HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. LTD.

1. COMPANY OVERVIEW:

FIGURE 1: SWAJIT ENGINEERING PVT. LTD

It is a pleasure to introduce SWAJIT, as a leading 'Customized solution provider
for Industrial chains. Swajit Engineering Pvt. Ltd. is based at Aurangabad (M.S),
India. Swajit has evolved in as the leading Conveyor chain manufacturer,
Conveyor chain supplier & Conveyor chain exporter of all type of Roller conveyor
chains and any types of Link, Pin and Bush mechanism for Material handling
systems. Also SWAJIT manufacturing 2", 2.5", 3" & 3.5" Simplex, Duplex &
Triplex transmission chains.
Since the inception in 1992;Swajit is equipped with latest technology
comprising state-of-art-plant with all Infrastructure facilities & processes,
advanced metallurgical laboratory to manufacture all types Conveyor chains and
Slats of
finest quality.
Swajit has a dedicated and technically qualified team of experienced Engineers &
Metallurgists for fulfilling precisely the customers needs on the continuous basis.
We have developed an expertise to provide a wide range of Conveyor chains and
its components for diversified industry segments like Sugar, Cement, Automobile,
Steel, Solvent, Boiler& Thermal power plant, Co-generation, Bakeries, Asphalt,
Breweries, Chemical & Fertilizers, Bottling, Food Processing, Agriculture,
Mining, Paper and Allied Industries.
Excellent Quality is Swajits inherent strength and in a journey of two decades
organization has strongly emerged as the unchallenged leaders in the ever-growing
Indian Market and we are now looking beyond the boundaries to increase our
business in the Global market. Organization has attained this niche position by
creating the best products to exceed customer expectations, creating everlasting
Customer Satisfaction with trust and service to generate repeated orders. Swajit
adhere to global business practices and also an ISO 9001: 2008 company certified
by TUV NORD (Germany).
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HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. LTD.

Organization has a list of valued clients and look forward to add your distinguished
name into it, hence requesting you to solicit your enquiries. Swajit assures
excellent solutions to specify your specified requirements supported by timely
delivery. They are looking forward to build a technically proven & mutually
beneficial relationship in future.
(A leading Conveyor Chain Manufacturer, Supplier & Exporter of all type of
Roller conveyor chains, Transmission chains & Slates since 1992)

HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. LTD.

2. OBJECTIVES

To study production planning and control practices used during Heat

Treatment processes at Swajit.
To study the shop floor management during handling heat treatment
operations at swajit.
To check the strength, hardness and wear resistance of material.
(Bulk hardening, surface hardening)
To check toughness of the material. (Tempering, recrystallization annealing)

HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. LTD.

3. INTRODUCTION TO SWAJIT PLANT

Since the inception in 1992;Swajit is equipped with latest technology
comprising state-of-art-plant with all Infrastructure facilities & processes,
advanced metallurgical laboratory to manufacture all types Conveyor chains
and Slats of finest quality. Swajit has a dedicated and technically qualified
team of experienced Engineers & Metallurgists for fulfilling precisely the
customers needs on the continuous basis. We have developed an expertise
to provide a wide range of Conveyor chains and its components for
diversified industry segments like Sugar, Cement, Automobile, Steel,
Solvent, Boiler & Thermal power plant, Co-generation, Bakeries, Asphalt,
Breweries, Chemical & Fertilizers, Bottling, Food Processing, Agriculture,
Mining, Paper and Allied Industries.
Overseas Market

01.
02.
03.
04.
05.
06.
07.
08.
09.
10.
11.
12.
13.
14.
15.

Philippines
Mauritius
Malaysia
Uganda
Kenya
Tanzania
Zambia
Indonesia
Rwanda
Ethiopia
Spain
Jamaica
Sudan
Nepal
Vietnam

HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. LTD.

FAQs
Product range?
- Pitch 75 to 400 mm.
- Breaking Load 10 to 250 ton.
Delivery time?
- 8 to 10 weeks.

MISSION
1. Providing products as complete solutions.
2. To become a leading name in global market by Best performance.
3. To become the first choice for the established trade.
4. Be Accountable for Human resource development, occupational &
Customers health & safety.

VISION
1. To establish as a brand associated with quality and consistency in
Manufacturing all kind of chains in Asia & Europe by 2020.
2. Perfect Implementation of Occupational Health and Safety
Management System (OHSAS).
3. Improving employee skills, involvement & Quality of Life (QOL).

