Industrial Training in Sifl Industrial Athani

INDUSTRIAL TRAINING IN SIFL INDUSTRIAL ATHANI
DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING

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JYOTHI ENGINEERING COLLEGE, CHERUTHURUTHY
ACKNOWLEDGEMENT
We would like to express our sincere gratitude

towards Shri M.K. Sasikumar (MD SIFL) and
Shri.Krishnakumar Rajan (Sr. Manager A & HRD SIFL) for
permitting us to undergo training at SIFL Athani.
Also express our heartfelt gratitude towards

Mr.Jayakrishnan (A &HRD) , Mr.Jijesh and Mr.Sadanandhan
for their support and guidance during our internship
programme.
We would like to thank the staff and work force of

SIFL for giving us an insight into forging, Organizational setup
and Substation of SIFL.

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INDEX
1. INTRODUCTION……………………………………………………………………….4
2. COMPANY HISTORY…………………………………………………………………5
3. COMPANY PROFILE………………………………………………………………….6
4. ORGANISATION CHART……………………………………………………………7
5. DIE SHOP…………………………………………………………………………………8
6. FORGE SHOP…………………………………………………………………………..12
7. SUBSTATION…………………………………………………………………………..15
8. MAINTENANCE DEPARTMENT………………………………………………..16
9. MATERIAL TESTING LABORATARY…………………………………………..18
10.QUALITY CONTROL………………………………………………………………….20
11.HEAT TREATMENT…………………………………………………………………..22
12.FINISHING AND DISPACTH……………………………………………………...26
13.TECHNICAL DEPARTMENT………………………………………………………28
14.MARKETING……………………………………………………………………………29
15.MATERIALS MANAGEMENT DEPARTMENT(MMD)…………………30
16.CONCLUSION………………………………………………………………………….31

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INTRODUCTION
Steel and Industrial Forgings Limited is a public sector undertaking of
government of Kerala which manufactures forged components required for
various industries.
Forging is a mechanical operation in which components of required
shape are obtained by first heating the raw materials to their plastic state and
then forming the heated metal under pressure to the required shape using
dies.
The impressions of components are made in components called die
blocks. Each component to be manufactured requires two die blocks on of
which is attached to the ram and the other is fixed to the sow block.
The industry has a 11 KV substation for its electricity uses in the industry.
Step down transformers are used here to step down the voltage to ~440 V. The
output from the transformer is used for compressors, electric furnaces,
operating cranes, running machines and also for office purposes.
The main machinery used in the industry are ;
 Furnace for heating raw materials and also for heat treatment.
 Hammers for ramming heated materials into impression.
 CNC Milling machines for manufacturing die blocks.
 Lathes, copy milling machines for machining dies and jobs.
 Quench tanks for heat treatment, Air compressors.
 Shot blasting machine and grinding machines.
 Equipments for non-destructive testing including ultrasonic testing,
magnetic particle inspection and liquid penetrant test.
 Equipments such as spectrometer and metallographic microscope for
inspection of raw materials and finished products.
 Equipment for measuring mechanical properties of the finished products
and raw materials.

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 Equipment such as band saw for cutting raw materials to required size
from the billets.
COMPANY HISTORY
The story of the state-owned steel and Industrial forgings limited (SIFL)
at Athani in Thrissur district is one of a dramatic turnaround. The sick unit
which was referred to the Board for Industrial and Financial Reconstruction
(BIFR) in the mid-1990s is now a profit-making manufacturer of high-end steel
and industrial forgings. SIFL, a subsidiary of steel Industries Limited Kerala
(SILK), which had an accumulated loss of about Rs.15 corers in 1993-94 has
been making profit of RS.1.3 crores. By then it had made an accumulated profit
of about Rs.25 lakhs after making up for all the accumulated losses. According
to the officials, SIFL had achieved the turnaround without much additional
investments or acquisition of machineries. The government made a
contribution of Rs.6 crores to Rs.7 crores for arriving at one time settlement
with financial institutions under a BIFR revival package. The banks are advised
to reduce the interest rates on loans advanced to SIFL. Interestingly, some
other public sector companies in the forging sector were also accorded similar
packages around the same time. But not many could make a similar comeback
as SIFL did. Their main strength is their innovative capacity and the dedication
of worker. They could develop sophisticated and high-quality products needed
by the sectors as the aviation and the defense. Today Solaces complex and high
precision forgings for establishments such as the Indian Space Research
Organization, Railways, Bharat Heavy Electrical limited and Bharat Earth
Movers, Besides the defense and civil aviation units. Their decision to
concentrate on high value forgings for the sophisticated industries helped them
achieve the turnaround. An increase in demand for forgings and a hike in their
prices also contributed significantly. SIFL now exports products directly to
countries such as Indonesia and Qatar and indirectly to the U.S. and U.K.

