Project on Bullhead Hammers

8/12/2019 Project on Bullhead Hammers

1/55

PROJECT REPORT

ON

G HE CHG FE F B HEAD HAE (CH

G HAE ED E A) .

P

S P,

B..EAM (M) ES&F D. SP.

SBMITTED B

G.LALITHA DEI 105

K.NAGAMBICA 106

E.LAKSHMI PARATHI DEI 107

P.DEI DRGA 108

D

M & M E


2/55

RGKT IIIT

NID521201

AHAAA EE A

CEFCAE

T E HE

CHG FE F B HEAD HAE (CHG HAE) ED

E A B

AE F HE DE AD BE

G.AHA DE 105

.AGABCA 106

E.AH AAH DE 107

.DE DGA 108

.., (), &,

, .

00 000.

G

. B.. EA


3/55

A GADH E F EDGE ECHGE

(AP G A 18 2008)

M R ,N,K D 521202

D M & M E

CERTIFICATE

T D I C B H

H

E...DE(081195),G.AHADE(081263),.DEDGA(081974),.AGABCA(081187) O 3 2013

F B.T M & M E

O R G K T

.

HEAD F HE DEAE (E)

D. A. A


4/55


5/55

ACEDGEE

. B..EA, M

(M) ES&F D. S P .

. .AGABHHAA, S M (ES&FF S), D.

S P

.

. AABABES&F D.

S P

.

ES&F

D. .


6/55

ABSTRACT

S 700 ,

. A

. H

G HE CHG FE F B HEAD HAE S SP.

O ES&F,

,

.

T

. F

SAIL

50CM4 100 . & . I

CMS .

H

.


7/55

CE:

1. ABSTRACT

2. INTRODCTION (SP)

. P SP

. L

. M

. M . M T

3. E S F.

. C M S.

. F S..

. S .

. F

. E R S.

4.BLL HEAD HAMMERS.

. I.

. .

. P .

D.

5.REASONS AND SGGESIONS


8/55

DC

S P

, NH5 B B

,

.T

, I

.N

T , , . A

. T R I

N L, 18F

1982.

I I 16 K

.. .E , SP

3 M T L S 2.656M

. A SP

,

I . SP

JIS, DIN, BIS,BS .

SP 1 S I

ISO9002 .T

. M, , T

M 4 R M .20

22 .SP

R.460 C E C

E 3

, T , ,

3 4 . SP I S , M,

N, M E, SA&S E A( ). RINL SP "S

T H " 19972000. H

.


9/55

SP . H

17250 SP

S

.

MAJOR PLANT FACILITIES:

:

4 67 41.6 M3 .

2 S 312 M3 .

3 B 3200 M3 .

S M S L.D. 150 T 6

N0. 4 .

L M M M 710000 T .

850,000 .

M M & S M 850,000 .

B 286.5 M, O

, A A ,

SP.N B. A

SP C B , 7 M 67 O . E

41.6 3 & 31.6 T .

MINOR DEPARTMENTS:

P .

.

T .

E .

.

Q

C .


10/55

MODERN TECHNOLOG:

S

. M

, . A :

S

7 .

D .

O .

C ,

, 100%

G

.

H .

E

.

C .

S , .

MAJOR DEPARTMENTS IN SP:

1)A AEA HADG A(H):


11/55

SP ,

, . 1213

3 . T

SP ,

. T ,

T, G T H ,S

C P , S, S ,

B R .

(RMHP) O F, I O L, S

I O, L (BF SMS ), D (BF SMS ), D ,S, Q , M L F F .

MAJOR SORCES OF RA MATERIAL

I O L & F B , MP

BF L J , A P

SMS L S AE

BF D M, AP

SMS D M , AP

M O C , AP

B C T , O

C C A

M C C (MCC) G /S/R/K


12/55

:

C : I M, M

: I O F, L (BF), D, S M F.

B F: S I O , L(BF), M L, Q.

: D (SMS), F S I O

C: L (SMS), D (SMS), D C

: B C.

