YAMUNA NAGAR , HARYANA

SUBMITTED BY :- SUBMITTED TO :-
GOURAV Dr. R.K. Garg and Dr. S.K. Jarial
19001004017. (Professor ) ( Professor)
Mechanical Engg. Mechanical Engg. Deptt.
B.TECH

DEENBANDHU CHHOTU RAM UNIVERSITY OF SCIENCE AND TECHNOLOGY,

MURTHAL (SONIPAT)

DEPARTMENT OF MECHANICAL ENGINNERING

Industrial Training Report - August 2022

on

‘CONSTRUCTION OF MECHANICAL PRESS - MBD'

 DECLARATION

I hereby declare that the report being presented in the project report entitled as
“CONSTRUCTION OF MECHANICAL PRESS- MBD ” submitted in the fulfilment of
INDUSTRIAL TRAINING in Bachelor’s of Technology in Mechanical Engineering department
, DCRUST , Murthal and submitted to the TRAINING AND DEVELOPMENT department of
ISGEC heavy Engineering Ltd. , Yamuna Nagar , Haryana is based upon my experience and
learning and a genuine work of mine carried out during a period of 4 weeks dated 01 – 08 - 2022
to 05 – 09 – 2022 under the supervision of Mr D.N.Mishra (Training and development
deptt. ) .This time period of 4 weeks is full of hard work , fun and new learnings.

GOURAV

19001004017

Mechanical Engg. deptt.

 ACKNOWLEDGEMENT

First of all I would like to state that this project has been great learning experience through this
training at ISGEC Heavy Engineering Ltd, Yamuna Nagar, Haryana. I gained valuable
insights into the production process followed at world class ‘Machine Building Division'. and
various Inspection techniques and their management carried out in production industry .I feel
immense pleasure in showing my gratitude to all people who have made my training successful
by offering guidance . I am deeply indebted to MR. D.N. Mishra ( Training and Development
Department) for providing me this opportunity and their valuable time in carrying out this study
whenever required. Needless to say, without their support and active guidance, this training and
thus this report would have not been possible.

I also thank the workers of their respective stations, who were always ready to clarify my doubts
and helped me to increase my knowledge by illustrating me to the finer points.

I wish to express my deep gratitude to all the concerned persons, whose enthusiasm, support and
coordination have given me the success to complete my training in the organization.

I hope that my report will reflect my technical knowledge and innovativeness, which I gained at
ISGEC Heavy Engineering Ltd, Yamuna Nagar, Haryana
 TABLE OF CONTENTS

S. No. TOPIC PAGE

1. ISGEC – INTRODUCTION OF ISGEC
2. OVERVIEW OF DIFFERENT ASPECTS
3. INFORMATION ABOUT MACHINE BUILDING
DIVISON
3.1 PREPARATION SHOP
3.2 FABRICATION SHOP
3.3 MACHINE SHOP
3.4 ASSEMBLY SHOP
4. FABRICATION AND QUALITY TESTING FOR
PRESSURE VESSELS
4.1 Fabrication of Vessels
4.2 Quality Test for Pressure Vessels
5 MECHANICAL PRESS
5.1 PRINCIPLE
5.2 ADVANTAGES
5.3 STEPS TO INSTALL MECHANICAL PRESS :- ( H –
frame Mechanical press)
5.4 FUNCTIONS OF VARIOUS COMPONENTS
5.5 INSPECTION OF PRESSES
 LIST OF FIGURES

CHAPTER 1 : INTRODUCTION – ISGEC

Fig. 1.1 – ISGEC Manufacturing Plant ( Source – Internet)

CHAPTER 2 : OVERVIEW OF DIFFERENT ASPECTS

Fig. 2.1 – About Various products in Various Shops( Source – ISGEC)

CHAPTER 3 ; INFORMATION ABOUT MACHINE BUILDING DIVISION (MBD)

Fig 3.1 – Plasma Cutting( Source – ISGEC )
Fig. 3.2 (A schematic diagram of submerged arc welding )( Source – Internet)
Fig. 3.3 Pieces of slag from Submerged arc welding ( Source – ISGEC)

Fig 3.4- SAW ( Source – ISGEC)

Fig. 3.5 GMAW Circuit diagram. (1) Welding torch, (2) Workpiece, (3) Power source, (4)
Wire feed unit, (5) Electrode source, (6) Shielding gas supply