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COMPANY PROFILE
Steel & Industrial Forgings Limited (SIFL) is an AS9100 C certificated,

Public sector undertaking fully owned by Government of Kerala, Incorporated
in1983and Started commercial production in 1986, SIFL rapidly forged ahead to
become a name to reckon with. They are masters in titanium and special alloy
forgings. Untiring efforts of two decades has saddled SIFL firmly in the forging
Industry of India and abroad with the best ratings for its products and services.
Forgings with exquisite designs and shapes, flawless forms and contours, broad
band sand spectra of meals like ALLOY STEEL, SUPER ALLOYS, ALUMINIUM and
TITANIUM. All in wide range of weight sand unmatched quality have made SIFL
the most sought after forging company in the country for critical components.
SIFL diverse product mix caters to a wide range of sectors. These include
complex and high precision Aerospace forgings, specialized forgings for
Defense, Heavy Forgings for commercial vehicles, Railways and other
components for automobiles etc.
FACT SHEET:
Year of establishment :- 1986
Nature Of business :- Manufacturer
Executives :- 63 nos.
Workmen :- 252 nos.
Contact workers /
temporary :- 185nos.
Total :- 500nos.
Major markets :- India & Other countries .

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ORGANISATION CHART
Figure 1

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DIE SHOP
This department produces the dies which contains the impression of the
product to be made. Dies are machined on die blocks which are made of die
steel (DN 1.2714 grade). They are machined using CNC Milling machine.
Dies are made of two halves- a top die and a bottom die. The top die is
attached to hammer, while the bottom die is attached to the anvil.
For manufacturing products of smaller dimensions, it may not be

economically feasible to use die block of normal dimensions. Hence it is carried
out using an arrangement called insert die block. Here the required impression
is sunk in a smaller piece of die block which is then inserted into a cavity inside
a die block of standard dimensions. The bigger die block to which inserted die
is fitted is called a die holder. The inserted die is fitted into the die holder by
shrink fitting. Damage which occurs to die blocks in course of their use such as
cracks are repaired by machining and welding.
Figure 2

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The main equipments used in die shop are as follows:
 CNC Milling machines (2 Nos.)
Make : (1) John Ford DMC-2100H
(2) BFW Agni
One of these is used for machining dies of normal size and one is
used for machining insert dies.
John Ford machine has a spindle speed of 6000 rpm and 25 HP

spindle motor power.
These machines have very high rate of production and are

convenient to use. Their operation can be summarized as follows:
i. A digital 3 dimensional drawing of the die to be made is produced

using software such as Del-CAM, Master CAM, and Pro V.
ii. This drawing is converted into corresponding programming codes

by the software, which is then fed to the CNC Machine using
microchips.
iii. The die block is set in the correct position inside the machine by
the operator. The operator of the machine selects the tool for
machining, depending on the operation to be carried out and once
the machine is started, it starts to machine the die.
iv. The tool may be changed at different stages of machining such as

rough cutting, finish cutting etc.
Figure 3

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 Copy Milling Machines (2nos.)
Make: (1) Yoneda YD-800-DS

(2) Heyligenstaedt
Both of these were initially used to copy an impression from a

wooden pattern to a die block. The first one is electronic while the
second is electromechanical which works on the based on clutch
mechanism.
Yoneda milling machine has a 11KW motor. Spindle speed of 40-

2000 rpm servo cut is the coolant used in it.
Now they are used for machining long keys, cross keys and
match dies. Long keys and cross keys are used for attaching die to the
ram and anvil.Match dies are used as an interlocking mechanism
between top and bottom dies.
Figure 4

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 Lathe
Make: Beco
These are two lathes which are used for machining outer
diameter of insert die blocks. Insert die blocks consist of two parts, one
is the insert die and other is the outer die block.
 Milling machine
Make: (1) Keller

(2) Sharda
(3) Bharat fritz werner
The first machine is used for facing operation on surface of the die
blocks and also for setting the depth of dovetail. It has a spindle speed of
1500 rpm.
The second machine is used for machining the angles on the

dovetail. Its milling head can be swiveled at an angle to the vertical.
The third milling machine is used for machining slots, keyways,

grooves etc.
 CNC Lathe
Make: HMT
This machine is used for machining forged components to the
required dimensions. Its spindle drive motor has a power of 30 HP,22.5
KW. The machine cuts in the x and z axis.
 Other machines like Radial drilling machine, welding machine, grinding

machine are also used in dye shop for drilling holes, finishing die etc.

