KYAMBOGO UNIVERSITY

P.O.BOX 1, KAMPALA (U)

FACULTY OF ENGINEERING

DEPARTMENT OF MECHANICIAL AND PRODUCTION ENGINEERING

BACHELORS OF ENGINEERING IN MECHANICAL AND MANUFACTURING

ENGINEERING

NAME: OJIE CHARLES

REG.NO: 17/U/15145/EMD/GV

SIGN: ……………………………………….

PLACEMENT: PRAMUKH STEEL LIMITED

P.O.BOX 988 NJERU-JINJA

DEPARTMENT: FACTORY WORKSHOP

THIS INDUSTRIAL TRAINING REPORT IS SUBMITTED TO THE DEPARTMENT

OF MECHANICIAL AND PRODUCTION ENGINEERING AS AN ACADEMIC
REQUIREMENT FOR THE AWARD OF A BACHELORS DEGREE IN
MECHANICAL AND MANUFACRTURING ENGINEERING.

MAY-AGUSUT 2018

1
 DECLARATION
I OJIE CHARLES registration number 17/U/15145/EMD/GV declare that the information
written in this report is out of my own experience and effort and not a photocopy of
someone’s work. It is a summary of activities carried out during the 10 weeks of industrial
training at Pramukh Steel Limited.

Sign

………………………

Date

………………………

i
 APPROVAL
This is to certify that OJIE CHARLES registration number 17/U/15145/EMD/GV has
successfully completed his industrial training at Pramukh Steel Limited and this is a summary
of his original work that he was actively engaged in under supervision.

This is true work that was able to be done and is now ready to be submitted to the department
of Mechanical and Production Engineering at Kyambogo University.

Human Resource Pramukh Steel Limited

Mr. ONYANGO GODFREY

Sign: …………………….

Date: …………………….

Machine shop supervisor (TURNER)

ENGINEER OPIYO JUSTINE

Sign: …………………….

Date: …………………….

Kyambogo University Supervisor (inspector)

Mr. TWESIGYE AMBROSE

Sign: ……………………….

Date: ……………………….

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 DEDICATION
I dedicate this report to my beloved father Mr. OJIE CHARLES and my sisters and brothers
who have always been there for me and given me courage and strength to reach this far.

Long live Pramukh Steel Limited, Long live Kyambogo University. God bless you.

Lastly I dedicate this report to Eng. OPIYO JUSTINE, .Eng. JONAH, Eng. JOSEPH,
RAMA, MUJALA, EMA and to friends plus my fellow trainees.

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 ACKNOWLEDGEMENT
I thank the almighty God for the protection, care and good health during my industrial
training at Pramukh Steel Limited.

I acknowledge with great pleasure the staff and management of Pramukh Steel Limited for
granting me an opportunity to do my industrial training with them. Great thanks go to the HR,
Engineering Manager, the machine shop turners Opiyo, Joseph, Ramathan and the different
sub-section superintendents and supervisors at the guidance, care and support rendered to me
leading to successful industrial training at Pramukh Steel Limited.

Great thanks go to my fellow trainees in the factory engineering section, whose different
contributions made the compilation of this report possible.

Finally I thank my loved friends for their support during the compilation of this report. May
the Good Lord bless you all abundantly!

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 PREFACE
Industrial training is a period that the college accords to its students that offer practical
subjects to put into practice what they would have studied for that academic year and even
learn more skills that are applicable in there courses.

This industrial training report explains the development of practical and professional skills in
the field of mechanical/ factory department carried out at Pramukh Steel Limited.

Chapter one is about the company PRAMUKH STEEL LIMITED where I carried out the
training and other Chapters talk about the work done during the training and the skills
acquired from the training, conclusion and recommendations for strengthening the training
program.

To this effect therefore I would like to thank the entire PRAMUKH STEEL LIMITED
fraternity for the opportunity they rendered to me and my colleagues during the time we were
doing industrial training within the company.

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 TABLE OF CONTENTS
DECLARATION........................................................................................................................i
APPROVAL..............................................................................................................................ii
DEDICATION..........................................................................................................................iii
ACKNOWLEDGEMENT........................................................................................................iv
PREFACE..................................................................................................................................v
TABLE OF CONTENTS.........................................................Error! Bookmark not defined.
CHAPTER ONE....................................................................................................................- 1 -
1.0 INTODUCTION..............................................................................................................- 1 -
1.1 HISTORICAL BACKGROUND....................................................................................- 1 -
1.2 COMPANY VISION.......................................................................................................- 1 -
1.3 COMPANIES AIM.........................................................................................................- 1 -
1.4 COMPANY OBJECTIVES.........................................................................................- 1 -
1.5 PRODUCTS PRODUCED..............................................................................................- 2 -
1.6 AIMS AND OBJECTIVE OF INDUSTRIAL TRAINING............................................- 2 -
1.7 LITERATURE REVIEW AND BRIEF OF TASKS DONE..........................................- 3 -
1.7.1 Machining.................................................................................................................- 3 -
1.7.2 Welding and fabrication............................................................................................- 3 -
CHAPTER TWO...................................................................................................................- 4 -
2.0 MACHINE SHOP...........................................................................................................- 4 -
2.1 DEFINTION....................................................................................................................- 4 -
2.2 SAFETY PRECAUTIONS IN THE MACHINESHOP..................................................- 4 -
2.3 MACHINING OPERTIONS...........................................................................................- 4 -
2.4 MACHINING..................................................................................................................- 4 -
2.4.1 Classification of machined parts...............................................................................- 5 -
2.4.2 OPERATIONS AND THEIR BRIEF DESCRIPTIONS DONE ON THE LATHE
MACHINE AND TOOLS USED......................................................................................- 5 -
2.4.2.1 Turning...............................................................................................................- 5 -
2.4.2.2 Facing.................................................................................................................- 5 -
2.4.2.3 Contour turning..................................................................................................- 5 -
2.4.2.4 Chamfering.........................................................................................................- 5 -
2.4.2.5 Cutting off or parting off....................................................................................- 5 -
2.4.2.6 Threading...........................................................................................................- 5 -
2.4.2.7 Boring.................................................................................................................- 5 -
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 2.4.2.8 Drilling...............................................................................................................- 6 -
2.4.2.9 Tapping..............................................................................................................- 6 -
2.4.2.10 Contour boring.................................................................................................- 6 -
2.4.3 methods of holding work in a lathe machine............................................................- 6 -
CHAPTER THREE...............................................................................................................- 8 -
3.0 Introduction.....................................................................................................................- 8 -
3.1Guide Assembly...............................................................................................................- 8 -
3.1.0 Operations done on the smaller shaft........................................................................- 8 -
3.2.0 Operations done on the longer shaft...........................................................................- 13 -
3.3.0 Nozzle and its operations............................................................................................- 14 -
3.4.0 Threading of bolts and pipes......................................................................................- 19 -
3.5 Threading of L-bolts;.....................................................................................................- 21 -
3.6 Threading of pipes.........................................................................................................- 22 -
3.7.0 Eccentric shaft and its operations...............................................................................- 23 -
3.8.0 Making a stepped shaft...............................................................................................- 25 -
3.9.0 A nozzle......................................................................................................................- 27 -
CHAPTER FOUR...............................................................................................................- 32 -
4.0 Introduction...................................................................................................................- 32 -
4.1 WELDING AND FABRICATION...............................................................................- 32 -
4.1.1 Definition...............................................................................................................- 32 -
4.2 Types of welding...........................................................................................................- 32 -
4.3 Welding positions..........................................................................................................- 32 -
4.4 Welding joints...............................................................................................................- 33 -
4.5 Welding equipment and machines.................................................................................- 33 -
4.6 Safety precautions.........................................................................................................- 34 -
4.7 OPERATIONS ON GAS CUTTING............................................................................- 35 -
4.8 0 OPERATION ON BEAD LINING.................................................................................37
CHAPTER FIVE......................................................................................................................39
5.0 Furnace...............................................................................................................................39
5.1 Introduction........................................................................................................................39
5.2 CONSTRUCTION OF THE FURNACE..........................................................................39
5.3 CAPACITY OF THE FURNACE.....................................................................................39
5.4 HEATING OF SCRAP......................................................................................................40

