PROJECT PROFILE ON METAL

CASTING/FORGING AND THEIR MACHINING

WORKSHOP

Detailed Project Report on Metal Casting /Forging and

their Machining Workshop
(Small Scale production Enterprises)

Name of the Company: NABHIJA METALLIC PRIVATE LIMITED

Registered Office: C-473, Street No. 7, Ashok Nagar,

Shahdara, Delhi-110093

Projected Plant: Khasra No. 118, Village Sadiqpur, Post

Shakrullahpur, Tehsil Kayamganj,
District-Farukhabad, Uttar Pradesh-
209503

Location: Farukhabad - Delhi via Kayamganj Road

CIN: U27320DL2017PTC310676

GSTIN: 07AAFCN5238D1ZM

Udyog Adhar: DL07A0001919

NIC Code: 2419

Introduction:

This project envisages production of machines and their parts & accessories having a bright
prospect in Iron & steel bars ingot/billet industry, sugar mill, paper industry and other heavy as well
as small scale industry.

In the development of every nation, industrialization are very important and for industries
machinery is a key factor. For continuous check of development of any industry, we have to focus
on its machinery. The majority of machine and their parts & accessories are manufactured after
casting of metal by using basic hand and power tools such as Lathe, Mill, Press, CNC, BMC, Hobbing
machine, Boring machine and drill machines etc. Other auxiliary equipment may be used for certain
portion of their fabrication by the technicians in the machine shop.

A machine shop is a room building or company where machining is done. In a machine shop
machinist use machine tools and cutting tools to make parts, usually of metal. The production can
consist of cutting shaping drilling finishing and other processes. The machine shop includes metal,
milling machine, machining centers, multitasking machine, drill process or grinding machines
controlled with CNC.

Due to liberalized economic policy followed and encouragement by Govt. of India i.e. “Make in
India” future prosperity of this machine shop is undoubtedly bright.

The manufacturing complex divided into two sections one is mechanical (machine shop) and the
other is casting and forging workshop.

Market Potential

The Indian steel industry is considered as one of the few bright spots in the global steel industry.
The steel industry in the country revived from the demonetization and the goods and services tax
(GST) reform and is growing at a rapid pace.

The market has transformed to a great extent over the past few years. The technological
developments, though the adoption rate is low in the sector, have not only improved the delivery
times, but also helped the industry in producing accurate designs of steel structures.

The India metal fabrication market (henceforth, referred to as the market studied) is fragmented in
nature, with the presence of a large number of small- and medium-sized companies and EPC
companies.

The rising demand for goods and services across various sectors in India, combined with the fact
that global manufacturing companies focus to diversify their production by setting-up low-cost
plants in countries, like China and India, is expected to drive the Indian manufacturing sector.
Key Market Trends

The Indian manufacturing sector is expected to register a growth of more than six times than the
current value, by 2025, to INR 1,00,000 crores. This growth in the Indian manufacturing sector, in
turn, is likely to increase the number of manufacturing facilities in the country, which is, thus,
expected to drive the demand in the market studied.

For instance, the number of mobile manufacturing plants that were setup in India has increased by
more than 60 times since 2014. This shows the increasing demand in the market studied, owing to
the increasing number of manufacturing units in the country. In July 2019, the Singapore-
headquartered electronics manufacturing and business services provider Flex opened a new
manufacturing facility in Chennai, taking the total number of manufacturing facilities of the
company in India to four.

Capacity Utilization in the manufacturing sector is measured by Reserve Bank of India in its
quarterly Order Books, Inventories and Capacity Utilization Survey. It indicates not only the
production levels of companies, but also indicates the potential for future investments.

Competitive Landscape

The India metal fabrication market is fragmented in nature, with the presence of a large number of
small- and medium-sized companies and EPC companies. Majority of the large fabricators present in
the market studied are majorly EPC companies, which handle end-to-end solutions for structural
steel fabrication and process equipment fabrication services. In structural steel, fabricators in the
market are focusing on expanding their product portfolio through pre-fabricated buildings and
providing engineering solutions to their clients. The increasing construction sector and the
preference toward pre-engineered buildings are expected to further increase the competition
within the market studied.

Manufacturing Process:

PROCEDURE

1. Work piece is given by the assistant engineer.

2. Brief explanation by assistant engineer on how to operate the lathe machine.
3. Take a dimension of the workpiece and compare with given dimension anddrawing.
4. Apply safety tools.
5. Start operating the lathe machine.
6. Design the work piece according to the given drawing and given measurementincluding
turning, miling and turning by angle.
7. Take a final measurement.
8. Do finishing for the work piece.
9. Keep tools in safety tool box.
 10. Clean the metal pieces aroung the machine with brush & broom.
11. Brief explanation about report by lecturer.

