1.

1 INTRODUCTION TO VSP

 To set up an integrated steel plant at Visakhapatnam was announced on 17th

August1970 by Smt. Indira Gandhi in Parliament and the formal inauguration was
done on 20th January 1971.

 The plant annual capacity was 3 million tons of liquid steel in October 1977. USSR
helped India in setting up the 3.4 million tons integrated steel plant at Visakhapatnam
in the year 1979. The project is estimated to cost Rs. 6,269.57 tons based on Mills as
on first quota of 1986.

 VSP became the first integrated steel plant to achieve the distinction of covering all
the process and products under ISO 9002, ISO 14000, and ISO 18000 for the entire
plant.

 Having a total manpower of about 17,000, VSP has envisaged a labour productivity
of not less than 230 tonnes per man per year of steel which is the best in the country
and comparable with the International Levels.

 The main consideration for setting up the steel plant at Visakhapatnam was to have
location advantage of port on the coast of Bay of Bengal. However, location advantage
could not be utilized fully by the company due to various constraints and non-
development of captive harbour adjoins the plant site. The main objectives of RINL
on its incorporation were to take over the VSP from SAIL with all its assets, liabilities,
rights, and obligations and to carry on in India and elsewhere manufacturing, trading,
importing, and exporting of iron and steel of all qualities.
 1.2 FACILITIES IN VSP

S.NO. DEPARTMENT FACILITIES CAPACITY PRODUCTION

x1000 tons x1000 tons

1 RAW Iron ore,

MATERIAL lumped ore,
HANDLING coal,
PLANT (RMHP) limestone,
slag

2 COKE 3 Batteries of 2261 2055

OVENS(C&CCD) 67 ovens each
having
volume 41.8
cum with 7mt
tall.
3 SINTER PLANT 2 sinter 5256 4855.86
machines of
312 sq. of
grate area.
4 BLAST 2 furnaces of 3400 3485.475
FURNACE 3200 cum
useful 1
volume – bell
less top
conveyor
charging
system.
5 SMS 3 LD 3000 3082.8
converters of
133cm
capacity, 6
continuous
casting
machines of 4
stand each.
MISSON:

To attain 16-million-ton liquid steel capacity through technological up-gradation,

operational efficiency and quality and expansion, to produce steel at international
standards of cost and quality and to meet the aspiration of the stake holders. To be a
continuously growing company by producing steel of international standards and to
satisfy the customer by Products and services.

VISION:

To be a continuously growing world class company. Deliver high quality and cost
competitive products and be the first choice of the customers. Achieve excellence
enterprise management

OBJECTIVES:

To maximize profits through appropriate strategies including cost reduction

measures. To ensure a continuous presence in the export market with flexible export
strategy.

CORE VALUES:

 Commitment
 Customer satisfaction
 Continuous improvement
 Concern for environment
 Creativity & innovation
 1.3. Infrastructure Facilities

Location:

The plant is located on the coast of Bay of Bengal. 16Kms to the Southwest of
Visakhapatnam port. It lies between the northern boundary of National Highway from
Madras to Calcutta and 7 Kms. The south of the Howrah-Madras Railway line.
Visakhapatnam is well connected by own with unique cities of India.

The area enclosed within boundary wall of steel plant is about 2,600 hectares.
Additionally, 2,600 hectares is occupied by Steel Plant Township and 350 hectares by
Kaniti Balancing Reservoir.

Power:

Total requirement of power in VSP is 280 MW where 3.0 million tons stage is
reached. Parts of this requirement are met from 4x60 MW generators at VSP ‘s own
captive power plant.

Two steam turbine generators of 7.5MW each generates power using waste heat of
dry quenching unit of coke ovens and 2x12.0 MW temperature pressure recovery turbines
will generate power utilizing high pressure available from temperature gases of BF.

The balance 1.39 MW (about 150MVA) of power is to be supplied by the Andhra

Pradesh State Electricity Board to meet the maximum demand requirement of power at
VSP.

Water:
 The total water requirement of the plant will be 73 million gallons per day, which
is to be met by the Eluru water supply scheme, which is an Andhra Pradesh government
project.

Auxiliary Facilities:

Extensive facilities have been provided for repair & maintenance as well as
manufacture of spares. The repair shop complex houses machine shop. Structural shop,
Steel and NF foundry, Forge shop, Loco & wagon repair shops, Electrical repair shop,
Utilities equipment repair shop, Air conditioning & ventilation system repair shop.

In addition to the above basic units to s\carry out various operations. VSP is having
fully equipped Research & Control Laboratories to monitor and control all the operations
carried out in the plant.

It is also having well established Training and Development Centre to train the
newly recruited personnel and to conduct refresher courses for the employees and make
them able to handle jobs assigned to them during their regular duties.
 1.4. Main Departments in VSP

1. Raw Material Handling Plant (RMHP)

2. Coke & coal chemical Department
3. Sinter Plant (SP)
4. Thermal power plant (TPP)
5. Blast Furnace (BF)
6. Steel Melting Shops (SMS)
7. Rolling Mills
8. Light & Medium Merchant Mill (LMMM)
9. Wire Rod Mill (WRM)
10. Medium Merchant & Structural Mill (MMSM)
11. Auxiliary Shops
12. Forge Shops
13. Steel Structural Mill
14. Central Machine Shop
15. Foundry
16. Field Machinery Department (FMD)
17. Ore Mines and Quarries (OMQ)
18. Traffic Department (TD)
19. Energy Management Department (EMD)
20. Production Planning and Monitoring (PPM)
21. Safety Eng. Department
22. Quality Assurance& Technology Development (Q, A& TD)
 MAJOR PRODUCTION UNITS