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FORGE SHOP
The main production activity is carried out in the forge shop. The main
equipment used includes hammers, furnaces and presses.
FURNACES
Two types of furnaces are used:
i. Oil fired furnace
ii. Electrical furnace
In oil fired furnaces, a mixture of furnace oil and air is supplied to the
burner in a fixed proportion. These furnaces are used for heating of materials
such as steel (different grades). Temperatures achieved are about 1150 0C to
13000C. The temperature inside the furnaces is measured using
thermocouples. These furnaces are lined by different layers of refractory bricks
which prevent escape of heat to the surroundings. The control of the
temperature inside the furnaces is not as precise in the case of electrical
furnaces.
In electric furnaces, precise control the temperature inside the furnace is
possible. The heating is carried out by passing current through electrical coils
inside the furnace. These are used for heating materials such as aluminum and
titanium. The temperature range used for aluminium and titanium are 450-
5500C and 850-9500C respectively. The outside of the furnace is lined with
refractory bricks.
HAMMERS
These are used for exerting impact load on the heated metal placed on
the blocks to deform them to required shaped. They are pneumatic hammers
which derive power required for their operation from compressed air. The
main parts of the hammer are ram, sow, block, anvil, piston rod, main cylinder,
valves and control system.

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The two halves of the die block are attached to the ram and sow base of
the hammer using long key and cross key. The number of blows given by the
hammer for a particular product depends on the size of the product,
complexity of the component and material for the product. The hammers are
manually operated using hand lever or foot pedal.
In between consecutive blows of the hammer the two halves of the die
block are sprayed with a mixture of oil and compressed air. This helps to
remove the scales which have been formed as a result of the oxidation and
sticking to the die block. These scales would otherwise cause pitting action on
the die block if not removed. Besides the oil sprayed reduces the friction
between the two surfaces. It also prevents scales from adhering to the surface
of the die blocks.
Figure 5
The different hammers used are:

i. 16 ton
ii. 10 ton
iii. 6 ton
iv. 1 ton
16, 10, 6 ton hammers are used for closed die forging while 1 ton hammer is
used for open die forging.
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The compressed air required for their operation is obtained using

reciprocating compressors. The compressors used are two stage compressors.
They consist of a high pressure side and low pressure side.
A common crankshaft drives the pistons in both high pressure and low
pressure sides. Compressed air from low pressure side moves to the high
pressure side through an intercooler. The intercooler is a device used for
reducing the temperature of compressed air. This is because efficiency of a
compressor depends on temperature of the gas being compressed. Intercooler
consists of a large number of thin copper tube closely bound and covered by
an outer metal tube through which water is circulated. The air gets
compressed to a higher pressure in high pressure side and gets collected in
storage tanks cuts off air supply to suction side of the compressor once the
desired pressure has been attained.
PRESSES
Presses are used for trimming of forged components. Forged
components will posses flash which are projections along the parting line of die
blocks. The excess material present inside the die cavity will be forced out
under load exerted by the hammer into flash and gutters. They have to be
removed before subsequent machining of the product. This is done with the
help of trimming dies and punch. The trimming die posses a cutting edge
having outer profile of the component through the trimming die and the flash
gets sheared.
A type of press called forging press is used for cold compression of
aluminium forging after solutionising. This operation relieves the internal stress
developed in the forging. It is also used for forging of certain small
components.