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5.5 Brief process in the manufacturing of the TMT bars.........................................................41
CHAPTER SIX........................................................................................................................42
6.1 SKILLS GAINED IN THE COMPANY WORKSHOP...................................................42
6.2 CHALLENGES FACED DURING THE INDUSTRIAL TRAINING.............................42
6.3 GENERAL CONCLUSION..............................................................................................42
6.4 RECOMMENDATIONS...................................................................................................43
6.5 REFERENCES...................................................................................................................44

viii
 CHAPTER ONE
1.0 INTODUCTION
Pramukh Steel Limited is one of the leading producers of TMT bars in Uganda and if not
could be the leading producer in Eastern Uganda. Its located along Kayunga Road and in
Njeru municipality in Jinja but about 2km away from Njeru town council occupying 35 acres
of land on plot number 2/20. Tel. No. 0434251712 and Email address;
info@pramukhsteel.com.

1.1 HISTORICAL BACKGROUND

Pramukh Steel Limited was established way back in 2007 and the quantity produced by then
was limited but now days it has grown into one of the finest and most reliable steel
manufacturing companies in Uganda and East Africa with an annual production capacity of
over 80,000 metric tons per annum.

At the establishment it started with US$ 5millions but as now continually expanded to up to
US$ 20millions. From then it started expanding its investments and business by investing in
buying a cotton industry called A Joy Cotton Limited in 2009.

With the success of those investments the board of Pramukh Steel Limited planned a
magnificent sugar plant in the year 2010. The production of sugar plant was commenced in
the year 2014 and has also come up with another Aluminium Rolling Company located near
Mbiko town in Njeru Municipality.

1.2 COMPANY VISION

To become one of the leading companies producing steel in Uganda.

1.3 COMPANIES AIM

They Aim to provide the high quality and effective construction materials for customers in
Uganda and across the globe.

1.4 COMPANY OBJECTIVES

Pramukh main objective is to enhance the image by consistently identifying and meeting its
customer’s requirements.

1
They improve a health working environment for all stake holders through the application of
environmentally friendly good manufacturing practices.

1.5 PRODUCTS PRODUCED

They produce TMT bars with a ribbed shape in various diameters for example 8mm, 10mm,
12mm, 16mm, 20mm, 25mm and 32mm depending on the customers demand.

1.6 AIMS AND OBJECTIVE OF INDUSTRIAL TRAINING

The industrial training is primarily meant for students to gain practical skills and experience
and converting theory parts into practice. Industrial training is mainly geared for developing
skills, knowledge and attitude needed by a student to make an effective start as a member of
ever growing scientific and technological engineering profession. The following are some of
the objectives of industrial training;

 For academic excellence as a requirement.

 To help students know and learn the organization structure of industries and firms.
 To acquire skills used in industrial works.
 To enable students to explore employment opportunities in organizations.
 To provide the organizations with highly motivated energetic and talented students
who are able to execute work in key areas and a potential work force with a soft touch
for future recruitment.
 To enable students understand employment relations within different organizations.
Generally at the end of the training, learners should acquire hands on skills relevant to their
course of study and they should be able to;

 Operate machines.
 Carry out practices and real component making.
 Write a report detailing the entire activities carried out and the knowledge or skills
learned.
 Know the organization structure of companies and industries.

2
1.7 LITERATURE REVIEW AND BRIEF OF TASKS DONE

1.7.1 MACHINING
Traditionally, any machine we see is produced with the help of another machine. These
machines which are used to produce other machines are called MACHINE TOOLS which are
normally found in the machine shop. These among others include lathe machine, drilling
machine, shaping machine, grinding machine with their names reflecting the kind of the basic
operations they perform apart from the lathe machine which is able to do multiple operations.

1.7.2 WELDING AND FABRICATION

An important use of welding and fabrication is the design and repair of plant machinery and
equipment. In this respect, welding is an indispensable tool without which production
operations would soon shut down. Fortunately, welding machines and electrodes have been
developed to the point where reliable welding can be accomplished under the most adverse
circumstances.

3
 CHAPTER TWO
2.0 MACHINE SHOP
2.1 DEFINTION
A machine shop is an organized place containing different types of machines such as lathe
machine, drilling machine, shaping machine, grinding machine etc

2.2 SAFETY PRECAUTIONS IN THE MACHINESHOP

o If you are not an operator, do not go beyond the safe working space described
by the red lines.
o Never put any part of your body near moving parts of the machine
o Never wear loose clothing that could be tangled in the moving parts of the
machine
o Never operate the machine without proper instructions and supervision
o Wear safety glasses and safety shoes
o Stop spindle completely before changing or adjusting the work piece or tool.
o Do not engage the gear when the machine is running
o In case of heavy loads, use a crane or any other safe method

2.3 MACHINING OPERTIONS

 Turning and related operations
 Drilling and related operations
 Machining centers and Turning centers
 High speed machining

2.4 MACHINING
Material removing process in which a sharp cutting tool is used to mechanically cut off or
reduce the material so that the desired part remains.

Most common applications: to shape metal parts

Machining is the most versatile and accurate of all manufacturing processes in its capability
to produce a diversity of part geometries and geometric features-Casting and also produce a
variety of shapes, but at lacks the precision and accuracy of machining.

4
2.4.1 CLASSIFICATION OF MACHINED PARTS
 Rotational –cylindrical or disk- like shape
 Non rotational (also called prismatic) – bloc- like or plate- like.

2.4.2 OPERATIONS AND THEIR BRIEF DESCRIPTIONS DONE ON THE LATHE

MACHINE AND TOOLS USED.