VALUES
1. Ethical Business Practices.
2. Excellent Services.
3. Continuous Customer Focus.
4. Technology Enhancement.

HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. LTD.

Customer Segments:Type of chain

1 Automobile
1. Slat conveyor chain
2 Boiler and Thermal Power plant
1. Ash handling chain
2. Coal Handling chain
3. Gate chain
4. Travelling Grate chain
3 Cement Industry
1. Drag & Flow conveyor chain
2. Paul retarder & retarder chain
3. Bucket Elevator chain
4. Pan Conveyor chain
5. Reclaimerstaker chain
6. Deep bucket conveyor chain
7. Enemas conveyor chain

4 Chemical and Fertilizer

1. Conveyor chain for coal feeding
2. Feeder breaker chain for Collieries
3. Bucket elevator chain for Fertilizer

5 Solvent Industry
1. Bucket elevator chain
2. Drag chain
3. Extractor chain

6 Steel Industry
1. Cooling bed conveyor chain
2. Transfer bed conveyor chain
3. Conveyor chain for cold draw bench
4. Mandrill insert chain
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HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. LTD.

5. Shell pusher chain

6. All types of conveyor chain
7 Sugar Industry
1. Baggase carrier chain
2. Block type & inter carrier chain
3. Cane carrier chain
4. Feeder table chain
5. Sugar elevator chain
6. Sugar bag staker chain
7. Slates and fabricated rake
8 Other Applications
1. Agriculture
2. Food Processing
3. Bakeries
4. Home Appliances
5. Paper mill
6. Amusement park

FIG.3.1 VARIOUS CONVAYER CHAINS

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HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. LTD.

4. HEAT TREATMENT
Heat treatment is an operation or combination of operations involving
heating at a specific rate, soaking at a temperature for a period of time and
cooling at some specified rate. The aim is to obtain a desired microstructure
to achieve certain predetermined properties (physical, mechanical, magnetic
or electrical).
Fundamentals
Fe-C equilibrium diagram. Isothermal and continuous cooling
transformation diagrams for plain carbon and alloy steels. Microstructure
and mechanical properties of pearlite, bainite and martensite. Austenitic
grain size. Hardenability, its measurement and control.
Processes
Annealing, normalizing and hardening of steels, quenching media,
tempering, Homogenization. Dimensional and compositional changes during
heat treatment. Residual stresses and decarburisation.
Surface Hardening
Case carburising, nitriding, carbonitriding, induction and flame hardening
processes.
Special Grade Steels
Stainless steels, high speed tool steels, maraging steels, high strength low
alloy steels.
Cast irons
White, gray and spheroidal graphitic cast irons
Nonferrous Metals
Annealing of cold worked metals. Recovery, recrystallisation and grain
growth. Heat treatment of aluminum, copper, magnesium, titanium and
nickel alloys. Temper designations for aluminum and magnesium alloys.
Controlled Atmospheres
Oxidizing, reducing and neutral atmospheres.
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HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. LTD.

4.1 Hardening
Hardening is performed to impart strength and hardness to alloys by heating
up to a certain temperature, depending on the material, and cooling it
rapidly. Steel is heated up to austenitic region and held there until its carbon
is dissolved, and then cooled rapidly, the carbon does not get sufficient time
to escape and get dissipated in the lattice structure. This helps in locking the
dislocation movements when stresses are applied.
Quenching is performed to cool hot metal rapidly by immersing it in brine
(salt water), water, oil, molten salt, air or gas. Quenching sets up residual
stresses in the workpiece and sometimes results in cracks. Residual stresses
are removed by another process called annealing.
4.2 Annealing
Annealing is performed to reduce hardness, remove residual stresses,
improve toughness, restore ductility, and to alter various mechanical,
electrical or magnetic properties of material trough refinement of grains.
Cooling rate is very slow around 10oC per hour. Process is carried out in a
controlled atmosphere of inert gas to avoid oxidation. Partial annealing is
incomplete annealing and there is partial phase transformation however in
sub-critical annealing there is no phase transformation. Used to achieve
ductility in work hardened steels.
4.3 Normalizing
The process is similar to annealing and is carried out to avoid excessive
softness in the material. The material is heated above austenitic phase and
then cooled in air. This gives relatively faster cooing and hence enhance
hardness and less ductility.
In this process, austenite is decomposed in ferrite and carbide at relatively
lower temperature and fine pearlite is produced. Normalizing is less
expensive than annealing. In normalization variation in properties of
different sections of apart is achieved. The selection of heat treatment
operations is strongly influenced by the carbon content in the steel. Heat
treatments on phase diagram of steel.

HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. LTD.

4.4 Tempering
Martensite is very hard and brittle. Tempering is applied to hardened steel
to reduce brittleness, increase ductility, and toughness and relieve stresses in
martensite structure. In this process, the steel is heated to lower critical
temperature keeping it there for about one hour and then cooled slowly at
prescribed rate. This process increases ductility and toughness but also
reduces hardness, strength and wear resistance marginally. Increase in
tempering temperature lowers the hardness.
4.5 Surface Hardening
Heat treatment methods in general change the properties of entire material.
Hardening improves wear resistance of material but lowers impact resistance
and fatigue life. Therefore sometimes there is requirement of surface
hardening Two methods are used, first is heating and cooling to get required
phase, and second is thermo-chemical treatment. Induction heating Flame
hardening High frequency resistance heating Laser beam hardening Electron
beam hardening Carburizing Nitriding Cyanding.

.
FIG.4.1 HEAT TREATMENT FURNACE
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HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. LTD.

FIG.4.2 ROTARY FURNACE

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HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. LTD.

5. HARDNESS TESTING
5.1What is Hardness?
Hardness is the property of a material that enables it to resist plastic
deformation, usually by penetration. However, the term hardness may
also refer to resistance to bending, scratching, abrasion or cutting.
5.2

Measurement of Hardness:
Hardness is not an intrinsic material property dictated by precise
definitions in terms of fundamental units of mass, length and time. A
hardness property value is the result of a defined measurement
procedure.
Hardness of materials has probably long been assessed by resistance
to scratching or cutting. An example would be material B scratches
material C, but not material A. Alternatively, material A scratches
material B slightly and scratches material C heavily. Relative hardness
of minerals can be assessed by reference to the Moh's Scale that ranks
the ability of materials to resist scratching by another material. Similar
methods of relative hardness assessment are still commonly used
today. An example is the file test where a file tempered to a desired
hardness is rubbed on the test material surface. If the file slides
without biting or marking the surface, the test material would be
considered harder than the file.
If the file bites or marks the surface, the test material would be
considered softer than the file. The above relative hardness tests are
limited in practical use and do not provide accurate numeric data or
scales particularly for modern day metals and materials. The usual
method to achieve a hardness value is to measure the depth or area of
an indentation left by an indenter of a specific shape, with a specific
force applied for a specific time. There are three principal standard
test methods for expressing the relationship between hardness and the
size of the impression, these being Brinell, Vickers, and Rockwell.
For practical and calibration reasons, each of these methods is divided
into a range of scales, defined by a combination of applied load and
indenter geometry
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HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. LTD.

5.3

Hardness Test Methods:

Rockwell Hardness Test
Rockwell Superficial Hardness Test
Brinell Hardness Test
Vickers Hardness Test
Microhardness Test
Moh's Hardness Test
Scleroscope and other hardness test methodS

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HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. LTD.

Rockwell Hardness Test

The Rockwell hardness test method consists of indenting the test material
with a diamond cone or hardened steel ball indenter. The indenter is forced
into the test material under a preliminary minor load F0 usually 10 kgf.
When equilibrium has been reached, an indicating device, which follows the
movements of the indenter and so responds to changes in depth of
penetration of the indenter is set to a datum position. While the preliminary
minor load is still applied an additional major load is applied with resulting
increase in penetration. When equilibrium has again been reach, the
additional major load is removed but the preliminary minor load is still
maintained. Removal of the additional major load allows a partial recovery,
so reducing the depth of penetration. The permanent increase in depth of
penetration, resulting from the application and removal of the additional
major load is used to calculate the Rockwell hardness number.

HR = E - e
e = permanent increase in depth of penetration due to major load F1
measured in units of 0.002 mm.
E = a constant depending on form of indenter: 100 units for diamond
indenter, 130 units for steel ball indenter.
HR = Rockwell hardness number.
D = diameter of steel ball.

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HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. LTD.

FIG.5.1 ROCKWELL HARDNESS TESTING MACHINE

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HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. LTD.

