VOCATIONAL TRAINING REPORT

[18-JUN-2017 to 30-JUN-2018]

SUBMITTED BY

ANKUR KUMAR PASSI

LOKNATH YADAV
ANAND KR BARI
BTECH,7th SEM
MECHANICAL ENGINEERING
ACADEMY OF TECHNOLOGY, ADISAPTAGRAM
 ACKNOWLEDGEMENT
Acknowledgement is not just a formality but is generous opportunity
to express the thank you to all of those without whose active support
and encouragement this technical report is impossible to make. I
extend my heartiest thank to METAL & STEEL FACTORY,
ISHAPORE, which has given us a great opportunity to gain some
hand on knowledge is different production and development used for
the defence purposes of our country.
I also extend my thanks to:
Mr. Rajnish Jauhari (GM/MSF)
Mr. Tularam Patel (AGM/ADMIN)
Mr. PK Pattnayak (Jt. GM/ADMIN)
Mr. B.C. Kashyap ALWC(C)
Mr. Dilip Banerjee (JWM/HRD)

For their immense help and tremendous co-operation and spontaneous

encouragement to make the training a grand success.
 ATTENDANCE
NAME OF THE TIME PERIOD NAME OF THE SIGNATURE
SECTION ADVISOR &
DESIGNATION

NEW ROD MILL 18/06/2018

(NRM) to
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

NEW GUN 25/06/2018

FORGING (NGF) to
26/06/2018

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

CARTRIDGE 29/06/2018
CASE SHOP (CCS) to
30/06/2018
 INDEX
 FACTORY PROFILE

 NEW ROD MILL [NRM]

 RADIAL FORGING SHOP [RFS]

 STEEL MELTING AND REFINING[SMR]

 NEW GUN FORGED[NGF]

 AMMUNITION COMPONENT SHOP[ACS]

 CARTRIDGE CASE SHOP[CCS]

 CONCLUSION
 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.
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
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.

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
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
 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
 RADIAL FORGING SHOP(RFS)
FOUR DIE FORGING
Four-die forging device is a special forging tool designed for manufacturing
forgings with long axis by four-side radial forging method in conventional
open-die hydraulic forging press. A similar stand-alone machine is known as
a radial forging machine.
The device is used for deformation treatment of ingots and blanks from ordinary
and high-alloy steels and alloys, including hard-to-deform ones, in wide range
of shapes and grades to obtain various solid and hollow forgings, including
round, square and polygonal forged bars of constant and variable cross-section,
blanks of smooth and stepped shafts, axles, thick-wall pipes, mechanical tube,
shells, etc.

DESIGN AND OPERATION

The device consists of the upper case and the lower case with the upper die and
the lower die installed therein respectively, and sliders that are kinematically
interconnected with the cases by means of guides of special design and hold
side dies attached thereto. The device is installed on a tool table of an open-die
forging press as easy as ordinary dies. Thereat, the lower case of the device is
fixed to the tool table and always remains stationary while the upper case is
attached to the press ram and always travels along with it. When the press ram
goes up the upper die also goes up and the side dies are retracted opening the
device working space where to a work piece is fed by a manipulator. When the
press ram goes down the work piece is reduced simultaneously by four dies.
Then the cycle repeats.
 FOUR DIE FORGING DEVICE
Advantages of Forging with Four-Die Forging Device
The use of four-die forging devices in hydraulic forging presses provides for the
following advantages in comparison with conventional methods of forging by
two dies:

 Capability of forging low-ductility and hard-to-deform steels and alloys due

to favourable stress and strain state of metal in the zone of deformation
 Increase in the forging process productivity at the average by 2 times due to
the absence of lateral spread of metal and consequently the lower number of
press strokes required to obtain the forging of the required size and shape
 Electric power saving because of lower press running time as well as lower
consumption of energy carriers required to reheat metal between forging
passes and lower metal loss during reheating
 Higher dimensional accuracy of forgings after sizing in the device allowing
to decrease forging tolerances by 2-2.5 times and forging allowances by 1.5
time for further machining
 Higher metal yield by 10-12%
 High flexibility in operation and fast adjustment of equipment to varying
range of forging stock
 Relatively low cost, low operating expenses and high reliability of the four-
die forging device proven by many years of its industrial operation.
GUN BARREL
A gun barrel is a crucial part of gun-type ranged weapons such
as small firearms, artillery pieces and air guns. It is the straight shooting tube,
usually made of rigid high-strength metal, through which a contained rapid
expansion of high-pressure gas(es) is introduced (via propellant combustion or
via mechanical compression) behind a projectile in order to propel it out of the
front end (muzzle) at a high velocity. The hollow interior of the barrel is called
the bore. The measurement of the diameter of the bore is called the caliber.
Caliber is usually measured in inches or millimetres.
CONSTRUCTION
A gun barrel must be able to hold in the expanding gas produced by
the propellants to ensure that optimum muzzle velocity is attained by the
projectile as it is being pushed out. If the barrel material cannot cope with the
pressure within the bore, the barrel itself might suffer catastrophic failure and
explode, which will not only destroy the gun but also present a life-threatening
danger to people nearby. Modern small arms barrels are made of carbon
steel or stainless steel materials known and tested to withstand the pressures
involved. Artillery pieces are made by various techniques providing reliably
sufficient strength.
CANNON TUBE
A cannon (plural: cannon or cannons) is a type of gun classified as artillery that
launches a projectile using propellant. In the past, gunpowder was the primary
propellant before the invention of smokeless powder in the 19th century.
Cannon vary in caliber, range, mobility, rate of fire, angle of fire, and firepower;
different forms of cannon combine and balance these attributes in varying
degrees, depending on their intended use on the battlefield. The word cannon is
derived from several languages, in which the original definition can usually be
translated as tube, cane, or reed. In the modern era, the term cannon has fallen
into decline, replaced by "guns" or "artillery" if not a more specific term such as
"mortar" or "howitzer", except in the field of aerial warfare, where it is often
used as shorthand for autocannon.
 CANNON MATERIAL, PARTS AND TERMS