2.4.2.1 T URNING
A single point cutting tool removes material from a rotating work piece to generate a
cylindrical shape. V- high speed steel tool, side high speed steel tool, and tungsten carbide
tipped tools can be used.

2.4.2.2 F ACING
Material removal is done at the face side of the material being machined and the tool is fed
radially inwards or outwards depending on what the operator desires. And here side high
speed steel tools, V- high speed steel tool, tungsten carbide tipped tools are mostly used.

2.4.2.3 CONTOUR TURNING

Instead of feeding the tool parallel to the axis of rotation, the tool is follows a contour that is
other than straight, thus creating a contoured form or curved surface on the material being
worked on.

2.4.2.4 CHAMFERING
Is cutting the edge cuts at an angle on the corner of the cylinder, forming a “chamfer” and a
V- high speed steel tool is mostly used though sometimes it can depend on which type of
work your working on. Mostly V- high speed steel tools are used.

2.4.2.5 CUTTING OFF OR PARTING OFF

Is where by the tool is fed radially into a rotating work at some location to cut off end of any
part on the material already machine and here basically a parting tool is use.

2.4.2.6 T HREADING
A pointed form of tool known as a V- HSS tool is fed linearly across the surface of the a
rotating work piece parallel to the axis of rotation at a large feed rate, thus creating threads.

2.4.2.7 B ORING .
5
This is an operation of enlarging the size of a drilled hole on any material. The cutting tool is
a boring bar.

The difference between boring and turning:

Boring is performed on the inside diameter of an existing hole and turning is performed on
the outside diameter of an existing cylinder.

In effect, boring is an internal turning operation.

2.4.2.8 D RILLING
Creates a round hole in the work piece and contracts with boring which can only enlarge the
existing hole. The cutting tool is a drill or drill bit customarily done on a drill press.

2.4.2.9 T APPING
Is an operation use to provide internal screw thread on an existing hole and the tool used is
called a tap and a holding tap wrench.

2.4.2.10 CONTOUR BORING .

Provides a stepped hole, in which a diameter follows a smaller diameter partially into the hole
and the tool used is called a pilot.

2.4.3 METHODS OF HOLDING WORK IN A LATHE MACHINE.

 Holding work between centers
 Chuck
 Collets
 Face plate
Some of the operations I carried out in the work shop are listed below with all their
operations taken into consideration and the various tools used to come up with the required
component are listed below in the next chapter and include all ideologies considered in
coming up with them.

The various components I came up with may be listed below;

 A guide assembly
 A nozzle
 An eccentric shaft
 A stepped shaft
6
  Threading of bolts and pipes
And many other components to list but a few

Note; working on a lathe machine needs care and accuracy in taking of readings
required for production purposes. So one has to be keen in reading the vernier caliper
and also must be able to properly set up the given work on the lathe machine.
 Working while over talking may lead to one making mistakes so at least silence and
great care should be taken while at work.
 When coming up with shafts of various materials, there should be a clearance of about
1-2 micro lines depending on the type of fit one is required to come up with.

CHAPTER THREE
3.0 INTRODUCTION
7
This chapter basically deals all what I managed to come up with though it wasn’t easy getting
all my work here but I placed the major jobs and tasks I had been given by my supervisor.

3.1 GUIDE ASSEMBLY.

Fig 3.1.1 and 3.1.2 showing parts of the assembly

3.1.0 OPERATIONS DONE ON THE SMALLER SHAFT.

For the smaller cover part of the assembly the following operations are the ones I carried out
in coming up with that top cover.

3.1.1 Setting of the work on the machine was a necessity that is two setting idea is the one I
used since I had to work on it in two different sides that’s why it’s called a two way setting. I
used a chuck key and a scribing block to check on the proper setting of my work and ensure
the right rotation too. I got use of the hammer too for setting operation.

3.1.2 Drilling using drills of 18mm, 22mm, 25mm and 31mm to a relatively exact diameter
of the bore 35mm that I needed.

8
Fig 3.1.2.1showing a drilling operation using a final drill of 31mm

3.1.3 After drilling to 31mm I thereafter had to bore to roughly 33mm leaving the 2mm for
finishing after the final operation of tapering that I made on the opposite side after the second
setting of the material. I used a boring tool for the operation.

Fig 3.1.3.1showing
the boring action I
did to a diameter
of 33mm

3.1.4 Turning
operation was the
next I did after the
second setting.

I had to turn the material I was given to a diameter of 79.8mm as it was required by the
supervisor. It involved reducing the materials diameter from the outside to the wanted
diameter of 79.8mm and here I used the V-HSS tool and finally the side HSS tool for
squaring to a length of 60mm that was needed.

9
Fig 3.1.4.1showing the turning operation

Step turning operation to a length of about a half the length of 60mm of the already turned
diameter so as to enhance the tapering operation

3.1.5 Tapering operation

Involves setting the tool post at an angle of 45 degrees and the use of a V-HSS tool for the
operation of tapering and the taper is cut according to the length required plus taking into
mind that when feeding the tool a slow but relatively same speed of feed is needed so as to
produce a smooth finish.

Fig 3.1.5.1showing the tapering operation at an angle of 45 degrees

10
Then after tapering finally the diameter of the bore is made to final by boring the previous
rough 33mm bore to a final bore of 35mm and here a boring tool is used taking in mind that
all the above measurements are done with the help of a vernier caliper.

Next operation was for working on the ring plates one of which was of a different diameter
form the other two but all having the same bore of 80.2mm knowing that an allowance of 1-2
micro lines in case of fitting of shafts and their respective hole diameters

3.1.6 Setting the plates which where welded together for the case of the ones which
possessed the same outer diameter of 128mm , bore of 80.2mm and thickness of 12mm and
the other plate of outer diameter of 164mm, a bore of 80.2mm and thickness of 11.5mm as
shown below.

Fig 3.1.6.1showing the setting operation done on the plates

3.1.7 Drilling operation is there after done to create a hole and drills of 34mm and 40mm
are used to come up with a relatively larger hole.

11
Fig 3.1.7.1showing the 2 plates of outer diameter 128mm drilled to a hole size of 40mm and
turning operation being done to 128mm.

3.1.8 Turning operation on the plates: this operation involves a simple technique when
drilling the inner hole the outer surfaces should be welded together so as to avoid the work
separating from each other. And when drilling is finished, then the inner drill created is the
welded and turning the outer surface to the required diameter is done thereafter then boring is
done to increase the hole size to a required bore of 80.2mm that is wanted.

3.1.9 Facing operation is then done on both plates so as to get the required thickness of
12mm. But after finishing one plate to the required thickness then its separated from the
other by grinding it off and then facing operation is also done on the other plate. The
following operations are also done to the plate with outer diameter of 164mm and bore
80.2mm by the help of the above mentioned tools and settings done. Below is the facing
operation involving the use of the V- HSS tool.