CCC:I , .

T

.

HE FACE AAABE EC AE A FA:

CA HADG A E HADG A

2 T . 3 T.

5 G & 10 T H. 10 G& 10 T H.

S (10 ). S (12 ).

B . L .

S , R L . C

R.

R C. R C

S C. S C.

AE FEAHE F H:


13/55

P

.

B

.

CHP.

T

T

PLC

D SMS

P BF

D RMHP

.

A AEA ECFCA:T I O

B

D.

H :

A AEA

1 IRON ORE FINES

2 IRON ORE LMPS

3 SIED IRON ORE.

4 LIME STONE (BF )

5 LIME STONE (SMS )

6 D (BF )

7 D (SMS )

T CH :


14/55

A AEA

1.

2.3.

4.

5.

I

I M

P

B .

2.CE E AD CA CHECA A(C & CC):

B F,

,

.

C

10000 16 18 . T

B, A .

BF , LD . A

, .

A


15/55

. I

, , . .T

.

A SP , 7

67 . E 41.6

31.6 . T 10000 10500

16 18 .

R

. T

50 52 TPH. N . T

7.5 M .

T ( ), (

) , . CO

. A ,

BF , LD , . A ,

.

BAEE:

O (T)

C () 16

H (103 K/NM3) 6.86

C. (K /NM3) 1000

CE D CG A:


16/55

T , . C 5052 TPH. E

,

, .

T . R

. G

. T

. C ,

.

1) T ( ) 9501050

2) T (0 ) 200250

3)S (T/) 2025

CE G A:

F ,

. F ,

. H +70 70

. T +70 .T

70

2570 025 .25 70

.B 600

.

0 25

.N

.B .

CE :


17/55

&

.

1600 1400 1200 1000 800 650 500

Q 9 49 6 11 4 2

T 87

T L 15000

3.E A ():

S

,

. S

, ,

, M F , M , LD .

S 2 . 312 ,

D L

1200013000.


18/55

H

5 50

.

EG CE: P .

M &B.

M

.

C .

I .

F CHG A:

F H L D


19/55

4.BA FACE(BF):

H , . T

B F .

R , , (, )

11000 13000 5.75 KSCH

. T 80% .

SP 3200 (

I) P B .

R G K A.P ,

A P.

P 100%

(1.5 2

) 12 M

.

T

9720 3.4 MT S

.


20/55

5.EE EG H():

1.8%.H

C (3.4 4.25%) ,(0.4

0.5%) M(0.3 0.4%), (0.04% )

(0.04% ) E M.T , .

LD (L D L D A

) B O F /C.

133 . 3 MT

. B , ,

.

199.5% 1516 KSCG

.

. D

. ,, C


21/55

17000 .

D

FS, FM , SM, , AL . . /LD

.

CHAACEC F CEE:

C 150 T /

133

C . 0.886

T 45 60

H 1.36

L T D

L LD C B . H,

, , A ,

IRT(I & )/L F.

6.C CAG DEAE:


22/55

C

/ (S

& )

.

F

, , , &

,

(A.6 ).

A SP 64

2.82MT / 250250

250320.E (100%)

.

7.G :

BLOOMS SMSCCD


23/55

, , ,

( &), , IPE , HE BEAMS ,

, , ,

, L & M , M M(LMMM), R

M(RM) M M S M(MMSM).(A)GH AD ED ECHA ():

L M M M (LMMM)

(+5.0 MTS).T

.T

. .B

LMMM (3 ) 150

16 (2 ).A

(+5.8 ) (+.8 ).T

, .T

.

H

. H

. B 125 7 ,


24/55

1.3 1.6 /. B LMMM .

I LMMM RM

, T 710,000

, , , , ,

.

(B).E D () :

R M 4 , 25

. T (

) 200 TPH

LMMM 1200 C. T 4

. N 8,50,000 R

.

7 4

6 4

2 4

1 4

T 5.5 12 8

12 .T

,

., BIS, DIN, JIS, BS .,


25/55

, .