RAW MATERIAL HANDLING PLANT (RMHP)

The raw material handling plant receives the basic raw materials requires for the
steel making process from various sources through railway wagons. The raw materials
like Iron ore fines, Iron ore lumps, sized iron ore, Limestone, Dolomite, etc.., are stocked
in ore and flux yard. Imported coking coal, medium cooling coal and boiler coal is
stocked in coal yard. These raw materials are sent in different proportions to nations
departments through conveyor system.
 SAILENT FEATURES OF RMHP:

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

2. Blender reclaims for blending of ores and flux in which the bucket wheel has a
lateral motion across the bed.
3. Wheel on bloom reclaims for reclaiming different materials from some bed in ore
of flux yard and same type coals in CHP.
4. Ring Granulators for crushing of boiler coal.
5. PLC control of all systems.
6. Driers for dying SMS sized one.
7. Mixers for mixing lime in purchased and generated fires.
8. Preparation of sized iron ore for use in BF to enable close size range of raw
materials.
 COKE OVENS:

 The coal is proposed before charging into coke ovens in coal tower. The prepared coal
in the coal tower is drawn by a changing car on the top of the batteries and charged
into the ovens as per the sequence -0. The charged coal is gradually heated in absence
of air to attain a temperature of 1000-1050 C which generally takes about 16hrs for
the coke to be ready. The volatile matter escaping during carbonization is collected in
a gas collection main through standpipe. The stone is cooled by Ammonia liquid spray
and sent to coal chemical plant. The ready coke is pushed out of the oven by a pusher
car into a coke car and is taken to the dry cooling plant for discharging the hot coke
into cooling chambers.

 There are three batteries, each having 7 ovens. Each oven is having a volume of 41.6
m2 and can hold 31.6 T of only coal charge. The heat for carbonization is being
supplied is being supplied by a mixture of blast furnace gas and coke oven gas having
a calorific value of 1000 Kcal/NM3.Batteries are of under jet, compound type having
twin heating filled and recalculation of waste gases.
BY-PRODUCTS:

 For consumers wanting suppliers of Naphthalene, Pitch, Anthracite oil, Neonate oil,
Coal tar, Wash oil, Light oil, Benzene, Toluene, Xylene etc.., By products from its 60
Modern coke oven plant will be useful in many industries.

SINTER PLANT DEPARTMENT:

 In Sinter plant ore fines are made into Sinter before being charged into blast furnace.
An initial mix consisting of ore fines and blue dust, manganese ore, metallurgical
wastes, dolo-fines, sand, 80% of coke fines is prepared. This mix along with sinter
returns, sinter screenings 20% of lime fines and 20% of fine coke is stocked in
 bunkers. Moisturizing and palletizing are carried out in 4.2 * 24m drum mixer to
obtain homogeneous mixture with partial palletizing and optimum moisture.
 10-25 mm size sinter is used as hearth layers of about 40mm thick. This decreases
dust entrapment by exhaust gases, reduce grate bar consumption. Sinter mix up to
300mm thick is laid on the heath layer. A mixture of coke oven gas and blast furnace
gas having a calorific value of 2,000 Kcal. NM3 is used for ignition.
 The prepared sinters are crushed to about 15mm size and cooled by forcing
atmospheric air. This sinter is then sends to blast furnace through conveyors.
 BLAST FURNACE:

 There are two blast furnaces of 3,200 cubic meter useful volumes, each capable of
producing 1.7 Mt of hot metal per year while operating for 350 days are installed.

 There are four hot blast stores for each furnace with a total heating surface of 224,000
square meters. The dome can be heated to a temperature of 1450 C maximum while
the waste flue temperature is up to 400 C. Stores are heated, by a mixture of blast
furnace gas and coke oven gas having a calorific value of 1100 Kcal/N Cum, up to
1300 C pressure of mixed gas before burners is 600 mm W.C.

 Hot metal is discharged into 140 T hot metal ladles by rocking runners in east house.
There are four railway tracks for hot metal transportation, one service sub-track and
once track for flue dust disposal independent running railway tracks are provided for
 delivery of hot metal to SMS requirement = 0.5 – 3 T as per blowing conditions Raw
or calcines coke – used to increase lining life of converter. Lump coke – Use to preheat
the lining of newly lined converter.

Steel Melting Shop (SMS):

 Steel is an alloy of iron with carbon up to 1.8%. Hot metal produced in Blast Furnaces
contains impurities such as Carbon (3.5 – 4.25%), Silicon (0.4 – 0.5%), Manganese
(0.3 – 0.4%), Sulphur (0.04% max.) and Phosphorous (0.14% max.) is not suitable as
a common Engineering Material. To improve the quality the impurities are to be
eliminated or decreased by oxidation process.
 VSP produces steel employing three numbers of top blown Oxygen Converters called
LD Converters (L & D stand for Linz &Danowitz – two towns in Austria where this
process was first adopted) or Basic Oxygen Furnaces/Convertors. Each convertor is
having 133 Cu.M. Volume capable of producing 3 million Tonnes of liquid steel
annually. Besides hot metal, steel scrap, fluxes such as calcined lime or dolomite form
part of the charge to the convertor.

 In Steel Melting Shop of Visakhapatnam Steel Plant, LD Process of steel making has
been adopted. The liquid steel obtained from LD process is cast into Blooms through
Continuous Casting Machines (Bloom Casters).

For better exploitation of the available facilities and to have efficient

administration in the biggest department of VSP, Steel Melting Shop is divided into two
major sections.

1. Converter Shop
2. Continuous Casting shop

Each of these shops has been further divided.