Fig3.1.9.1 showing the facing operation on the plates

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3.2.0 OPERATIONS DONE ON THE LONGER SHAFT
3.2.1 Facing the shaft using the V-HSS tool to create flat surfaces at both ends of the shaft
then after the facing operation, step drilling the shaft at one end to allow taper creation at one
end of the shaft .

Fig 3.2.1.1showing drilling operation fig 3.2.1.2showing a step drilled

shaft
3.2.2 Tapering the stepped drilled end by use of a V high speed steel tool and turning the
tool post to an angle of 47 degrees. The tapered part meshes with the previous top cover I
made above but the difference in angles ensures that there is allowance of space for water to
flow easily through the guide so as to help cool the hot TMT bar which passes through it.

This shaft also involves a two setting technique and therefore tapering is made on both sides
of the shaft and operations of tapering on the outer diameter is done to a size of 79.8mm and
this acts as a sit for ring plate of larger outer diameter of 164mm and bore of 80.2mm.

But the shaft has a bore of 34mm less than the one for the top cover so as to ensure proper
passage of the bar through this larger shaft then through the larger bore of 35mm at the top.

13
Fig 3.2.2.1 showing a taper cut at an angle fig 3.2.2.2 showing a taper cut at an angle of

of 47 degrees 20

3.2.3 All the above components are then combined together by welding the shafts and the
various ring plates made so as to produce one fixed component and the a small hole is drilled
onto the cylindrical shaft used for joining the ring plates so as to allow fixing of a water
passage pipe or anything which will help supply water through the assembly.

This is how the whole assembly looks like when assembled after carrying out the necessary
operations on various parts

Fig 3.2.3.1showing the guide

3.3.0 N OZZLE AND ITS OPERATIONS.

A nozzle also helps in directing the TMT bars through the right passages they are meant to
follow so in other wards it’s a guide for the bars being produced to get to the cooling bay. In
case of any mistake like poor finish in the inside taper, it may lead to break down issues
arising in the mill so great care is undertaken when coming up with the nozzles.
14
Operations include;

3.3.1 Setting of work on the machine; this involves the use of a scribing block and chuck
key for checking on the proper rotation the mounted work onto the head of the lathe machine.
It’s basically done by untying and tying the opposite jaws on the chuck using the chuck key.

Fig 3.3.1.1showing the setting operation

3.3.2 Facing: this operation is basically done on both sides of the shaft and therefore coming
up with a shaft of length 85mm. The tool used in this operation is a V-HSS tool in case of
mild steel but for the case of hardened materials I often used a tungsten carbide tipped tool.

Fig 3.3.2.1showing the facing operation

3.3.3 Drilling operation; this involves the use of drills so as to make holes of preferred
diameters depending on which size of bore one would wish to have. But for my case I u
wanted a bore of 50.5mm so I had to use drills of 18mm the through hole bore in the material
I had, 24mm, 31mm and also 40mm. The drills are fed to different lengths so as to create
steps which ease the operation of tapering in the shaft.

15
Fig 3.3.3.1showing me drilling using 18mm drill Fig3.3.3.2 showing me using the 40mm
drill

3.3.4 Boring operation; this is the act involving the increase in the size of the drilled hole
and the tool used is known as the boring bar. I had to bore to a diameter of 50.5mm and to a
length of 30mm.

Fig 3.3.4.1showing boring operation

3.3.5 Internal tapering; this is making of an inside taper in any material. So I had to twist
the tool stand at an angle of 21 degrees then set the boring tool for the operation of tapering.
So this time round when tapering one has to freely keep feeding in the tool and keeping keen
eyes on the length of taper got. If the length is short then the angle can be reduced but in case
the length of the taper is much longer than the wanted then increasing the angle is necessary.
Below is a figure showing the operation of tapering:

Fig 3.3.5.1showing tapering operation

16
After tapering to the required length and fine finish I had to apply some sand paper to
smoothen the inside taper and bore so as to remove the little roughness that was left within
my nozzle.

3.3.6 I had to open up the jaws then set for the second time and this operation is known as
second setting and on the same material because it involves operations in two settings and on
both sides of the material one is working on.

This involves the same idea as before but in this there is setting the bore too so as to ensure
that it’s rotating as required before the final finish is done since the exact bore to be made is
supposed to be of diameter 19mm. The fig below shows the above second setting.

Fig 3.3.6.1showing the second setting

technique

3.3.7 Turning operation; this involves the

reduction of the outer diameter of the material
to the required size of the nozzle. I had to turn
to a length of 77mm and leaving out a smaller length of 8mm on the extreme end and also to
the outer diameter of the nozzle which was 60mm. To get a finer finish on the material ensure
that the speed of the shaft of the machine is slow and use of a sharp tool for cutting. I used a
V-HSS tool and side HSS tool for finishing and squaring to the exact needed length as below.

Fig 3.3.7.1showing the turning operation

3.3.8 I thereafter had to step turn to a half the length of the outer diameter I managed to turn
too. This procedure of step turning looks tiresome but makes outside tapering more easier

17
than you would expect it without doing the steps on the outside diameter. This is how the step
turning idea looks like. I used a V-HSS tool for the operation.

Figs 3.3.8.1and 3.3.8.2 showing the step turning operation

3.3.9 Outside tapering; This is the making of an outside taper on the material and is the
same as the inside taper only that here the tool used is different and the taper is on the outside
of the material being worked on. It also involves setting the tool post to an angle of 21
degrees on the outside of the angle scale and also the feed should be as slow as possible so as
to create a taper which is smooth or having a fine finish. This operation is shown below

Fig 3.3.9.1showing outside tapering operation

3.3.10 Re-boring of the 18mm bore so as to get the final finish of 19mm bore that is
required. This involves use of a boring bar and being keen on the measurement so as to get to
the 19mm bore that is wanted. The operation is shown below

18
Fig 3.3.10.1showing the finishing boring fig3.3.10.2 showing the finished
nozzle

Note; care should be taken when setting the work because when one fails to set fully then
there may be wobbling in the material and this may lead to breaking of the tool or even create
poor work

Also when working, mind much on the work that you have other than talking much because
you may end up making lots of mistakes on your work that you are trying to produce.

3.4.0 T HREADING OF BOLTS AND PIPES

Threading is generally the creation of threads on any material and this generally depends on
which type of thread is needed.

3.4.1 There are two types of threads namely;

 Whit worth threads which are the threads in inches and,

 Metric threads which are threads per millimeter
3.4.2 Some of the basic threading operations I did where;

3.4.2.1 Threading of 32mm TMT bars so as to make the CCM bolts of size 3.5 and these
bolts are metric threads. So there was need of changing the gears on the machine before
getting to work with the metric threads and vice versa in case one needed to use the whit
worth threads.

3.4.2.2 Setting the TMT bar on the machine and ensuring that the tool touches all sides of the
bar before starting to turn. This involved the use of a V-HSS tool and chuck key.