Fig. 3.6 GMAW torch nozzle cutaway image. (1) Torch handle, (2) Molded phenolic
dielectric (shown in white) and threaded metal nut insert (yellow), (3) Shielding gas diffuser,
(4) Contact tip, (5) Nozzle output face

CHAPTER – 4) FABRICATION AND QUALITY TESTING FOR PRESSURE

VESSEL

CHAPTER – 5 MECHANICAL PRESS :-

Fig, 5.1 Mechanical presses at ISGEC ( Source – ISGEC )

Fig 5.2 Drawing of Foundation ( Source – ISGEC )
Fig. 5.3 – Base Plate(Source – ISGEC)
Fig. 5.4 – AVM ( Source – ISGEC )
Fig. 5.5 – Die Cushion ( Source – ISGEC )
Fig. 5.6 – Moving Bolster ( Source – ISGEC )
Fig. 5.7 – Tie Rod ( Source – ISGEC )
Fig. 5.8 Slide of mech. Press ( SOURCE – ISGEC )
Fig. 5.9 Crown Placed ( Source – ISGEC )
Fig.5.10 1. Section of material with a surface-breaking crack that is not visible to the
naked eye. 2. Penetrant is applied to the surface. 3. Excess penetrant is removed. 4.
Developer is applied, rendering the crack visible.
Fig. 5.11 – DPI Schematic diagram ( Source – Internet)
LIST OF TABLES
ABBREVIATION
ABSTRACT
 CHAPTER 1 : INTRODUCTION –ISGEC

ISGEC Heavy Engineering ltd.(formerly known as Indian Sugar and General Engineering
Corporation) is a Process plant, Sugar plant , boilers and agricultural equipment company
headquartered in Noida, U.P., India.

Established in 1933 as Saraswati Sugar Syndicate, company held a revenue of 

Rs.5,477 crore (US$690 million) in 2021 with exports to approximate across 91 countries. It
was ranked 252 in the ET 2021listing, and 253 in the Fortune India 500 Listings. It is one of
Asia's largest Sugar Plant Machinery producers.

It produces various types of machines, including boilers, Steel casting, Presses and Sugar
Machinery. It has its manufacturing unit in Yamunanagar , Bawal , Muzaffarnagar, Dahej
and its products are sold in over 91 countries and have officies in Noida , Pune , Chennai ,
Kolkata .

• ISGEC has been approved by Lloyds Register Asia (LRA) of quality assurance as an
ISO-9001: 2000 company.

• The American Society of Mechanical Engineers (ASME) approves ISGEC for the
use of ASME ‘U’, ‘U2’, R & S code stamps.

Fig 1.1- ISGEC Manuf. Plant ( Source :- Internet)

• Lloyds Register Asia as class-I Manufacturing of Fusion welded pressure vessels

approves ISGEC up to 200 mm thickness.

• Engineers India Ltd. (EIL) approves ISGEC for Manufacture of vessels and columns
in carbon and alloy steels up to 155mm thickness and in clad steel up to thickness of
130mm.
 • Engineers India Ltd. approves ISGEC for Manufacture of Heat Exchangers up to
maximum tube sheet thickness of 300mm.

CHAPTER 2 : OVERVIEW OF DIFFERENT ASPECTS

ISGEC, the heavy engineering plant unit of Saraswati industrial ltd. was established in 1946
and is located at Yamunangar, Haryana about 200kms from New Delhi. The annual turnover
of ISGEC is US $ 50 million and group turnover of the Saraswati Industial Syndicate ltd.
Exceeds US $ 100 million.

2.1 ) Infrastructure :-

• Machine Used for Lifting :

Crane capacity- 200 Mega Tonne
(Hydraulic Lifting Machine is also used for heavy loads - 250 Mega Tonne)

• Area Covered By Shop :

43,000 Square Meter (51,427 Square yards)

• Total Area Covered By Plant ;

250,000 Sq. Meter (298,998 Sq. yards)

2.2 ) Forming Processes Used :-

• Rolling :

Thickness of sheets - > 200 mm (8 in.)

2.3 ) Welding processes :-

• Narrow Gap Welding with seam tracking

• Strip Cladding using single as well as double layer technique

• Automatic small diameter nozzle cladding.

