METAL & STEEL FACTORY, ISHAPORE

A METALLURGICAL UNIT DEDICATED TO DEFENCE PRODUCTION

ARKA BASU
B.TECH AND M.TECH DUAL DEGREE
METALLURGY AND MATERIALS ENGINEERING
4th Semester

VOCATIONAL TRAINING REPORT

SUBMITTED BY

SUDIPTA MAITY, ASHIM BIKASH MANDAL,

PRASUN KUMAR BISOI, SOUMYA SUVRA MAHATO,
SOURADEEP SAHA, MURALIDHAR YADAV,
VIJAY KUMAR GUPTA, ARIJIT SAMADDAR, &
KUNDAN KUMAR.

BRANCH : METALLURGY & MATERIALS ENGINEERING.

YEAR : THIRD

INDIAN INSTITUTE OF ENGINEERING SCIENCE AND TECHNOLOGY, SHIBPUR.

ACKNOWLEDGEMENT

We would like to express our deepest appreciation to all those who provided us the possibility to
complete this report. A special gratitude we give to
Mr. Rajnish Jauhari
(GM),

Dr P.S Bandhopadhay
(A.GM),

Mr. Praveen Kumar

(D.GM admin),

Mr. Dilip Banerjee

(JWM/HRD)
whose contributions helped us to accomplish this training especially in writing this report.

Furthermore we would also like to acknowledge with much appreciation the crucial role of the
staff of MSF ishapore and FTI who helped us understanding the operations going on at
individual sections and provided us the necessary information that we needed to complete this
report. Last but not least, many thanks goes to Prof S.Chatterjee and Prof.. Sumit Ghosh,
Associate Professor and Head, Department of Metallurgy And Materials Engineering
of Indian Institute of Engineering Science and Technology, Shibpur, who provided us the
opportunity to receive this training.
We have to appreciate the guidance given by other supervisor, thanks to their comment and
advices.

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 TRAINING SCHEDULE

NAME OF THE
NAME OF THE
TIME PERIOD ADVISOR & SIGNATURE
SECTION
DESIGNATION

18/06/2018
NEW ROD MILL
to
(NRM)
19/06/2018

RADIAL 20/06/2018
FORGING SHOP to
(RFS) 21/06/2018

STEEL MELTING 22/06/2018

& REFINING to
SHOP (SMR) 23/06/2018

25/06/2018
NEW GUN
to
FORGING (NGF)
26/06/2018

AMMUNINATION 27/06/2018
COMPONENT to
SHOP (ACS) 28/06/2018

29/06/2018
CARTRIDGE
to
CASE SHOP (CCS)
30/06/2018

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 INDEX

Sl. SHOP DURATION SIGNATURE NAME

No.
RADIAL FORGING 11.12.17-
1. SHOP 13.12.17

NEW GUN FORGE 14.12.17-

2. 15.12.17

GUN HEAT 16.12.17-

3. TREATMENT 19.12.17

GUN MACHINE 20.12.17

4. SHOP

MELTING 21.12.17-
5. PLATFORM SHOP 23.12.17

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 FACTORY PROFILE
Metal & Steel Factory, Ishapore is the main producer of basic Ferrous and Non-
Ferrous raw material for military hardware.

Present day military hardware requires use of metals of high strength coupled
with superior toughness. Combination of both these properties requires use of
alloy steel of Super-ultra clean quality.

MSF has facilities for state-of-the-art steel making in the form of Electric Arc
Furnace, Ladle Furnace Vacuum Degassing & Electro Steel Re melting –
ensuring production of Ultra clean steel.

A high capacity PLC-Controlled 2650T Forging Press with fully integrate and
double manipulators gives shape to the products like Gun Barrels & other
components of Artillery and Tank Guns. A state of art CNC-Controlled Redial
Forging Press of 1250T for each hammer can forge various sections and profiles
with high degree of isometric mechanical properties, near-net finish and
repeatability.

The Factory also possesses a hot rolling mill, a high precision 2 hi / 4 hi

combination cold rolling mill (setup in 2006) for making thin strips of ferrous and
non-ferrous material with online x-ray and mechanical gauging system.

Precision controlled heat treatment facilities impart high Mechanical Properties

in the metal, making it capable of performance under conditions of high stress.

Such integrated facilities for making, shaping & treating of Super-Ultra clean
alloy steel-grades makes it possible to cater to any metallurgical need.

Production of steel cartridge cases starting from making of deep drawing quality
steel (HSLA Grade) for forming the finished products is the major strength of the
factory. MSF is the leader in this field.

Electric induction Brass Melting Furnaces produces high quality 60:40

with/without Pb Brass Billets/Pigs, Mn-brass etc.

Quality intelligence personnel with sophisticated machinery consisting of

Ultrasonography, Laboratory Chemical Testing, Computer aided Spectrographic,
XRF Spectrometry, Hydrogen Gas Analyser, and 3D coordinator for precision
dimensional measurement etc.

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LOCATION
Metal & Steel Factory, Ishapore is situated in West Bengal on the Eastern Bank
of River Hoogly (Ganges) at a distance of 28 KM from Kolkata and is connected
by Rail and Motor-Road. Nearest Airport Terminal is Netaji Subhash Chandra
Bose Airport, Dum Dum.

HISTORICAL BACKGROUND
The factory has its origin as part of Gun & Shell Factory at Cossipore - then
known as "Foundry and Shell Factory"- in the year 1872, when metallurgical
operations by way of melting and rolling of Cartridge Brasses were first taken up.
Subsequently in the year 1892, manufacture of steel was taken up when open-
hearth steel making furnace was commissioned. With this, the first authentic
production of steel was introduced in India. The Steel Rolling Mills were installed
later on, in 1896. Further expansion of metallurgical activities necessitated
shifting of metallurgical plants to Ishapore.

Relocated to its new site at Ishapore in the Year 1905, the Factory continued to
function as a part of the Gun & Shell Factory, Cossipore. In 1920 it became an
independent unit in the family of Ordnance Factories and had come to be known
as "Metal & Steel Factory, Ishapore (MSF)"

MSF has been the cradle of military-metallurgy in India. The facilities &
expertise available in carrying out development of products and investigation of
failures by the attached inspectorate led to the formation of Technical
Development Establishment (Metals) in the year 1951 which was upgraded in the
year 1956 to the Defence Metallurgical Research Laboratory (DMRL) within its
premises. DMRL was later on shifted to Hyderabad in the year 1963 after
bifurcation into DMRL and CI (Metals).

PRODUCTION FACILITIES
The development of new weapon systems calls for stringent metallurgical
property requirements for the special Alloy Steels and Non-ferrous Alloys that
go into making of weapon systems. Special characteristics of the Defence
Materials are the multiplicity of specifications, adherence to high quality
standards and special metallurgical properties. Quantity of supply ranges from
fifty Kilograms to hundreds of MT. In fulfilling these requirements, MSF has
played a unique role in quick development and productionisation of new
armaments in the country. In addition, MSF has taken adequate care and advance
action in order to not only be competent but also to be at the forefront in quality

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standards and latest in technological advantages by developing core competencies
in the following areas:

Manufacture of highly specialised steels through the latest technology i.e. ESR &
LF-VD for tank gun barrel like T-72, 130mm, 155mm and all types of steel blanks
required for sister factories for various types of cartridge cases for 30mm Sarath,
23mm Schilka, 73mm, 76.2mm and 125mm ammunition. This factory has
established the capability for the manufacture of the specialised forgings for
Arjun Tank.

