Internship Project-based Report on

PROGRAMMING AND OPERATION OF CNC GAS

CUTTING

A report submitted as a part of the Vocational Training in Steel Structural Shop

(SSS), Visakhapatnam Steel Plant

By

NAME TRAINEE INSTITUTION

NUMBER
ABHISHEK KUMAR 100024857 SLIET, LONGOWAL.

Under the esteemed guidance of guidance of

Sri K. Srinivas Rao (Sr Manager, SSS, ES&F)
 Rashtriya Ispat Nigam Limited (RINL), Visakhapatnam

(Duration: 3rd JULY 2023 to 29th JULY 2023)

CERTIFICATE

This is to certify that the project work titled “Programming and Operation of CNC
Gas Cutting Machine” by ABHISHEK KUMAR is being submitted in partial
fulfilment internship programme for award of Bachelor of Engineering in Mechanical
department at Sant Longowal Institue of Engineering & Technology is a record of
bonafide work carried out by them under my guidance and supervision for a duration
of 4 weeks from 3rd July 2023 to 29th July 2023.

DATE:29/07/2023

(Signature of Guide)

Sri K.SRINIVAS RAO

Sr.Manager, SSS, ES&F
 ACKNOWLEDGEMENT
First of all, I thank Visakhapatnam Steel Plant, who gave me the opportunity and
strength to carry out this work. The success and outcome of this project review
required a lot of guidance and assistance from many people, and we are incredibly
privileged to have got this all along with the completion of our project.

Our sincere thanks to Mr. M.V.S. Durga prasad, GM, (HOD)/ I/c Engineering Shops
& Foundry, Visakhapatnam Steel Plant, for his encouragement and valuable
suggestions.

I feel grateful to Mr. N. M. Maha Muni, AGM, Steel Structural Shop,

Engineering
Shops & Foundry, Visakhapatnam Steel Plant, for his valuable suggestions and
encouragement towards the completion of my project work.

I take this opportunity to sincerely thank Mr. K. Srinivasa Rao, Sr. Manager &
K.V.V Pavan Kumar, Deputy Manager, Steel Structural Shop, Engineering
Shops & Foundry, Visakhapatnam Steel Plant whose advice, and guidance has
helped me to complete my project work successfully.

Also, I give special thanks to our guide, Mr. K.V.V. Pavan Kumar, Deputy
Manager of SSS department who was the backbone for this successful journey
of learning throughout. Not only that, his support and guidance for this
internship built special skills like teamwork, decision making, problem solving,
etc.
 ABSTRACT

Engineering shops & Foundry is one of the most important service departments
in Visakhapatnam Steel Plant. It plays a crucial role in providing spare parts,
repair of damaged parts and assembly of various parts, which costs a lot, in a
very efficient way.

In this project “Programming and operation of CNC gas cutting”, one can get
exposure to the industrial processes and procedures that are required to fabricate
a spare part or any job and to develop repair shapes by cutting required shape
from plates or sheets.

The process of gas cutting, which starts with the need of the customer or user,
attains its drawing required for a worker to understand the dimensions to be
made and then a code is written and fed to the machine which cuts the plate
accordingly. This whole process is as essential in many industries as there will
be a continuous urge of new fabricated parts.

Various departments of steel plants require fabricated structural, and equipment

spares like Tundishes, Ladle covers, scrap holding buckets, hoppers, gratings,
slag pots etc. and various activities like drilling, shearing, forming, pressing,
gas cutting, bending of cone from sheet, welding are required to carry out
fabrication.
 TABLE OF CONTENTS

ACKNOWLEDGEMENT ................................................................................2
INTRODUCTION TO VSP ..............................................................................6
MAJOR PRODUCTION UNITS ......................................................................9
RAW MATERIAL HANDLING PLANT (RMHP) ..................................11
COKE OVENS & COAL CHEMICAL PLANT (COCCP) .......................12
SINTERING PLANT (SP) ..........................................................................16
CALCINING & REFRACTORY MATERIAL PLANT (CRMP) ............18
BLAST FURNACE (BF) ............................................................................18
STEEL MELTING SHOP (SMS) ...............................................................22
ROLLING MILLS ......................................................................................26
LIGHT MEDIUM MERCHANT MILL (LMMM) ....................................26
WIRE ROD MILL (WRM) .........................................................................28
MEDIUM MERCHANT AND STRUCTURAL MILL (MMSM) ............29
ROLL SHOP & REPAIR SHOP (RS&RS) ................................................31
SPECIAL BAR MILL (SBM) ....................................................................32
STRUCTURAL MILL (STM) ....................................................................33
ENGINEERING SHOPS & FOUNDRY (ES&F) ..........................................34
Central Machine Shop (CMS):....................................................................35
Steel Structural Shop (SSS): .......................................................................41
Forge Shop: .................................................................................................48
Pattern Making & Foundry: ........................................................................51
PROJECT ....................................................... Error! Bookmark not defined.
 PROJECT 1 : MODIFIED SUPPORT/PEDESTAL FOR SLAG POT
TRANSFER CAR (STPC) ..........................................................................58
PROJECT 2 : INNOVATION OF LADLE REPAIR .................................60
PROJECT 3 : HOOD ASSEMBLY FOR SMS LP BAY LINE DRIER ...67
PROJECT 4 : CUTTING OF SUPPORT FRAME FOR DUMP CAR BY
USING G-CODES AND M-CODES ON CNC-1 MACHINE ..................72
CONCLUSION ...............................................................................................77
 INTRODUCTION TO VSP

Visakhapatnam Steel Plant (VSP), the first coast-based Steel Plant in India, is
located 16 KM South West of the city of Destiny, i.e., Visakhapatnam.
Bestowed with modern technologies, VSP has an installed capacity of 3 million
Tonnes per annum of Liquid Steel. At VSP there is an emphasis on total
automation, seamless integration, and efficient up gradation, which results in a
wide range of long and structural products to meet the stringent demands of
discerning customers within India and abroad.

VSP products meet exacting International Quality Standards such as JIS, DIN,
BIS, BS, etc. VSP has become the first integrated Steel Plant in the country to
be certified to all three international standards for quality (ISO9001),
Environment Management (ISO-14001) & Occupational Health & Safety
(OHSAS-18001).

The certificate covers quality systems of all Operational, Maintenance, and

Service units besides Purchase systems, Training, and Marketing functions
spreading over 4 Regional Marketing Offices, 24 branch offices, and stockyards
nationwide. VSP, by successfully installing & operating Rs. 460 crores worth
of Pollution Control and Environment Control equipment and converting the
barren landscape by planting more than 3 million plants, has made the Steel
Plant, Steel Township, and surrounding areas into a haven of lush greenery.
This has created 6 Steel Township a greener, cleaner, and cooler place, which
can boast 3 to 4° C lesser temperature even in the peak summer compared to
Visakhapatnam City. VSP exports Quality Pig Iron & Steel products to Sri
Lanka, Myanmar, Nepal, the Middle East, the USA, China, and Southeast Asia.
RINL VSP was awarded "Star Trading House" status during 1997- 2000.
Having established a fairly dependable export market, VSP plans to make a
continuous presence in the export market.
BACKGROUND –To give impetus to Industrial growth and to meet the
aspirations of the people from Andhra Pradesh, the Government of India
decided to establish an Integrated Steel Plant in the Public Sector at
Visakhapatnam (AP).

