INPLANT TRAINING REPORT

ATraining Report

Submitted to The HR &Technical Engineers

Of

MESSER CUTTING SYSTEMS INDIA PVT LTDBy

------------------------------------------------

P. RAGHUL

-------------------------------------------------

OF

SRI ESHWAR COLLEGE OF ENGINEERING, COIMBATORE-641 202

TRAINING PERIOD: 20-06-2016 to 25-06-2016.

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INDEXPage no

Acknowledgement------------------------------------------------------------- 4

Introduction---------------------------------------------------------------------5

Vision & Mission--------------------------------------------------------------6

Our Experience in Messer---------------------------------------------------- 8

Our Interaction with GM----------------------------------------------------- 9

Understanding about Metal Cutting---------------------------------------- 10

Different types of cutting

-Oxyfuel cutting-----------------------------------------------------------11

-Plasma cutting------------------------------------------------------------13

-Laser Cutting-------------------------------------------------------------16

Hand Torch--------------------------------------------------------------------18

An overview about cutting machines

-Omnimat------------------------------------------------------------------19

-Multitherm----------------------------------------------------------------21

Observations in shop floor--------------------------------------------------25

Procurement Department----------------------------------------------------26

QED Department-------------------------------------------------------------27

Maintenance and Service Department------------------------------------28

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Finance Department------------------------------------------------------30

Store--------------------------------------------------------------------------30

Gas Regulators-------------------------------------------------------------31

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ACKNOWLEDGEMENT

We heart fully thank Mr. Mani N, Managing Director of Messer Cutting Systems India Pvt Ltd for granting us permission to undergo Inplant training. We also thank Mr. Hariharan V, General Manager for his guidance during the internship training.

We would also like to thank all Managers, Human Resources [HR], Engineers and Workmen who helped us and guided us during the internship training. We also had a great learning experience and able to understand about the roles of Management, Process involved in manufacturing & Technologies used during the Internship training. It’s been a great experience that we had in the company having experiencing many new technology aspects.

We would also like to thank our Chairman, Director, Principal, Dean and HOD of Mechanical and Electrical Engineering Department of Sri Eshwar College of Engineering, Coimbatore-641 202. And our special thanks to Assistant Professor Mr. Rajan Babu, senior Professor of Electrical Engineering Department for his Support to undergo inplant training.

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INTRODUCTION

Messer Cutting Systems is a global supplier of cutting edge technology. We provide services for the metal working industry setting standards worldwide. As the industry pioneer we offer complete solutions and focus strategically on our customer and on customer driven innovation. We in active in more than50 countries and about 800 employees in 5 main locations with production sites.

Our products range include oxyfuel, plasma and laser cutting systems, from hand-guided machines right up to special machines for shipbuilding as well as plant and equipment for oxyfuel welding, cutting, brazing and heating. Spare parts, repairs and modernization services round off the program as well as environmental equipment for the systems. Our software solutions optimize production and business processes. We focus on intensive dialogue with our customers –our modern training and applications facilities reinforce this claim.

We are the Cutting Systems Partner of choice and are consultants for our customers.

Messer Cutting Systems partner of choice and are a consultant for the customers. Messer Cutting systems, products and service for the metalworking industry stand for cutting edge technology worldwide for more than 115 years.

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VISION & MISSION

VISION:

“WE ARE A WORLD COMPANY”

MISSION:

To use the unlimited opportunities we have. To create value for the benefit of our customers. To open up, to think multidimensional.

With this in mind we are able to build bridges for our customer’s future.

For Messer Cutting Systems being a World Company is a fact and a vision at the same time. In the past our worldwide growth has led us to success, market leadership and multicultural diversity.

We believe in the future potential we have as a World Company. Across all countries and regions we want to make the most out of our joint capabilities to guarantee the long-term partnership with our customers.

“Excellence” is a result of our values and our key success factor.

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Messer Cutting System is Global supplier of cutting edge technology. We provide services for the metal-working industry, setting standards worldwide. As the industry pioneer we offer complete solutions and focus strategically on our customer and on customer-driven innovation. The company is active in more than 50 countries, with more than 800 employees in 5 main locations with production sites.