CONVERTER SHOP:

1. Bulk Material Handling Section (BMHS)

2. Mixer shop
3. Converter Bay
4. Scrap Yard
5. Slag Yard
6. Ladle Preparation Bars.
CONTINUOUS CASTING SHOP:

1. Tundish preparation Bay (TP Bay)

2. Argon Rinsing Station (ARS) & IRUT & LF
3. Continuous Casting Machines
4. Gas Cutting Machines
5. Bloom Storage Yard.

ROLLING MILLS:

The cast blooms produced in SMS-CCD do not find many applications as such and
are required to be shaped into products such as Billets, Rounds, Squares, Flats, Angles
(equal & unequal), T-bars, Channels, I-PE beams, HE beams, Wire rods, and
Reinforcement bars by rolling them in three sophisticated high speed high capacity, fully
automated rolling mills. They are:

1. Light & Medium Merchant Mills

2. Wire Rod Mills
3. Medium Merchant & Structural Mills.

All the above-mentioned Rolling Mills are HI-TECH Rolling mills with full
automation and all modern equipment’s.
LIGHT-MEDIUM MARCHENT MILL

WIRE ROD MILL

END PRODUCT OF MILLS
 ROLL SHOP AND REPAIR SHOP

 Roll shop & Repair shop (RS & RS) Roll shop & Repair shop is in the complex of
Rolling Mills catering to the needs of mills in respect of roll assemblies, guides few
Maintenance Spares and roll pass design. Geographically this dept. is in three areas as
Roll shop-1, Roll shop-II and Area Repair Shop. The main activity of this shop is Roll
pass Design, grooving of rolls, assembly of rolls with bearings, preparation of guides
and their service and manufacture / repair of mill maintenance spares.

 For the first time in the country, VSP has adopted CNC technology for grooving of
steel rolling mill rolls. High constant respective accuracy, higher productivity, use of
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 one.
In VSP Steel plant there are two role shops are there they are as follows.
1. Role shop 1
2. Role shop 2
3. Area repair shop

ROLL SHOP 1:
Roll Turning accuracies:

True running – 0.02 mm

Cylindricity – 0.00/300 mm
Deviations from profile from: 0.02 mm through L80 degrees
Surface finish (peak valley height): 6U

MATERIALS & SPECIFICATIONS:

 Alloy forged steel

 alloy cast steel
 nodular C.I
 chilled C.I
 doubled poured CI

Roll turning process

Steps followed in the roll turning and redressing process are

Roll Pass Design

According to the required product by the customer, roll passes are designed. Series of
roll passes are designed to achieve required product by rolling. These roll pass profiles
are sent to programming section.

Developing-master tracings

After obtaining roll pass profiles, standardized drawings are prepared. AutoCAD is
being used to draw the profiles. After drawing these in Auto-CAD, 1:1 tracings are
taken and standardized.

Part-programming for templates

Part programming is done for the profile and is fed into the CNC milling machine for
cutting template. This programming is done manually or using Gibbs-CAM software
according to the convenience. R-parameter programming is also used for developing
programs for the profile of same shape.
Cutting template and standardizing

Template is cut using programs and compared with master tracing and the template is
standardized. Conventionally, using fitting techniques, bench-wise, file and hacksaw,
templates were prepared. But this is very cumbersome and requires high workman
skill. Use of CAD/CAM and CNC technology reduced the operator intervention and
resulted in several advantages.

Part programming for roll turning

For roll turning also part programs are developed. They are used for roll turning on
CNC lathes. This is also accomplished using Gibbs- CAM or R-parameter
programming or by using coordinates of various points from CAD drawing.

Actual roll turning beginning

Roll turning is performed by using these programs and master templates are used for
checking the correctness of groove pass.New rolls are turned using canned cycles and
after that prepared programs are used for getting required profile. Redressing is also
done using these programs.
 BEARING ASSEMBLY SECTION

Bearings for Rolling mill Rolls:

 Rolling mills for rolling of steel differ in many aspects with each other. The rolling
mills are of different sizes and capacities. The mills roll steel materials of different
cross-sections, sizes, and qualities and in material conditions which are either hot or
cold. The mills have different configurations and speeds of rolling. The configurations
of the mills can vary from cross country, reversing, semi continuous to continuous.
The equipment’s of rolling mills can have manual operations, mechanical operations,
electro-mechanical operations, pneumatic operations, hydraulic operations, or a
combination of all of these. The controls provided in the mills can be manual controls,
remote controls, instrumented controls, or fully automated controls. Further in many
types of mills even heat treatment processes are integrated.

 Despite so many differences, all the rolling mills have in common some basic
technologies and equipment’s. All the rolling mills have rolls for the rolling of
materials which are fitted in roll stands. Rolls are either driven by electric power or
friction driven and are to resist many forces for normal rolling. The roll stands can
have two rolls, three rolls, four rolls, six rolls, or a set of multiple rolls mounted on
them depending on the types of mills. During rolling, the load on the rolls gets
transferred to the roll neck bearings and their assembly (chocks).

 Rolls for their smooth rotation as well as for resistance to different forces need
‘bearings’. Roll bearings are to meet the basic need of the rolling mill which is the
smooth rolling of the steel products. They are friction reducing devices which provide
support to the rolls for effective rolling with minimum of energy loss. The bearings
are designed to withstand high rolling loads, heavy shocks, varying speeds, and high
temperatures. Apart from this, bearings are designed to endure ingress of scale, dirt,
and water. They play important role in reducing the power consumption and
improving the rolling condition.