The announcement to this effect was made in the Parliament on 17th April 1970
by the then Prime Minister of India, the late Smt. Indira Gandhi. A site was
selected near Balacheruvu Creek near Visakhapatnam city by a Committee set
up for the purpose, keeping in view the topographical features, greater
availability of land, and proximity to a future port.

The foundation stone for the plant was laid by Smt. Gandhi on 20.01.1971.
Seeds were thus sown for constructing a modern & sophisticated Steel Plant
with an annual capacity of 3.4 MillionTonnes of hot metal. An agreement was
signed between the Governments of India and the erstwhile USSR on June 12th,
1979, for setting up of an Integrated Steel Plant to produce structural & long
products based on a detailed Project report prepared by M/s M.N. Dastur &
Company. A Comprehensive revised DPR jointly organized by Soviets & M/s
Dastur & Company was submitted in Nov 1980 to Govt. of India. 7 The
construction of the Plant started on 1st February 1982. Government of India, on
18th February 1982, formed a new Company called Rashtriya Ispat Nigam Ltd.
(RINL) and transferred the responsibility of constructing, commissioning &
operating the Plant at Visakhapatnam from Steel Authority of India Ltd to
RINL.

The rationalized concept was based on obtaining the maximum output from the
equipment already installed, planned/ordered for procurement, and achieving
higher levels of operational efficiency and labour productivity. Thus, the plant
capacity was limited to 3.0 million tonnes of Liquid Steel per annum. In the
process, one of the Steel Melt Shops and one of the mills were curtailed. The
availability of resources was continued to be lower than what was planned and
further delayed the completion of the plant's construction.
Finally, all the units were constructed and commissioned by July 92 for Rs.
8529 crores. The plant was dedicated to the nation by the then prime Minister
of India Late Sri P. V. Narasimha Rao, on 1st August 1992. Coke rate of 509
Kg/Ton of Hot metal, average converter life of 2864 heats, an average of 23.6
heats per sequence in continuous Bloom Caster. Specific energy consumption
of 6.07 G Kal / ton of liquid steel, specific refractory consumption of 8.94 kg,
and labour productivity of 265 Ton/man per year are some of the peaks achieved
(during 2004- 05) in pursuit of excellence.
PRODUCTION FLOW CHART
 MAJOR PRODUCTION UNITS
RAW MATERIAL HANDLING PLANT (RMHP)

The Raw Material Handling Plant (RMHP) receives the basic raw materials
required for the making of steel from various sources through railway wagons
and by road. These are stacked by stackers and reclaimed by reclaimers and
distributed to various departments of Vizag Steel Plant through a conveyor
system. The Iron Ore Fines, Iron Ore Lump, Sized Iron Ore, Limestone
(BF&SMSgrades), Dolomite (BF & SMS grades), Sand, Quartzite and
Manganese lumps are stacked at Ore & Flux Yard. The Imported Coking Coal
(ICC), Medium Coking Coal (MCC), Boiler Coal (BC) are
stacked in Coal Yard. Coal is sent directly here after tippling from ore and flux
wagon
tipplers.

Peripheral unloading system for railway wagons coming directly up to pushers.

• Blender Reclaimers for blending of ores and flux in which the bucket wheel
has a lateral motion across the bed. The wheel on Boom Reclaimers for
reclaiming different materials from the same bed in Ore & Flux yard and the
same type of coals in CHP.
• 2 Ring Granulators for crushing of Boiler Coal.
• 3 Blender Reclaimers for blending of Iron ore fines and flux.
• PLC control of all systems.
• Dryer for drying SMS Sized Ore.
• Preparation of Sized iron Ore for use in BF to enable close size range of raw
materials.
Sl. No. Raw Materials

1. Iron ore fine

2. Iron ore lump

3. Sized iron ore

4. Limestone (BF grade)

5. Limestone (SMS grade)

6. Dolomite (BF grade)

7. Dolomite (SMS grade)

8. Sand

9. Manganese lump

• A dust extraction is provided at various locations of RMHP to absorb the

dust generated during the process

COKE OVENS & COAL CHEMICAL PLANT (COCCP)

COAL PREPARATION PLANT:

From the storage yard, the raw coal is sent to foreign object separation section
(FOSS) to remove foreign matter of above 150 mm size. Iron traps for
ferromagnetic particles and cylindrical screens are provided for this. For
averaging and proportioning of coal, 16 nos. of Silos, each of 800T
capacities are provided along with continuous action weigh-feeders of up to 120
tons per hour capacity each. After blending, the material is crushed with the
help of impact crushers. The crushing is carried
out in reversible hammer crushers, 2 operating and 1 standby. Crushing is done
to take care of petrographic non-uniformity, high hardness and mineral content
of coal. The crushed and blended coal (74-75% of -3mm size) is conveyed to
two coal towers each of 4000 T capacity. Weighbridges are provided under coal
towers to weigh the coal charge. System of pneumatic blow down of the blend
is provided in the coal tower to take care of jamming or hanging of coal in the
coal tower.

BATTERY:
The prepared coal charge from the coal tower is drawn by a charging car on the
top of the batteries and charged into the ovens as per the sequence. The heating
walls of the oven gradually heat the charged coal in the absence of air to attain
a temperature of 1000-1050°C at the central axis of the coke mass towards the
end of the cooking period. The cooking period is generally specified between
19 hrs and 22 hrs depending upon oven condition and production requirements.
The volatile matter of coal liberated during carbonization is collected in gas-
collecting mains in the form of raw
coke oven gas passing through standpipes and direct contact cooling with
ammonia liquor spray. The gas-cooled from 800oC to 700oC is drawn to the
coal chemicals plant by Exhauster. The residual coke is pushed out of the oven
by a pusher car through a guide into the coke bucket.
The red-hot coke is taken to the coke dry cooling plant for cooling.
There are 4 batteries, each having 67 ovens. Each oven can hold 32 tons of dry
coal charge.
The volumetric capacity of each oven is 41.6 m3.
The heat for carbonization is supplied by under firing of coke oven gas having
CV of 4200 Kcal/Nm3 or a mixture of BF gas & CO gas having CV 1000
Kcal/Nm3.
GAS CONDENSATION SECTION:
The Coke Oven Gas (CO Gas) leaves the ovens at a temperature of 8000C and
is cooled from 8000C to 800C in goosenecks and in gas collecting mains at the
batteries by spraying Ammoniacal liquor (Flushing liquor). 60-70% of Tar
present in CO-Gas is condensed here. The CO-Gas, along with Tar and liquor
comes to a separator to remove liquor and condensed Tar. The cooled CO-Gas
is then
taken to primary gas coolers (each having a heat transfer area of 2425m2) where
it is cooled indirectly by water to about 25 to 300C. Along with the Tar, some
amount of Naphthalene in coke oven gas is
also condensed.
The gas is then sent to Electrostatic Precipitators (each of 27000 Nm3/hr
capacity) to remove the foggy Tar (about 5%) from CO gas. In ESP, foggy Tar
particles are electrically charged and collected
on the surface of the electrodes and separated. The gas purified from Tar is
compressed in Exhauster to a pressure of max.2800 mm water column. There
are five electrically driven exhausters provided and each having capacity of
76000 Nm3/hr.