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SUBSTATION
The plant has 11 KV Substation. There is a yard for receiving the
supply.3 AB switches are used in the yard. Main function of this is to isolate the
Transformer, Overhead lines, System or Cables from distribution network.
Dropout fuses are used. A CTPT is also used in the yard for measuring the
power, voltage etc. before reaching to the transformer. Then it is passed to the
transformer through cables.
TRANSFORMER
There are two transformers (Three phase) inside the electrical
substation. The rating of the transformers are as follows:
H T VOLTS - 11KV
L T VOLTS – 433V
H T CURRENT - 105 A
L T CURRENT – 2667A
The temperature is monitored using a thermal relay. If the temperature inside
the transformer exceeds a safe level it turns on an alarm. For further increase
in the temperature automatically cut off the supply. The temperature will be
around 420C. Temperature is lowered by circulation of air through its wings.
The output from the transformer is connected to oil circuit breaker,
air circuit breaker and then finally supplied to compressors, furnaces,
operating cranes, running machines and also for office purposes.
Eight Capacitors of 25 KVAR are used to enhance the power factor.
The average electricity usage per day at the industry is 12240 KWh .
GENERATOR
The industry has diesel generator (~1000L capacity) for its smooth
functioning even though the KSEB supply is not available. The ratings of
generator are as follows:
Power factor - 0.8 lagging, Current -250 A, Rpm -1500
Voltage – 415 V, Reactance – 180 KVA

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MAINTENANCE DEPARTMENT
It is one of the main departments functioning in SIFL. The main
objective of the maintenance department is to minimize the downtime and
keep all machineries in good condition, for maximum utilization of equipment
to achieve the required level of quality in the items produced such that
customer is satisfied.
The main types of maintenance are
1. DAILY MAINTENACE 2. PREVENTIVE MAINTENANCE
3. BREAKDOWN MAINTENACNE 4. UTILITY MAINTENANCE
1. DAILY MAINTENANCE
It includes the preparation of daily maintenance checklist for each
equipment. A list of machine manuals is also made and updated for each
machine. The operator has to check as per the checklist for the relevant check
points and tick on the particular date before starting the machine and a
production supervisor has to verify it randomly. At the end of every month the
production supervisors signs the record and hands it over to maintenance
head. The maintenance head verifies the details, signs and files for future
reference.
2. PREVENTIVE MAINTENANCE
Preventive maintenance for all the equipment will be based on the
breakdown analysis done once in a quarter. The Maintenance In Charge
prepares the list of machines. The schedule for the preventive maintenance is
prepared after the warranty period keeping in mind the usage of each
machines. The maintenance activity is carried out in the planned month. The
details of any spares replaced are entered in the machine equipment history
card. A detailed report is prepared about the maintenance activities carried
out for each machine and filed for reference.

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3. BREAKDOWN MAINTENACE
Any breakdown in machine is entered in the breakdown register kept in
the maintenance department by the user. The maintenance in charge reviews
the nature of breakdown. If needed an external agency should be called. After
the repair the report is sought from the external agency and filed for records.
The corrective action and the time loss are entered in the breakdown register.
The concerned machine card is updated. If it is a major breakdown the
machine needs to be revalidated to ensure that it meets the requirements.
Maintenance in charge will analyze the history card of a particular machine in
case of frequent breakdown, does the root cause analysis and initiate the
corrective preventive actions for the major causes.
4. UTILITY MAINTENANCE AND SAFETY AUDITS

It is also called building maintenance or housekeeping maintenance.
Building maintenance is generally monitored once in 3 months through
housekeeping audits. Housekeeping audits and safety audits will be conducted
in all areas. Necessary trainings will be provided to the auditors and all
employees. The frequency of audits will be once in a month.

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MATERIAL TESTING LABORATORY

Material testing lab is considered as an important section of SIFL as it ensures
the quality of the products that are delivered. It works in accordance with the
QA dept. The main functions of the material testing lab are:
1. Testing of incoming raw materials to ensure conformance with

specifications.
2. Metallurgical testing of finished products to inspect microstructure,
grain size, inclusions etc.
3. There are two sections namely- Chemical lab and Mechanical lab.
CHEMICAL LAB
The testing equipments in the chemical lab include spectrometer and

metallurgical microscope.
1. SPECTROMETER
The spectrometer is used to analyze the exact chemical composition of

raw materials. A small piece of metal and etched to get mirror finish.
It is then placed on the machine. The metal is heated to a high

temperature by passing an electric arc through it. As a result, it emits
electromagnetic radiation characteristic of its atomic make up. The
radiation is passed through a slit, diffraction grating and finally falls on some
kind of photodetector. This process is automated and controlled by a
computer. The atomic makeup of the metal can be determined based on
the wavelength of the radiation falling on the photodetector.
2. METALLURGICAL MICROSCOPE
The metallurgical microscope is used to analyze the microstructure of

both raw materials and forged components.
Microstructure analysis of raw materials is carried out to check their
purity. Raw materials possess various types of inclusions such as sulfides,
aluminates, silicates, oxides etc. Their content is represented by using index
numbers after observing under the microscope. If the content of inclusions
is within the acceptable limits, then the lot is accepted.