Various types of steel cartridge cases and blanks.

In addition to above, MSF has got the following Production facilities:

Steel Making:

Melting: 15 Ton & 2 Ton Basic Electric Arc Furnace with

cored-wire Ca-Si Injection, Argon purging and Slide Gate
Teeming, Bottom Pouring facilities.

Secondary Steel Refining: 20 Ton capacity Ladle Furnace -

Vacuum Degassing (LF-VD) and 10 Ton capacity Electro Slag
Re-melting (ESR) units in conjunction with 15 Ton EAF.

Press Forging: 2650 Ton ZDAS Forging Press, with rail bound
manipulator for heavy forgings.

Hammer Forging: 5 Ton MASSEY pneumatic Hammer and battery

of other Pneumatic Hammers (1Ton, 10 CWT) for medium and smaller
section forgings and tools.

Rolling: 28 inches 2-high reversing LAMBERTON make Bar Mill

with Manipulator and Roller

High 550 mm X 1500mm MORGARDSHAMMER Billet Rolling Mill,

Double Duo Rod

Rolling Mill of 10 inches diameter stands. Bright bar processing

facilities.
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Upset Forging: 1200ton Horizontal Forging Machine.

Hollow Forging: Battery of 280 Ton and 150 Ton vertical Forging
presses for hollow forgings up to 125 mm diameter and 550 mm length
with one or both ends open.

Drop Stamping: 10 Ton double acting forging machine, battery of

Drop Stamp Hammers (1Ton, 15 CWT, 7 CWT).

Heat Treatment: Bogie-hearth Electric Annealing and normalizing

Furnaces. Pit type Electric Furnace with quenching facilities for
hardening and tempering.

Brass Melting: Battery of Electric Induction Brass Melting furnaces

comprising of: 2 Nos. 540 kgs.

GEC make Brass melting furnaces, Four Nos. 300Kgs and three nos.
500Kgs AJAX Watt medium frequency melting furnaces.

Cold Rolling: Cold Rolling Mills for rolling of brass slabs.

Extrusion: 1250 Ton Hydraulic Direct Extrusion Press for brass

rods/tubes and Draw Benches.

Cupping and Deep Drawing: Cupping and Deep drawing of Brass

and Steel, Chemical Passivation and finishing.

Die Casting and Flow Forming Machines.

MISSION AND VISION

To Equip our Armed Forces with Modern Defence and Battle Field
Equipment.
To Continuously Modernise our Production Facilities
To Train and Motivate Personnel
To equip ourselves with Technologies through Acquisition, Synergy and

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In-house R&D
To Continuously Improve Quality
To improve operational efficiency and communications by extensive use
of information technology
To improve highest level of customer satisfaction
To increase customer base in Defence, Non-Defence and Export markets
and establish Global Presence

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 DEFENCE FACTORY ALL OVER INDIA

There are 41 Ordnance Factories geographically distributed all over the country
at 24 different locations. A visual idea of how our factories and headquarters are
distributed can be had from our location map.
Indian Ordnance Factories is a giant industrial setup which functions under the
Department of Defence Production of the Ministry of Defence. Indian Ordnance
Factories, headquartered at Kolkata, is a conglomerate of 41 Factories, 9 Training
Institutes, 3 Regional Marketing Centres and 4 Regional Controller of Safety.
Today OFB along with its 41 factories spread over India provide

strict adherence to quality standard (all the units are ISO-9000 certified)
original as well as adaptive research & development to make need-based
refinement and modifications
project engineering capability
a strong base for industrial training facilities
ready market access due to convenient location
a broad and versatile production base with multi-technology capabilities
state of the art manufacturing facilities
large reservoir of skilled and professionally qualified manpower and
managerial personnel.

The plant and technologies have been so chosen as to ensure high degree of
quality and reliability and is a unique blend of old and the most modern state-of-
the-art CNC technologies. The manufacturing process covers wide spectrum of
engineering - Mechanical, Electrical, Metallurgical, Chemical, Textile, Leather,
Optics and Electronics.
NAME OF STATES/UNION NUMBER OF FACTORIES
TERRIOTORIES
Maharashtra 10
Uttar Pradesh 9
Madhya Pradesh 6
Tamil Nadu 6
West Bengal 4
Uttaranchal 2
Andhra Pradesh 1
Chandigarh 1
Orissa 1
Bihar 1

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Page | 10
RADIAL FORGING SHOP

INTRODUCTION
Radial forging is one of the latest technology in the forging industry of advance process through
which we can convert ingot into radial shape. It is a revolution in forging considering the drastic
improvement of both forging speed and also surface finish of product prior machining.
Radial forging is more superior than other conventional comparing with forging speed in radial
forging machine four dies speed higher than other conventional forging. Due to this we obtain
fine surface finish product in RFS. The temp. Loss is less in RFS for high forging speed. For this
reason we get desired shape and properties of the material in one step.

MACHINES
 Heating furnace
 Radial forging machine.
 Annealing furnace
 Overhead cranes
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  Power saws
 Ultrasonic test

HEATING FURNACE
In the furnace ingot is heated up to 1150oC to 1200oC and soaked a particular time dependent
upon the dimension of the ingot. Here is used batch type heating furnace.

Heating Cycle:-

1180-12000C

7 hr.
Temperature

Heating rate- 800C/hr

0
750 C

7 hr.

5000C

TIME

RADIAL FORGING MACHINE

Radial forging machine is one of the advance machine. It has one press and two manipulators and
in the press it contains four dies. During radial forging process the manipulator rotated along
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with the ingot and change their position. When the four dies give the stroke to the ingot at that
time manipulator does not rotate. After giving the stroke manipulator works in same process.
The dies stroke is 200 times/min, e.g. for Barrel (T-72) this process completes within 18 mins.
The principle of operation is illustrated below:

Capability:-
To produce T-72, ARJUN, T-90, 155mm Gun Barrel Forging, Tubes and Bar product.
Specification:-
 Input Dimension:-
 ESR INGOT-650mm Dia
 LF-VD Ingot-23”(OCTAGON)
 Max weight-7.05
 Output Dimension:-
 Min Dia-75mm
 Square-80mm
 Max length-11000mm
 Tube Dimension:-
 Min Bore-60mm
 Max Bore-250mm
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  Starting Length-4300mm max
 Forging Force/Die-12000KN
 Forging Power-1260KN
 No of strokes/Die-200/min
 Adjustment range in dia - Up to 330 mm

Overhead cranes
These are used to handle very heavy or large objects.

Power saws
They are used to cut forged ingot down to needed size. The blades are of high carbon steel.

Ultrasonic Testing kit

A rare problem of radial forging is that it requires ingots with negligible internal defects like blowholes.
These are tested by ultrasonic testing kit. The entire length of the ingot is scanned, to find defects. When
worked radially, these defects can expand in length in transverse direction.

