a hob. Compared

to other gear forming processes it is relatively inexpensive but still quite accurate, thus it

is used for a broad range of parts and quantities.

It is the most widely used gear cutting process for creating spur and helical gears and more

gears are cut by hobbing than any other process since it is relatively quick and inexpensive.

Hobbing uses a hobbing machine with two skewspindles,one mounted with a blank work

piece and the other with the hob. The angle between the hob's spindle and the work

piece's spindle varies, depending on the type of product being produced. For example, if a

spur gear is being produced, then the hob is angled equal to thehelix angle of the hob; if a

helical gear is being produced then the angle must be increased by the same amount as the

helix angle of the helical gear. The two shafts are rotated at a proportional ratio, which

determines the number of teeth on the blank; for example, if the gear ratio is 40:1 the hob

rotates 40 times to each turn of the blank, which produces 40 teeth in the blank. Note that

the previous example only holds true for a single threaded hob; if the hob has multiple

threads then the speed ratio must be multiplied by the number of threads on the hob. The

hob is then fed up into work piece until the correct tooth depth is obtained. Finally the

hob is fed into the work piece parallel to the blank's axis of rotation.
http://en.wikipedia.org/wiki/Machininghttp://en.wikipedia.org/wiki/Gearhttp://en.wikipedia.org/wiki/Rotating_splinehttp://en.wikipedia.org/wiki/Sprockethttp://en.wikipedia.org/wiki/Milling_machinehttp://en.wikipedia.org/wiki/Cutting_tool_(metalworking)http://en.wikipedia.org/wiki/Spindle_(tool)http://en.wikipedia.org/wiki/Helix_anglehttp://en.wikipedia.org/wiki/Helix_anglehttp://en.wikipedia.org/wiki/Spindle_(tool)http://en.wikipedia.org/wiki/Cutting_tool_(metalworking)http://en.wikipedia.org/wiki/Milling_machinehttp://en.wikipedia.org/wiki/Sprockethttp://en.wikipedia.org/wiki/Rotating_splinehttp://en.wikipedia.org/wiki/Gearhttp://en.wikipedia.org/wiki/Machining


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Up to five teeth can be cut into the work piece at the same time. Oftentimes multiple

gears are cut at the same time. For larger gears the blank is usuallygashed to the rough

shape to make hobbing easier.

HOB-

The hob is the cutter used to cut the teeth into the work piece. It is cylindrical in shape

withhelical cutting teeth. These teeth have grooves that run the length of the hob, which

aid in cutting andchip removal. There are also special hobs designed for special gears such

as the spline and sprocket gears.

The cross-sectional shape of the hob teeth are almost the same shape as teeth of arack

gear that would be used with the finished product. There are slight changes to the shape

for generating purposes, such as extending the hob's tooth length to create a clearance in

the gear's roots. Each hob tooth is relieved on the back side to reduce friction.

Most hobs are single-thread hobs, but double-, and triple-thread hobs increase production

rates. The downside is that they are not as accurate as single-thread hobs. Depending on

type of gear teeth to be cut, there are custom made hobs and general purpose hobs.

Custom made hobs are different from other hobs as they are suited to make gears with

modified tooth profile. The tooth profile is modified to add strength and reduce size and

noise of gears.
http://en.wikipedia.org/wiki/Gashinghttp://en.wiktionary.org/wiki/helicalhttp://en.wikipedia.org/wiki/Swarfhttp://en.wikipedia.org/wiki/Rack_gearhttp://en.wikipedia.org/wiki/Rack_gearhttp://en.wikipedia.org/wiki/Rack_gearhttp://en.wikipedia.org/wiki/Rack_gearhttp://en.wikipedia.org/wiki/Swarfhttp://en.wiktionary.org/wiki/helicalhttp://en.wikipedia.org/wiki/Gashing

Documents

Bhushan Training Report