(C)ED ECHA AD CA ():

T 20 3

.

R 8 (4 , 2

2 ).

I 6 . 2 .

2 .

2 / .

6 .

2 .

4 /4 .

T 250 250 ,

1200 C , , , ,, .


26/55


27/55


28/55

2.FGE H

I: I , SMS, , .

P S: R , , , , ,

, SMS, .

T , :

. , , ,

. T . T

2,400 O 300

. T , ,

.

I , ,

, . 2

. E .

F C . I

, 1 , 500 K, 200 K

. A 2

. . F , ,

. F ,

.

3.EE CA H:

I: S , , , .

& : A , SMS, M. A SMS, M. O SMS

, SMS,500 SMS, . KAMAG

FMD. R LMMM, RM. T

4,500 ,

, , , , . 5,100 T.


29/55

F , , ,

, , . , F ,

. P

. , . . A

, , .

.

4.FD:

T SP

SMS, ,

, , . T

. T

. T SP

SP

. R

.

A ,

12000 T 5400

T , 6240 T 360 T . K

.

T :

T 10 T.


30/55

T 10 T.

T 1T.

C

25 , 160

.

AB B : R

BC B : S ,

CD B : M, ,

DE B : F

EF B : H

5) EE EA H (E):

:S, P , C, A , B, B, R F

S S, S & I .

DC AD ECE:

M I ,

GCP ID F, R S SMS, C D , & ,

, C I, PCM R .


31/55

CEA AG EC (C):

C E S & F

ESF

, , . D C

S , .

P , MBC .

P .

I B (B/D), MBC .

I / 5 . D .

B/D .

M MBC .

P .

C .

L ESF.

A MO .


32/55

BULL HEADBULL HEADBULL HEADBULL HEAD

HAMMERSHAMMERSHAMMERSHAMMERS


33/55

B HEAD HAE

CE ED EAA F BHEAD HAE:

T B H H,

SAIL 50CM4 6000100100

C S M.

CG EA HGH CD HEA ACHE:

B C S M (216) .

COLD SHEAR MACHINE


34/55

C M B 216

CE F EAA F B HEAD HAE:


35/55

DEA F B HEAD HAE

B HEAD HAE DAG :

50 C M04

17.5.

BILLET COLD SHEARCUTTING MACHINE

BARS

FURNACE(HEAT TREATMENT)

MANIPULATOR(TO TRANSPORT THE BARS FOR

FORGING & TO HOLD WHILE FORGING)

BULL HEADHAMMERS

INSPECTION

ANNEALING

HEAT TREATMENT

DRILLING


36/55

O ES&F B H H

D L.

T H F S C M

S. I F , ;

CMS

.

T B H H SNL, BHADRAA

THI , 50CM4.T B H H

17.5.A 60 .

B HEAD HAE

:

H .

H . P


37/55

.

S .

T 17.6

H 380500 BHN.

AE EED B BHH AE :

. H

. T

.

.

HADE: I . I / .I S

. N/2 .

380 0 500 BHN . I .

GHE:I .

T

. S .

EA EACE: B . . BLL HEAD.

AE EE EGH: T .T

. T . T

. T

BHH

.


38/55


39/55

A

,

. T

. T . H

. I

. I ,

, .

T

. I

. T . D ,

. I

, ,

.

T

.F

2,I ,

. A

. C ,

,

.

BA F EECG 50C 4 A A AEA F B HEAD

HAE:

C F 50C4:

C : 0.460.54

S : 0.150.4


40/55

M : 0.50.8

P : 0.03 M

S : 0.03 M

C : 0.90.12M : 0.250.3

CH(C) T ,

. C

. T C

.A

.

BD() I .

I .M

,N .M

. E

.

C I . .T

, ,

.

AGAEE , .

.

HEDED AEAG T .

A ,

. T

.