[ Bucket to carry hot coke]

SINTERING PLANT (SP)

The Sintering Plant at VSP (Visakhapatnam Steel Plant) is a crucial component

of the steel manufacturing process. It plays a significant role in the production
of high-quality iron ore sinter, which is an essential raw material used in the
blast furnace.
The primary function of the Sintering Plant is to agglomerate fine iron ore
particles, along with other additives such as limestone, dolomite, and coke
breeze. These materials are mixed in specific proportions and then sintered at
high temperatures. Sintering refers to the process of heating the mixture without
melting it, causing the individual particles to bond together and form larger
porous agglomerates called sinter.

The sintering process involves several stages:

Mixing and Preparation: The raw materials, including iron ore fines, fluxes
(limestone and dolomite), and fuel (coke breeze), are carefully measured and
mixed in the correct proportions. This mixture, known as sinter mix, is then
thoroughly blended to ensure uniform distribution.

Ignition and Sintering: The sinter mix is ignited in a sinter machine, which
consists of a series of pallets or grids. The ignited mixture is heated to a high
temperature (around 1300-1500°C) within the sinter machine. The heat causes
the fine particles to melt and bond together, forming agglomerates partially. The
sintering process also helps in the removal of volatile impurities and moisture.

Cooling and Sizing: The hot sintered material is then cooled using a system of
coolers. It is carefully broken down into smaller pieces and screened to obtain
the desired size distribution of the sinter. The cooled and sized sinter is then
ready for further processing in the blast furnace.

The sinter produced in the Sintering Plant serves as a valuable feedstock in the
blast furnace, where it is charged along with other materials such as iron ore,
coke, and fluxes. The sinter acts as a permeable matrix, allowing the proper
flow of gasses and facilitating the reduction of iron ore to produce molten iron.
The Sintering Plant at VSP is designed to produce high-quality sinter while
ensuring minimal environmental impact efficiently. Measures such as dust
suppression systems and waste heat recovery systems are employed to enhance
operational efficiency and reduce emissions.

CALCINING & REFRACTORY MATERIAL PLANT (CRMP)

Calcining & Refractory Materials Plant (CRMP) is an integrated unit of
Visakhapatnam Steel Plant. This plant plays a significant role in the
manufacturing of liquid steel. The output of CRMP is the input for Steel
Melting Shop (SMS). It has 2 units:
1. Calcining plant
2. Brick plant

BLAST FURNACE (BF)

Blast Furnace is the most important part of an integrated steel plant. It is

considered as the heart of an ISP. The objective of Blast Furnace is to take the
raw material from RMHP, coke from Coke Ovens, and Sinter from Sinter Plant
and convert it into pig iron or “Hot Metal”. Coke serves as the heat source and
reducing agent while Limestone and Dolomite are used as flux, which combines
with gangue to produce
slag. A Blast Furnace is so called because it uses air blast with oxygen as a
source for the process.
PARTS OF A FURNACE:
1. Hot blast from Cowper stoves
2. Melting zone
3. Reduction zone of ferrous oxide
4. Reduction zone of ferric oxide ‘
5. Pre-heating zone
6. Feed of ore, limestone and coke
7. Exhaust gasses
8. Column of ore, coke, and limestone
9. Removal of slag
10. Tapping of molten pig iron
11. Collection of waste gasses

PROCESS in BF:
HOT AIR BLAST BURDEN CHARGE: Model BF is a counter-current heat
and mass exchanger, in which solid raw materials are charged from the top of
the furnace, and hot blast is sent through the bottom via tuyeres. The heat is
transferred from the gas to the burden, and oxygen from the burden to the gas.
Gas ascends up the furnace while burden and coke descend down through the
furnace. The counter-current nature of the reactions makes the overall process
an extremely efficient one in reducing the atmosphere.
The real growth of blast furnace technology came with the production of high-
strength coke which enabled the construction of large-size blast furnaces.
The main chemical reaction producing the molten iron
Fe2O3 + 3CO → 2Fe + 3CO2

C + O2 → CO2
CO2 + C → 2CO
CaCO3 → CaO + CO2
SiO2 + CaO → CaSiO3
Preheated blast air blown into the furnace reacts with the carbon in the form of
coke to produce carbon monoxide and heat. The carbon monoxide then reacts
with the iron.
STEEL MELTING SHOP (SMS)

The SMS department plays a crucial role in the steel production process by
melting raw materials, such as iron ore and scrap metal, to produce liquid steel.
The SMS department is responsible for operating and maintaining various units,
such as electric arc furnaces, ladle refining furnaces, and continuous casting
machines. These units are used to melt the raw materials and convert them into
steel of the desired composition and quality. The department also ensures
proper temperature control, alloying, and degassing processes to meet the
specific requirements of different steel grades.

(LD converter)

The molten iron containing 4% carbon and other foreign materials are taken to SMS
department from Blast furnace. This molten metal is brought from Torpedos. It is a
cylindrical shape containing bricks inside. It is in the shape of wagon. The refractory
lining is made inside the torpedo in order to maintain the high temperature. It is then
dumped into ladle from torpedos. This ladle is taken to LD convertors by hook
machine. Inside the LD convertor, the molten metal is heated above some temperature
since some temperature has been lost during transportation. Now, oxygen is pumped
into increase temperature and form exothermic reaction. Carbon in molten metal
reacts with oxygen. This reduces carbon content to 2% and hence Steel is obtained of
required grade. Next process goes in Continuous casting department.

(Torpedo)

Here, graphite is added to give steel required properties. The dummy car is placed in
such a way that the operator operates the lever. If the lever is released, molten metal
will flow fast and the shape will be deformed. Hence a dummy car is used to make
sure these low flow gives support at the end of the billets.

CONTINUOUS CASTING DEPARTMENT

VSP has six-4 strand continuous casting machines capable of producing 2.82 million
Tonnes / year Blooms of size 250 x 250 mm and 250 x 320 mm.
Entire quantity of molten steel produced (100%) is continuously cast in radial bloom
casters which help in energy conservation as well as production of superior quality
products. Facilities at continuous casting machines include a lift and Turntable for
ladles, Copper mould, oscillating system tundish, Primary & Secondary Cooling
arrangement to cool the steel bloom.

Gas cutting machines for cutting the blooms in required lengths (Av. 6metres
long).After controlling the composition and temperature, and removing non-metallic
inclusions, the molten steel is transferred into a ladle 26 and poured into a mould,
where it solidifies to produce semi-finished or finished products. In the past, the ingot
casting and rolling (slabbing, blooming, or billeting) processes
were commonly used. In this process, the molten steel was poured into many fixed
cast-iron in got mould sand, when the solidification was complete.
The concept of continuous casting process which is a continuous process, and has
now virtually replaced this earlier method. In continuous casting, the molten steel in
the ladle is poured into an intermediate vessel (tundish), released into a hollow water-
cooled copper mould, and continuously withdrawn from the bottom of the mould as a
shell begins to form around the molten metal.