Annealing Furnaces
Due to forging lots of stress are generated in ingot. To reduce stress, ingot is put into Bogie type
annealing furnace.

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Annealing cycle:-

Heating rate-50oC/hr

8900C
6800C±10
Temperature

10 hrs

F/C 16 hrs
F/C
3600C
2000C

TIME

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Process in Flowchart

Ingot (From SMS)

Heating Furnace (Batch type, Heat temp-1150oC)

Radial Forging

Annealing Furnace (Bogie Hearth Furnace)

End parting

Testing

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STEEL MELTING AND REFINING SHOP(SMR)

OVERVIEW
Before undertaking a detailed study of the processes involved in steelmaking, it
is helpful to have an overview of the whole operation, so that the inter-relation of the
various steps can be seen in perspective.
Raw Materials
The basic raw materials of large-scale steelmaking are:
• iron ore, treated in some way after it comes from the mine;
• coal, which must be converted to coke;
• limestone;
• steel scrap - important both to the integrated steelworks as secondary feed
to the steelmaking furnace, and to the smaller scale "mini-mill" operator and special
• steel producer;
• fluxing materials;
• refractory materials; and
• alloys, which are elements added to steel to give it special properties for a
variety of uses.
The Steelmaking Process
Integrated steelmaking operations fall into three main phases:
Reduction: Ironmaking
Iron ore, as mined, is a combination of iron with oxygen and various other
unwanted substances, generally known as "gangue". The first metallurgical step is to
reduce iron ore to metallic iron, a process which is mostly carried out in a blast
furnace, using coke as both a fuel and reducing agent. The metallic iron produced by
such a furnace contains a relatively high proportion of carbon (4%) and is passed to
the steelmaking process as a liquid at approximately 1450C, called "hot metal".

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 Refining: Steelmaking
The refining of iron to make steel is where the carbon content of hot metal is
lowered, usually to less than 1% by an oxidation process in a steelmaking furnace. At
the same time, alloying materials are added to the furnace to achieve the required
chemical composition of the final product. The chemical content is controlled very
closely during this stage. Originally most steel was produced by the "Bessemer" and
"open hearth" processes but these have been replaced by the more modern "basic
oxygen steelmaking" (BOS) and "electric arc furnace" (EAF) processes.
The BOS process uses pure oxygen, injected by a lance, for refining the relatively
impure hot metal (and scrap is used for temperature control).
The electric arc furnace uses primarily electrical energy to supply heat to melt
scrap steel, sponge iron, or mixtures of scrap and other iron units. Compared to the
BOS process, the EAF requires less chemical reaction for refining.
Shaping & Coating
The liquid steel can then be cast or formed into a variety of solid shapes via the
'continuous casting' process. The cast steel can then be forged or rolled in successive
steps to produce anyone of the many required shapes. Rolling is the most common
method of shaping. The modern rolling mill is a huge installation, costing millions of
dollars and incorporating highly complex
electronic control systems. The amount of work to which the steel is subjected,
and the schedule on which this work is carried out, have significant effects on its
physical characteristics - it dictates whether the steel can be subsequently bent,
machined, cut, or subjected to any other engineering operation, or formed into tubes,
pipes or wire.
Materials Used to make Steel
Iron Ore
Composition
Iron very rarely occurs in the earth's surface as a metal. It is widely
distributed, combined with oxygen as iron oxides. Infact it is believed that
iron makes up about 5% by weight of the earth's crust. Geologists
recognise various types of iron ore, classified chiefly according to iron
(Fe) content (see Table 1 below).

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 Table 1: Iron Ore Classification

Name Classifi Theoretical maximum iron content

cation (%)"
Hae Fe2O3 70.0
matite
Mag Fe3O4 72.4
netite
Goet FeO.O 62.8
hite H
Sider FeCO3 48.3
ite
Taconite Wide variety of iron-bearing rocks, usually 20 to 40%
(actual)
Jaspilite Contains magnetite or haematite
Table 2: Typical Analysis of Iron Ores (%)

Iron Ore F S A M P S H2O(c

e iO2 l2O3 n omb)
Mt. 6 4 1 0 0 0 2.5
Newman 4.7 .15 .60 .06 .054 .007
High Grade
LumpW
A (H)
Mt. 6 5 2 0 0 0 2.2
Newman 2.0 .55 .60 .04 .069 .009
High Grade
Fines
WA (H)
Yandi 5 4 1 0 0 0 9.6
Fines WA 8.5 .9 .3 .03 .043 .005
(G)
Whyalla 6 3 1 0 0 0 3.12
Pelletis 2.8 .76 .85 .27 .050 .033
ing Fines
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SA (H)

Ore Type: H = Haematite, G = Goethite

Iron Ore Agglomeration

The sinter process was introduced around 1910 to treat flue dust
extracted from blast furnace exhaust gases. It was quickly adapted to
agglomerate fine ore and its use spread rapidly.
At the sinter plant, pre-blended fine ore is mixed with:
• coke breeze (small particles of coke from the screening plant);
• fine fluxes such as fine limestone, dolomite, quartzite, and
serpentine;
• mill scale (small flakes of iron oxide from the rolling mills); and
• flue dust and precipitator dust (fine ore bearing particles)
collected from the blast furnace and BOS furnace exhaust gases.
Steel scrap
Steel scrap is a major source of metallic iron for steelmaking. About half of the
700 million tones of crude steel now produced annually in the world will be
recycled as scrap to the steelmaking furnaces sooner or later. (Every tonne of
scrap consumed in steelmaking is estimated to conserve about three tonnes of
natural resources.)

Steelmaking – the refining process

General Characteristics of Steelmaking – the refining process
All steelmaking processes have to complete three basic steps:
Step 1 - removal of impurities (oxidation),
Step 2 - control of temperature (charging),
Step 3 - addition of alloy elements.

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Electric arc furnace

An electric arc furnace (EAF) is a furnace that heats charged

material by means of an electric arc.
Industrial arc furnaces range in size from small units of approximately
one ton capacity (used in foundries for producing cast iron products) up to about
400 ton units used for secondary steelmaking. Arc furnaces used in research
laboratories and by dentists may have a capacity of only a few dozen grams.
Industrial electric arc furnace temperatures can be up to 1,800 °C (3,272 °F),
while laboratory units can exceed 3,000 °C (5,432 °F).
Arc furnaces differ from induction furnaces in that the charge material is
directly exposed to an electric arc and the current in the furnace terminals
passes through the charged material.

Although the modern electric arc furnace is a highly efficient recycler of

steel scrap, operation of an arc furnace shop can have adverse environmental
effects. Much of the capital cost of a new installation will be devoted to systems
intended to reduce these effects, which include:
Enclosures to reduce high sound levels
Dust collector for furnace off-gas
Slag production
Cooling water demand
Heavy truck traffic for scrap, materials handling, and product
Environmental effects of electricity generation
Because of the very dynamic quality of the arc furnace load, power systems
may require technical measures to maintain the quality of power for other
customers; flicker and harmonic distortion are common side-effects of arc
furnace operation on a power system. For this reason the power station should
be located as close to the EA furnaces as possible.