The Brinell Hardness Test

The Brinell hardness test method consists of indenting the test material with
a 10 mm diameter hardened steel or carbide ball subjected to a load of 3000
kg. For softer materials the load can be reduced to 1500 kg or 500 kg to
avoid excessive indentation. The full load is normally applied for 10 to 15
seconds in the case of iron and steel and for at least 30 seconds in the case of
other metals. The diameter of the indentation left in the test material is
measured with a low powered microscope. The Brinell harness number is
calculated by dividing the load applied by the surface area of the indentation.
The diameter of the impression is the average of two readings at right angles
and the use of a Brinell hardness number table can simplify the
determination of the Brinell hardness. A well-structured Brinell hardness
number reveals the test conditions, and looks like this, "75 HB 10/500/30"
which means that a Brinell Hardness of 75 was obtained using a 10mm
diameter hardened steel with a 500 kilogram load applied for a period of 30
seconds. On tests of extremely hard metals a tungsten carbide ball is
substituted for the steel ball. Compared to the other hardness test methods,
the Brinell ball makes the deepest and widest indentation, so the test
averages the hardness over a wider amount of material, which will more
accurately account for multiple grain structures and any irregularities in the
uniformity of the material. This method is the best for achieving the bulk or
macro-hardness of a material, particularly those materials with
heterogeneous structures.

FIG.5.2 BRINELL HARDNESS TESTING MACHINE

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HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. LTD.

A Brinell hardness result measures the permanent width of indentation

produced by a carbide indenter applied to a test specimen at a given load, for
a given length of time. Typically, an indentation is made with a Brinell
hardness testing machine and then measured for indentation diameter in a
second step with a specially designed Brinell microscope or optical system.
The resulting measurement is converted to a Brinell value using the Brinell
formula or a conversion chart based on the formula. Most typically, a Brinell
test will use 3000 kgf load with a 10mm ball. If the sample material is
aluminum, the test is most frequently performed with a 500 kgf load and
10mm ball.
Brinell test loads can range from 3000 kgf down to 1 kgf. Ball
indenter diameters can range from 10mm to 1mm. Generally, the lower
loads and ball diameters are used for convenience in combination testers,
like Rockwell units, that have a small load capacity. The test standard
specifies a time of 10 to 15 seconds, although shorter times can be used if it
is known that the shorter time does not affect the result. There are other
conditions that must be met for testing on a round specimen, spacing of
indentations, minimum thickness of test specimens, etc.
Test Method Illustration
D = Ball diameter
d = impression diameter
F
=
load
HB = Brinell result

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HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. LTD.

6. VARIOUS DEPARTMENTS OF SWAJIT ENGINEERING

1. PRODUCT DEVELOPMENT

1. Preparations of design drawings.

2. Laying down standards and acceptable norms.
3. Assemble and make new design in development shop.
4. Testing of new design prototype or design verification.
5. Modify old products to suit new market norms.

2.

INDUSTRIAL ENGINEERING

1. Planning related to manufacturing methods.

2. Set up manufacturing facilities.
3. Selection of machines, technologies and process based upon the product and
design requirements.
4. Designing and ensuring availability of tools, jigs and fixtures.
5. Industrial engineering, fixing time standards, computation of manpower and
capacity requirements.

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HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. LTD.

3.

LOGISTICS

1. Receipt and processing of orders placed by sales division.

2. Scheduling - involving assignment of priorities based on urgency and
material availability.
3. Procurement and administration of raw materials.
4. Overall co-ordination between marketing, client, excise etc.
5. Management of stores.
6. Dispatch of complete consignments.

4.

MANUFACTURING

1. Pre manufacturing manufacture of components and brazing of parts.

2. Assembly of manufactured and bought out components.

PRE-ASSEMBLY
This consist of various processes such as riveting, spot welding,
soldering through which various in-house and bought out parts are
assembled to form subgroups which are fed to the main product assembly
line after testing.

ASSEMBLY
The final product is assembled in the well laid out and balanced lines.
The product is thoroughly tested and packed before dispatch.

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HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. LTD.

5.

QUALITY ASSURANCE

1. Inspection of incoming materials.

2. Inspection during stages of manufacturing and assembly processes.
3. Verification of standards of finished goods.
4. Routine testing after the products is ready.
5. Verify compliance with client requirements.

6.

COMMERCIAL

1. Source customers.
2. Studies the requirements of the customers.
3. Collaborates with the technical and manufacturing sections.
4. Markets product made by factories.
5. Product cost calculation
6. Cost accounting & control
7. Planning and budgeting
8. Financial accounting
9. Inputs for companys balance sheets.