(Dummy Car)
ROLLING MILLS
Blooms produced in SMS-CCD are shaped into products such as Billets, rounds,
squares, angles (equal & unequal), Channels, I-PE Beams, HE Beams, Wire rods, and
reinforcements bars by rolling them in three sophisticated high-capacity, high speed,
fully automated rolling mills, namely Light & Medium Merchant Mills (LMMM),
Wire Rod Mill (WRM) and Medium Merchant and Structural Mill (MMSM).

LIGHT MEDIUM MERCHANT MILL (LMMM)

The bloom of 250 x 320 mm coming out from the SMS-1 department, with the help
of Dummy Bar, is cooled down in the presence of air; it is then taken to the LMMM
department.

Here the blooms are made into billets inside the hearth furnace. The dimension of
the hearth furnace is 42mx10.92m. The fuel used is mixed gas coming from SMS,
blast furnace, and coke oven. Its thermal efficiency is 70%. Nearly 187 billets can be
accommodated in the hearth furnace. There are 6 flat plate burners and 6 long flame
burners.
The billets are used to make circular cross-section rods, and blooms are used to
prepare I-section beams.
There are 3 hearth furnaces. After heating the billets, it is taken out with the help of
a rod and passed through rollers. The cross-section area is reduced. Since volume is
constant, as the area decreases, the length increases.
Volume = Area x Length
It is then passed through a number of paired rollers in which one roller is fixed, and
the other one moves up and down according to adjustment and requirement of size.
It is then passed through rollers for the required diameter, and it is quenched with
water to make it harder. This required diameter is obtained by gradually reducing the
cross-section of the billets and shaping them gradually with the help of different
cassettes. The rods are made of different shapes. It can be herringbone-shaped or
crescent-shaped rods. These are long rods and then cut by a machine. They are then
moved toward the strapping machine. They are then tied together and are ready to go
for use.
WIRE ROD MILL (WRM)
WRM is a sophisticated and automatic mill. With an annual capacity of
8,50,000 Tonnes of Wire rod coils, billets are rolled in a high-speed continuous
manner, producing various dimensions of rounds and rebars.
● Rounds: 5.5mm-14mm
● Rebars: 8mm, 10mm, 12mm

WRM-1: The Mill is high speed 4 strand No-Twist continuous mill designed to
produce 8,50,000 Tons of wire rod coils per year. Rolled billets of 125 mm x
125 mm square cross section, length ranging from 9.8 m to 10.4 m and weighing
approximately 1250 kgs are used. Its input is obtained from LMMM which gets
its input from SMS-1. The mill is designed to roll steel stock of 0.9% max.
carbon content.
WRM-2: The Mill is designed to produce 6,00,000 tons per year of rounds in
coil form. The Mill is designed to roll low, medium and high carbon steel, case
hardening steel, cold heading quality steel, electrode steel, spring steel, bearing
steel and free cutting steel. The mill shall use continuous cast billets of 150 mm
X 150 mm square cross section, 12 m length and weighing 2100 kgs
approximately, as input material which is provided directly from SMS-2 unlike
in WRM-1.

MEDIUM MERCHANT AND STRUCTURAL MILL (MMSM)

Blooms of dimension 250 x 250 mm from SMS-1 is the input to the MMSM
department. These are stored in the BS bays of SMS-1, which is at the end of
the MMSM dept. Blooms are first pre-heated to a temperature of about 800-
1000oC and then heated to around 1200oC in the furnace. These hot blooms are
based on the rolling beds to gradually reduce the cross-section to make billets,
channels, and angles of different dimensions, according to the requirement of
the customer. This reduction of the cross-section is made with the help of
cassettes by varying the dimension through the hot blooms pass. Various
dimensions of the following products produced in MMSM:
● Billets - 65mm, 77mm, 90mm
● Angles - 75 x 6/8mm, 90 x 6/8mm, 100 x 8/10mm
● Channels - 100mm, 125mm, 150mm, 200mm

There were also I-beams, and HE beams(Universal beams) that were produced
here which is the symbol of RINL (I). These Universal beams have been rolled
for the first time in India with the help of Universal stands. But due to the lack
of need for these beams, they are not produced now.
ROLL SHOP & REPAIR SHOP (RS&RS)
Roll Shop & Repair Shop is one of the complex Rolling Mills catering to the
needs of mills in respect of roll assemblies, guides, few Maintenance Spares,
and roll pass design. This department is mainly placed in MMSM and LMMM
departments for their respective repairs or spares. The main activity of this shop
is Roll pass Design, grooving of rolls, preparation of cassettes, assembly of rolls
with bearings, preparation of guides and their service, and manufacture/repair
of mill maintenance spares.
VSP, for the first time in India, has adopted CNC technology for the grooving
of steel rolling mill rolls. High constant respective accuracy, higher
productivity, use of the standard tool for any groove turning, elimination of the
use of different templates, easier to incorporate groove modification, etc., are
some of the advantages of CNC lathes over the conventional ones.

SPECIAL BAR MILL (SBM)

Special Bar Mill produces plain rounds in straight length and in coil form by
using an input of Continuous cast billets of 150 mm x 150 mm x 12 m from
SMS-2 weighing approximately 2050 kgs. This mill is designed to roll medium
and high carbon steel, case hardening steel, cold heading quality steel, electrode
steel, spring steel, bearing steel, and free-cutting steel.
Different types of forms produced in SBM:
● Straight Form: Chain transfers, Cold Shear, Bundling Facilities and
Strapping machines.
● Coil Form: Garret coilers, Cooling conveyors, Hook conveyors,
Compacting and Strapping Machines Product mix
● Round Form Outputs:

Rounds - 20 mm to 45mm diameter (with a special provision to roll 16

mm to 18 mm for railway purposes only).
Coils - 2.0tons (as per billet weight).
● Straight Form Outputs: Straights - 12.0 m bundle with 6 straps.
 Furnace in SBM (around 1200oC)

Hot billets passing through guides to reduce cross-section

STRUCTURAL MILL (STM)

Structural Mill is a Continuous mill that consists of 17 stands of housing-less
design. The input for this mill is a Continuous cast cold bloom of 200 mm x
200 mm x 12 m weighing approximately 3760 kgs obtained directly from SMS-
2, unlike other rolling mills, and the outputs are of various kinds of structural
parts like Beams, Channels, Angles, and Flats.