Our product range include oxyfuel, plasma and laser cutting systems, from hand-guided machines right up to special machines for shipbuilding, as well as plant and equipment for oxyfuel welding, cutting, brazing and heating. Spare parts, repairs and modernization services round off the program as well as environmental equipment for the systems. Our software solutions optimize production and business processes. We focus on intensive dialogue with our customer-our modern training and applications facilities reinforce this claim.

We are the Cutting Systems Partner of choice and are consultants for our customers.

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OUR EXPERIENCE IN MESSER

We experienced a great learning condition in Messer. Our interaction with Managers and Engineers in Messer was Memorable. We learned so much about cutting technology and we experienced a vast knowledge about the how the industry works and we learned what are the duties of the different section in an company.

The people of Messer shared their experience with Messer and they taught us more about industry. It was very useful for us to gain a great exposure about a MNC. We really thank Messer People for giving us guide in our life.

After finishing inplant training in Messer we gained a more technical knowledge and how to work in industry. The working environment in Messer was very good, we have not seen in any company with such good working environment. The People in Messer treated as their home people and the accommodation was excellent. We really thank Messer for such good environment.

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OUR INTERACTION WITH GM

On the first day of our inplant training in Messer we have a discussion with,company GM Mr. V. Hariharan, He was such a wonderful person, we have an interaction with him about half an hour, the time with him was very useful and we learned about that what the Messer is doing really in the industry market, He guided our group to learn more about Messer and guided to have vast knowledge about the industry.

Having such interaction with most experienced person for college students is not easy to have it. So that we were so lucky and blessed to have such discussion with him. He had interacted with freely and discussed more about industry and guided our group to how to do undergo inplant training in general.

He also advised us to how to learn the technical aspects and how to learn technical things. It was a memorable one.

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Understanding about metal cutting

Before our internship in Messer, we don’t know more about cutting process and their process. But after completing internship in Messer we came to know about much more about cutting process and the different types of cutting machines, that are used for different purposes. We also had understood the type of cutting process should be employees for particular type of process and for a particular metal.

We also understood the, how the cutting of the material is done and how the cutting process is controlled, and high accuracy is maintained with good finishing property. We came to known about different types of machines that are produced by Messer for different cutting process oxy-fuel, plasma and laser. And why the customers arechoosing the particular machines for their requirement.

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Oxyfuel Cutting

Oxyfuel flame cutting is the most economical process for the cutting of mild and low alloy steels, even with weld preparations. It is one of the most important production processes in the metal industry.

Oxyfuel cutting is a combustion process using oxygen and fuel gas flame. The heating flame brings the material up to its ignition temperature. Then a jet of oxygen at least 99.5% pure is blown onto the heatedspot. The oxygen jet oxides the metal. The torch is moved and a narrow cutting kerf is created, removing the slag from the kerf. The quality of the cut depends on the surface condition of the material, cut-velocity and thickness.

All low alloy steel with a material thickness up to several decimeters can be cut with this process. Despite the increasing significance of the other cutting processes such a plasma and laser cutting, oxyfuel flame cutting is still a very economical process. For heavy material thickness up to 35ich (900mm) there is no alternative to flame cutting.

Machine flame cutting ensures reliable hole-piercing, high cutting speeds and allows the production of components to their finished sizes without the need for the further processing. For weld seam preparations V, Y and K cuts can be produced.

CHARACTERISTICS:

Plate thickness: 3mm to 900mm. Typical: 10mm to 300mm.

KEY FEATURES:

Good cut quality Smooth, vertical planes of cut

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Carbonizing and hardening within the area of the heat affected zone High heat input Limited range of material

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Plasma Cutting

Plasma cutting was originally developed for the thermal cutting of materials which were unsuitable for flame cutting, suchas high alloy steels or aluminum. Today, the process is also used for the economical of thin, low alloyed steels.

One common description of plasma is to describe it as the fourth state of matter. We normally think of the three states of matter as solid, liquid and gas. For a common element, water, these states are ice, water and steam. The difference between these states relates to their energy levels. When we add energy in the form of heat to ice, the ice melts and forms water. When we add more energy, the water vaporize into hydrogen and oxygen, in the form of steam. By adding more energy to steam these gases become ionize. This ionization conductive, ionized gas is called a plasma.

The plasma cutting process, as used in the cutting of electrically conductive metals, utilizes this electrically conductive gas to transfer energy froman electrical power source through a plasma cutting torch to the material being cut.