 The roll bearings, in which the rolls in roll stands are supported, are subjected to high
loads. The specific loads are also high. In order that the bearings can reliably support
 the rolling forces, they are to have high load carrying capacity. On the other hand, the
mounting space available for these bearings is restricted, especially in relation to the
section height of the bearings.

4 ROW CYLINDRICAL ROLLER BEARING

 Roll neck bearings need proper lubrication for the enhancement of the overall
efficiency. Proper lubrication of the bearings not only increases the bearing life but
also reduces frictional and energy losses.

 Different types of bearings for rolls are used in different types of rolling mills for the
meeting of the specific requirements of the mills. Some types of bearings need
substantial capital investment but low recurring expenditures while other types of
bearings need low capital investments and substantial recurring expenditures. There
are the three basic types of bearings (Fig 1) which are used in different rolling mills.
These are (i) slider bearings, (ii) anti frictional bearings, and (iii) oil film bearings or
hydrodynamic bearings.
Oil film bearings:

Oil film bearings are hydrodynamic bearings. These bearings are flood lubricated,
precision journal bearings which operate on a hydro-dynamically generated film of oil.
These bearings completely enclose the roll neck. The bearing surfaces are separated by a
liquid film. These bearings have a low co-efficient of friction at high speeds. They have
a long life and low space requirement. These are used in flat rolling in slabbing mills, hot
strip mills and cold rolling mills.

Oil film bearing being of hydrodynamic design distributes the bearing load over a large
area with no concentration points. The film of oil on which the bearing operates has
enormous load carrying capacity. Because of its continuous, unbroken nature, the film
eliminates wear caused by metal-to-metal contact. This oil film is constantly maintained
by the hydrodynamic action of the rotating sleeve to which a surplus of oil is presented
at controlled temperatures. The cross section of the oil film bearing.
 Roll and chock assembly of rolling mill

 The principal parts of the oil film bearings are few and are of simple construction.
The rotating sleeve is usually an alloy steel forging, heat treated and ground a mirror
finish of around 50 micro millimetres to 100 micro millimetres. The sleeve has a
taper bore which fits on and is keyed to the tapered roll neck, thus becoming the
journal.
 ROLLERS TURNING SECTION

A turret (shown canter), with tooling attached is programmed to move to the bar of raw
material and remove material to create the programmed result. This is also called
“subtraction machining” since it involves material removal. If the centre has both
tuning and milling capabilities, such as the one above, the rotation can be stopped to
allow for milling out of other shapes.

 The starting material, though usual round, can be other shapes such as squares or
hexagons.
 Depending on the bar feeder, the bar length can vary. This affects how much
handling is required for volume jobs.
 CNC lathes or turning centres have tooling mounted on a turret which is computer
controlled. The more tools that that the turret can hold, the more options are
available for complexities on the part.
 CNCs with “live” tooling options, can stop the bar rotation and add additional
features such as drilled holes, slots, and milled surfaces.
 Some CNC turning centres have one spindle, allowing work to be done all from
one side, while other turning centres, such as the one shown above, have two
spindles, a main and sub-spindle. A part can be partially machined on the main
spindle, moved to the sub-spindle, and have additional work done to the other side
this configuration.
 There are many kinds of CNC turning centres with various types of tooling options,
spindle options, outer diameter limitations as well as power and speed capabilities
that affect the types of parts that can be economically made on it.
 GUIDE SHOP
 Roll shop & Repair shop is in the complex of Rolling Mills catering to the needs of
mills in respect of roll assemblies, guides few Maintenance Spares and roll pass
design. Geographically this dept. is in three areas as Roll shop-1, Roll shop-II and
Area Repair Shop. The main activity of this shop is Roll pass Design, grooving of
rolls, assembly of rolls with bearings, preparation of guides and their service and
manufacture / repair of mill maintenance spares.

 For the first time in the country, VSP has adopted CNC technology for grooving of
steel rolling mill rolls. High constant respective accuracy, higher productivity, use of
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 one.
 CASSTTE ASSEMBLY

ROLL STORAGE YARD

 CAD/CAM System
Computer Aided Design (CAD)

Computer aided design (CAD) can be defined as the use of computer systems to
assist in the creation, modification, analysis, or optimization of a design. A
typical CAD system consists of hardware such as computer, graphic display
terminal, keyboards and other peripheral devices, software for implementing
certain engineering application programs as required by the user.

Application of CAD:

The various design related tasks, which are performed bymodern CAD
system are:

1. Geometric modelling
This includes computer compatible mathematical description of the
geometry of the object. This allows the image of the object to be displayed
and manipulated on a graphics terminal through signals.

2. Engineering Analysis
Analysis of the product may involve stress calculations, heat- transfer
computations, or use of differential equation to describe the dynamic
behavior of the system being designed. The computer can be used to aid
in this analysis work. Finite element analysis and mass properties analysis
are the two analysis features.
 3. Design review and evaluation
It is concerned with the measurement of design against the specification
established in the problem definition phase. The graphics terminal can
conveniently accomplish this.

4. Automated drafting
Creation of hard copy of engineering drawings can be done directly using
CAD database. Many drafting package features for automatic
dimensioning, scaling of the drawing are available.

5. Parts classification and coding

CAD database can also be used to develop a parts classificationand
coding system. This involves grouping of similar parts based on design
and manufacturing aspects.