3.4.2.3 Turning operation; this involved turning of the bar to an outer diameter of 29.5mm
or sometimes a diameter of 29mm and this operation involved the use of a V-HSS tool so as
to reduce on the diameter of the TMT bar and this can be clearly seen from below.

19
Fig 3.4.2.3.1showing the turning operation on a TMT bar

3.4.2.4 After turning to the required diameter of the thread to be cut, then there is need to set
the machine to the required size of the gear needed by simply changing the gears levers to the
required according to the chart and also changing the lever of speed of the gears to be cut
since every thread to be cut has its own speed level and if not aligned to its needed speed
level then meaning that one may fail coming up with the exact type of threads that he or she
would have wished to have. Then after doing that, ensure that you set the lever to neutral and
engage the half nut lever which enhances the lead screw assist in the threading operation
needed. So this is the operation as it was in threading.

Fig 3.4.2.4.1showing the threading operation

One can know that the size of the thread has been reached by just looking at the nature of the
crest formed. In case it’s a bit blunt the there is need to continue threading but in case one
gets a sharp crest then there is need to check using the nut you where given as a sample. The
figure below shows my work in threading.

20
Fig 3.4.2.4.2showing the TMT bars I threaded to a size 3.5

3.5 THREADING OF L-BOLTS;

These are bars which are fixed in the roughing system so as to provide some firm grip in the
rollers that are used within the roughing. These bolts are made by first centre drilling them at
one end so as to be held between the two center’s that is the tail stock and the chuck.

3.5.1 After the operation of center drilling, then the bolt is attached to the lathe machine and
the L form being held in the jaws of the chuck and the center drilled part supported at the
tailstock. The rotation of the bar should be uniform so as to remove the wobbling action due
to poor setting of the material.

3.5.2 After the setting operation then turning operation follows and this involves the removal
of the outer material on a work piece and hence reducing its outer diameter to the required
size needed. Turning operation takes place until the material is now 31mm or even 32mm but
not less than or more than that because when you turn to a diameter more than the required
for a given size of bolt, you may either take much time getting to the required size or even
fail to get the exact size of shape of threads that one may need leading to wastage of the
material.

Below is an illustration on the turning operation of the L-bolt.

21
Fig 3.5.2.1showing the turning operation

The L-bolt is of size 7 in whit worth threads meaning it’s the threads per inch and the setting
of the threads is done by following the threading chart and doing all the necessary changes in
setting the gears needed for the threading operation and also the level of speed at which the
shaft of the machine has to rotate. Then engaging the half nut lever and changing the machine
to neutral form so as to enable threading take place. Below is one of the L-bolts that I came
up with in the workshop.

Fig 3.5.2.2showing the L-bolt

3.5.3 The tools that I used in coming up with this type of bolt were the side high steel speed
tool for turning and V-high steel speed tool for threading operation.

3.6 THREADING OF PIPES

Threading operation in pipes is the same like all other threading operations only that some
great care is needed when dealing with such water pipes. When setting them on the machine,
there should be care on how tightens the jaws because when you apply too much energy then
you r bound to make them bend so little energy should be used in making the jaws tight.

Pipes can be determined of which size of thread size it should be by merely using a thread
gauge to check on the size of threads on the sample nut given to you. After one getting the
22
size then the operations follow as those above in the bolts by setting the gears and the speed
level then engaging the half nut and turning the machine to neutral so as to start the operation
of threading. But for the pipes, there is need to try reducing a little material and to about a
half inch by somehow making it in a tapered form. This is because pipes are not like the
bolts since they enter in nuts which are somehow of a tapered form though not easy to realize
that ideology.

3.7.0 E CCENTRIC SHAFT AND ITS OPERATIONS .

This shaft is basically used in a machine used for making bricks and simply serves the roll of
being a hammer in the vibrator assembly. As it rotates the protruding unturned part keeps
revolving and piles force on the springs in the machine which keeps the springs in
compression and tension hence making it easy for the mixture of sand to make the concrete
bricks.

Operations involved in making the shaft include the following;

3.7.1 Setting operation; is ideally often the first operation to be undertaken when dealing
with any work on the machine. This involves use of a chuck key and scribing block so as to
come up with a perfectly rotating material on the lathe machine.

3.7.2 Facing operation; is the idea of making the face of the shaft perfectly flat and this
operation involves the use of a V-HSS tool for simply removing the rough cutting that was
created when cutting the shaft using gas cutting equipment.

Fig 3.7.2.1showing facing operation

3.7.3 Marking off; marking off the center line by simply feeding the tool across the face of
the shaft and this helped in marking off and creation of the off center which was 17mm from
the outer diameter of the machine shaft. This was simply done by using a vernier caliper and
23
measuring the 17mm on it then shading the face of the shaft using chalk and the moving the
jaws of the vernier caliper one passing on the outer diameter and the other jaw passing over
the shaded part hence leaving a mark on the face of the shaft.

3.7.3.1 After marking off and getting the center point where the center line and the mark put
by the vernier have met hence I had to remove the shaft and then take it for center drilling.

3.7.3.2 Before the act of drilling, center punching was needed so as to know the exact
position of the off-set center and thereafter center drilling took place.

3.7.4 After all the above operations I had to mount back the shaft on the lathe machine for re-
setting but this time round being supported between the chuck and the tailstock. The setting
ideology is shown below and there was need of checking all sides of the shaft whether they
were clearly set and running ok to the axis of the off-set center.

Fig 3.7.4.1showing the setting operation between two centers

3.7.5 Turning operation

This operation involved use of a side HSS tool for removing the material on the shaft but in
an eccentric form because the work was set using an off-set center. Implying that only some
part of the shaft is mostly affected by material removal and the other is less affected by the
tool.

The shaft has two bearing seats each of diameter 30mm on either side of the shaft and they
are of different lengths that are; the shortest is of 18mm and diameter 30mm and the other
52mm and diameter of 30mm.

It also has a pulley seat too which is of diameter 26mm and length 67mm.
24
And finally also having a turned portion of diameter 45mm and length 10mm on both sides
of the shaft.

The whole length of the shaft was 320mm long. Below is a figure showing all the above
operation of turning to the various diameters and lengths

Fig 3.7.5.1showing
the eccentric shaft
operations

3.8.0 MAKING A

STEPPED SHAFT

3.8.1 This shaft was

having a gear fitted to it by welding but later some part of the shaft got broken so I was given
to make a shaft of the same kind for re-fitting.

3.8.2 I had to remove the gear from the old shaft so as to get to know the dimensions of the
original shaft and be able to come up with the same kind of shaft. This shows how I was
trying to face and remove the gear from the shaft because it had been welded on it and I had
to first drill using drill 18mm just to give room for my side tool to face the welded part.

Figs 3.8.2.1 showing drilling and facing operations

The need for removing the gear was to allow me get comparative measurements using a
vernier caliper and also get the gear as a sample for the new one to be got from the store.

