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FFP WORKSHOP :- 04
This shop is divided into two sections. One is Machining and the other is Heat treatment section. In Machining section various machining operation is performed with the help of different types of lathe, VTB Machine, deep hole boring machine, horizontal boring machine, milling machine etc. And Heat treatment section has induction hardening machine & furnace.

This shop mainly manufactured Crank Shaft for locomotive diesel engine. For this, HEC purchase shaft from USA and then by various machining operation performed they got finished job. In the manufacture of crank shaft there are 96 different operations performed by the well skilled operator to achieve good finished job.

Fig - Crank Shaft

MACHINING:- It is the process of removing metal from the job to get required shape & size. Various machining operations are 1. Turning :- In this process of metal removing, cone-shaped or a cylindrical surface is produced. 2. Drilling :- In this process holes are drilled. 3. Boring :- In this process already drilled holes are enlarged. 4. Planning :- In this process flat surface are produced. 5. Milling :- This process is used for generating flat surface, angular surface, curved surface etc. by using various types of cutter.

6. Reaming :- This process is used to finish a previously drilled holes.

7. Grinding :- This process is used to finish the surface by removing very little metal by using a grinding wheel.

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MACHINES USED IN SHOP HORIZONTAL BORING MACHINE The boring machine is one of the most versatile machine tools used to box holes in large and heavy parts such as engines frames, steam engine, cylinders, machine housing etc. which practically impossible to hold and rotate in an engine lathe.

Type Diameter Vertical movement Horizontal movement

WD 200 200x8000 3150m 8000m

SHAPER Shaper is a versatile machine which is intended for producing flat surfaces may be horizontal, vertical or inclined. This machine involves the use of a single point tool held in a properly tool box mounted on reciprocating ram. The main significance of this machine lies in its greater flexibility on account of ease in work holding, quick adjustment and use of tool of relatively simple design.

Fig : Shaper

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CENTRE LATHE S-2100 Machine no. Swing over bed Swing over carriage Maximum length of job Maximum trepanning length Maximum weight of job 1001-04 2080mm 1700mm 46m 24m 28 M T

LATHE MACHINE 04-2010 Type Distance between centres Swing over bed Swing over carriage Maximum weight of job SR M100 8000mm 1000mm 710mm 10 MT

LATHE MACHINE 04-3001 Type Distance between centres Swing over bed Swing over carriage Maximum weight of job SR1600*10000 10000mm 1600mm 1200mm 28 MT

ROLL GRINDING MACHINE Max. dia to be ground 575-1600 mm Distance between centres 2/3 to 6/7 m Max. weight of roll 3 to 6 T Rigid design for better efficiency and accuracy Accurate concave & convex grinding Electronic/mechanical feed counter for pre selection of cross feed Built in dynamic balancing device

HEAT TREATMENT SECTION HEAT TREATMENT:- It refers to a combination of heating and cooling of a metal or alloy in the solid state for the purpose of obtaining desired properties. In this shop various heat treatment process like nitriding, volume hardening, tempering, normalising, annealing.

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INDUCTION HARDENING:Induction hardening is a heat treatment process in which the surface of the steel is heated to high temperatures (by direct application of a flame, or by induction heating) then cooled rapidly, generally using water; this creates a "case" of martensite on the surface. First the job (rolling steel) is preheated at nearly 350C then it is allowed to cool for about half an hour. Then again it is heated upto 905-910C. Quenching is done in an oil bath which is maintained at 110C and the job is kept there for 48 hrs. Induction hardening processes: High frequency Medium frequency Low frequency >8000 Hz 3000-8000 Hz <2500 Hz 2-5 mm depth 5-8 mm depth 15-30 mm depth

MACHINES USED: 1. Low frequency induction hardening machine Job length 5 m(max) Barrel diameter 300-600 mm Job weight 15 tonnes Power input 1000 KW

2. Medium frequency induction hardening machine Job length 1-6 m Barrel diameter 150-800 mm Job weight 15 tonnes Power input 600 KW

3. Cyaniding machine 4. Nitriding machine 5. Electric furnace