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Microstructure analysis is also carried out after heat treatment of forged

components. The microscope is fitted with a camera which is connected to
a computer. The microstructure is analyzed using software to check
whether the desired gain distribution is obtained.
MEHANICAL LAB
Mechanical lab contains equipment used to find out the mechanical
properties of the product. Properties such as tensile strength, Rockwell
hardness are found out.
The main equipments are:
1. UNIVERSAL TESTING MACHINE (100 ton)
Make: FIE
This machine is used mainly to find out the ultimate tensile
strength of test specimen and to plot their load extension curve. The
specimen is prepared by machining according to Indian standards.
The load extension curve is plotted with the help of an
extensometer. The machine is connected to a computer which
automatically plots the deformation curve, measures various properties
such UTS, yield point, breaking load etc. The computer constantly
monitors loading of the specimen from beginning to end and gives
instructions to be carried out at different stages of loading
2. IMPACT TESTING MACHINE

This machine is used to find out the impact strength of test specimen
Two test are performed using this machine; IZOD test and CHARPY test
The specimen is prepared by cutting notches of standard size using a
notch broaching machine.
The profile of the notch is inspected using a profile projecting machine
to check its dimensions.
3.ROCKWELL HARNESS TESTING MACHINE

This machine is used to evaluate the Rockwell hardness of test
specimen To study properties of the product after heat treatment, a test
bar is usually subjected to the same heat treatment cycle of the product
either along with the batch of forged products or separately in a small
electric furnace present in the lab. The test bar is then used for evaluation
of properties such as UTS, impact strength, hardness etc.

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QUALITY CONTROL
SIFL is an ISRO 9001:2008 certified company along with AS-9100C certification

of fulfilling requirements related to the aerospace segment.
The procedures followed to ensure the quality standards are:
 Acceptance plan and testing of 100% raw materials supplies.

 Continuous vendor evaluation.
 Setting and control of quality standards for forging as per quality plan.
 Strict implementation of established processes
 Corrective and preventive actions are implemented promptly for
minimizing defects to zero level.
 Calibrating and maintenance of testing, measuring and thermal control
equipments.
 Certifications to facilities by IBR, EIL, IRS and other inspection agencies.
 Constant and continuous consultation with customers and suppliers on
all technical aspects.
 In-depth testing and research, based on specific customer requirements.
 Maintenance of high vendor rating with customers.
The quality control procedures followed during production are as follows
1. Raw material inspection

2. Hot inspection
3. Cold inspection
4. Final inspection including Non destructive tests(NDT’s)
Raw material inspection involves checking of the billets for

defects such as cracks, porosity etc. A small section of the billet is cut and
etched to examine defects such as porosity. It is also subjected to

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microstructure analysis to find out defects such as micro segregation and

macro segregation.
Hot inspection involves checking of forged components in hot stage
(shortly after forging). Due to the high temperature of the items it is not
possible to inspect all the products in a batch. Hence random sampling
inspection is adopted. Here one or more control dimensions of the item will be
checked using hot Go-NO-Go Gauges.
Defects such as unfilled, die mismatch, lap, cracks, in the die can be detected
through hot inspection.
Cold inspection involves inspection of the products after they have

cooled down. During cold inspection each and every item of a batch is
inspected.
Its dimensions are checked and defects are also inspected. If The item is
found to be satisfactory it is forwarded for heat treatment.
The microstructure of the item after the heat treatment is studied to

check whether the desired microstructure has been obtained. The Brinnel
hardness of the item is also found out. Mechanical Properties of the item such
as UTS, impact strength are evaluated.
Final inspection involves inspection for defects which are not visible with
naked eye such as very fine cracks. Non destructive tests,
Such liquid penetrant test, magnetic particle inspection and ultrasonic
testing are employed. The dimensions of the item are checked and it is
cleared for dispatch.

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HEAT TREATMENT
Heat treatment consist of series of operation involving heating and cooling of
the forged product for obtaining certain desirable properties.
The heat treatment processes are designed based on the information from the
phase diagram and tine temperature transformation diagrams and continuous cooling
transformation diagrams related to specific alloy. A process is selected for a specific
component based on desired properties of the component.
OBJECTIVES OF HEAT TREATMENT:
1.To improve properties like tensile strength, ductility and impact resistance.
2.To improve machinability.
3.To refine grain structure after hot working.
The equipments in heat treatment shop are;
1. Electrical and oil fired furnaces for heating normal components.
2. Pit and furnace which is economical for heating smaller components.
3. Drop bottom furnace which is used for solutionising of aluminium alloy.
4. Quench tank.
5. Charging machine which is used for loading and unloading of heat treatment
charges.