25
After getting the gear off from the shaft I had to start making a new one by simply following
the procedures below.

3.8.3 Setting work

This involved use of a scribing block and chuck key for opening and tightening of the jaws. I
had to ensure that the work was set properly well and also ensuring that the tool touches all
sides of the set work so as to allow removal of material from the work equally on all the sides
of the work. And the shaft was supported between two centers because of its being long.

Fig 3.8.3.1showing work setting on a lathe

3.8.4 Turning; There after I had to turn to the nearest largest diameter of 32mm by making
mine to 32.5mm having in mind that the 0.5mm will be removed during my finishing
operation.

3.8.4.1 After getting the 32.5mm I then had to deal with one end of the shaft were by I turned
it roughly to 30.5mm having the 0.5mm for finishing of the material and also taking in mind
the length of the 33.5mm diameter which is 50mmlong.

3.8.4.2 Next step was turning roughly to 23.5mm gear seat and leaving out a length of 85mm
for the 30.5mm diameter turn.

3.8.4.3 Also the same turning idea was next when I was turning to a diameter of 16.5mm
rough turn and this was to a length of 46mm leaving out the 23mm length for the 23.5mm
rough turn.

I then had to turn to a diameter of 20.5mm gear seat and this was to a length of 35mm.

3.8.4.4 After which I had to finish up the rough turns to the expected final diameters and this
needed being more critical because any mistake would lead to wastage of the material.

26
Below is a figure showing the step turned shaft to the required diameters

Fig 3.8.4.4.1showing the step turned shaft

3.9.0 A NOZZLE
This is somehow different from the previous one I made first but though having a small taper
on one side and a bore of 40mm in the side and also possessing some under cuts of the same
depth but of different lengths. Below is the old one that I needed to follow when coming up
with mine.

Fig 3.9.0.1showing the old nozzle

Operations involved in making the sample are as below;

3.9.1 Setting the work; involves mounting work on the lathe and getting it properly set in
rotation so as to remove the wobbling of the work being worked on. Tools used are the chuck
key and the scribing block.

27
3.9.2 Facing the shaft; This involves getting the exact length of the shaft by simply reducing
it on both ends and also making the surfaces smooth for some operations such as drilling and
boring.

Fig 3.9.2.1showing the facing operation

3.9.3Drilling operation

Involves use of drills of various diameters depending on the size of bore would wish to
generate. I managed to use 18mm, 24mm, 31mm and 34mm drills leaving the rest of the
6mm for boring operation. Drilling ideally creates holes of any diameter so as to ease the
boring job on any material. Below is an operation in drilling of the shaft

Fig 3.9.3.1showing the drilling operation

3.9.4 Boring operation

28
This involves the use of a boring bar so as to increase on the size of drilled hole that one is in
any work being machined. I had to bore to 38mm leaving the 2mm for finishing after the
second setting operation and all other operations were over.

3.9.5 Turning operation

Material removal on a work piece reducing it to the required diameter of 60.5mm and this
involved the use of a V-HSS tool for such an operation and also taking measurements using a
vernier caliper. The operation is shown below

Fig 3.9.5.1showing turning

3.9.6 Internal tapering operation

Creation of an internal taper in the material so this is done by twisting the angle of the tool
stand to angle 22 degrees and then attaching a boring tool to the tool post thereafter starting
the feed manually and at a slow speed so as to attain the best finish of the taper needed.
Operation is shown below

Fig 3.9.6.1showing internal tapering operation

29
After the operation of tapering, then I had to set the work the other way round and also finish
to 60.5mm thereafter I further turned to a diameter of 50.2mm for a length of 29mm of the
material so as to cater for my undercuts I made.

After turning to 50.2mm I had to start making the undercuts that I had wanted and began with
the one at the extreme end and I turned it to a diameter of 49mm and a length of 9mm from
the face of the material. I made use of the V-HSS tool to come up with this undercut although
I had to use a side HSS tool too for squaring the end of the undercut.

Next was the last undercut but being separated from the other by a bridge wall of like 6mm so
with the help of a vernier caliper and a parting tool I had to make the second undercut to a
diameter of 49mm and length of 14mm but later squared the walls of each end using a side
HSS tool. This is how my outcome of the work I produced looks like

Fig 3.9.6.2showing the final finish of my work

Note;

 In all have done in the machine shop at least have learnt various ideas in coming up
with various components and it’s not been an easy task grasping the techniques.
 All thanks goes to the machinists who truly made me acquire this kind of skill
 Working in the workshop needs one to truly be set for any kind of job that comes
across him or her because its tasking for one to be having an idea in various
components that are carried out in the workshop or even outside the workshop itself.

30
 I managed to know how to come up with most of the components above and the
angles that one has to use depending on the length of taper needed by the owner of the
work.
 When threading work one should be quick in withdrawing of the tool after the cut so
as to avoid breaking the tool due to knocking.

31
 CHAPTER FOUR
4.0 INTRODUCTION
This chapter simply involves the various methods of joining metal works and also how some
of them are applied in day to day jobs in various fields of Engineering.

4.1 WELDING AND FABRICATION

4.1.1 DEFINITION
Welding refers to the joining together metal pieces or parts by heating the surface to the point
of melting using a blow torch , electric arc , or other means and uniting them by pressing and
hammering

Fabrication refers to the action or process of manufacturing or inventory something or is the

building of metal structure by designing, cutting , bending and assembling processes.

4.2 TYPES OF WELDING

4.2.1 Electric arc welding: Is the process of using a coated rod or an electrode to carry an
electric current which is an arc that creates sufficient heat between the gap at the end of the
electrode and the work to melt both the electrode and the work, forming a weld joint when it
solidifies.

4.2.2 Gas welding: Oxy-fuel gas welding is the process of fusion welding. In this process,
the high temperature flame required to fuse or melt the parent metal is provided by burning
the mixture of oxygen gas and a fuel gas in varying proportions according to the type of
flame needed.

4.2.3 TIG (Tungsten inert gas welding): Is an arc welding process that uses a non –
consumable tungsten electrode to produce the weld.

4.2.4 MIG (Metal inert gas welding): Is a process in which an electric arc forms between a
consumable wire electrode and the work piece metal which heats the work piece metal
causing them and joins. And other various types of welding.

4.3 WELDING POSITIONS

 Flat position: In a flat position a weld is performed along largely horizontal access
and from above the joint
32
  Horizontal: In the horizontal positions the weld’s axis the horizontal plane or the axis
of the weld runs parallel to the horizontal plane and above the surface of the work
table.
 Vertical: In vertical position the weld axis is largely in vertical or upright position.
 Overhead: In this position welding is performed from under of the joint.

4.4 WELDING JOINTS

A welding joint is appoint or edge where two or more pieces of metal or plastic are joined
together

 Butt welds: Is where two pieces of medal to joined are in the same
plane.
 Lap joint: It is a joint made with two pieces of metal by halving the
thickness of each member at the joint and fitting them together.
 Fillet joints: Are joints formed as a result of the welding process of
joining two pieces of metal together weather they are perpendicular
or at an angle.
 Tee joints: It is joining of two metal pieces perpendicular to one
another.