ENGINEERING SHOPS & FOUNDRY (ES&F)

Engineering shops & foundry department is a service department that is
responsible for spare parts manufacturing, repair of structures, and reclamation
of various jobs from other departments. Engineering shops typically specialize
in designing, engineering, and fabrication of metal components and systems,
with the help of a variety of tools and technologies to create accurate and
complex metal parts. Foundry facilities the casting of metal parts and
components from molten metal, using molds, patterns, and other casting
techniques to produce large quantities and varieties of parts quickly and
efficiently.
This department consists of five sections for various purposes:
1. Central Machine Shop (CMS)
2. Steel Structural Shop (SSS)
3. Forge Shop
4. Pattern making & Foundry
5. Utility Equipment Repair Shop (UERS)
Central Machine Shop (CMS):

Iron & Steel castings, forgings, rolled sections, repair and rectification parts,
non ferrous casting are done here.
Final products are Shafts, Pinions, Gears, Crane Wheels, Rollers, Machining of
various fabrication jobs done in SSS, Repair & reconditioning of various
assembly jobs like L&T Column, TK stands, pulleys, provisioning of gear
boxes.
The shop operates on a two-shift basis for 300 days in a year and annual
production is 5, 200’t. For preparing the raw material for machining, material
saws, facing and centering machines, hacksaws, and gas cutting facilities are
provided. The machining section has over 100 major machines including lathes,
milling, boring, and planning, slotting, shaping, grinding and other machines.
The assembly section undertakes medium repair and general overhauling of
mechanical equipment. Horizontal and vertical presses, induction heaters are
provided. The tool room has facilities for manufacturing of special tools, jigs
and fixtures, re-grinding of tools and cutter and brazing of tipped tools. The
heat treatment section is provided with annealing, normalizing, tempering
furnaces, carbonizing furnaces, heat treatment furnace with protective gas
atmospheres, high frequency hardening machine, quenching tanks will oil
cooling arrangements, welding generator and transformers for normal welding,
submerged arc welding machines etc. Facilities for surface grinding, pipe
bending and threading are also provided.

Equipment used in Central machine shop

• Surface Grinding machine
• Centerless grinder
• Cylindrical Grinding machine
• Turret lathe
• Radial drilling machine
• Column drilling machine
• Ram head Milling machine
 • Vertical milling machine
• Horizontal milling machine
• Gear hobbing machine
• Slotting machine
• Planer machine
• Heavy lathes
• Plano milling machine
• Horizontal boring machine
• Vertical turret boring machine
• Vertical press
• Plano milling machine
• Bevel gear generator

SURFACE GRINDING MACHINE

Surface grinding is a finishing process that uses a

rotating abrasive wheel to smooth the flat surface
of metallic or nonmetallic materials to give them
a more refined look by removing the oxide layer
and impurities on workpiece surfaces.
The components of a surface grinding machine
are an abrasive wheel, a workholding device
known as a chuck, and a reciprocating or rotary
table.
CENTERLESS GRINDING MACHINE

Centerless grinding is a machining process that uses

cutting to remove material from a workpiece.
Centerless grinding differs from centered grinding
operations in that no spindle or fixture is used to
locate and secure the workpiece,the workpiece is
secured between two rotary grinding wheels, and the
speed of their rotation relative to each other
determines the rate at which material is removed from
the workpiece.Such a machine will always include
the grinding wheel, regulating wheel, and some
means of supporting a workpiece.

CYLINDRICAL GRINDING MACHINE

Cylindrical grinding is used for grinding workpieces

with a central axis of rotation, like rods and
cylinders. In this machine, the workpiece is rotated
between two centers on its axis. From a
high-speed rotation, the grinding wheel grinds the
two centers on its axis so as to produce a smooth
surface.
RADIAL DRILLING MACHINE

Radial drilling machines are used to drill holes in

mediums to large and heavy workpieces. These
machines are used to drill holes in a given radial
distance. With the use of this machine the tool is
moved to the desired position instead of moving
the work to bring the latter in position.

COLUMN DRILLING MACHINE

The box column drill or pillar drill has a heavy foot that
is firmly mounted in the floor or a workstation. A column
runs over the foot of the drill machine and extends into
the housing. On the column is also an adjustable drill or
machine table, which can be brought to the appropriate
height via a threaded spindle. Column drill machine can
be used to drill large diameter drills. This machine can
perform high speed drilling with a multi spindle head.

SLOTTING MACHINE

A slotting machine is a type of reciprocating machine

in which the ram holds the tool and moves downward
and upward only in the vertical axis and produces a
variety of products such as keyways, grooves, slots,
etc. In the slotter machine a single point cutting tool
is used.
GEAR HOBBING MACHINE

Gear Hobbing is the process

of generating gear teeth by
means of a rotating cutter
referred to as a 'hob'.The hob
has a number of flutes around
its periphery, parallel to the
axis, to form cutting edges. In
this machine cutting is
carried out by a tool called
hob. The work is fixed on a
rotary table and the hob is
rotated by means of an electric motor and work is fed across the hob.

HEAVY LATHE

The HEC LC 100/ LC

125 type center lathes
are heavy-duty lathe
machines used in CMS.
Their rigid structure
permits roughing and
precision finishing work.
It uses cemented carbide
tipped tools and high-
speed steel tools. The main parts of the heavy lathe machine are bed, head stock,
tailstock and carriage. Heavy duty lathe machines are used to face and turn
materials to exact diameter and length. They also perform operations such as
vertical and horizontal drilling, boring, tapering, threading bolts fasteners,
knurling and internal boring.

PLANING MACHINE

A Planer machine is used to do heavy work or to take

heavy cuts. The cutting tools used in a planing operation
are all single-point cutting tools. Planning operation is
often used to perform two types of tasks; making perfect
flat surfaces and cutting slots such as keyways.
The tool is held vertically in the tool head mounted on
the cross rail. The work table together with the job is
made to reciprocate past the vertically held tool.
PLANO MILLING MACHINE

Plano milling machine is a milling machine but

designed to execute certain work formerly confined
to the planer. It is a multipurpose machine on which
milling, planning, drilling, boring etc. can be done.
It has a cross rail, capable of being raised or
lowered, carrying the cutters, their heads and the
saddles, all supported by stout uprights. In this
machine the table is moved to give feed to the
workpiece.The length of the bed is 8m, and the width of the bed is 2 m. So that
16 m length jobs can be done easily. This machine is safe on the mechanical
side using German technology. The electrical power to the machine is
immediately cut off when overload or any other interruption like lack of
lubricating oil etc. occurs.

Steel Structural Shop (SSS):

Different types of fabrication jobs and manufacturing jobs, like slag dump cars,
thrust cars, ladles, hoods, etc., are done in this section. Repair works like ladle
repair, dump car repairs, etc., also take place here. Most of these jobs are done
on CNC gas cutting which uses a combination of acetylene and oxygen to cut
through metal sheets or plates of various thicknesses. These jobs are also done
using different machines.
 (SSS Shop Layout)

Sequence of Operations for a Job preparation:

1. Drawing (study of production drawing of the job).

2. Marking of the raw materials.

3. Material preparation.

4. Cutting to prepare material for the object (i.e., shearing & gas-cutting).

5. Drawing the layout of the job assembly.

6. Assembly of various parts or plates prepared.

7. Welding process (mostly in steel structural shops we use Arc welding

process).

8. Inspection of job.

9. Dispatching to customers.
Equipment used in Steel Structural Shop:
1. Gas-cutting Machine
2. Radial Drilling Machine
3. Plate Bending Machine
4. Vertical Pressing Machine
5. Shearing Machine
6. Combined Shearing Machine

All these machines are placed in the material preparation areas in the shop. In
the Material preparation area, plates and metal sheets of various dimensions and
thicknesses are placed for immediate use as and when required.