COMPUTER AIDED MANUFACTURING (CAM)

CAM can be defined as the use of computer system to plan, manage and
control the operation of a manufacturing plant through either direct or indirect
interface with the plant’s production resource.
Applications of CAM:
Application of CAM falls into two broad categories

a) Computer monitoring and control

These are the direct applications in which computer is connected to
the manufacturing process for the purpose of monitoring or
controlling the process. Examples for this are Computer Numerical
control, Industrial robots, Computer Integrated production
management systems etc.

b) Manufacturing support application

These are indirect applications in which the computer is used in
support of the production operation in the plant, but there is no direct
interface between computer and manufacturing process. Computer
assisted part programming, computer automated process planning,
production scheduling, material requirement planning etc belong to
this class.
Automation is the technology concerned with the
application of complex mechanical, electronics and computer-based
systems in the operation and control of production. CAD/CAM
integrates design and manufacturing aspects by pervasive use of
computers, so it can be simultaneously called as Computer
Integrated Manufacturing (CIM). Automation is concerned with the
physical activities in manufacturing such as processing, assembly,
material handling and inspections whereas CIM takes care of
information processing functions such as product design,
manufacturing planning and control etc. Both involve reduced human
intervention in production process.
 CNC LATHE MACHINE

 A lathe is traditionally used in metalworking, metal spinning, thermal

spraying, parts reclamation, and glass-working. One or two centres typically
hold the workpiece, and at least one centre can be moved horizontally to
accommodate workpieces of different lengths. CNC lathes are quickly
replacing older production lathes due to their ease of setting, operation,
repeatability, and accuracy. CNC lathe work is just one type of CNC
machining.
 But what is a CNC lathe? First, CNC stands for computer numerical
control and refers to a machine operated by a computer system. A CNC lathe
is operated with precise design instructions to machine parts to precise
specifications. A CNC lathe is a machine tool where the material or part is
held in place and rotated by the main spindle as the cutting tool that works
on the material is mounted and moved on various axes.

 A simple CNC lathe operates on two axes with the cutting tool in a fixed
position at 8 to 24 station turrets. The rotating action of the workpiece is called
"turning." Therefore, certain types of CNC lathes are called CNC Turning
Machines. CNC lathes produce precise round shapes with an outer diameter
(OD) and an inner diameter (ID). Many kinds of structures can be machined
with this machine tool, depending on their various industries' needs. They are
commonly used in oil and gas, automotive, aerospace, medical, electronics,
mining, power plant, steel and paper mills, and shipbuilding industries.
 Types of CNC Lathes
CNC lathes are classified into types by how many axes they have. They are
available with different axes, allowing more complex parts to be produced
without manually switching machines or tools. The different axes affect how the
machined part, or the tool can be positioned, rotated, and approached during the
machining process.

2-Axis CNC Lathe

This basic CNC lathe machine has two linear axes that can perform outer
diameter/inner diameter, basically cylindrical machining, and facing operations,
or drilling and tapping at the centre of the part. It has an X and Z axis and does
not allow for milling.

3-Axis CNC Lathe

With a 3-axis CNC lathe, a C axis and life tool system are added, allowing the
part to be positioned so that standard milling operations, boring, and tapping
operations can be performed. Helical milling operations that require the slow sync
rotation of the workpiece are possible.

4-Axis CNC Lathe

A 4-axis machine has an added Y-axis so that off-centre machining operations

can be performed. The fourth axis works well for more irregular and complex
lathework.

5-Axis CNC Lathe

In 5-axis lathes, a second turret is added to a 3-axis CNC lathe. Such machines
would then have two axes at each upper and lower turret plus the C-axis on the
rotating spindle. This enables the use of two tools at the same time on the part,
which drastically increases machining speed.

6 Or More Axis CNC Lathe

With more than five axes, the permutation may include the following: two C-axes
with a primary and second spindle; two turrets, with an upper and lower turret,
each with two linear axes; one Y-axis at the upper turret; and a second spindle
that can move towards the main spindle to pick up the part. There are even
machines with more than eight axes. However, 8-axis lathes are highly
sophisticated and complex machines that aren't generally needed for everyday
manufacturing needs.
Applications of CNC lathes
 The material being worked by a CNC lathe machine is slowly sheared away.
The result is a precisely finished product or an intricate part. Because these
machines are so versatile, many industries use them, including automotive,
electronics, aerospace, firearm manufacturing, sporting, and others.

 A CNC lathe can produce plane surfaces and screw threads or, in the case of
ornate lathes, three-dimensional products that are quite complex. They can be
used on both small and large parts with extreme accuracy. The workpiece is
typically held firmly in place by one or two centres, but the material can also
be secured with collets or clamps.

 Some examples of items a CNC lathe machine can make include baseball bats,
camshafts, bowls, crankshafts, cue sticks, sign boards, musical instruments,
and table and chair legs.

Considerations
 A CNC lathe must be used with care. Although the process is automated, an
operator must understand computer programming parameters, safety
standards, and other vital information. With the lathe's focus on detail, a
qualified professional must run the machine. Manufacturing processes are
made easier due to the automation, which consists of complex commands and
speed rate instructed by an internal computer, but a human operator must still
oversee the overall process.

 When choosing the right CNC lathe machine, there are many factors to
consider, such as the quality of clamps that hold the workpiece steady and the
CNC lathe machine's tolerance level. Weight is a significant factor in
choosing a CNC machine. A heaver machine will survive the rigorous
vibrations and other operations that impact a CNC lathe's effectiveness. A
lightweight CNC lathe can get out of balance more quickly, thus impacting
the output result.