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LADLE FURNACE
Secondary Refining
For purposes of this article, Secondary Refining or Secondary Metallurgy is
defined as any post steelmaking process performed at a separate station prior to
casting and hot metal desulfurization. It does not include normal alloying
practice in the furnace or at the ladle during tapping. This definition is not
universally applied and many include operations at the tundish, electromagnetic
stirring in the mold, etc. The purposes of secondary refining are many:
temperature homogenization or adjustment; chemical adjustments for carbon,
sulfur, phosphorus, oxygen and precise alloying; inclusion control; degassing,
and others. The equipment and processes are equally varied. Secondary
Refining processes are performed at atmospheric pressure or under a vacuum,
with or without heating, solids and/or gas injection, and stirring. Fully nine
different vacuum processes are sold for carbon steels alone.

Description and Operation of a Vacuum Tank Degasser (VTD)

By James C. Simmons, Sr. Vice President Meltshop Division, Techint

Technologies Inc. A Vacuum Tank Degasser (“VTD”) is used to reduce the
concentrations of dissolved gases (H2, N2, O2) in the liquid steel; Homogenize
the liquid steel composition and bath temperature; remove oxide inclusion
materials from the liquid steel; and, provide the means and technical conditions
that are favourable for final desulfurization. The fundamental requirements for
the ladle degassing process include: ß Sufficient freeboard in the ladle to contain
the vacuum-induced slag and steel boil; ß An inert gas percolating through the
steel bath for stirring, inclusion separation, and enhancement of vacuum
degassing performance; ß Sufficient superheat in the steel to avoid skull
formation; and, ß Means to deliver additives while the ladle is inside the vacuum
tank.

During operations at the VTD, the liquid steel is stirred to promote

homogenization by percolating argon gas through a single refractory stir plug
arrangement in the bottom of the ladle. The argon connection to the ladle is
established when the ladle is set in place inside the vacuum tank. The vacuum
tank is evacuated to the required operating pressures by one of three ways: steam
jet ejector, steam jet ejectors and a water ring pump, or, mechanical pumps.
Emissions are evacuated through a vacuum pumping system and are collected
prior to the pumps or they are discharged under water contained within a weir
wall-equipped concrete hotwell. The process gases, including those entrained in
the intercondenser discharge water, are exhausted from the hotwell via a motor
driven fan to a vent stack equipped with a flare burner. Hotwell water is pumped
to a cooling tower of the contact water system.

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NEW GUN FORGE (NGF) SHOP
Introduction
Here, the raw material is ingots and slugs, made in SMS and purified by ESR. The ingot/slug is
subject to cycles of heating and mechanical working, until the desired dimensions are achieved.
It is then sent off for machining.

Machines
The New Gun Forge has the following machines
 2650 T Hydraulic Press
 Manipulators
 Oil fired forging Furnaces
 Electrical Annealing Furnaces
 Overhead Cranes
 Band Saw Mills

2650 T Press
This is to shape the work-piece. The press is of hydraulic nature, using HLP-46 oil. In the figure
below, we see an anvil and the press in action.

The anvils are changed, depending on the target shape.

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Manipulators
These are used to hold the work-piece while the press is in operation, from both sides. This can
move (vertically and horizontally) and rotate the ingot. In images below, we see the manipulator,
on standby and in operation

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Forging furnaces
These are used to forge the work pieces. They are oil fired. They can hit temperatures of 1150 0C.
They are of following types:

 Tata Korf
 Wesforge

Here, we see furnaces, in action, forging work-pieces.

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Annealing Furnaces
They are used for initial heating and stress relieving. They are electrically powered, capable of
achieving 9000C. They are of following types:

 Wellman
 Thermochem
 Benco
 Birlec

Overhead Cranes
They are used to move the work-pieces between various machines. Depending the shape of work-piece,
various attachments are used, as shown below

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Process
In this section the basic operation is forging. This is done in hot condition, i.e. hot forging. The raw
material in this section is the slug, ingot coming from the ESR and SMS section. Before sending to the
forging furnace the cold raw materials are heated in a pre-heating (Annealing) furnace. This is done in
order to minimize the thermal shock which the material experiences if directly placed in a forging
furnace. Then the material is sent to the forging furnace (oil fired) for heating the material above its
recrystallization temperature to ensure hot working. Before completion of hot forging as required
temperature the temperature of the work piece falls down, so it has to be reheated from time to time.
After the forging, the work piece is sent to annealing/anti-flaking furnace for the diffusion of hydrogen.

Heating Cycle
1. Pre -heating

5000C Heating Rate-50oC/hr

3500C 5 hr
Temperature

3 hr

Time

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 1. Forging cycle:

11500C

7 hr.

10000C

6 hr.
Temperature

Heating rate-50oC
0
700 C

2 hr.

5000C

1 hr.

Time

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3. Annealing cycle:

8500C

8-10 hrs

7000C
Temperature

F/C cooling

Room Temp

Time
4. Anti-flaking cycle:

9000C

15 hrs

7000C
Temperature

6600C

12 hrs

60 hrs
3200C

20 hrs

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PRESS FORGING

The forging done with the help of presses is known as press forging. It is
usually referred as hot pressing and is carried out either using hydraulic presses
or mechanical (crank type) presses.

The press forging is similar to drop forging but uses a single, continuous, slow
squeezing action instead of a series of impact blows. Because of slow ram travel
and continuous action of the hydraulic presses, the deformation penetrates
deeper so that the entire volume of the work piece simultaneously and
uniformly undergoes plastic deformation. While in case of drop forging, the
energy is only transmitted into the surface layers of the work part.

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FORGING PRESS AND DIFFERENT PARTS:

Like drop forging hammer, mechanical forging press is also used for mass
production of forging components.

The billet is heated up to the recrystallization temperature and kept over the
bottom half of the die.
The bottom half of the die is kept fixed.
The top die goes up and down repeatedly to shape up the billet to final product.
The billet is pressed (or squeezed) rather than hammered in a mechanical
forging press. So the life of the die is more in case of mechanical press forging.
The production rate of mechanical forging press is greater than that for a drop
forging hammer.

Various parts of a mechanical forging press and their functions are as below:
Flywheel: Flywheel supply power for forging. The flywheel is connected to
a prime mover (either electric motor or diesel engine) either directly or
through a drive (belt drive or gear drive). The fly wheel is supported
by bearings. The speed of the flywheel is directly proportional to production
rate of forging components.
Board: The board is connected eccentrically to the flywheel.
This mechanism converts rotary motions of the flywheel into vertical linear
motion of the board.
Ram: The ram is the connecting member between the board and
the upper half of the die. The ram is guided by lubricated guide
shafts (not shown in picture) for maintaining proper vertical
motion.
Die: The forging die has two halves. The top half moves up and
down with the ram, whereas the bottom half is kept fixed by the

Page | 31
anvil. The design of the die cavity decides the final shape of the
forged component.
Anvil: The anvil keeps the bottom half of the die rigidly fixed.
Rigidity of the anvil is important for proper functioning of any
forging press.
Forging Furnaces :

Forge Furnaces are also known as Billet Heaters. The key considerations
are heating efficiency to minimize operating cost and cycle time, and
maintainability.
This type of forging furnace is available in many versions:
1)Rotary Forge Furnace: Located next to the forge where – in the operator
extracts the hot, feeds the forge, and inputs a cold billet in a semi-
continuous fashion.
Forging Rotary Furnace Billet Heaters
ROTARY FORGING FURNACE
2)Continuous Slot Forge Furnace: where-in the product thru-feed is the
same as the forge cycle.
CONTINUOUS SLOT FORGE FURNACE
3)Hand Fed Slot Forge Furnace: where-in the forge operator manually and
alternately extracts a hot bar and loads a cold bar.