1.GAS-CUTTING MACHINE
Gas cutting, also known as profile cutting, is done by using oxy fuel gas.
Acetylene, as fuel, burns in oxygen to produce a strong flame which is
used to cut through the metal sheets, or plates. LPG can also be used,
which has similar properties to that of acetylene, as acetylene can be a bit
dangerous when mishandled.
This machine can cut through a range of thicknesses from 0.5mm to
200mm. Also, the equipment cost is relatively cheap and efficient to be
operated manually or automatically.

TYPES OF GAS-CUTTING MACHINES USED:

● Manual gas-cutting machine
• Pug gas-cutting machine

• CNC gas-cutting machine

2.RADIAL DRILLING MACHINE

Radial drilling is used for drilling heavy works and especially for the jobs
where high degree of accuracy is required. In this machine, the job and the tool
will be perpendicular to each other. Drilling machine in which head can be
moved along an Arm that radiates from the Machine's Column and the tool is
perpendicular to job. Operations that can be performed in this machine are
Drilling, Reaming and Tapping.

3.PLATE BENDING MACHINE

Plate bending or straightening machine is a universal forming equipment

used to bend the plates or sheets in order to form into cylindrical shape,
conical shape and other curved shapes as well as to straighten the curved
and abstracted plates or sheets and make them flat. This machine has 5
rollers in which 2 are supporting rollers and the other 3 rollers are framed
in a triangle pattern. Mainly these 3 rollers play the bending role of a
metal sheet.
4.VERTICAL PRESSING MACHINE

The Vertical Pressing machine is used for pressing large shafts, castings
etc. The pressure of oil is increased by pump, and it is transmitted to the
cylinder in order to lift the ram off or to force the ram downwards. The reason
for the increase in pressure of the fluid is the design of the hose pipe through
which this fluid is flowing. Suitable oil is used as the fluid. This mechanism
will be used for lifting and sudden pressing of shafts. The maximum pressing
force that can be achieved from this machine is 200 tonnes.
5.SHEARING MACHINE

Shearing machine is a machine that shears a sheet by reciprocating linear

motion with one blade relative to the other blade. By means of the moving
upper blade and the fixed lower blade, a reasonable blade gap is applied to
apply shearing force to the metal sheets of various thicknesses, so that the
plates are broken and separated according to the required size.

6.COMBINED SHEARING MACHINE

 The Combined Shearing machine is completely mechanically operated. It
is very similar to the straight shearing machine except that one or more
operations below can be performed simultaneously. The five types of
operations can be done simultaneously on the machine:
1. Punching
2. Shearing
3. Notching
4. Angular cutting
5. Cropping/Rod cutting

Forge Shop:

Forging is a manufacturing process involving metal shaping using localized

compressive forces. The blows are delivered with a hammer (often a power
hammer), a die, or by rolling. Forged parts can range in weight from less than a
kilogram to hundreds of metric tons. Smiths have done forging for millennia; the
traditional products were kitchenware, hardware, hand tools, edged weapons,
cymbals, and jewelary. Since the Industrial Revolution, forged parts have been
widely used in mechanisms and machines wherever a component requires high
strength; such forgings usually require further processing (such as machining) to
achieve a finished part. Today, forging is a major worldwide industry.

Types of forging based on temperature:

● cold forging
● warm forging
● hot forging

Hot forging of steel: The forging temperatures are above the

recrystallization temperature and are typically between 950°C–1250°C.
Roll forging: (also known as hot forge rolling) is a process for simultaneously
reducing the cross-sectional area and changing the shape of heated bars, billets,
or plates by passing them between two driven rolls that rotate in opposite
directions and have one or more matching impressions in each roll.

(Banning)
In the Forge Shop of ES&F, spare parts for other major departments are forged.
There are 9 furnaces which can heat up to a temperature of 1200-1300°C.
Different jobs were observed in this Forge shop which include, V-hooks, forged
rounds, jobs forged from 125 x 125mm billets for various purposes.

V HOOKS

FORGED ROUNDS
Pattern Making & Foundry:

INPUTS: Pig Iron, MS scrap, Ferro alloys, graphite electrodes, sodium silicate,
silica sand CO2 gas, molding additives etc.

PRODUCTS:- Steel, cast iron & non ferrous castings, Emergency containers,
tundish covers, bull gear for SMS, hot metal runners, ladle paw for blast
furnace, coke roll liners, sprockets, pallets for sinter plant, raw supports, bowl
for RMHP, guide troughs for WRM, face of scrap bucket for MMSM, slag pot
segments for SSS repair, ingots for forge shop, non ferrous castings like bushes
(below 20 kg) etc.
Iron castings up to a weight of 5 tons will be produced. A main frequency
coreless induction furnace with two 2-ton capacity crucibles and a 5T capacity
main frequency coreless induction furnace for melting iron are provided. There
is a centralized sand preparation unit. A drier and a bin is provided for green
sand. Belt conveyors transport green sand, prepared mix and burnt sand. Molds
and cores are drier in 3 ovens lip pour ladles with capacity between 50 kg and
10 tons is provided for handling hot metal. Two swing frame grinders and two
pedestal grinders are provided for finishing of iron castings.
Total annual production is 3,200Tons. Steel castings up to maximum piece
weight of 10 T and Steel Ingots up to 1.3 tons for forging are produced. An 8
Ton arc furnace and a two-ton medium frequency electric induction furnace is
installed for melting of steel scrap and pig iron. Each of the two sand mixers
has a 1.5-ton batch. A bogie hearth furnace for annealing/ normalizing of plain
carbon steel castings and fixed hearth furnace for heat treatment of manganese
steel castings with quenching facility is provided.
The woodwork shop manufactures patterns for foundries. The principal
equipment for pattern making are saws, disc grinding, and woodworking lathe,
adequate facilities are provided for saw grinding, painting, timber, and pattern
storage, etc.

Utility Equipment Repair Shop (UERS):

INPUTS: sheets, plates, channels, angles, beams, billets, rounds for forge shop
for manufacturing Shafts, steel, and iron castings.

PRODUCTS & SERVICES:- Manufacturing. Of impellers to various

departments, repair of GCP Id fan, repair of steam exhausters for SMS, supply
of cones & ducts of various sizes, in house manufacturing of MBC impeller for
CCCD, buildup & machining of various components, reclamation jobs like
valve repairs, conveyor idlers, PCM rollers, etc. Total annual production is 950
Tons. Repair of ventilation, air conditioning, and water supply equipment is
carried out here. There is a machining section having 15 major machines like
lathes, milling, slotting, shaping and grinding
machines, Sheet bending machines, Guillotine shear & semi-folding machines
are provided in the fabrication section. a 250 kg pneumatic hammer with
necessary facilities and a welding section for semi-automatic, automatic, and
shielded arc welding machines are provided in the plumbing section. There is a
separate
equipment repair section.

