PRACTICE SCHOOL-1

PRESENTATION
ADITHYAN K A
BITS Pilani 2021A4PS2989H
Hyderabad Campus DEPARTMENT OF MECHANICAL ENGINEERING

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Brief introduction about RSP
Rourkela Steel Plant (RSP) is one of the integrated steel plants
operated by Steel Authority of India Limited (SAIL). Located in
Rourkela, Odisha, India, it is the first integrated steel plant in the
public sector in India. Rourkela Steel Plant plays a significant role
in the industrial and economic development of the region.
● Established in collaboration with West Germany in 1954.
● The steel plant encompasses multiple units, including a blast
furnace, coke ovens, a steel melting shop, a hot strip mill, a
cold rolling mill, and various auxiliary facilities.
● The plant has a diversified product portfolio that includes
hot-rolled coils, cold-rolled coils, galvanized coils, plates,
rails, and structural products.
● Apart from its core steelmaking operations, Rourkela Steel
Plant also engages in community development and welfare
activities.
● It caters to both domestic and international markets,
exporting its products to several countries.
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DEVELOPMENT OF TOOLING SYSTEM
IN HORIZONTAL BORING MACHINE

OUR GUIDE:
A.K.MISHRA SIR

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What is a Horizontal Boring Machine?

A horizontal boring machine or horizontal boring mill is a

machine tool which bores holes in a horizontal
direction.Boring means enlarging the hole where as drilling
means creating a hole.

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Different parts of the machine
Bed: The bed is a large, heavy, and rigid base that supports all other machine
components. It provides stability and ensures accurate positioning of the workpiece.

Column: The column is a vertical structure mounted on the bed. It supports the crossrail
and spindle head assembly and provides vertical movement.

Crossrail: The crossrail is a horizontal beam that connects the columns on both sides. It
can move vertically along the columns, allowing for height adjustment and
accommodating different workpiece sizes.

Spindle Head: The spindle head houses the spindle, which is the rotating cutting tool
used for machining operations. It can move vertically, horizontally, or both, allowing for
precise positioning of the spindle for drilling, boring, or milling operations.

Spindle: The spindle is the rotating shaft that holds and drives the cutting tool. It is
responsible for rotating the tool at various speeds to perform cutting operations. The
spindle may have different attachments or tool holders to accommodate different cutting
tools.
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Boring machine at RSP
SPECIFICATION

● Model – SKODA W200G

● Spindle diameter – 200mm
● Spindle taper – metric 120
● Max boring depth with spindle – 2000mm
● Speed of spindle – 195 – 2450 m/min
● Max speed – 3000rpm
● Max extension of Ram – 1600mm

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Tooling System
➢ Tooling systems are a critical component of
any horizontal boring machine. They allow for
precise and efficient drilling, milling, and
cutting operations.
➢ Due to the outdated version of the boring
machine in RSP some tools available in the
market do not fit in the spindle.
➢ Due to this vibrations occur during the
operation of the machine.
➢ The current procedure followed by the
officers to tackle this problem is using
modified tools and adjusting cutting speed
and feed rate.
➢ Unless the operator is experienced improper
adjustment may cause vibrations and
damage the machine and job.
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Pull Stud
In a horizontal boring machine, a pull stud is a device used to secure
the tooling in the spindle. The pull stud is a type of tool holder that
connects the tool to the machine's spindle and ensures proper
alignment and stability during machining operations.

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Uses
● Tool Attachment: The pull stud is inserted into the spindle of the horizontal
boring machine. It typically has a tapered end that fits into a corresponding
taper in the spindle.
● Retention System: Once the pull stud is inserted into the spindle, it is secured
using a retention system. The most common retention system is the pull stud
being pulled up into a drawbar mechanism. The drawbar is actuated by a
hydraulic or pneumatic system, which exerts force on the pull stud, pulling it up
and creating a tight connection between the tool and the spindle.
● Tool Stability: The pull stud plays a crucial role in maintaining the stability of
the tool during machining operations. It ensures that the tool is securely held in
place, minimizing vibrations and maintaining accuracy during cutting or boring
processes.
● Alignment: The pull stud also helps in achieving proper alignment between the
tool and the workpiece. It ensures that the tool is positioned correctly within the
spindle, enabling precise machining and preventing issues such as tool runout.
● Quick Tool Changes: Another advantage of using pull studs is that they
facilitate quick tool changes. By releasing the drawbar mechanism, the pull
stud can be easily disengaged, allowing for the removal and replacement of
tooling in a relatively short time.
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Problem
● Vibration due to outdated machine and worn out tools.
● Unable to perform operations other than boring such as
milling,drilling,tapping,facing due to unavailability of compatible tools with the
pull stud.
● The tools available in the market these days are iso 50 which require a
different pull stud compared to iso 60 tools that are used in the SKODA
machine
● The SKODA machine’s spindle and tool holder are designed to conform to DIN
2080 standard model of pullstud for secure and standardized clamping of
milling head (DIN 2080 is a standard that defines the dimension and specs of
pullstuds).
● DIN 2080 pull studs are compatible with iso 60 and not with iso 50 tools

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Solution

The only way to make the tool available in the market to fit
in the pullstud is to match their threading.
We have found that there is an italian tool manufacturing
company called D’andrea which had decided to
manufacture tools of iso 50 thereby allowing us to fix tools
of iso 50 in the SKODA machine

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 Summary
A horizontal boring machine or horizontal boring
mill is a machine tool which bores holes in a
horizontal direction and our job in this project is to
eliminate the vibration problems faced by the
workers by suggesting better techniques and tools.
In conclusion, we have learned that tooling systems
are an essential component of horizontal boring
machines. They have evolved over time, from
simple mechanical systems to complex computer-
controlled ones, and have greatly improved the
efficiency and accuracy of these machines.
However, implementing a tooling system also
comes with its own set of challenges, including
maintenance, calibration, and safety considerations.

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