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Furnaces are provided with thermocouple which constantly monitor the
temperature inside the furnace. The temperature is controlled by controlling the fuel
supply or current using control panels.
Electric furnaces are provided with baffles which cover the coils. Their
functions to prevent direct radiation from striking the metal and to prevent localized
heating. They are also provided with fan to ensure uniform heating of the product. Drop
bottom furnaces have a water quench tank beneath the furnace and furnace bed can be
moved to facilitate quenching of the product after heating. This furnace is used for
solutionising of aluminium.
The various heat treatment processes used are as follows:
1.FOR STEEL
1. ANNEALING
Here steel is heated to the austenite state followed by very slow

cooling. The objective of annealing is to remove all structural
imperfections by complete recrystallisation and to relieve internal
stress developed. It improves ductility of steel. Steels are heated
50-900C above their critical temperature lines (a3 for
hypoeutectoid steels and a1 hypereutectoid steels) and retained
at that temperature. Upon very slow cooling in the furnace
austenite decomposes into ferrite and cementite. Along with this
complete recrystallisation occurs and the structure gets refined.

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2. NORMALISING
Normalising uses a faster cooling rate than used in annealing,
thereby producing fine pearlite. By controlling the fineness of
pearlite the effect of dispersion strengthening in steel can be
managed. The purpose of normalizing is to obtain relatively good
ductility without reducing hardness and strength. It is used as a
finishing treatment for steel giving higher strength than that
obtained by annealing. The material is heated to about 50 0C upper
critical temperature. After retaining the material at this
temperature for specific duration, it is allowed to cool in air to
room temperature.
3. HARDENING AND TEMPERING
HARDENING:
This is a heat treatment process carried out to increase the

hardness of steel. The hardness is attained due to formation of
martensite. The main purpose of hardening is to increase the
hardness, strength and wear resistance .The first step in hardening
is heating the steel to austenite stage. It is held at this
temperature for sufficient time so that the transformation is
uniform throughout the thickness. Then it is quenched in water or
oil which leads to the formation of martensite.
TEMPERING:
This heat treatment process is carried out immediately after

hardening. Tempering done to reduce brittleness and to improve
toughness of hardened steel .It increases toughness by relieving
internal stresses developed during quenching .The process
involves reheating the hardened material to temperature line (AI
line) followed by slow cooling.

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2.FOR ALLOYS OF ALUMINIUM AND TITANIUM

Non ferrous alloys generally cannot be heat treated by the techniques
on ferrous alloys . The reason being that they do not undergo phase like those
in steels. They are hardened and strengthened by the process called
precipitation hardening. Their heat treatment consist of mainly two process -
solutionising and aging.
1.SOLUTIONISING
In solutionising the alloy is heated to within the solid solution
kappa phase and then cooled rapidly by quenching it in water. The
structure obtained after quenching consists of only single phase
kappa. This alloy has moderate strength and considerable
ductility.
2.AGING
The structure obtained by solutionisiing can be made stronger by
precipitation hardening. The alloy is reheated to an intermediate
temperature and held there for a period of time, during which
precipitation take place. because of precipitation process is one of
time and temperature, it is called aging and if carried out at room
temperature it is called natural aging. Natural aging is usually
followed by artificial aging.
Besides some aluminium forgings are also subjected to an intermediate

process called compression. This is carried out after solutionising and before
aging .it is used as a stress relieving process.