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HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. LTD.

7.

MAINTENANCE

Maintenance has been defined as a combination of any action carried

out to retain any item or to restore to it an acceptable condition. This action
may be some major adjustment, repair work, replacement of same part or
periodic check up or inspection, periodic lubrication, over hauling of parts,
sub assembly or equipment as whole.
In other words Maintenance may be defined as an application of an
assembly of man and machine to keep the plant running at maximum
efficiency and profitability to keep it in maximum availability of plant and
conserve the life of plant and equipment.

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HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. LTD.

7. QUALITY INSPECTION AND QUALITY REPORTS

In Swajit first preference is always given to the quality though it might come
at higher cost but no chance is taken against the quality. Metal sheet and bars
are the primary raw material used in production department. When these
material arrive from source those are given to vendor to slash them into
required size. These materials are then inspected at arrival area of
department, for their dimensions and other quality parameters. Then those
are moved to storage areas present near each punching press.
While carrying out production process, at the beginning of each production
cycle few samples are produced and given for quality check if they are
passed then only further production is carried out, else necessary action is
taken with help of tool maintenance department.

7.1 QUALITY TESTS

In case of material treatment 2 types of tests are performed to check quality

of those.
1.Grinding test

2. Hardness test

For contacts quality test are performed using microscopic check for its shape
and vernier caliper is used to measure the dimensions.

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HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. LTD.

7.2 QUALITY REPORTS

Report is prepared by quality assurance department. Inspector from this

department draws samples of each product by predetermined method and
inspect its quality. If any defects are observed in quality of those samples
then that person prepares I report and submits that report to concerned
department.
The concerned department to which report is issued prepares second report.
This department inspects the entire lot, from which those samples were
collected which got rejected. For each department there is 2% tolerance level
allowed, if the no of rejection from that entire lot are exceeding that limit of
2% then the concerned department is required to prepare second report. This
report contains details of the incident and justification for the same.

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HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. LTD.

Fig:7.1 ISO certification of Swajit Engineering

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HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. LTD.

8. DISPOSAL OF SCRAP

The scrap generated while production process is required to be disposed

using some proper guidelines. This generated scrap is categorized mainly
into hazardous waste, ferrous scrap and non ferrous scrap. While disposing
hazardous wastes like grinding dust, araldite waste etc. along with these
waste form 3 and form 12 are attached which helps in identify that its
hazardous waste and proper procedure is followed while it`s disposal. In
case of non-ferrous scrap, this scrap is sold to vendor from which that raw
material was bought. Being a non-ferrous material it is very expensive and
hence waste of such material also gives good value. In case of both i.e.
disposal of hazardous and non-ferrous waste records are maintained. These
records contains amount or quantity of waste (weight), packed in which
container (plastic, metal, any other), originator, vendor details etc.
While in case of ferrous scrap, being non hazardous and also not having
much re-sell value record of such is not maintained and is directly sold to
vendors.

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HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. LTD.

9. CONCLUSION

Production planning and control practices used in Heat treatment department

are very efficient. Capacity utilization is very effective and efficient.
Production targets are met on regular basis. Also the number of defects or
numbers of rejections are very less, even less than 4.2% of total production.
Shop floor management system implemented in Heat treatment department
is very effective. It has helped in establishing proper chain of command and
proper channel for communication. It also helps in understanding, what all
activities are taking place on floor at that movement and also helps in
keeping track of various performance parameters like additional cost, quality
issues, safety etc.
With help of FOCUS ( ERP software) and scientific techniques of inventory
management, HT and Production department are able to keep low levels of
inventory while also achieving high inventory turnover.

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HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. LTD.

10.

RECOMMENDATIONS

1) Conventional instrument should be replaced by the Digital instrument.

That will give more accuracy and minimize errors.
E.g. Digital Vernier caliper should be used.
2) Quality inspection should be carried out after every stages of during Heat
treatment operations.
3) Inspection record of daily as well as monthly production should be
maintain as per the ISO standards.

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HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. LTD.

11.

Bibliography

https://en.wikipediya.org
https://en.swajit.com
www.iso.org/iso/about/iso_members.htm
www.thermotreatedwood.com
www.anvilfire.com/FAQs/Heattreating.htm
www.osti.gov/servlets/purl/836878/
www.can-eng.com/HeatTreatment

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