The basic plasma are cutting system consists of a power supply, an arc starting circuit and a torch. These system components provide the electrical energy, ionization capability and process control that is necessary to produce high quality, highly productive cuts on a variety of different materials.

The power supply is a constant current DC power source. The open circuit voltage is typically in the ranger of 240 to 400 VDC. The output current (amperage) of the power supply determines the speed and cut thickness capability of the system. The main function of the power supply is to provide the correct energy to maintain the plasma arc after ionization.

The arc starting circuit is a high frequency generator circuit that produce an AC voltage of 5,000 to 10,000 volts at approximately 2MH. This voltage is used to

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Create a high intensity arc inside the torch to ionize the gas, thereby producing the plasma.

The Torch serves as the holder for the consumable especially nozzle and electrode, and provides cooling (either gas or water) to these parts. The nozzle and electrodeconstrictand maintain the plasma jet.

CHARACTERISTICS:

Plate thickness: 0.8mm to 150mm. Typical: 3mm up to 75mm.

KEY FEATURES:

Low to high cut quality Smooth, edge surface Metallurgical perfect surfaces for welding Medium Heat input Excellent Cutting speed Hardening within the area of the HAZ Wide range of material

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Plasma Cutting

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Laser Cutting

The laser cutting process uses a strong focused laser beam, produced by a laser diode. The high energetic laser beam heats the surface of the material and melts rapidly a capillary responds to the diameter of the used laser, during the cutting process, an assistant gas is used to eject the molten material from the kerf. As a result, the cut quality and speed are very high compared with other cutting technologies.

Flame Oxygen Cutting by contract, is characterized by the fact that the material is only heated to its ignition temperature. Oxygen is used as cutting gas, so that the material burns and forms as oxide which melts through the additional energy from burning. The cutting oxygen then forces the slag out of the cut. Typical material is, for example, low alloy steel (Mild steel).

For Fusion Cutting, the material is melted directly by the laser beam. As the sublimation cutting, an inert gas, usually nitrogen, is also used here to force the molten material out of the cut. This process is typically used for alloyed steels (stainless Steel).

All processes have in common that, because of the narrow focus of the laser beam, the width of cut is very small compared to the other thermal cutting processes. Thus minimum material is melted and the laser energy is used very efficiently. The heat input into the material is thus relatively low so that even small geometries can be cut.

In addition, the cut edge is relatively straight which in all gives very high componentaccuracy from the cutting process.

This means that laser cutting is used in the most diverse areas, especially wherever high accuracy for the componentgeometry and the cut edge is required. The preferred range for steel sheets is up tp a material thickness of 20mm under certain circumstances up 25mm. n For this application mainly the co2 laser and

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Fiber Laser are used. For greater thickness, Laser cutting only makes sense for special applications, more unusually other cutting processes are used here.

CHARACTERISTICS:

Plate thickness: 0.1mm to 25 mm. Typical: 1.5mm up to 20mm.

KEY FEATURES:

Laser light can be well focused from 25mm to 0.2mm. Laser radiation: coherent, monochromatic, high energy Very high power density The light melts or partially vaporizes the material and an additional gas

stream blows it away High to medium cut quality Smooth to rough, vertical planes of cut Metallurgical perfect surfaces or metallic blank surfaces Low heat input High to low cutting speeds Hardening within the area of the Heat-affected-Zone Dust as well as UV and IR-radiation

HAND TORCH17 | P a g e

For local and for more comfort of Cutting Hand torch is used for cutting materials. Usually Hand torch works on oxyfuel only hence it can also cut thickness of about 300mm also.

Here the oxyfuel mixture, oxygen and fuel gas is used. Gas regulators are used to adjust the flow of the Gas in the torches.

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OmniMat

For large working areas and square or bevel cuts using oxyfuel or plasma, the OmniMat is the ideal machine. A full spectrum of marking processes is, of course, also available.

OmniMatis a large size CNC cutting machine with a heavy-duty structure and multi axis control, suitable for a wide field of applications and complicated cutting jobs. A number of different torch suspensions with tool holders is available, e.g. marking tools, punching and drilling devices, strip cutting attachments, triple torch or rotating triple torch, plasma arc contour bevel unit.

The CNC cutting machine has a sturdy portal design, positive bilateral longitudinal drives and a precise machine guiding profile, providing you high cutting accuracy and contouring precision.