• Twin wire and tandem head welding SAW, SMAW, TIG, and MIG etc. Over 850
WPS and 1000 PQR

2.4 ) Drilling :-

An Thickness drill the item up to 1000 mm ( 40 inches) using deep hole CNC
Drilling machine

2.5) Heat Treatment :-

• Four Gas Fired Furnaces

Size upto: 4500 mm x 4000 mm x 14500 mm

• Stress Relieving, Annealing, Quenching and Tempering as well as Solution

Annealing of Stainless Steels

• Local Stress Relieving by Electrical Resistance Method

 • Stress Relieving by Internal Firing Method

• Stress Relieving of large jobs in Temporary Furnaces

2.6) Radiography :-

• Cobalt 60 is used for Radiography up to 200 mm (8 in.)

2.7)Testing :-

• Tensile testing including Elevated Temperature Testing up to 8000 C (14700 F)

• Impact Testing up to (-) 1960 C (-3200 F)

• Metallurgical Microscope X-2000 with Photography facility

• Ferrite Measurement

• Recordable/ Mechanized Ultrasonic Testing

• Magnetic particle Testing

• Liquid Penetrant Testing

• Holiday Testing for Painting

• IGC Testing

• Complete laboratory supported by spectrometer

2.8) Types of Products Manufactured :-

There are different types of products manufactured by ISGEC. ISGEC produces range
of products - ISGEC serve industry from Automobile and ship building to oil & natural gas,
defense products , aeronautics and nuclear power. The product range is as such :-

 Hydraulic and Mechanical Presses :-

ISGEC has successfully commissioned around 100 presses built till date which
also include a 3700 tone capacity hydraulic presses for defence industry and a 2500 tones
capacity mechanical press.

• Process plant equipment :-

Pressure vessels, columns ,heat exchangers , storage and transport vessels & reactors etc.
For petrochemical , fertilizer industry and other industries.
 • Industrial & power boilers :-

Including pulverized fuel boilers up to 60 MW size bubbling as well as circulating fluidized

bed boilers up 200 TPH size).

• Custom made equipment :- (for India’s nuclear plants )

ISGEC’s equipment is also used by Bhabha Atomic Research Center (BARC) in last 18
years, ISGEC also built equipment for Nuclear power Corporation and Center of Advanced
Technology.

• Chlorine, Ammonia and other gases containers:-

ISGEC is the largest manufactures of chlorine in the world.

2.9 ) DIVISION Of SHOPS IN ISGEC :-

The various divisions of ISGEC are as follows;

2.9.1 ) PROCESS EQUIPMENT DIVISION (PED) :-

Process Equipment Division ( PED) is the oldest division of ISGEC and products
manufactures here are pressure vessels , boilers, heat exchangers etc. It has sub-divisions
as follow :-

• PED-I

• PED-II

• PED-III

• PED-IV

2.9.2). MACHINE BUILDING DIVISION (MBD) :-

Machine building division is a division of ISGEC used to manufactures machinery of sugar

mill , Press components and other Steel plant machinery. It is further divided into following :

• PREPARATION SHOP-I,II

• FABRICATION SHOP-I,II

• ASSEMBLY SHOP

• QUALITY SHOP
 2.9.3). FOUNDRY GROUP (FG) :-

Foundry group division is there for casting in large volume production for various
industries.

2.9.4). TUBE MANUFACTURING DIVISION :-

Tube shop deals with tube manipulation and also for the fabrication of tubing system used in
economizers and superheaters.

Fig. 2.1 – About Various products in Various Shops

CHAPTER 3 ; INFORMATION ABOUT MACHINE BUILDING DIVISION (MBD) :-

The step by step procedure followed during the project & explanation of the same is as
follows;
3.1 ) PREPARATION SHOP :-

This is the store where raw materials are brought in for delivery to other stores and where
they are recognised in accordance with specifications established by manufacturers.
Preparing items needed by various other shops is the preparation shop's primary goal.

The amount of material needed is determined at the start of the fiscal year in October. The
amount is determined by the delivery date and the customer's requirements. The raw
material is first identified and then delivered inside the shop where cutting operations are
carried out on the material utilising manual gas cutting & CNC machines in accordance
with its fabrication requirements.

Drawings and material-specific information are the two primary needs for cutting the
material.