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FINISHING AND DISPATCH
SURFACE FINISH
Surface finishing is broad range of industrial processes that alter the
surface of a manufacture item to achieve a certain property. Finishing
processes may be employed to improve appearance, adhesion or wettability,
solder ability, corrosion resistance, hardness, modify electrical conductivity,
remove burns and other surfaces flaws and control the surface friction. In
limited cases some of these techniques can be used to restore original
dimensions to salvage or repair an item. An unfinished surface is often called
mill finish.
Surface finishing processes can be categorized by how they affect the work
piece:
1. Grinding
2. Shot blasting
1. GRINDING
Grinding is a metal cutting operation performed by means of abrasive
particles rigidly mounted on a rotating wheel. Each of the abrasive particles act
as a single point cutting tool and Grinding wheel act as a multipoint cutting
tool. The Grinding operation is used to finish the work pieces with extremely
high quality of surface finish and accuracy of shape and dimensions. Grinding is
one of the widely accepted finishing operations because it removes materials
in very small size of chips 0.25 to 0.50mm. Grinding of very hard material is
also possible.
TYPES OF GRINDING
There can be different criteria to classify grinding into different
categories. On the basis of quality of grinding, it is classified as rough grinding
and precision grinding.
ROUGH GRINDING
It involves removal of stock without any reference to the accuracy of
results. Generally rough grinding is followed by precision grinding. The defects
removed through grinding include burr at parting line area, folds, seams, lap,
mismatch, scale pits etc.

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FINISHING GRINDING
Finishing grinding removes smaller amount of metal.it is used to
produce finished parts and accurate dimensions. The defects removed same as
that in rough grinding.
PNEUMATIC GRINDING
Here grinding is done with help of air rotated grinding wheel. It is used to
finish those parts which cannot be reached hand easily.
2. SHOT BLASTING
Shot blasting is surface treatment process using high velocity steel abrasive.
Shot blasting is method through which it is possible to obtain excellent cleaning
and surface preparation for secondary finishing operations.
Shot blasting is commonly used for:

• The cleaning of surface of forgings.
• Preparing surface to be painted, coated etc.
In general shot blasting concentrates abrasive at high speed (65-110m/s) in a

controlled manner at the material thereby removing surface contaminates due
to the abrasive impact.
DISPATCH
Dispatch means sending the finished good to customer after evaluation and
inspection. Here in SIFL the dispatch team inspects the finished goods and
ensures there are no defects. If any defect exist they send it back to finishing
section. This team also punches the logo, number and name of product before
they dispatching. They also keep records of the products dispatched.

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TECHNICAL DEPARTMENT
This department prepare the process chart for obtaining final products.
The drawings of components required by customers are analysed by the
technical department. The customer usually provides three types of drawings-
Machined drawing, Proof machined drawing and forged drawing.
The technical department analyses the drawing and designs the die
required for the job. This department decides the various allowances to be
provide in the die such as machining allowance, flash, draft angle etc. The
drawing of the die is made and forwarded to the die shop.
This department identifies the type and grade of raw material and its
quantity considering net weight, flash weight etc and forwards the data sheet
to the raw materials section.
Depending on the complexity of the job, the number of stages of forging
required for the job is decided. Complex jobs require three or four stages
which are blocker die, intermediate die, and finisher die whereas simple jobs
require only one or two stages.
They decide whether to use open die forging or closed die forging
depending on the complexity of the item.
The power consumption for production of the component is estimated.
Depending on properties required by the customer, heat treatment processes
are identified and forwarded to heat treatment shop.
The additional quality control measures required by the customer are
forwarded to the quality control section.
Before a product is forged in large quantity as required by customer, a trial
production run is carried out to produce about five numbers of products. This
is done to check whether the final product with desired properties is obtained
by following the process chart and whether any unforeseen hindrances exist
during any stage of production. If the trial production run is satisfactory, full
fledged production is carried out.

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MARKETING
Marketing department is the heart of any business organization. The main

functions of marketing department are:
1. Interacting with customers and booking orders.

2. Co-ordination with production department to ensure that the products
are made available to the customers as per schedule.
3. Sales realization.
4. Co-ordination of third party inspection and customer complaints.
Interaction with customers will result in getting enquiry. Enquiry will be

registered and will be sent to technical department for studying technical and
economical feasibility. Technical department will generate a data sheet and
return it to the marketing department. Based on this data sheet, marketing
department will prepare a cost estimation. A cost sheet will be prepared and
quotations will be submitted to customer. On receipt of orders, drawings and
technical delivery conditions will be forwarded to technical department along
with sale order. Based on sale order the manufacturing activity will take place
and product will be dispatched to the customer. When payments are due,
marketing department interacts with customers and ensures sales realisation.
Certain customers require third party inspection. When items are ready
for inspection, QC department after in house inspection and acceptance
intimates the matter to marketing dept. Marketing department coordinates
with third party inspection agencies and makes arrangements for inspection.
On receipt of customer complaint, the details are forwarded to QC

department and instructions are given to solve the issue.