4.5 WELDING EQUIPMENT AND MACHINES

 Welding machine: The current used for electric Arc welding is produced by three
basic types of machines; the generator welding machine, transformer welding
machine, rectifier welding machine.
 Electrode holder or gun: Electrode holder is a handle like piece of equipment used to
grip the electrode.
 Connecting Cables; these are used to connect the welding machine to the electrode
holder and work piece
 Ground clamp: Is a metal connection joined to the end of the electrical cable that is
connected to the work or worktable
 Chipping hammer: This is used for chipping off the slag formed on the weld bead.
 Wire brass: It is used for further cleaning of the weld bead after chipping.

33
  Welding helmets: This is used to protect the head, throat, face and forehead from the
infrared and ultra-violet rays produced by the arc.
 Welding hand shield: These are used to protect the face during welding to prevent
Arc eye.
 Leather gloves and aprons: Are flame retardant outfits won by a welder to protect the
under clotting and the body to prevent them from sparks, the hot metal and molted
metal being welded.
 Welding electrodes: These are coated or bear metal rod with the same metallic
composition as the parent metal to be welded. Electrodes can be classified according
to the type of metal to the welded. The main classes include;
 Mild steel  Special
(ms) 6013 Alloy steels
 Low  Non ferrous
hydrogen metal
7018 electrode
 Stainless  High carbon
steel 304 steel
 Cast iron

 LPG cylinder, Oxygen cylinder, Welding blow pipe, LPG safety cap, Oxygen safety
cap, Pressure regulators, detachable nozzle, Welding hoses and connectors, Welding
goggles, Spark lighter, Nozzle cleaner

4.6 S AFETY PRECAUTIONS

 Face shields , Helmets ,Goggle , Visors , Ear muffs , Gloves , Sleeves ,
Fire proof aprons and safety footwear must be worn .
 Ensure that no loose items are left lying over head.
 Never line up holes with your fingers.
 Make sure that heavy objects are securely positioned
 Know how to use fire extinguishers and / or blankets provided
 Know the fire drill and emergency exit
 Do not use water on electrical fires
 Ensure that oxy-fuel gas operations are only carried out in areas with
non combustible flooring.

34
  Hot metals should not be left un attended. However if it is un
avoidable, then it should be marked “hot” and time and date.

4.7 OPERATIONS ON GAS CUTTING.

Specifications; (50x70x12.5) mm for bead lining

Oxy-fuel gas cutting is the use of a flammable fuel gas and oxygen to re-heat metal to red hot
and then uses pressurized pure oxygen to blow away the pre heated metal. But the fuel gas
which is being used in Pramukh Steel Limited is LPG that is Liquid Petroleum Gas which is a
pressurized gas kept in red and bigger cylinders than those for oxygen.

Materials and tools used.

 Piece of mild steel

plate. (12.5mm (half
inch thick))
 A piece of chalk for
marking
 G-clamps
 LPG cutting unit,
ready set up
 Gloves
 Goggles
 Spark lighter
 Steelrule

35
4.7.1 Procedure

During this operation below are the procedures to follow;

 Marking out 50x70 rectangular plates using chalk and a steel rule
 Setting up the work piece (plate) on the working table, allowing an over hung of
the cutting line
 lighting the flame using the spark lighter and adjust for neutral pre-heating flame
 Standing at a clear and safe position where i could see the cutting line property
 Positioning the pre-heat flame so that one flame re- heats the metal directly in the
front of the cut.
 Holding the blow pipe steadily , I kept the pre-heat flame (1.5 -3) mm or 1/16inch
to 1/8 inch above the metal surface and pre-heat
 When the metal was hot enough, I slowly depressed the cutting lever.
 As cutting was beginning, I fully depressed the lever and directed the blow pipe
along the cutting line with the nozzle held at 90 to the work.

Fig 4.7.1 showing gas cutting.

Remarks:

 I successfully mastered the process of gas cutting and performed all the duties which
were assigned to me.
 When turning off the torch one should first turn off the LPG gas valve then the one for
oxygen so as to reduce the risk of being burnt

36
  When lighting the torch, you turn the LPG gas valve to give a small opening in the valve
then light the torch with the help of a burning flame and thereafter open the oxygen valve
to a smaller way and then balance the flame by either opening LPG valve or tying It and
vice versa with the oxygen valve also.

4.8 0 OPERATION ON BEAD LINING

Bead lining is the de position of filler metal from a single pass or line.

4.8.1Materials used

 Mild steel plate (50×70×12.5)

 Welding electrode Ms (6013)
 Electric Arc welding unity already set
 Gloves and aprons
 Face shields
 Chalk and steel rule.

4.8.2 Procedure

During bead lining; followed the procedures as describe below;

 Scribing parallel lines 1∕2 inch apart on the surface of the metal using steel rule
and chalk
 Striking on the arc at the end of one line of the marked lines and maintain it to pre
heat the work.
 Moving slowly over the lines towards the other ends the electric angle used was
900 and the arc angle was 150.
 Maintaining the arc length constantly lowered the electrode as it melts down.
 I repeated the same procedure from 1 to 4 on all the other lines using different
patterns and movements.

37
Remark:

 I successfully made the weld bead and acquired the skills of welding at different
positions.

Figs 4.8.2.1 and 4.8.2.2showing bead lines.

 Great care should be put on the speed of travel of your hand when welding in order to
produce a uniform bead line and deposition of the weld metal.
 Protective equipments should always be worn to safe guard one’s eyes from direct light

4.8.3 Carrying out welding of the on a thick plate

This plate that I welded was for making a cover to a shaft that I made and was to include a
bearing seat on one end of it.

I had to it onto a pipe to ensure proper balance before I carried out the welding activity.

This involved use of a welding torch, electric welding generator, welding mask, welding rod and
cables for connection of the gun to the generator and also the earthing. But the earthing was
connected almost everywhere so welding is done by connecting the parent metal to be welded
onto the earthing wire.

This is the operation of welding that I managed to come up with

Fig 4.8.3.1showing the welding operation

38
 CHAPTER FIVE
5.0 FURNACE
5.1 INTRODUCTION
The type of furnace that is used in Pramukh steel limited is an electric type of furnace and there
for the heating is initiated by switching on the electric current and the heating first occurs on the
former that is a cylindrical metallic sheet constructed within the hearth of the furnace.

5.2 CONSTRUCTION OF THE FURNACE

The furnace is a metallic component having connections of conducting copper wires and also
having coolant pipes that is water pipes one which brings in cold water and another taking out
heated water. Air supplying pipes are also connected within the furnace and most of the above
are beneath the constructed furnace.

It also has hydraulic mechanisms underneath it and this helps when lifting and lowering of the
furnace incase of pouring or when there is need for construction of the inner core of the furnace.