 The swing measurement is another consideration. It is the maximum amount

of diameter of any material which can be cut or machined on a lathe. This
measurement is taken from the bed of the lathe to the centre of the spindle. If
the desired output size is known, this measurement will help when choosing a
CNC lathe.
 Outlined above are the basics of what a CNC lathe is, the types of CNC lathes,
and some of the considerations that may be considered by manufacturers and
machine shops when deciding whether CNC lathing is the most optimal
solution for their machining application. To find more information on
domestic commercial and industrial suppliers of custom manufacturing
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 The term CNC stands for ‘computer numerical control,’ and the definition of
CNC machining is that it is a substandard manufacturing process that typically
employs computerized controls and machine tools to remove layers of
material from stock grinding which Known as a blank or workpiece and
produces a custom-designed part. The process is suitable for wides ranges of
materials, including metals, plastics, wood, glass, foam, & composites, & the
finds applications in a variety of industries, such as larges CNC machining,
prototyping for parts machining and telecommunications, & CNC machining
Aerospace parts, which require stricter tolerances than other industries.

BLOCK DIAGRAM OF CNC LATHE MECHINE:

 Automated natures of CNC machining enable the production of high precision
and high accuracy, simple parts, and cost-effectiveness when one-time and
moderate-volume production runs. However, while CNC machining exhibits
some advantages over other manufacturing processes, the degree of
complexity and complexity for part design and the cost-effectiveness of
producing complex parts are limited.

 The cutting operation performed by CNC is called CNC machining. CNC

machining programs are first designed or prepared and then fed to a CNC
machine. According to the program, CNC controls the speed and speed of
machine tools.

 CNC lathes are one of the most widely used CNC machine tools. It is mainly
used for cutting inner and outer cylindrical surfaces of shaft parts or disc parts,
inner and outer conical surfaces with arbitrary cone angles, complex rotating
inner and outer curved surfaces, cylinders, and conical threads. It can also
perform grooving, drilling, reaming, and reaming. Hole and boring etc.

 The CNC machine tool automatically processes the processed parts according
to the pre-programmed processing program. We compile the machining
process route, process parameters, tool motion trajectory, displacement,
cutting parameters and auxiliary functions of the part into a machining
program list according to the instruction code and program format specified
by the CNC machine tool, and then record the contents of the program list on
the control medium, it is then input into the numerical control device of the
numerical control machine tool to direct the machine tool to process the parts.
 MAIN PARTS OF CNC LATHE

HEAD STOCK:

There are many parts to the headstock, and this is where many of the functional
pieces of the machine reside. Here you will find the main spindle, the change
gears, and the speed change mechanism. Within the headstock you will have a
robust design because it must cut with a variety of force. If it were light it would
create problems with vibration that would distort the finished piece and destroy
its quality.

TAIL STOCK:

 A tailstock, also known as a foot stock, is a device often used as part of an

engineering lathe, wood-turning lathe, or used in conjunction with a rotary
table on a milling machine.

 It is usually used to apply support to the longitudinal rotary axis of a

workpiece being machined. A lathe centre is mounted in the tailstock and
inserted against the sides of a hole in the centre of the workpiece. A tailstock
has a Dead Centre, while headstock has Live Centre. A Tailstock is
particularly useful when the workpiece is long and slender. Failing to use a
tailstock can cause "chatter," where the workpiece bends excessively while
being cut.
 It is also used on a lathe to hold drilling or reaming tools for machining a hole
in the work piece. Unlike drilling with a drill press or a milling machine, the
tool is stationary while the workpiece rotates. Holes can only be cut along the
axis that the workpiece is set to spin.

 Usually, the entire tailstock is moved to the approximate position that it will
be needed by manually sliding it along its ways. There, it is locked in place
and the tool mounted to it is moved with a leadscrew to the exact position
where it is needed. When a cutting tool such as a drill bit or reamer is used,
the feed is done with this leadscrew. The tailstock quill or extendible portion
usually has a mount in the end of it to secure the drill or reamer. If the work is
heavy the drill may be further secured from turning with a lathe dog as shown
in the photo.

FOUR-JAW CHUCK:

A 4-jaw chuck is a great, almost essential, accessory for any serious lathe worker.
While it lacks the self-centring convenience of the 3-jaw chuck, it has other
capabilities. Some things you can do with the 4-jaw are:

 Grip rectangular and other non-cylindrical shapes for turning or facing

 Form rectangular shaped objects
 Precisely centre cylindrical stock to within the limits of the lathe's accuracy
 Hold stock off-centre for turning cams or drilling off-centre holes
TOOL POST:

 A tool post is the part on a lathe that holds the cutting tool securely during
Machining operations. The post then bolts onto the compound rest via a
conventional hex or Allen head bolt or a quick release locking mechanism.
There are many different designs of this device which cater to various cutting
bits and machining operations. A tool post may accommodate a single cutting
tool or have locking facilities for several different tools. Most are static,
although rotary posts are available for cutting spherical shapes.
 The tool post on a lathe is the part of the machine which holds the tool tip
during cutting. It consists of a tool steel base or column featuring a single or
multiple slots or holes to accommodate tool tip shanks. These tool slots are
shaped to accept a specific profile of shank and may be square, dovetailed, or
round. The tool bit is held securely in place in the tool post slot by two or more
locking bolts.
 TELESCOPIC BED:

 It is the base of the machine tool.

 It is made up of cast iron.

 It should be sufficiently rigid to prevent deflections under tremendous cutting
pressures transmitted through cutting action.
 It should have sufficient dimensions to absorb vibrations.

 Carriage and tailstock move along the lathe bed during machining.

 It has two set of guide ways:

1. Outer ways: provides sliding surface for carriage

2. Inner ways: provides sliding surface for tailstock

 WORKING PROCEDURE OF CNC LATHE:

 When it comes to CNC lathe machining, there are several different types, such
as CNC turning lathes, milling lathes, 3D printer lathes, and so on. Although
the concept for all the machines is similar, there are some unique aspects of
each. In fact, even CNC lathe machining techniques vary to some degree.
Regardless, the information addresses the overall operation of the lathe
machine to give you a better understanding of its capabilities.