Cannon in general have the form of a truncated cone with an internal cylindrical
bore for holding an explosive charge and a projectile. The thickest, strongest,
and closed part of the cone is located near the explosive charge. As any
explosive charge will dissipate in all directions equally, the thickest portion of
the cannon is useful for containing and directing this force. The backward
motion of the cannon as its projectile leaves the bore is termed its recoil and the
effectiveness of the cannon can be measured in terms of how much this
response can be diminished, though obviously diminishing recoil through
increasing the overall mass of the cannon means decreased mobility.
NEGATIVE SPACES
 Bore: The hollow cylinder bored down the centre of the cannon, including
the base of the bore or bottom of the bore, the nearest end of the bore into
which the ordnance(wadding, shot, etc.) gets packed. The diameter of the
bore represents the cannon's calibre.
 Chamber: The cylindrical, conical, or spherical recess at the nearest end of
the bottom of the bore into which the gunpowder is packed.
 Vent: A thin tube on the near end of the cannon connecting the explosive
charge inside with an ignition source outside and often filled with a length
of fuse; always located near the breech. Sometimes called the fuse hole or
the touch hole. On the top of the vent on the outside of the cannon is a flat
circular space called the vent field where the charge is lit. If the cannon is
bronze, it will often have a vent piece made of copper screwed into the
length of the vent.
SOLID SPACES
The main body of a cannon consists of three basic extensions: the foremost and
the longest is called the chase, the middle portion is the reinforce, and the
closest and briefest portion is the cascabel or cascable.

The chase: Simply the entire conical part of the cannon in front of
the reinforce. It is the longest portion of the cannon, and includes the following
elements:

The neck: the narrowest part of the chase, always located near the foremost end
of the piece.

The muzzle: the portion of the chase forward of the neck. It includes the
following:

The swell of the muzzle refers to the slight swell in the diameter of the piece at
the very end of the chase. It is often chamfered on the inside to make loading
the cannon easier. In some guns, this element is replaced with a wide ring and is
called a muzzle band.

The face is the flat vertical plane at the foremost edge of the muzzle (and of the
entire piece).

The muzzle mouldings are the tiered rings which connect the face with the rest
of the muzzle, the first of which is called the lip and the second the fillet

The muzzle astragal and fillets are a series of three narrow rings running around
the outside of the chase just behind the neck. Sometimes also collectively called
the chase ring.

The chase astragal and fillets: these are a second series of such rings located at
the near end of the chase.

The chase girdle: this is the brief length of the chase between the chase astragal
and fillets and the reinforce.
 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".
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).
 Table 1: Iron Ore Classification
Name Classification Theoretical maximum iron content (%)"

Haematite Fe2O3 70.0

Magnetite Fe3O4 72.4

Goethite FeO.OH 62.8

Siderite FeCO3 48.3

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 Fe SiO2 Al2O3 Mn P S H2O(comb)
Mt. Newman 64.7 4.15 1.60 0.06 0.054 0.007 2.5
High Grade
LumpWA (H)
Mt. Newman 62.0 5.55 2.60 0.04 0.069 0.009 2.2
High Grade
Fines WA (H)
Yandi Fines 58.5 4.9 1.3 0.03 0.043 0.005 9.6
WA (G)

Whyalla 62.8 3.76 1.85 0.27 0.050 0.033 3.12

Pelletising
Fines 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.
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.
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.
 NEW GUN FORGE(NGF) SHOP

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.
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
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.
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.
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.
FLOW CHART OF FORGING OF HEAVY ALLOY STELL
 NEW ROD MILLS(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."
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.
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
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
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.
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.
 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
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.

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
 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 anti-
materiel 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.
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
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.

CHEMICAL COMPOSITIONS
%C %Si %Mn %S %P %Ni %Cr %C %Al
u
30m .09-.13 .13max .3-.5 .025 .025max .15max .20max .20m .03-
m ax .09
 CONCLUSION
Enthusiasm and motivation of work comes from inner heart of the mankind.
These virtues make a human being sound in specific subjects. In case of
clearing the mechanical competitions, they must know the practical uses of what
they visualised in the theoretical classes. During my course of vocational
training in Metal and Steel Factory, Ishapore I came across different aspects of
Mechanical Engineering. It gave me a good opportunity to learn what I have
read in books. The working employees of Metal And Steel Factory, Ishapore are
very much friendly and helpful and they have helped us throughout the
complete training period through their valuable guidance and time.