The furnace is constructed locally by the workers in the furnace section. They use 40bags of lime
stone that is known as lining mass at Pramukh steel limited and also having a metallic sheet
called a former that is made in a cylindrical shape and of the same diameter as that of the size of
the furnace and then followed by the lining mass between the walls 0f the moving carriage and
the former fitted in the hole.

After filling the empty space in the walls with lining mass or the lime stone, then the furnace is
left to set for some time before the act of centering occurs.

Centering this already built furnace means heating the upper parts of the wet limestone and
former so that they may become intact.

5.3 CAPACITY OF THE FURNACE

The furnace takes a capacity of 15tons of scrap before it’s poured off to re-heat other scrap
metals. Here scrap isn’t measured in the ratios but rather fine and light scrap is poured into the
furnace almost at the end of the heating occasion.

39
5.4 HEATING OF SCRAP
The heating temperatures of about 1650 degrees celicious and the electric current which is
transmitted through the high conducting copper wires heats up the former there by initiating the
heat within the furnace which therefore melts the former and in turn melt the scrap too.

And when heating the scrap, they make sure that the light scrap is poured in last when the heat is
almost being poured off. This is because light scrap easily melts and so cannot be melted at the
same time with the heavy and medium scrap.

Scrap is being collected in trough and then lifted by the cranes which is then taken and poured
into the burning furnace and the aid of heating is given by people who keep feeding in the
metallic scrap brought by the crane so as to make sure that the scrap is totally heated to liquid
form.

Occasionally tapping off of slug is done by pouring off the upper layer of the un burnt metallic
components and this is done by raising the furnace as though pouring but rather at a smaller
angle so that all the bubbling un burnt metallic scrap is tapped off into a ladle and then melting
of the metal is continued. This operation of tapping off slug is done about twice or thrice when
conducting one heating session.

The slug tapped off is taken and poured off then after it’s again transferred to the slug section for
break down and this operation reduces the slug into some small pieces of metal and also black
stones which are mostly used at railway stations. But the metallic compounds got are again taken
back for re-melting operations.

The heating of the ladle first before the melted metal scrap is picked up from the furnace is to
ensure that the collecting ladle is at a higher temperature as required of the CCM and also keep
the molten metal in its liquid state so as to ease pouring of the liquid metal. This operation takes
some few minutes thereafter the heat collected from the furnace when its fully heated up to its
molten state as required.

This then is lifted by the crane to the CCM and then poured so as to release the needed billets
within the rolling mill.

40
Billets produced at the CCM are according to which size of TMT bar is to be produced so the
weights of these billets differ from size to size of the bars to be produced.

Note;
 At the furnace, it’s always risky and one should be highly careful.

 Protective equipments should be worn such as helmets, nose muffs, ear wrapping
clods, safety shoes and over rolls.

 Due to the furnace always being open and heat readily seen, carelessness should
be looked into so as to reduce on the risk of being burnt or falling in the fire.

5.5 Brief process in the manufacturing of the TMT bars

When the billets are produced from the continuous casting machine and cut in the size expected
to produce, the billets run through conveyors until they reach the rolling mill which starts with
the roughing system and then through intermediaries then through the finishing rollers to the
cooling bay and thereafter to the last section where the bar is collected from.

The roughing system has rollers which are cut to different paths and these roughing rollers
reduce the size of the billet by lengthening the billet and by that process the billet reduces in size
and also elongates in size. This roughing system is cooled by continuous flowing water supplied
by the water pump so reducing on the friction between the hot billet and the rollers squeezing it
so as to elongate the billet.

In so doing the elongated billet goes through various rollers that are set accordingly depending
on which type of bar is really needed that exact day.

The more the elongated billet goes through various rollers the more it’s length increases and also
the size is diminished too in that process.

41
 CHAPTER SIX
6.1 SKILLS GAINED IN THE COMPANY WORKSHOP
I managed to learn the following from the various tasks that I personally got engaged in during
my time at the company workshop, furnace and CCM.

 I learnt how to make a nozzle

 I learnt how to make stepped shafts
 I learnt various operations like threading, tapering, drilling, boring and tapping
activities.
 I learnt how various setting operations can be done on different kinds of jobs to be
handled.

6.2 CHALLENGES FACED DURING THE INDUSTRIAL TRAINING

 Inadequate means of transport to areas of work.
 Inadequate spare parts for the machines used hence delaying operations.
 Negligence of some workers about the company properties causing it great loses.
 Information flow among workers was inadequate leading to making of unreliable working
programs.
 Language barrier as some operators did not know English.
 High costs of living due to expensive things around and transport whenever a journey was
to be made.
 Language barrier at the place of work and around the factory which gave me hard times in
requesting, research, buying and conversing with the members who were a round at large.
 There was a challenge of poor communication skills by some of the trainers in the
workshop because most of these people were technically knowledgeable, but it was quite
hard for them to explain most concepts and make someone understand.

6.3 GENERAL CONCLUSION

I successfully completed my industrial training at Pramukh Steel Limited with help of my fellow
trainees and company employees. The practical skills and knowledge I acquired will add a lot to
my ability in designing and fabricating machines, machining of components, servicing and
42
maintenance of different machines in the field of mechanical engineering and working with
different people at different levels.

My field attachment at Pramukh Steel Limited was very successful and I thank the management
of Pramukh Steel Limited for the skills passed onto me and I believe I can now face the
challenging working world and with all the confidence, I will be successful.

This training attachment has made me to explore all the basic work done in agriculture
workshop. I also got to know what is done in the factory during production of steel bars.

6.4 RECOMMENDATIONS
I recommend that the following should be done at Pramukh steel limited;

 Training programs should be organized to provide technical knowledge to operators

about machines they operate.
 Periodic maintenance and service of machinery should be emphasized to reduce on the
frequent breakdowns.
 Machines should be purchased along with their original spare parts to avoid being
cheated with fake spare parts. .
 A register for trainees should be availed to reduce on the problem of unnecessary
absenteeism.
 Use of the protective gear should be made compulsory both for trainees and workers to
minimize accidents at work.
 I recommend the company to allow more students to carry on their training because it
improves on the close contact and cooperation with higher institutions of learning and to
increase the quality of work force for sustainable development within and outside the
company.
 There is a need for Pramukh Steel Limited to cater for intern students because they play a
positive role as regards to accomplishing the assigned tasks of the company workers as
well.
 I recommend fellow students who wish to go for internship training to treat this exercise
more of a personal consumption because the benefits derived to a greater extent go to the
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 student than other parties. Since the exposure of the student to the different working
conditions impart a physical relationship in the field of work, it therefore contributes
great to the betterment of the student’s future.

6.5 REFERENCES.
 Machine shop practice by Karl Hans Moltrecht, 1971
 Fundamentals of Fabrication & Welding Engineering by F.J. Smith, 1993
 Metalwork Technology by J.K.N. Sackey, 1996
 Pramukh steel limited website and internet.
 Consulting from the turners and other workers in various departments.

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