 A lathe machine utilizes CNC technology, which is the acronym for Computer
Numerical Control. This machine creates customized products, including shafts
for the automotive industry, wood legs for the furniture industry, househo ld
products, and more, using workpieces made of metal, plastic, and wood.

 Choosing the right CNC lathe tools to accompany the machine is essential for
achieving the desired outcome. While there are many options, some are
essential, such as the turning tool, which is capable peeling a significant
portion of the stock quickly, the finishing tool that ensures a precision finish,
and the parting/cut-off tool, which works by cutting multiple parts from a piece
of bar stock. Other tools worth consideration inclu de drill and tap holders, bar
puller, and boring bar. CAD or CAM processes control all the tool paths.

 Then, a menu-type interface on a computer is what controls the lathe. While an

operator oversees the process, the work is performed automatically due to
computerization. What it comes down to is that a computer, digitized data, and
a CAD or CAM program automate, control, and monitor the movements of the
machine. The CNC controller works in conjunction with a series of motors and
drive components responsible for moving and controlling the axes, thereby
executing the programmed movements.

 Each movement of a lathe machine is precise. For that reason, the finished part,
component, or product is extremely accurate. Remember, CAD and CAM are
not what operate a CNC lathing machine. Instead, they create the code based
on the customer’s specifications, which is followed by the machine.

 This type of CNC machine is exciting because of its sophistication and

responsive nature. Thanks to developments in technology, lathes are more
widely used, achieving much better results than ever before. For superior
products and services, we invite you to visit our NexGen Machine website, or
you can call to speak one-on-one with a representative.
Properties of CNC machines:

Based on Motion Type : Motion control -the heart of CNCPoint-to-Point or

Continuous path

Based on Control Loops:

Open loop or Closed loop

Based on Power Supply:
Electric or Hydraulic or Pneumatic
Based on Positioning System:
Incremental or Absolute

Point to point tool movements:

 Point-to-point control systems cause the tool to move to a

pointon the part and execute an operation at that point only.

 The tool is not in continuous contact with the part

while it ismoving.

 Examples: drilling, reaming, punching, boring and tapping.

Continuous – path tool movement:
 Continuous-path controllers cause the tool to maintain
continuous contact with the part as the tool cuts a contour
shape.

 These operations include milling along any lines at any

angle,milling arcs and lathe turning.
 CNC’s Used in ROLL SHOP AND REPAIR SHOP :

 Conventionally, roll turning was envisaged with copy-turning

technology. Machines are purchased from Germany right from the
inception of the plant. Some are of WALDRICH SEIGEN make
with SINUMERIK 810-M controller for milling machine and
SINUMERIK 850-T controllers for lathes and some are
HERKULES make with SINUMERIK 3T controller Lathes. All
these machines are being controlled by a central computer and work
as DNC system.

 The Programming is done in a centralized programming room in RS

1 and all programs of Billet Mill (BM), Bar Mill (BRM), of Light
and Medium Merchant Mill (LMMM), wire Rod Mill (WRM) rolls
and for all templates. Programs are transferred from this computer
through DNC system. The programs for Medium Merchant and
Structural Mill (MMSM) are also developed here and are loaded
into program Transfer PC in RS 2. From this PC programs are
transferred by DNC system to lathes.
Specifications of WALDRICHSEIGEN CNC Lathe

a) Work piece dimension DH 1000 DH 750

Max Work piece turning dia (mm)

1000 750
Max work piece length (mm) Work
3500 3000
piece weight (tons)
10 10
b) Machine parameters

Machining diameter (mm) 0-1000 0-750

Center distance (mm) 3500 3000
Center height over machine bed (mm) 800 700
Center height over carriage bed (mm) 800 700
DC Main Drive (KW) 90 90
Torque at the face plate (Nm) 50000 50000
Faceplate speed (rpm) 1-175 1-175
Clamping range of the face plate 100-550 100-550
(mm) 2-3000 2-3000
Feed range (mm/min) 3000 3000
Rapid traverse (mm/min) 80000 80000
Cutting force (N) 40 38
Total machine weight, approx (tons)
Specifications of HERKULES CNC Lathes

a) Machine Type NWD 350 CNC WD 600 LL CNC

b) Main Dimensions
8.0*7.3 m2 11*6 m2 1
Floor Space Required
3000 mm 3150 mm
Max Turning Length
750 mm 1100 mm
Max Turning Diameter
750 mm 1100 mm
Max Swing
275 mm 425 mm
Max cross feed range
40 mm 40 mm
Tool Height
6 tons 10 tons
Heaviest work piece to be permitted
2.5-200 rpm 1.25-100 rpm
Speeds of Face Plate
350-90 mm 550-100 mm
Clamping range of Face Plate
25000 Nm 35000 Nm
Max Torque at the Face plate
0.6-300 mm/min 0.6-300 mm/min
Longitudinal Feed
0.6-300 mm/min 0.6-300 mm/min
Cross Feed
2000 mm/min 2000 mm/min
Rapid Motion Cross Rapid
3000 mm/min 3000 mm/min
Motion Longitudinal
6 5
No of tool position on turret head
50000 N
Max Cutting Force
6 tons 12 tons
Max Working Pressure on Center
Max Movement of the Tail Stock
100 mm 150mm
Centre
Programming Aspects

The program format, block format and other functions are like the NC
Part Programming. Preparatory functions, miscellaneous functions
and other variables used are shown in program key represented by
charts for WASI machine.
In addition to above functions, these WASI controllers support some
advanced programming techniques.