Planning Section:
In every department, planning plays an important role. The planning section
takes care of the jobs that need to be done within a stipulated time. Organization
of different tasks and assigning them to different shops of ES&F is done here.
INTRODUCTION TO CNC PROFILE GAS CUTTING MACHINE

CNC stands for Computerized Numerical Control. In olden days, the machining
process was done manually which brought dimension errors and damage to the
workpiece.It was also tedious. Later, it was shifted to Numerical Control which
reduced the machining time. It involved human control over NC machines.
Later to perform accurate operation, CNC came into picture.
It has G-codes(Geometric Codes) and M-codes (Machine Codes).
CNC uses an arc method to cut the workpiece. It has pressurized oxygen and
LPG gas which are then controlled for cutting. The diameter of the Oxygen
passage nozzle is double the diameter of the LPG flow nozzle. The code is
written manually and input is given to CNC machines. The codes are checked
whether they perform accordingly or not. If there is any adjustment, it is made
Manually.

PREPARATORY FUNCTIONS (G-CODES)

G-codes (also RS 274) or Preparatory functions play a major role in the
operation of cutting machines. These codes run as a cycle till it is either
canceled or changed with different G-codes.
Few important G-codes are
G00 - Rapid Transverse Linear Interpolation
G01 - Linear Interpolation
G02 - Clockwise Circular Interpolation
G03 - Counter Clockwise Circular Interpolation
G04 - Dwell
G20 - Select English units (Inches)
G21 - Select Metric units (millimeters)
G40 - Disable Kerf Compensation
G41 - Enable Kerf Compensation
G42 - Enable Right Kerf Compensation
G90 - Absolute Programming Mode
G91 - Incremental Programming Mode
G92 - Set Axis Presets

Incremental & Absolute Modes:

Absolute and Incremental modes are the different ways to define the position
of the tool with respect to the workpiece or machine origin.

Absolute Mode: Absolute mode is selected using the G90 code where the
tool coordinates are always referenced, usually from the machine origin or work
offset or any fixed point and followed throughout. Displacements are
mentioned with the X and Y coordinates (2-dimensional). The same mode
continues till we change the reference or set axis using the G92 code. I and J
may also represent relative displacements from the start point.

Incremental Mode: Incremental mode is selected using the G91 code

where displacements are specified by X, Y, I, and J letters, which are relative
to the previous point; that is, the endpoint of one block is taken as the start point
(or origin) or the corresponding block.
Metric Units: English and metric units are selected by the G20 and G21
codes, respectively. English units are in inches, while metric units are in
millimeters. In industries usually, metric units are used.

Line segments and arcs: Line segments are specified by the G01 code
along with the X and Y coordinates of the endpoint of that line to cut in that
direction. Similarly, curves or arcs are cut using the G02 for clockwise arcs and
G03 for counterclockwise arcs. Along with G02 or G03, the radius of the arc is
also specified with the letter ‘R.’ The X and Y coordinates are specified for the
endpoint of the segment along with the I and J values for the center of the circle
of which the arc is a part.

KERF Compensation: KERF is generally the width of cut or the width

of material removed during the cutting process. So, during cutting, to get the
required dimensions, an allowance is given beforehand and the direction of
allowance is also mentioned according to the requirements.
G41 and G42 codes are used to enable the left and right KERF compensations
of the torch path, respectively. To disable this block, G40 is used (disable KERF
compensation).

Dwell: Dwell or delay is programmed using the G04 code. Delay is used at
the corners where the lag in the flame can result in poor or rough cuts.

MISCELLANEOUS FUNCTIONS (M-CODES):

M-codes are used for non-motion operations of the cutting machine. So, these
codes are used for operations like ON/OFF of the device or spindle, etc.Some
of the M-codes are:
M00 - Program Stop
M01 - Optional Program Stop
M02 - End of Program
M07 - Cutting Device ON
M08 - Cutting Device OFF
M09 - Marking Powder ON
M10 - Marking Powder OFF
M11 - Marking Offset ON, Marking Preheat ON
M12 - Marking Offset OFF, Marking Preheat OFF
M15 - Cutting Device ON
M16 - Cutting Device OFF
M30 - End of Program with Tape Rewind
M31 - Reset functions to default State
M65 - End of Program with Auto Reload Active
PROJECT 1: CUTTING OF SUPPORT FRAME FOR SLAG DUMP
CAR BY USING G-CODES AND M-CODES ON CNC-1 MACHINE

Layout of work piece

CNC Code for Gas Cutting

G91
G21
G41
M07
G01 X0 Y-20
G01 X-185 Y-113
G01 X-295 Y0
G01 X0 Y-312
G01 X-75 Y0
G01 X0 Y312
G01 X-53 Y43
G01 X-284 Y0
G01 X53 Y-43
G01 X0 Y-312
G01 X-75 Y0
G01 X0 Y312
G01 X-490 Y0
G01 X0 Y20
G01 X285 Y113
G01 X1225 Y0
M08 G40
M03 M30
PROJECT 2 : INNOVATIVE RAPAIR OF LADLE

Ladle is used to transfer molten metal from one place to another. It can sustain
heat without getting damaged. The inner surface of the ladle is polished with
refinery material that can sustain large amounts of temperatures. It is in the
shape of a tumbler, tilted frustum or cone-shaped. These ladies have 2 pins on
the extreme points. These are supported with hooks which are used to lift heavy
weights.

Unfortunately, during the transportation of molten metal, some amount of it

spilled on the pins, which got damaged due to the hot temperature. It cannot be
further used with present conditions. So we have to design in such a way that
we can replace the damaged part with a new one.
Initially, we need a sheet of required thickness, cut it in a shape of trapezium.
It is then bent in the Bending Machine in the required curve. The curvature is
maintained in such a way that it fits in the damaged area. The trapezium shape
of sheet metal is cut in a CNC machine. The workpiece is then placed in a
bending machine.
It is bent into the required shape. The ladle pins are attached to the curved
workpiece through welding. These pins are made in a forging shop. This curved
workpiece is then placed onto the damaged area and it is then welded to make
a strong bond.

(Ladle drawings)
 Damaged Segment removed from
Damaged Laddle
the laddle

Design of New Segment which is to be replaced the damaged segment of

Laddle:

STEP-1: Finding out the Radius/Diameter of the removed

segment of the ladle
 STEP-2: calculating the required Radius and angle of the new
segment with the help of CONE DEVELOPMENT CHART

THE OUTPUT FROM THE CHART : CUTTING PARAMETERS:

OUTSIDE RADIUS : 22981
INSIDE RADIUS: 20955
ANGLE : 8 Deg.

Hence, the drawing is made in AutoCAD. The above shown figure shows that
it should be cut in trapezium shape having Top length of 3484 mm and bottom
length of 3186mm. During bending, the length decreases as it comes closer.
Hence, the repair workpiece is constructed.

STEP-3: Cutting of new segment on CNC profile gas cutting machine

STEP-4: Bending of new segment as per the required Diameter.
STEP-5: Fixing the New Prepared segment to the Laddle
PROJECT 3: HOOD ASSEMBLY FOR SMS LP BAY ONLINE
DRIER

A draft hood is a necessary part of any gas burning appliance. For a gas
furnace in particular it ensures steady air flow to the burners to avoid flares
or the pilot light being put out by fluctuation in temperature and air flow.