Basic Machine shop

A machine shop is a room, building, or company where machining is done. In a

machine shop, machinists use machine tools and cutting tools to make parts, usually
of metal. Machining is a material removal process in which a sharp cutting tool is used to
mechanically cut away material so that the desired part geometry remains. Machining is the most
versatile and accurate of all manufacturing process in its capability to produce a diversity of part
geometries and geometric features (e.g. screw threads, gear teeth, flat surfaces).

List of machines are used in the machine shop:

 Lathe machine.
 Face plate lathe machine.
 HDL (Heavy Duty Lathe).
 BVT (Boring Vertical Turret Lathe).
 Gear Hobbing lathe.
 Horizontal boring machine
 Milling machine.
 Drilling machine.
 Radial drilling machine.
 Column drilling machine.
 Shaper.
 Planner.
 Double housing planner
 Slotting machine.
 Grinding machine
 Overhead Crane

We may start our manufacturing process from the following machines:

1. Lathe machine.

The lathe is a machine tool used principally for

shaping articles of metal, wood, or other material. The
work piece is held and rotated around a horizontal
axis while being formed to size and shape by a cutting
tool. The cutter bit is held either by hand or by a
mechanical holder, and then applied to the work
piece. Principal capabilities of the lathe are forming
straight, tapered, or irregularly outlined cylinders,
facing or radial turning cylindrical sections, cutting
screw threads, and boring or enlarging internal
diameters.
2. Gear Hobbing Machine

Hobbing is a machining process for gear

cutting, cutting splines, and cutting sprockets
on hobbing machine, which is a special type
of milling. The teeth or splines are
progressively cut into the work piece by a
series of cuts made by a cutting tool called a
hob. It is the most widely used gear cutting
process for creating spur and helical gears.

3. Horizontal Boring Machine

A horizontal boring machine or
horizontal boring mill is a machine
tool which bores holes in a
horizontal direction. A horizontal
boring machine has its work spindle
parallel to the ground and work
table. Typically there are 3 linear
axes in which the tool head and part
move. Convention dictates that the
main axis that drives the part
towards the work spindle is the Z
axis, with a cross-traversing X axis
and a vertically traversing Y axis.
4. Milling Machine
 Milling is is
Milling the process
the processofof
machining
machining flat,
flat,
curved, or irregular surfaces by feeding
curved, or irregular surfaces by feeding the
work
the piece against
work piece a rotating
against cutter containing
a rotating
a number of cuttingaedges.
cutter containing number The
ofusual Mill
cutting
consists basically of a motor driven spindle,
edges. The usual Mill consists basically
which mountsdriven
of a motor and revolves
spindle, the milling cutter,
which
and a reciprocating
mounts adjustable
and revolves worktable,
the milling cutter,
which
and a reciprocating adjustable piece.
mounts and feeds the work
worktable, which mounts and feeds
the work piece.

5. Drilling Machine

Milling is the process of machining flat,

curved, or irregular surfaces by feeding
the work piece against a rotating cutter
containing a number of cutting edges.
The usual Mill consists basically of a
motor driven spindle, which mounts and
revolves the milling cutter, and a
reciprocating adjustable worktable,
which mounts and feeds the work piece.

6. Shaper
A shaper is a machine tool which holds
and locates a work piece on a table and
machines or cuts the work piece by
feeding it against a reciprocating
cutting tool. The work piece is held in
the vise of the shaper or secured to the
table of the shaper with clamps, T-bolts,
etc. When horizontal surfaces are being
machined, the table automatically feeds
the work to the cutting tool on each return
stroke of the ram. When vertical cuts are
being made, the work is fed to the cutting
tool on each return stroke of the ram
either manually or automatically. The
cutting tool on a shaper can be set to cut
horizontally, on an angle, or vertically
7. Planer

A planer is a type of metalworking

machine tool that uses linear relative
motion between the work piece and
a single-point cutting tool to
machine a linear tool path. Its cut is
analogous to that of a lathe, except
that it is linear instead of helical.

8. Grinding Machine

Grinding is a process of removing materials in the form of ground chips from a work piece
by mechanical action of many small abrasive particles bonded together in a grinding wheel.
Each abrasive particle is acting as a small cutting tool. It is a finishing process employed for
producing close dimensional accuracies and smooth surface finish the work piece. The
regulating wheel is having same direction of rotation as the grinding wheel. The axial
movement of the work piece is obtained a longitudinal feed by tilting the regulating wheel
at a slight angle of 1 to 8 degrees relative to grinding wheel.