Whether you want to cut with oxy-gas, underwater or dry plasma, whether straight cuts or weld preparations, the OmniMat offers you the ideal solution. The patented Global Rotator, equipped with advanced 5 axis robotic compound

Movement control technology, is ideally suited for "V" & "Y" contour bevelling

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with only one pass. This greatly reduces fabrication time and milling after the cutting process is now superfluous.

The system is now widely used in industries such as shipbuilding, heavy industry, engineering equipment, etc.

Key Features:

Depending on the machine equipment a working width up to 12000 mm can be reached

Stable construction to guide even the heaviest equipment accurately Linear guides on the bridge give smooth and precise cuts Designed with the most modern CAD tools for optimum dynamic

performance and maximum robustness High performance AC drives for speeds up to 35 m/min and high

acceleration Increased productive times through highest acceleration and positioning

speeds The system is characterized by its high durability

MultiTherm20 | P a g e

The MultiTherm is the workhorse amongst the Messer cutting range for top quality and productivity.

Whether plasma (straight or bevel), multi-torch gas cutting, marking or a combination of all is your requirement, the MultiTherm is THE machine for you. This powerful CNC-controlled machine is suitable for a wide range of applications. Twin sided longitudinal drives ensure high quality cuts.

A wide choice of marking processes means you can pick the ideal one for your production. Naturally multiple torch cutting is possible in both oxyfuel and plasma modes for high productivity.

Key Features:

The 35 m/min high power drives give fast positioning and accurate cuts, even around fine contours

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The ability to park unused heads over the wheel housings maximizes plate utilization with the heads used

Working widths up to 4 m Cutting Speeds up to 35 m/min Working lengths virtually unlimited Cutting Processes: Oxy-fuel, Dry Plasma, WIPC, Laser Bevel Cutting Units: Skew, triple torch unit N Marking Processes: HF Punch, Powder Marking, Plasma Marking, vibrating

stylus type Omni Script, Inkjet Wide range of equipment options available Very efficient Excellent dynamic performance and accuracy Light enough for high cutting speeds and accelerations Strong enough to take bevel cutting heads for oxyfuel and plasma Hoses and cables lie inside the bridge for safety and neatness Integrated transverse linear guide and rack for reduced wear and smoother

drive Latest cnc control for increased operator comfort and efficiency

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Plasma and Fiber LaserCombination

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Combination of plasma and laser

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OUR OBSERVATIONS IN SHOP FLOOR

We have spent almost three days of training in shop floor. It was very useful one we have observed a lot and also gained more knowledge. We got an opportunity to observe how the cutting machines are assembled and how they are checked.

We also observed how the gas regulators for different gases like oxygen, acetylene, carbon-dioxide, LPG are made and how they are tested. We have also come through the assembly line of the gas regulators, and it equipped with modern features and also seen how the standard of Messer is maintained, the workmen said actual cutting pressure is very low when compared to the pressure that they are actually testing on the gas regulators, we have also seen gas boosters for the purpose of boosting the gas to the required very high pressure.

We have also come through the laser zone, in this zone we have seen two advanced cutting machines swift blade and fiber blade, and also seen the working. The work men in the shop floor explained the working of both swift blade and fiber blade, it was very interesting and we were understood how the laser source if have been used for cutting purpose.

The cutting speed for swift blade is very high when compared to other models, this feature was awesome. The workmen operated the sift blade and explained the rest. We also have seen the assembly were the cutting machines and assembled checked. The assembly of each and every machine in unique, the models name are same but there was some difference between each and every machine.

We have also come through how the cutting machines are checked for there the cutting accuracy like diagonal test which is almost done for more number of times. The test for rack and pinion (Butter paper test).

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PROCUREMENT DEPARTMENT

For every manufacturing and Mass Production Company the procurement department is very important one which confirms the smooth running of production and assembly without any demands. It play a vital role in smooth running of the company and confirms that required components and materials are stored in store room for the required demand.

In Messer in procurement department how they select the contractors and how they order in respective to the project time, it includes the mode of transport also. The most of the products in Messer are imported from Germany, USA and some other European countries hence in Messer Procurement department plays a vital role for the smooth running of the firm.

The people in this department explained how they order the components and materials respective to the project lead time. The main important thing required for procurement department in bill of materials and make or buy decision. Which involves selection of the make and buy material. Procurement department also a vital role in satisfying customer expectation.