Page | 32
Advantages of Press Forging:

1. Higher productivity than drop forging.

2. Greater accuracy in terms of tolerances within 0.01 to 0.02 inch.

3. Dies used in press forging have less draft, therefore more complicated shapes
can be forged with better dimensional accuracy.

4. The speed, pressure and travel of the die are automatically controlled, in press
forging.

5. Possibility of process automation through mechanism of blank feeding and

forging removal.

Disadvantages of press forging

1. The initial capital cost is higher compared with drop forging, because the cost
of crank press is always higher than that of an equivalent hammer.

2. The difficulty of descaling the blank is another short coming of this process.

3. The process is economically suitable only when the equipment is efficiently

utilized.

Page | 33
Annealing:

Annealing, in metallurgy and materials science, is a heat treatment that alters

the physical and sometimes chemical properties of a material to increase its
ductility and reduce its hardness, making it more workable. It involves heating a
material above its recrystallization temperature, maintaining a suitable
temperature for a suitable amount of time, and then cooling.
In the cases of copper, steel, silver, and brass, this process is performed by
heating the material (generally until glowing) for a while and then slowly letting
it cool to room temperature in still air. Copper, silver and brass can be cooled
slowly in air, or quickly by quenching in water, unlike ferrous metals, such as
steel, which must be cooled slowly to anneal. In this fashion, the metal is
softened and prepared for further work—such as shaping, stamping, or forming.
Normalization

Normalization is an annealing process applied to ferrous alloys to give the

material a uniform fine-grained structure and to avoid excess softening in steel.
It involves heating the steel to 20-50°C above its upper critical point, soaking it
for a short period at that temperature and then allowing it to cool in air. Heating
the steel just above its upper critical point creates austenitic grains (much smaller
than the previous ferritic grains), which during cooling, form new ferritic grains
with a further refined grain size. The process produces a tougher, more ductile
material, and eliminates columnar grains and dendritic segregation that
sometimes occurs during casting. Normalizing improves machinability of a
component and provides dimensional stability if subjected to further heat
treatment processes.

Page | 34
FLOW CHART OF FORGING OF HEAVY ALLOY STELL

Page | 35
 NEW ROD MILL(NRM)
ROLLING(METALWORKING)

In metal working Rolling is metal forming in which metal stock is passed

through one or more pairs of rolls to reduce the thickness and to make the
thickness uniform. The concept is similar to the rolling of dough. Rolling is
classified according to the temperature of the metal rolled. If the temperature of
the metal is above its recrystallization temperature, then the process is known
as hot rolling. If the temperature of the metal is below its recrystallization
temperature, the process is known as cold rolling. In terms of usage, hot rolling
processes more tonnage than any other manufacturing process, and cold rolling
processes the most tonnage out of all cold working processes. Roll
stands holding pairs of rolls are grouped together into rolling mills that can
quickly process metal, typically steel, into products such as structural steel (I-
beams, angle stock, channel stock, and so on), bar stock, and rails. Most steel
mills have rolling mill divisions that convert the semi-finished casting
products into finished products.
MODERN ROLLING
Modern rolling practice can be attributed to the pioneering efforts of Henry
Cort of Funtley Iron Mills, near Fareham, England. In 1783, a patent was issued
to Henry Cort for his use of grooved rolls for rolling iron bars.With this new
design, mills were able to produce 15 times more output per day than with a
hammer.Although Cort was not the first to use grooved rolls, he was the first to
combine the use of many of the best features of various ironmaking and shaping
processes known at the time. Thus, modern writers have called him "father of
modern rolling."

Page | 36
HOT ROLLING
Hot rolling is a metalworking process that occurs above the recrystallization
temperature of the material. After the grains deform during processing, they
recrystallize, which maintains an equiaxed microstructure and prevents the
metal from work hardening. The starting material is usually large pieces of
metal, like semi-finished casting products, such as slabs, blooms, and billets. If
these products came from a continuous casting operation the products are
usually fed directly into the rolling mills at the proper temperature. In smaller
operations, the material starts at room temperature and must be heated. This is
done in a gas- or oil-fired soaking pit for larger workpieces; for smaller
workpieces, induction heating is used.
COLD ROLLING
Cold rolling occurs with the metal below its recrystallization temperature
(usually at room temperature), which increases the strength via strain
hardening up to 20%. It also improves the surface finish and holds
tighter tolerances. Commonly cold-rolled products include sheets, strips, bars,
and rods; these products are usually smaller than the same products that are hot
rolled. Because of the smaller size of the workpieces and their greater strength,
as compared to hot rolled stock, four-high or cluster mills are used.Cold rolling
cannot reduce the thickness of a workpiece as much as hot rolling in a single
pass.
PROCESSES
ROLL BENDING AND ROLL FORMING

ROLL BENDING
Roll bending produces cylindrical shaped product from plate or steel metal.

Page | 37
ROLL FORMING
Roll forming, roll bending or plate rolling is a continuous bending operation in
which a long strip of metal (typically coiled steel) is passed through consecutive
sets of rolls, or stands, each performing only an incremental part of the bend,
until the desired cross-section profile is obtained. Roll forming is ideal for
producing parts with long lengths or in large quantities. There are 3 main
processes: 4 rollers, 3 rollers and 2 rollers, each of which has as different
advantages according to the desired specifications of the output plate.
FLAT ROLLING
Flat rolling is the most basic form of rolling with the starting and ending
material having a rectangular cross-section. The material is fed in between
two rollers, called working rolls, that rotate in opposite directions. The gap
between the two rolls is less than the thickness of the starting material, which
causes it to deform. The decrease in material thickness causes the material to
elongate. The friction at the interface between the material and the rolls causes
the material to be pushed through. The amount of deformation possible in a
single pass is limited by the friction between the rolls; if the change in thickness
is too great the rolls just slip over the material and do not draw it in. The final
product is either sheet or plate, with the former being less than 6 mm (0.24 in)
thick and the latter greater than; however, heavy plates tend to be formed using
a press, which is termed forging, rather than rolling.
RING ROLLING
Ring rolling is a specialized type of hot
rolling that increases the diameter of a ring.
The starting material is a thick-walled ring.
This workpiece is placed between two rolls,
an inner idler roll and a driven roll, which
presses the ring from the outside. As the
rolling occurs the wall thickness decreases as
the diameter increases. The rolls may be
shaped to form various cross-sectional shapes. The resulting grain structure is
circumferential, which gives better mechanical properties. Diameters can be as
large as 8 m (26 ft) and face heights as tall as 2 m (79 in). Common applications
include bearings, gears, rockets, turbines, airplanes, pipes, and pressure vessels.
CONTROLLED ROLLING
Controlled rolling is a type of thermomechanical processing which integrates
controlled deformation and heat treating. The heat which brings the workpiece
above the recrystallization temperature is also used to perform the heat
treatments so that any subsequent heat treating is unnecessary. Types of heat