30
MATERIALS MANAGEMENT DEPARTMENT (MMD)

This department carries out systematic and impeccable procedures
regarding purchase of various necessary machinery spares, raw materials, fuel
oil etc. The procedures for purchase of any item is as follows;
i. The steps for purchase of any item is initiated only after the reception of
indent from the respective department. This may be regarding spare parts,
raw material etc.
ii. The details of the indent is directed to the stores dept. and the details of last
purchase price, stock etc. are sought.
iii. Based on information provided by the store, a committee consisting of

indenter, purchase department, chief of works, finance will meet and discuss
details regarding feasibility of the purchase and quantity of the item required.
iv. The next step involves sending an enquiry to various companies/dealers. One
or more quotations may be received and details in each quotations are tables
and analysed before sending it to the indenter.
v. Unless quality standards or other specific conditions remain unsatisfied the LI

(lowest price) tender is accepted. Recommendations by the indenter are
addressed and the proposal is sent to Works department, Finance department
and finally to the MD. Once MD signs on the proposal, purchase order is
placed.
vi. On receipt of the item, GRE (goods receipt cum inspection) is sent to indenter.
Unless the quality or quantity is unsatisfactory, the items accepted after
verification.
For purchase of materials whose price exceeds Rs.5 lakhs, the filing of an e-
tender is mandatory.
In cases of emergency such as requirement of a square without which

production has to be halted, there is a provision to cut the above time
consuming procedures and to purchase the item from the dealer through
direct payment.
In such situations price of the item should not exceed Rs.10000.

31
CONCLUSION
After undergoing the training programme, we obtained a better
understanding about the different arrangements, equipments in a substation
of an industry. Also come to know about significance of forging operations,
usage of electricity for carrying out this, advantages and limitations of forging
operations.
The hands of experience at a manufacturing industry was at the same
time eye opening and inspiring.
We were able to get an insight into the organizational setup of the
factory and could identify the significance of different departments. Also come
to know how electricity and the substation plays an important role in an
industry.
Finally, the experience has made us prepared to take up
responsibilities and challenges in our future careers.

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Industrial Training in Sifl Industrial Athani

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INDUSTRIAL TRAINING IN SIFL INDUSTRIAL ATHANI

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING

We would like to express our sincere gratitude

Also express our heartfelt gratitude towards

We would like to thank the staff and work force of

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING

9. MATERIAL TESTING LABORATARY…………………………………………..18

12.FINISHING AND DISPACTH……………………………………………………...26

15.MATERIALS MANAGEMENT DEPARTMENT(MMD)…………………30

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING

Steel & Industrial Forgings Limited (SIFL) is an AS9100 C certificated,

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING

For manufacturing products of smaller dimensions, it may not be

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING

The main equipments used in die shop are as follows:

 CNC Milling machines (2 Nos.)

Make : (1) John Ford DMC-2100H

(2) BFW Agni

John Ford machine has a spindle speed of 6000 rpm and 25 HP

These machines have very high rate of production and are

i. A digital 3 dimensional drawing of the die to be made is produced

ii. This drawing is converted into corresponding programming codes

iv. The tool may be changed at different stages of machining such as

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING

 Copy Milling Machines (2nos.)

Make: (1) Yoneda YD-800-DS

Both of these were initially used to copy an impression from a

Yoneda milling machine has a 11KW motor. Spindle speed of 40-

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING

Make: (1) Keller

The second machine is used for machining the angles on the

The third milling machine is used for machining slots, keyways,

 Other machines like Radial drilling machine, welding machine, grinding

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING

ii. Electrical furnace

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING

The different hammers used are:

The compressed air required for their operation is obtained using

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING

4. UTILITY MAINTENANCE AND SAFETY AUDITS

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING

MATERIAL TESTING LABORATORY

1. Testing of incoming raw materials to ensure conformance with

The testing equipments in the chemical lab include spectrometer and

The spectrometer is used to analyze the exact chemical composition of

It is then placed on the machine. The metal is heated to a high

The metallurgical microscope is used to analyze the microstructure of

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING

Microstructure analysis is also carried out after heat treatment of forged

2. IMPACT TESTING MACHINE

3.ROCKWELL HARNESS TESTING MACHINE

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING

SIFL is an ISRO 9001:2008 certified company along with AS-9100C certification

The procedures followed to ensure the quality standards are:

 Acceptance plan and testing of 100% raw materials supplies.

The quality control procedures followed during production are as follows

1. Raw material inspection