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FFP WORKSHOP :- 04
This shop is divided into two sections. One is Machining and the
other is Heat treatment
section. In Machining section various machining operation is
performed with the help of
different types of lathe, VTB Machine, deep hole boring machine,
horizontal boringmachine, milling machine etc. And Heat treatment
section has induction hardening machine
& furnace.
This shop mainly manufactured Crank Shaft for locomotive diesel
engine. For this, HEC
purchase shaft from USA and then by various machining operation
performed they got
finished job. In the manufacture of crank shaft there are 96
different operations performed
by the well skilled operator to achieve good finished job.
Fig - Crank Shaft
MACHINING:-It is the process of removing metal from the job to
get required shape & size.
Various machining operations are
1.
Turning :- In this process of metal removing, cone-shaped or a
cylindrical surface isproduced.
2. Drilling :- In this process holes are drilled.3. Boring :- In
this process already drilled holes are enlarged.4. Planning :- In
this process flat surface are produced.5. Milling :- This process
is used for generating flat surface, angular surface, curved
surface etc. by using various types of cutter.
6. Reaming :- This process is used to finish a previously
drilled holes.7. Grinding :- This process is used to finish the
surface by removing very little metal by
using a grinding wheel.
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MACHINES USED IN SHOP
HORIZONTAL BORING MACHINE
The boring machine is one of the most versatile machine tools
used to box holes in large and
heavy parts such as engines frames, steam engine, cylinders,
machine housing etc. whichpractically impossible to hold and rotate
in an engine lathe.
Type WD 200 Diameter 200x8000 Vertical movement 3150m Horizontal
movement 8000m
SHAPER
Shaper is a versatile machine which is intended for producing
flat surfaces may be
horizontal, vertical or inclined. This machine involves the use
of a single point tool held in a
properly tool box mounted on reciprocating ram. The main
significance of this machine lies
in its greater flexibility on account of ease in work holding,
quick adjustment and use of tool
of relatively simple design.
Fig : Shaper
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CENTRE LATHE S-2100
Machine no. 1001-04 Swing over bed 2080mm Swing over carriage
1700mm Maximum length of job 46m Maximum trepanning length 24m
Maximum weight of job 28 M T
LATHE MACHINE 04-2010
Type SR M100 Distance between centres 8000mm Swing over bed
1000mm Swing over carriage 710mm Maximum weight of job 10 MT
LATHE MACHINE 04-3001
Type SR1600*10000 Distance between centres 10000mm Swing over
bed 1600mm Swing over carriage 1200mm Maximum weight of job 28
MT
ROLL GRINDING MACHINE
Max. dia to be ground 575-1600 mm Distance between centres 2/3
to 6/7 m Max. weight of roll 3 to 6 T Rigid design for better
efficiency and accuracy Accurate concave & convex grinding
Electronic/mechanical feed counter for pre selection of cross feed
Built in dynamic balancing device
HEAT TREATMENT SECTION
HEAT TREATMENT:- It refers to a combination of heating and
cooling of a metal or alloy in
the solid state for the purpose of obtaining desired properties.
In this shop various heattreatment process like nitriding, volume
hardening, tempering, normalising, annealing.
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INDUCTION HARDENING:-
Induction hardening is a heat treatment process in which the
surface of the steel is heated
to high temperatures (by direct application of a flame, or by
induction heating) then cooledrapidly, generally using water; this
creates a "case" of martensite on the surface.
First the job (rolling steel) is preheated at nearly 350C then
it is allowed to cool for about
half an hour. Then again it is heated upto 905-910C. Quenching
is done in an oil bath which
is maintained at 110C and the job is kept there for 48 hrs.
Induction hardening processes:
High frequency >8000 Hz 2-5 mm depth Medium frequency
3000-8000 Hz 5-8 mm depth Low frequency