Page | 38
treatments include the production of a fine grain structure; controlling the
nature, size, and distribution of various transformation products (such
as ferrite, austenite, pearlite, bainite, and martensite in steel);
inducing precipitation hardening; and, controlling the toughness. In order to
achieve this the entire process must be closely monitored and controlled.
Common variables in controlled rolling include the starting material
composition and structure, deformation levels, temperatures at various stages,
and cool-down conditions. The benefits of controlled rolling include better
mechanical properties and energy savings.
FORGE ROLLING
Forge rolling is a longitudinal rolling process to reduce the cross-sectional area
of heated bars or billets by leading them between two contrary rotating roll
segments. The process is mainly used to provide optimized material distribution
for subsequent die forging processes. Owing to this a better material utilization,
lower process forces and better surface quality of parts can be achieved in die
forging processes.
Basically, any forgeable metal can also be forge-rolled. Forge rolling is mainly
used to preform long-scaled billets through targeted mass distribution for parts
such as crankshafts, connection rods, steering knuckles and vehicle axles.
Narrowest manufacturing tolerances can only partially be achieved by forge
rolling. This is the main reason why forge rolling is rarely used for finishing,
but mainly for preforming.
Characteristics of forge rolling;

high productivity and high material utilization

good surface quality of forge-rolled workpieces
extended tool life-time
small tools and low tool costs
improved mechanical properties due to optimized grain flow compared to
exclusively die forged workpieces
DEFECTS
In hot rolling, if the temperature of the workpiece is not uniform the flow of the
material will occur more in the warmer parts and less in the cooler. If the
temperature difference is great enough cracking and tearing can occur.
FLATNESS AND SHAPE
In a flat metal workpiece, the flatness is a descriptive attribute characterizing
the extent of the geometric deviation from a reference plane. The deviation from
complete flatness is the direct result of the workpiece relaxation after hot or
cold rolling, due to the internal stress pattern caused by the non-uniform

Page | 39
transversal compressive action of the rolls and the uneven geometrical
properties of the entry material. The transverse distribution of differential
strain/elongation-induced stress with respect to the material's average applied
stress is commonly referenced to as shape. Due to the strict relationship
between shape and flatness, these terms can be used in an interchangeable
manner. In the case of metal strips and sheets, the flatness reflects the
differential fiber elongation across the width of the workpiece. This property
must be subject to an accurate feedback-based control in order to guarantee the
machinability of the metal sheets in the final transformation processes. Some
technological details about the feedback control of flatness are given in.
FLATNESS
Maintaining a uniform gap between the rolls is difficult because the rolls deflect
under the load required to deform the workpiece. The deflection causes the
workpiece to be thinner on the edges and thicker in the middle. This can be
overcome by using a crowned roller (parabolic crown), however the crowned
roller will only compensate for one set of conditions, specifically the material,
temperature, and amount of deformation.
The different classifications for flatness
defects are:

Symmetrical edge wave - the edges on

both sides of the workpiece are "wavy"
due to the material at the edges being
longer than the material in the center.
Asymmetrical edge wave - one edge is
"wavy" due to the material at one side
being longer than the other side.

ROLL DEFECTS

Center buckle - The center of the strip is "wavy" due to the strip in the center
being longer than the strip at the edges.
Quarter buckle - This is a rare defect where the fibers are elongated in the
quarter regions (the portion of the strip between the center and the edge).
This is normally attributed to using excessive roll bending force since the
bending force may not compensate for the roll deflection across the entire
length of the roll.

Page | 40
SURFACE DEFECTS TYPE
Lap: This type of defect occurs when a corner or fin is folded over and rolled
but not welded into the metal. They appear as seams across the surface of the
metal.
Mill-shearing: These defects occur as a feather-like lap.
Rolled-in scale: This occurs when mill scale is rolled into metal.
Scabs: These are long patches of loose metal that have been rolled into the
surface of the metal.

Page | 41
AMMUNITION COMPONENT SHOP(ACS)

BALLISTIC CAP

BMP-II VEHICLE → CANNON GUN → ROUND → BALLISTIC CAP

_______________________________________
BALLISTIC CAP

MEANING
The armour-piercing capped ballistic cap (APCBC) is a type of armor-piercing
shell introduced in the 1930s. The ballistic cap was a thin shell, typically metal,
that fit over the rounded nose of an otherwise unchanged armour-piercing round
to improve its aerodynamics. This allowed the APCBC shells to retain higher
velocities delivering more energy to the target, especially at long range. On
impact the shell crumpled, allowing the armour-piercing component to impact as
normal.

PROCESS

STEP 1- BLANKING AND CAPPING OF METAL STRIPS

STEP 2- 1ST DRAW OPERATION

2ND DRAW OPERATION
3RD DRAW OPERATION

STEP 3- 1ST FORMING OPERATION

2ND FORMING OPERATION
3RD FORMING OPERATION
4TH FORMING OPERATION

STEP 4- COINING

STEP 5- LENFTH TRIMMING

BLANKING AND CAPPING

Blanking and piercing are shearing processes in which a punch and die are
used to modify webs. The tooling and processes are the same between the
two, only the terminology is different: in blanking the punched out piece is
used and called a blank; in piercing the punched out piece is scrap. The
process for parts manufactured simultaneously with both techniques is often
Page | 42
termed" pierce and blank." An alternative name of piercing is punching.

DRAW OPERATION
Drawing is a metalworking process which uses tensile forces to stretch metal
or glass. As the metal is drawn (pulled), it stretches thinner, into a desired
shape and thickness. Drawing is classified in two types: sheet metal drawing
and wire, bar, and tube drawing. The specific definition for sheet metal
drawing is that it involves plastic deformation over a curved axis. For wire,
bar, and tube drawing the starting stock is drawn through a die to reduce its
diameter and increase its length. Drawing is usually done at room
temperature, thus classified a cold working process, however it may be
performed at elevated temperatures to hot work large wires, rods or hollow
sections in order to reduce forces.

FORMING OPERATION

Forming processes are particular manufacturing processes which make use

of suitable stresses (like compression, tension, shear or combined stresses)
which cause metal deformation of the materials to produce required shapes.
The main material used is metal due to the massive need for various products
demanded by the public, nevertheless other compounds like metals can be
formed too due to a big market for plastic based products.
During forming processes no material is removed, i.e. they are deformed and
displaced.

COINING

Metal coining is a forging process by which very fine and intricate details
can be created on the surface of a work piece. Coining may be used to
control surface quality and detail on parts. Metal coining is often a finishing
process for manufactured products.