G CODES

G-CODES are preparatory functions, which involves actual tool

moves (for example control of machine). These include rapid moves,
feed moves, radial feed moves, dwell, and roughing and profiling
cycles. Most G-codes are modal, means that they remain active until
cancelled by another G-code.

A few of the usual preparatory functions, which are generally present

in all machining centers and are uniformly followed by all controller
manufacturers are given below:
Programming modes

G90 Absolute programming mode

G91 Incremental programming mode

Motion group

G00 Rapid positioning

G01 Linear interpolation
G02 Clockwise circular interpolation
G03 Counterclockwise circular interpolation
Dwell

G04 Dwell

Units group

G70 English (inches) units

G71 Metric (millimeters)

Cutter Radius compensation

G40 Cutter compensation cancel

G41 Cutter compensation left
G42 Cutter compensation right

Canned cycle group

G80 Canned cycle cancel

G81-G89 Canned cycles definition and ON

Pre-set

G92 Absolute position reference is defined or re-defined

Active plane selection group

G17 XY plane selection

G18 XZ plane selection
G19 YZ plane selection
G90 and G91 programming modes

Format: N_ G90
N_ G91

Dimensional data in program may be expressed as either absolute

or incremental values. It is placed at the beginning of the program
prior toany motion causing blocks, to set the programming mode
for the entirepart.

Incremental mode: In incremental mode the displacements

specified by X, Y, I, J words are offsets relative to the position of
the cutting device at the start of the block. The end point of the one
blockbecomes zero point of the next block.

Absolute mode: In absolute mode the displacement specified by X

and Y words are offsets from an absolute reference point, which are
fixed for the entire part unless changed using G92 (Preset). However,
I and J values are specified in incremental mode only.
M-CODES

M-codes are miscellaneous functions, which are used to control the

non-motion related operations of the cutting machine. M-codes take
effect in the sequence in which they are found.

M00 Program stop

M01 Optional program stop
M02 End of program
M03 Spindle On CW
M04 Spindle On CCW
M05 Spindle stop
M06 Tool Change
M07 Coolant On
M08 Coolant Off
M09 Subroutine end
M30 Program end
 NC PART PROGRAMING FOR WORK PIECE

% MPF 203
N05 (2RE 10 T/B B-MOD FINI DT 30-03-2022)
N10 600 D00 X 1850
N20 671 640 690
N30 M23 D22(USE RCMX 20 TOOL TYPE B)
N40 M03 S20
N50 600 21284 QX690
N60 642 601 X610
N90 21145.89
N100 603 21137.955 X595.950 K0.1-8.0
N110 601 21134.786 X544.319
N120 602 21123.868 X525.0 K 10.919
N130 603 21052.132
N140 602 21041.214 X544.319 K0.1110
N150 601 2103.045 X595.950
N160 603 21030.104 X610.0 K7.94019-75
N170 601 2959.806
N180 603 2951.955 X595.950 K00 1.80
N190 601 2948.746 X544.319
N200 G02 2937.668 X525.0 K10.918
N210 G01 2866.132
N220 G02 2855.214 X545.319 K11
N230 G01 2882.044 X595.950
N240 G03 2844.104 X310.0 K7.9401.975
N250 G01 2773.869
N260 G03 2765.955 X 595.950 K 8.0
N270 001 2762.786 X548.818
N280 G02 2751.868 X 525.0 K -10.918
N290 801 2680.132
N300 G02 2669.214 X 545.319 K 11.0
N310 G01 2666.044 X 595.950
N320 G03 2658.1 Q4 X 610.0 K-7.940
N330 G01 2585.896
N340 G03 2577.955 X 595.950 K 0.1
N350 G01 2574.796 X 545.319
N360 G02 2563.968 X 525 Q K – 10.918
N370 G01 2492.132
N380 G02 2481.214 X 544.319 K-111.0
N390 G01 2478.045 X 595.950
N400 G03 22470.104 X 610.0 K- 7.9401-975
N410 G01 2399.896
N420 G03 2391.955 X 595.950 K-8.0
N430 G01 2888.788 X544.818
N440 G02 2377.868 X525.0 K -10.918
N450 G01 2306.132
N460 G02 2295.214 X545.319 K-0.110
N470 G01 2292.045 X595.950
N480 G03 2284.104 X610.0 K- 7.9401-975
N490 001 2213.896
N500 G03 2205.955 X595.950 K-8.0
N510 G01 2202.786 X544.319
N520 G02 2191.868 X525.0 K- 10.918
N530 G01 2120.132
N540 G02 2109.214 X544.316 K – 0.111.0
N550 G01 2106.045 X595.950
N560 G03 298.104 X610 K-7.940
N570 G01 220
N580 G00 2-30.0 X 710.0
N590 G40 G00 D00 X 1850
N610 M02
 NC PART PROGRAME FOR TEMPLATE

% MPF 202
N05(2 RE 10 T/B B-MOD RTT DT 30-03-2022)
N10 M07 617 M03
N20 G00 690 671
N40 G00 X 63.104 Y 350.0
N50 T1 D1 (USING 6MM END MILL)
N60 G42 G01 X 73.104 Y 330 – O E30
N70 Y 305
N80 X 98.104
N90 G02 X 1006.045 Y 297.975 J-8
N100 601 X 109.214 Y 272.160
N110 G03 X 120.132 Y 262.500
N120 G01 X 191.868
N130 G03 X 202.786 Y 272.160 J 11.0
N140 G01 X 205.955 Y 297.975
N150 G02 X 213.898 Y 305.0
N160 G01 X 238.896
N170 Y 330.0
N180 X 73.104
N190 M8 M5