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QED DEPARTMENT

In Messer quality is not checked but it is inbuilt in every process for the manufacture of the component hence here quality is not checked but it is produced internally. The Quality Engineering Department is very interesting one and also very important to ensure the quality of the machines. The main duty of the quality engineering department is to build quality inside the process and very work that includes the manufacture of the machine.

Hence the quality is need not to be checked, because the quality is built inside through every process and work. We have not seen any kind of actions and process to check the quality in Messer. Because the quality build inside the each and every manufacturing process.

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MAINTANANCE AND SERVICE DEPARTMENT

In these departments we have come through how the maintenance of the plant is done and the services of the machines is done. They explained how the maintenance of this done and how the electrical supply is done to the Messer. And also about the building area which includes all the blocks.

We have understood in Messer maintenance department is giving more important to cleanness and good gardening. Which makes the Messer as a Heaven like working environment it was very good for the company and also for the people working in this firm and for the development of the company also.

The service department play a major role in getting good reputation from the customers. They have doing a great job by keep the promises that given to the customer while the machine is delivered to the customer. The service department takes the full charge of the machine when machine is delivered to the customer.

They have service engineers to service the machines in cyclic period and to also undergo any type of service when there is any malfunction in the machine, Which will affect the manufacturing ability of the company. The role of the service engineers after the delivery of the machine is very important. By providing very good service to the customer and replacing of the components which can become repaired.

Service Department offers a preventive maintenance (PM).  Tailored to meet your needs, the PM may be set up for regularly-scheduled or as-needed visits, or both options. Your systems are regularly adjusted and calibrated to ensure optimum performance. Potential problems can be addressed before they become issues that affect your productivity.

It can also help with budgeting as you will know your yearly maintenance costs in advance. Our systems are designed for long productive lives. However, this requires proper maintenance and service.

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Make sure of a high level of production reliability and avoid problems by inspections and preventative maintenance.

Key Features:

Systematic inspections Tests Performance Measurements Detection Adjustments to retain a functional unit in such a specified state that it can

perform its required functions Correction and prevention of incipient failures, before they become actual or

major failures

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Finance Department

In Finance Department we had learned how the financial status of the company is maintained and how the entire process is done. The Company Secretary and the staff explained about the entire process.

It is very big challenge for that employees to maintain and to show good economic status of the company in the world. It a big challenge in this Developing Nation. They also see the legal activities of the company regarding any problems.

They also have explained how the shareholding process is done and how it is working regarding the current status of the company. And they also perform money transform between the company, customer, contractors, etc., and they esnusre that all the money transfers are legal without any illegal activities. The Finance Department Play an important role in the smooth running of company without any economic crises.

Store

In Messer we had gone through store which supplies all the materials required for manufacturing, assembly and all the department. They explained how the store functions and how the materials are arranged in the store. They told that if a workmen shows required papers from the respective department then he/she will be able to take the required material without any interfere.

And the special feature of the shop is also is it is a open shop. It enables it to perform on full sing.

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GAS REGULATORS

Messer cutting systems are pioneers in manufacturing Gas regulators. The regulators manufactured by Messer Cutting Systems totally differ from other manufactures. They have three safety measures induced in regulators which is not found in any other manufacturers.

It consists of boosters which is used to convert small pressure into larger pressure Since Propane and Acetylene are generally considered to be explosives this safety measures are taken. Mostly industries uses propane instead of acetylene because cost of propane is minimum when considered to Acetylene .But efficiency of acetylene is greater than efficiency as propane

One of the safety measure is flash back arrest, this flash back arrest is mostly used in all Gas regulators.

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Regulator nose in the gas regulator is called as Bull nose. While cutting 150 bar pressure is compressed in the cylinder. While Oxygen is connected to 10 bar output. Cylinder pressure is shown in the inlet gauge .In propane gas 0.5-1 bar is enough to cut a material .Safety valve is used to avoid damage to the workers .Other measure taken for the purpose of safety is that all gas regulators consists of micro filters .

Some of the torches manufactured are Essen torch, Star cut torch, and Profile cut torch, Star cutting attachment.

Acetylene has low density so separate valve is used in the gas regulators.

Material used to make that acetylene valve is EPDM.

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THANK YOU

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