LENGTH TRIMMING

A trimmed mean is a method of averaging that removes a small

designated percentage of the largest and smallest values before
calculating the mean. After removing the specified observations, the
trimmed mean is found using a standard arithmetic averaging formula.
The use of a trimmed mean helps eliminate the influence of data points
on the tails that may unfairly affect the traditional mean.
Page | 43
NOSE ADAPTER

Nose Adapter connects Ballistis Cap and the Body of a round. It is made in
CNC MACPOWER MACHINE

OPERATIONS

1. Turning
2. Grooming and Parting
3. Drill
4. Boring
5. Internal Thread
6. External Thread

MATERIAL USED- MILD STEEL

INPUT MATERIAL- MILD STEEL ROD

INTERNAL THREAD- 14 TPI

EXTERNAL THREAD- 14 TPI

INNER DIAMETER- 32.85mm

EXTERNAL DIAMETER- 44.45mm

Page | 44
CARTRIDGE CASE SHOP[CCS]

MAIN PRODUCT- 30mm SARATH

MEANING
The 30 mm SARATH is a specific size of autocannon ammunition. Such
ammunition includes NATO standard 30×173mm and 30×113mmB rounds and
Soviet 30×165mm rounds which are widely used around the world.
30 mm ammunition is typically not used against personnel, but rather as an antimateriel
or armor-piercing round. Rounds of this size can be effective against
armored vehicles as well as fortified bunkers.
The Armed Forces of the Russian Federation use their 30 mm weapons in a
variety of vehicles, including the Su-25 attack aircraft, Mi-24 helicopter, Mi-28
attack helicopter, Ka-50 attack helicopter, and the BMP-2, BMP-3, and BTR-90
infantry fighting vehicles. The most modern anti-aircraft gun systems in use by
Russia are 30 mm SARATH. The U.S. military uses 30 mm weapons in their A-
10 Thunderbolt II and AH-64 Apache helicopter. It was going to be used in the
Expeditionary Fighting Vehicle until the project was cancelled.

OPERATIONS

1 ) BLANKING

Blanking and piercing are shearing processes in which a punch and die are used
to modify webs. The tooling and processes are the same between the two, only
the terminology is different: in blanking the punched out piece is used and
called a blank.

2) STAMPING AND CUPPING

Stamping (also known as pressing) is the process of placing flat sheet metal in
either blank or coil form into a stamping press where a tool and die surface
forms the metal into a net shape. Stamping includes a variety of sheet-metal
forming manufacturing processes, such as punching using a machine press or
stamping press, blanking, embossing, bending, flanging, and coining. This
could be a single stage operation where every stroke of the press produces the
desired form on the sheet metal part, or could occur through a series of stages.
The process is usually carried out on sheet metal, but can also be used on other
materials.

Page | 45
3) DRAWING

It is done in 4 steps
i) 1st Draw
ii) 2nd Draw
iii) 3rd Draw
iv) Final Draw

Drawing is a metalworking process which uses tensile forces to stretch metal or

glass. As the metal is drawn (pulled), it stretches thinner, into a desired shape
and thickness.

4) HARDENING

Ordinary hardening after 2nd draw at 940̇°C-1000°C and cooling down in water
for 15-25 mins.
With 145 VPN (min) hardness.

5) TAMPERING

Tampering is used to make the neck of the shell of desired shape.

6) POLISHING

Polishing and buffing are finishing processes for smoothing a workpiece's

surface using an abrasive and a work wheel or a leather strop. Technically
polishing refers to processes that use an abrasive that is glued to the work
wheel, while buffing uses a loose abrasive applied to the work wheel. Polishing
is a more aggressive process while buffing is less harsh, which leads to a
smoother, brighter finish. A common misconception is that a polished surface
has a mirror bright finish, however most mirror bright finishes are actually
buffed.

7) ELECTROPLATING
Page | 46
Electroplating is a process that uses electric current to reduce dissolved metal
cations so that they form a thin coherent metal coating on an electrode. The
term is also used for electrical oxidation of anions on to a solid substrate, as in
the formation of silver chloride on silver wire to make silver/silver-chloride
electrodes. Electroplating is primarily used to change the surface properties of
an object (such as abrasion and wear resistance, corrosion protection, lubricity,
aesthetic qualities), but may also be used to build up thickness on undersized
parts or to form objects by electroforming.

Page | 47
GUN HEAT TREATMENT (GHT)

Page | 48
Introduction
Heat treatment can be defined as a combination of heating and cooling operations applied to a metal or
alloy in its solid state to obtain desired conditions or properties.
Heat treatments can be used to homogenize cast metal alloys to improve their hot workability, to soften
metals prior to, and during hot and cold processing operations, or to alter their microstructure in such a
way as to achieve the desired mechanical properties.
Thermal treatments of metallic alloys are also used to alter the surface chemistry of a material. This is
achieved by diffusing Carbon, Nitrogen and other gaseous or solid material in to the surface of the
component. These processes are used to give defined surface hardness and to improve wear, corrosion
and fatigue resistance.

Machines

 Wellman furnace
 Horizontal furnace
 Water tank
 Oil tank
 Band saw
 Straightening machine

Operations

The parameters and processes that can affect the composition and material properties of metal
components include the following:

 Alloy type
 Heating
 Cooling
 Work input
 Time
Page | 49
  Atmosphere
 Surface plating
 Surface diffusion

To ensure that any metal component is suitable and adequate for the designed purpose, it may
need to be exposed to a selected range of conditioning and finishing treatments. The treatments
are conducted in such a way so as to ensure that the required combination of these parameters is
carefully controlled to achieve the desired finished component.
The heat treatment of metals involves raising the temperature of an alloy, often through a
prescribed thermal profile, to a defined temperature. The material is then held at this
temperature for a period of time before being cooled either at a prescribed rate or under rapid
quenching conditions to a fixed temperature.
Treatments are carried out in furnaces and ovens where, in addition to the changes in
temperature, gases are used to control the atmosphere for the process. Controlled atmospheres
are either used to reduce the effects of oxidization or to provide an enriching atmosphere for
surface chemistry effects, on the component being treated.
Heat Treatments are classified by their purpose:

General treatments

Homogenization
This treatment is used prior to hot working processes and is performed to equalise temperatures
throughout an alloy or to reduce the coring effect caused by the non-uniform chemical
composition.

Annealing
Annealing covers a variety of heat treatment processes used to soften alloys and increase their
ductility as an aid to cold working.

Page | 50
Normalizing Stress Relieving
Thermal treatments performed to remove internal stresses within components following
welding, casting or rapid cooling.

Heat Treating
Defined as the controlled heating and cooling of metals for the primary purpose of altering their
properties (strength, ductility, hardness, toughness, machinability, etc.)

 Can be done for Strengthening Purposes (converting structure to martensite)

 Can be done for Softening and Conditioning Purposes (annealing, tempering, etc.)

In GHT heat treatment is done by Refining, Hardening and tempering process.

REFINING
The removal of impurities from crude metals. After extraction from raw materials, crude metals
are between 96 and 99percent principal metal, the rest being impurities. Crude metals cannot be
used by industry at this stage because of inferior physical, chemical, and mechanical properties.
The impurities found in crude metals may have value in themselves; the gold and silver
recoverable from copper, for example, pay for the entire cost of the refining process.