The draft will change in the chimney as exhaust vents towards it – especially
when going from cold air to hot. A draft hood is placed above the upper most
part of the gas furnace to draw air into the chimney and makes it possible to
draw more or less air through the chimney as necessary to create a constant
flow.

It is made by assembling 6 bent trapezium shaped in a circular shape. It is then

given support by 4 curved bent sheets. Initially the shape of rectangle and
trapezium are marked on a steel sheet by a CNC machine. It is operated with
low flame. It is then cut with the help of a CNC machine with high pressurized
oxygen. Since the thickness is very small, it is done by CNC machine that can
intake AutoCAD graphic design as input. This will work with good efficiency
and increases production rate. These sheets are then bent in bending machine
providing depth for bends and giving required curves.
These parts are welded. It is done by Arc welding in which two joints are
attached by other material. The dome shape is made. On top of it, rectangular
shaped parts are attached which are used to be lifted by hooks when needed. 36
Equisized stiffeners are attached around the dome providing perfect connection
between 2 mating parts.

The hood in a furnace serves several important purposes:

Heat Distribution: The hood helps to distribute the heat generated by the furnace
evenly throughout the desired surface area. It captures the hot air rising from
the furnace and directs it into the room, ensuring that the heat spreads
effectively.

Ventilation: Furnaces produce combustion gasses and byproducts that need to

be safely removed from the living space. The hood incorporates vents or ducts
that exhaust these gases outside the building, preventing their accumulation
indoors and maintaining air quality.

Air Filtration: Many furnace hoods are equipped with air filters to trap dust,
particles, and other contaminants present in the circulating air. These filters help
improve indoor air quality by removing allergens and pollutants, creating a
healthier environment.

Aesthetic Appeal: In addition to their functional benefits, furnace hoods can

also enhance the overall appearance of a room. They come in various designs
and finishes, allowing homeowners to choose a style that complements their
decor and adds a decorative element to the space.

It's worth noting that furnace designs may vary, and some systems may not
require a hood if they have alternative methods for heat distribution, ventilation,
and air filtration. The specific configuration and use of a hood depend on the
type and model of the furnace, as well as the installation requirements and local
building codes.
Hence the final output is made and is ready to use. The size may vary from
chamber to chamber.
BILL OF MATERIALS

Part Description Matl. Specn. Qty Unit weight Total

No. (kg) weight
(kg)
1 PLATE STRL. STEEL 1 675.0 675.0
3650/1620 x Fe 410W
189 IS 2062
(10thk)
2 PLATE STRL. STEEL 4 0.93 3.72
237.5 x 50 x Fe 410W
10 IS: 2062
3 PLATE STRL. STEEL 2 2.65 5.30
675 x 50 x 10 Fe 410W
IS: 2062
4 PLATE STRL. STEEL 6 9.75 58.5
300 x 300 x 14 Fe 410W
IS: 2062
5 PLATE STRL. STEEL 4 0.63 2.52
161 x 50 x 10 Fe 410W
IS: 2062
6 PLATE STRL. STEEL 2 4.42 8.84
1125 x 50 x 10 Fe 410W
IS: 2062
7 PLATE STRL. STEEL 4 4.0 16.0
1031 x 50 x 10 Fe 410W
IS: 2062
8 STIFFENER STRL. STEEL 12 0.4 4.8
100 x 58 x 8 Fe 410W
IS: 2062
 9 PLATE STRL. STEEL 1 9.5 9.5
665 / 560 x 12 Fe 410W
IS: 2062
10 PLATE STRL. STEEL 1 214.0 214.0
1620 / 560 x Fe 410
10 IS: 2062
11 PLATE STRL. STEEL 2 2.65 5.30
675 x 50 x 10 Fe 410W
IS: 2062
12 PLATE STRL. STEEL 1 12.0 12.0
560 / 536 x 73 Fe 410W
IS: 2062
13 PLATE STRL. STEEL 1 149.0 149.0
3650 / 3630 x Fe 410W
166 IS: 2062
14 STIFFENER STRL. STEEL 36 1.75 63.0
176.4 x 150 x Fe 410W
10 IS: 2062

PROJECT 4 : MODIFIED SUPPORT/PEDESTAL FOR SLAG

POT TRANSFER CAR (STPC)

Ladle is a heavy carrier and can only be transported over a short range of
distance from hooks. It is because the ropes/chains due to heavy load come
under tension repeatedly and can lead to fatigue failure. Internal cracks can be
developed leading to hazardous accidents. It is necessary to design a carrier
vehicle in such a way that it can bear a large amount of load and transport over
some lober distance. Also it should also be made to withstand static load
conditions. But it is to be noted that a vehicle should maintain balance while
carrying a huge ladle with heavy mass molten metal during motion since it has
large inertia. Hence, a W-shaped wedge is attached to it at ends in parallel
direction.

A W-shaped wedge is cast in the Foundry shop, made of X material, melting X

material and forming casting operations. After it is cooled down, the output is
obtained. Angle made is nearly 60°. Generally, during casting, some allowances
are provided. It is mounted on a plate which is made of metallic sheets from
CNC gas cutting machines. They are then welded according to requirement and
strength and joined together. It is then fixed in a transfer car, which is then ready
to use.
Initially, the CAD drawing is developed. Two trapezium shapes are cut from
metallic sheets in such a way that the dimensions are met in a CNC machine.
Another 4 similar-shaped pieces are cut from the metallic sheet using a CNC
machine only. They are then welded as shown in the below figure.

When it is done, it is then kept for some time for strengthening. Generally, 2
components of different materials are attached later.

Later, it is then attached one upon the other from a manual crane machine. It is
welded together so that it can withstand heavy and bulky ladle along with
molten metal in it.

Hence it is made and placed in the transfer van.

 BILL OF MATERIALS

Part Description Proposed Qty Unit weight Total

No. Material (kg) weight
Specn. (kg)
1 PLATE CAST STEEL 1 1336.38 1336.38
1600 x 560 x 190 200-400
thk IS: 1030
2 PLATE SRTL. STEEL 1 485.64 485.64
2662 x 1162 x 20 E-250
thk IS:2062-2006
3 PLATE SRTL. STEEL 1 482.30 482.30
2662 x 1154 x 20 E-250
thk IS:2062-2006
4 PLATE SRTL. STEEL 2 57.40 114.80
1265 x 289 x 20 thk E-250
IS:2062-2006
5 PLATE SRTL. STEEL 3 52.36 157.08
1154 x 289 x 20 thk E-250
IS:2062-2006
6 PLATE SRTL. STEEL 1 69.64 69.64
1625 x 195 x 28 thk E-250
IS:2062-2006
CONCLUSION

CNC gas cutting is very prominent in industries because of its accuracy and
efficiency. More newer technologies are adopted but a CNC machine is
common in every industry. With improving technology, the productivity of
cutting machines and operations is very much refined. We could successfully
demonstrate the reliability of these machines due to its strength in cutting
through metal sheets of various thicknesses. It is a very cost-effective and
sustainable process that can be further improvised. We can optimize the
machine’s performance by enhancing the software or by installing newer
versions of the software, increasing its durability, productivity, and efficiency.
With more and more innovative ideas and improvements, CNC Gas Cutting
Machines can be more beneficial to many industries.