41/55

CE F F BHH:

T

S B

H 12500

F

A

I

T CMS

D 50

H

T

S

I

T

THE PROCESS INVOLVED IN FORGE SHOP:THE PROCESS INVOLVED IN FORGE SHOP:THE PROCESS INVOLVED IN FORGE SHOP:THE PROCESS INVOLVED IN FORGE SHOP:

L 3 .

H (230 246) 170 BHN.

S . 100100127 .

H 12500 /

.

, .

O 90 . S

193.5 . . A

BHN BHH . 350 BHN.

A 350

220.S . R

, 8500 .


42/55


43/55

BGE HEAH FACE :

T

. B ,

.

T ,

. A ,

. T

.T

, , .

A :


44/55

L P G

P C S C

I

N

T= A1

T=D

T

C /A

1. P S =7000C , 46 .

2. T S =8000C , 1015 .

:

. F

M FINE GRAINED STRUCTURE

. N

. M , T,S .


45/55


46/55

F C :

= C + (M)/6 + (C+M +)/5 + (N+C)/15

= 0.5+0.108+(0.51+0.275+0)/5 +(0+0)/15

= 0.760

0.760 C %.F FF3C

768

0

.B +60

0

, 8280.


47/55

HADEG F CAB EE:

T

H .

H ,

.

T H.

1.The Hammers upto 6000c+ at a constant rate of 1500c/hr.

We know that 6000c is a recrystallization temperature so we have to heat toupto 6000c.

H:

T

(D , ).

T .

H A3 (727910 0)

.


48/55

A A1(7270) .

H:

H F S

P F

. A ,

. I

:

1. T

.

2.T

3. T

.

2.Soaking at 6000c for 30mins.

.

T ,

.

S Homogeneous

austenite.

3.Raising the temperature from 6000c to 8750c at 1000c/hr.

8750

. 1000/

.

A3?

H

A1& A3, A P

F A M


49/55

F. S F ,

, .

4.Soaking 875+250c for 2hrs.

,

20 .

2

.

5.Quenching in water upto 100mm

.

?

R

.O M .A

, , .

.


50/55

HEA EAE CCE F EEG:

?

T

. T,

.

T retained austenite

.

Tempering is done in carburising furnace.

1. Heating the job up to 350+25at a const rate of 1001. Heating the job up to 350+25at a const rate of 1001. Heating the job up to 350+25at a const rate of 1001. Heating the job up to 350+25at a const rate of 1000000c / hr .c / hr .c / hr .c / hr .

E F EEG:

T

(. A M )

,

.


51/55

T , & .

T A.

:

H A1.T

100 & 7000.

(12 ) , .A

, M A.

M A

. T

. D , :

) L 1002000

) M 2005000

) H 5007000

:

D , C

.

1. T A

& . T A

MT

A. T .

2. T M D F

C. T F3C

.

3. T

. T

3500 ,

5000.T

.


52/55

2.Soaking 350+250c for 1hrs.

,

20 .

1

.

3.Air cooling.3.Air cooling.3.Air cooling.3.Air cooling.

T .

I , ,

. T

.

DISPATCH TO SINTER PLANT:DISPATCH TO SINTER PLANT:DISPATCH TO SINTER PLANT:DISPATCH TO SINTER PLANT:

O B H H

. T

.


53/55

T .T 45

H C L D

03 .C .T

.

BHH:

:

I

.

F :

B .

.

H

REASONS AND SUGGESTIONS:REASONS AND SUGGESTIONS:REASONS AND SUGGESTIONS:REASONS AND SUGGESTIONS:

H .F

,

. A .

H BHH

.I 573 BHN , 451 15 30

388 . T

.B .

GGE AD DEFEC HE CEG HE CHG FE:

I .

T .

F .


54/55

H

, .

We will also increase Crushing life of Hammers byWe will also increase Crushing life of Hammers byWe will also increase Crushing life of Hammers byWe will also increase Crushing life of Hammers by

:

A BHH BHH

T.S CR50 MO4

.

:

A

.

:

P

. A

.

:

A

.


55/55

Documents

Project on Bullhead Hammers