HARDENING
The use of this treatment will result in an improvement of the mechanical properties, as well as
an increase in the level of hardness, producing a tougher, more durable item. Alloys are heated
above the critical transformation temperature for the material, then cooled rapidly enough to
cause the soft initial material to transform to a much harder, stronger structure Alloys may be

Page | 51
air cooled, or cooled by quenching in oil, water, or another liquid, depending upon the amount
of alloying elements in the material Hardened materials are usually tempered or stress relieved
to improve their dimensional stability and toughness. Steel parts often require a heat treatment
to obtain improved mechanical properties, such as increasing increase hardness or strength. The
hardening process consists of heating the components above the critical (normalizing)
temperature, holding at this temperature for one hour per inch of thickness cooling at a rate fast
enough to allow the material to transform to a much harder, stronger structure, and then
tempering. Steel is essentially an alloy of iron and carbon; other steel alloys have other metal
elements in solution. Heating the material above the critical temperature causes carbon and the
other elements to go into solid solution. Quenching "freezes" the microstructure, inducing
stresses. Parts are subsequently tempered to transform the microstructure, achieve the
appropriate hardness and eliminate the stresses.

QUENCHING
Material is heated up to the suitable temperature and then quenched in water or oil to harden to full
hardness according to the kind of steels.
Material is heated to the suitable temperature for hardening, then cooled rapidly by immersing the hot
part is water, oil or another suitable liquid to transform the material to a fully hardened structure. Parts
which are quenched usually must be aged, tempered or stress relieved to achieve the proper toughness,
final hardness and dimensional stability.
Alloys may be air cooled, or cooled by quenching in oil, water, or another liquid, depending upon the
amount of alloying elements in the material and final mechanical properties to be achieved. Hardened
materials are tempered to improve their dimensional stability and toughness.

TEMPERING
Tempering is done to develop the required combination of hardness, strength and toughness or to
relieve the brittleness of fully hardened of steels. Steels are never used in as quenched condition. The
combination of quenching and tempering is important to make tough parts.

Page | 52
This treatment follows quenching or air cooling operation. Tempering is generally considered effective
in relieving stress induced by quenching in addition to lowering hardness to within a specified range, or
meeting certain mechanical property requirements.
Tempering is the process of reheating the steel at relatively low temperature leading to precipitation and
spheroidization of the carbides present in the microstructure. The tempering temperature and times are
generally controlled to produce the final properties required of the steel. The result is a component with
the appropriate combination of hardness, strength and toughness for the intended application.
Tempering is also effective in relieving the stress induced by quenching.

PRODUCTS
SL Hardness Range
Products Hardness point
NO. BHN
1 T 70/T 90 402-444(429) 07pt. (120◦D)

2 Arjun Barrel 311-240 (230) 19 pt. (120◦D)

3 Bofors (Dhanush final stage) 311-240 (230) 10 pt. (180◦D)

4 Pinaka Tube 210-240 (230) 6 pt.(3X2) (120◦D)

5 Nozzle Front 311-352 (331) 2 pt. (1x2) (180◦D)

6 Cold Swaging Barrel 277-321 (321) 8 pt. (4x2) (1807◦D)

7 84 mm RL Venturi MK (III) 285-321 (293) (n-1) or (n-2)

8 81mm Canon Tube 331-352 (341) 2pt

Page | 53
GUN MACHINE SHOP (GMS)

Introduction
Barrel are taken to GMS after forging to make machining operation on it. After machining final
product of GMS are transferred to Gun heat treatment (GHT) shop for heat treatment.

Process
The machining operation includes

 Turning
 Boring
 Cantering
 Parting
Page | 54
Turning operation
The forged metal contains some scales of oxides. CNC operated turning machine these
scales are removed. Moreover the forged barrel remains eccentric. Turning operation
also makes the barrel perfect cylindrical.

Boring operation
After turning the barrel is placed to boring machine. Boring means making hollow cavity
throughout centre axis. Two types of boring operations are done in MSF, ICHAPORE,
they are:
Tipping: A hollow rod is produced after boring.
Solid: Only chips are produced after boring.

Centring
A centre is made on the centre axis to hold the barrel while boring.

Parting
The parting machine cuts test pieces from two ends of the barrel.

Output
A finished barrel.

Note:-
 As the BARREL is tremendous heavy with a long length is a need to give
supports in between head tail and bottom tail. These supports are called
rests.
 Boring is carried out by two process EJECTION SYSTEM and STS
SYSTEM.
Page | 55
  High fluid pressure is maintained to remove chips.

MACHINE USED
Lathe machine:
A lathe is a machine tool which rotates the work piece on its axis to perform various operations
such cutting ,sanding ,knurling, drilling, or deformation with tools that are applied to the work
piece to create an object which has symmetry bout an axis of rotation .Lathers are used in
woodturning ,metalworking, metal spinning. Thermal parts reclamation and glass working.
Lathers can be used to shape pottery, the best known design being the potter’s wheel. Most
suitably equipped metal working lathes can also be used to produce most solids of revolution,
plane surface and screw threads or helices. Ornamental lathes can produce three dimensional
solids of incredible complexity. The material can be held in place by either one or two centres,
at least one of which can be moved horizontally to accommodate varying materials lengths.
Other work-holding methods include clamping the work about the axis of rotation using a chuck
or collect, or to a faceplate, using clamps or dogs. Lathe machine is employed to generate
cylindrical work, yet it may be used for many other operations such as drilling, reaming,
threading, milling, grinding etc.

BAND SAW:
A band saw uses a long sharp blade consisting of a continuous band of toothed metal stretched
between two or more wheels to cut material. They are used principally in woodworking, metal
working, and lumbering, but may cut a variety of materials. Advantages include uniform cutting
action as a result of an evenly distributed tooth load, and the ability to cut irregular or curved
shapes like a jigsaw. The minimum radius of a curve is determined by the width of the band and
its kerf. Most band saws have two wheels rotating in the same plane, one of which is powered,
although some may have three or four to distribute the load. The blade itself can come in a
variety of size and TPI which enables the machine to be highly versatile and able to cut a wide
variety of materials including wood, metal and plastic.

Page | 56
Process schedule:

Black forging
received from End parting &facing Centring
NGF /RFS/BSF

Rough turning / skin

turning
Dispatched in
GHT and Further
to OFC

Dispatched to Ultrasonic test

FGK

Ultrasonic
test End turning, facing &
chamfering

Finish Machining Boring and counter Boring

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CONCLUSION
Eagerness and Enthusiasm have no evolution if a suitable platform is not available. These will
also gap no practical visualization of what we read. For these reasons we come to here for our
Vocational Training. We are able to relate our mind with our eyes in the factory. We come
across different engineering operation, different mechanism and different employees. We
enhance our knowledge with technical and non-technical principles. From the vocational
training we really feel it, for this way METAL AND STEEL FACTORY, ISHAPORE has
many contribution. Here good industrial environment and professional attitude helps us to know
how to perform a job in a industry. Here every departmental training expert’s instructions help
us to gather good knowledge.

So, we give thanks to all staffs, JWM, trainee. HOS charge men of METAL AND STEEL
FACTORY which is a great ordinance factory for defence security over all India.

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