9. Slotting machine

Slotting machines or slotters are cutting machines designed to machine slots and
grooves into a work piece.

10. Overhead cranes

Overhead cranes, sometimes also

called bridge cranes, are cranes
with a hoist traveling along the
bridge between parallel runways.
They are designed to meet the
medium to heavy industrial lifting
requirements, covering all parts of
the manufacturing process

11. Welding machine & Tools

 Welding machines or welding guns are one of the most essential tools for a welding works.
It generates heat that melts the metal parts so that these parts can be joined.

Heat Treatment

After machining Heat Treatment is the controlled heating and cooling of metals to alter their
physical and mechanical properties without changing the product shape through the following
processes.

 Annealing
 Normalizing
 Hardening (Surface, Full, Case)
 Tempering
 Stress releasing
 Carburizing (Gas, Pack)
 Phosphating

Casting and Forging Workshop

1. Pattern Shop
“PATTERN MAKING IS THE ART OF MAKING AN ORIGINAL PATTERN OR FORM WHICH WILL
BE USED TO MAKE A MOLD IN WHICH MOLTEN MATERIAL WILL BE POURED DURING
CASTING PROCESS.”

2. CAST IRON & STEEL FOUNDARY

In the casting processes, a material is first melted, heated to proper temperature, and
sometimes treated to modify its chemical composition. The molten materials then poured
into a cavity or mold that holds it in the desired shape during cool-down and solidification.
In a single step, simple or complex shapes can be made from any material that can be
melted. By proper design and process control, the resistance to working stresses can be
optimized and a pleasing appearance can be produced.

The variety of casting processes use different mold materials (sand, metal, or
various ceramics) and pouring methods (gravity, vacuum, low pressure, or high
pressure). All share the requirement that the material should solidify in a manner that
will maximize the properties and avoid the formation of defects, such as shrinkage
voids, gas, porosity, and trapped inclusions.

A melting process must be capable of providing molten material not only at the proper
temperature, but also in the desired quantity, with required quality, and within a
reasonable cost. After the casting is removed from the mold, various Cleaning, finishing, and
inspection Operations will be done. Extraneous material is usually attached where the metal
entered the cavity, excess material may be present along mold parting lines, and mold
material often adheres to the casting surface. All of these must be removed from the
finished casting.

Foundry Process:

Foundries produce castings that are close to the final product shape, i.e., “near-net
shape “components. Castings are produced by pouring molten metal into moulds, with
cores used to create hollow internal sections. After the metal has cooled sufficiently,
the casting is separated from the mould and undergoes cleaning and finishing
techniques as appropriate

Forging Shop

There are two types of forging one is die forging and the other one is free forging.
A. Die forging
In this type of forging method specific dies are used to produce the
specific job for this allowance is very low.
 Requirements:
For die forging we need:
 Furnace
 Hammers
 Hammering machine
 Hydraulic press
 Power press
 Trimming press
 Other press
 Swelling crane

B. Free Forging
Free forging is method of producing jobs without using dies. In free forging large
allowance is present.
Requirements:
Different capacity of hammer

Pollution Control

There will be no harmful disposal of effluents. However company shall obtain NOC from
pollution control board as per statutory norms. Apart from this company will ensure to take
the measures for:

 Lower water consumption

 Recycle and reuse of solid waste
 Reduction in air pollution
 Efficient land use
 Improved occupational health and safety performance
 Dialogue and engagement with local stakeholders
 No cheap natural resources

Energy Conservation

The company will ensure to apply the following application for energy conservation:

 Energy saving using variable speed drive control

 Optimal cooling of drive motor
  Energy savings for miscellaneous power, lighting, and heaters (example: Stop while
idling)
 Optimal operation using energy saving control model (example: heating furnace
combustion control and mill pacing)
 Waste heat recovery

3. Quality Control Inspection

Quality control emphasizes testing of products to uncover defects and reporting to

management who make the decision to allow or deny product release, whereas quality
assurance attempts to improve and stabilize production (and associated processes) to
avoid, or at least minimize, issues which led to the defect(s) in the first place.
Inspection
An inspection is, most generally, an organized examination or formal evaluation
exercise. In engineering activities inspection involves the measurements, tests,
and gauges applied to certain characteristics in regard to an object or activity. The
results are usually compared to specified requirements and standards for determining
whether the item or activity is in line with these targets, often with a Standard
Inspection Procedure in place to ensure consistent checking. Inspections are usually
non-destructive.
Inspections may be a visual inspection or involve sensing technologies such
as ultrasonic testing, accomplished with a direct physical presence or remotely such as
a remote visual inspection, and manually or automatically such as an automated
optical inspection.

Infrastructural Facilities