The cutting is carried out in accordance with the programme by CNC machines, which
need an operator to feed the programme. While supervisors create some sophisticated
programmes, operators create the majority of them.

The AutoCad programmes are assembled, and using the Burney LCD scanner, they are
sent directly to the CNC.

3.1.1) Cutting Method - There are two cutting methods :-

3.1.1.1) Gas cutting :-

Metal is heated to igniting temperature using a cutting torch. A stream of oxygen is then
directed towards the metal, and the metal burns in the oxygen before exiting the cut as oxide
slag.

Table 3.1 ( Source – ISGEC )

3.1.1.2) Plasma cutting :-

High-speed inert gas is blasted out of a nozzle, and as it travels from the nozzle to the surface
that to be cut, an electrical arc occurs across the gas, turning some of it to plasma. The plasma
is fast enough to blast the molten metal away from the cut and hot enough to melt the metal
that is being cut.

fig 3.1 – Plasma Cutting ( Source – ISGEC )

3.2 ) FABRICATION SHOP :-

The fabrication shop is a component of the machine-building sector. Almost all types of
fabrication work are completed here. Thick sheets of mild steel are cut, welded, and bent at
this shop according to the design. The gas cutting technique is used for cutting plates and
sheets. The various chopped sections are then put together using welding.

Some of the welding processes used include:

• GMAW (Gas Metal Arc Welding)

• SAW (Submerged Arc Welding)

• SMAW (Shielded Metal Arc Welding)

• Semi Saw

• Plasma Arc Welding

Sheet bending is favoured in hydraulic presses. A specified type and size of die is retained
under the plate to be bent for bending, and then hydraulic pressure is provided above the
plate. The radius of curvature of the arc generated by the bend plate determines the extent of
bending. Gouging is a method of fixing a defective weld joint.

3.2.1) Instructions For Various Works in Fabrication Shop :-

 3.2.1.1) Gas Cutting :-

Instructions :-

1. Follow the supervisor's directions to select the best plasma cutting machine.

2. Follow the directions and work manner on the machine.

3. If cutting by gauging, leave 1.5mm from the marking punch and begin cutting.

General Instructions :-

1. Before cutting, clean the surface.

2. Only cut with your down hand.

3. In the event of circular cutting, use a guide (whenever possible).

4. During the straight cut, use a cookie machine.

5. When cutting, avoid undercuts.

6. If you have any doubts, consult with your supervisor.

Width in mm Size of nozzle in inch Oxygen pressure in Acetylene pressure in

kg/cm2 kg/cm2

2-6 1/32 1 0.2

7-12 3/64 1.5 0.5

14-40 1/16 2.5 0.5

45-56 5/64 3.5 0.5

63-80 3/32 5.0 0.5

100-150 1/8 6.0 0.5

200-300 1/8 9.0 0.5

Table 3.2 (Specifications as per width of sheet to be cut )

3.2.1.2) Cold Bending :-

1. Check the machine and dye as needed.

2. Check the material size and mark the bent line according to the arrangement.

3. Adjust the dye to the size of the material.

4. After assembling the machine, configure the bend marking and bend degree.

5. Bend the project slowly and examine the size using a template once completed.

6. Check the final work and have it approved by the supervisor.

3.2.1.3) Fitting via Welding :-

1. Examine the material in accordance with the BOM.

2. Obtain the drawing from the supervisor and the necessary materials from the
BOM.

3. Make sure the material is straight.

4. Straight material as directed by the supervisor.

5. Create a layout for fitting in accordance with the drawing and supervision.

6. Prioritize fitting according to the supervisor's instructions and the design or ND

table provided by Quality Assurance.
 7. Fit the task to the drawing or plan.

8. Record the work number, drawing number, mark number, serial number, and
fabrication weight, which must not exceed 5 tonnes.

9. Conduct a self-inspection for the next operation.Check material according to

BOM.

3.2.1.4)Painting a Job :-

1. Gather job-related information from your boss.

2. Examine the project for rust, oil, grease, or other type of dust particles.

3. Before painting, ensure that the project has been grit blasted or wire brushed in
accordance with the job drawing.

4. Using a piece of cloth, clean the task surface as needed.

5. Apply primer as directed by Quality Assurance.

6. If you have any doubts, consult with your supervisor.

7.Collect required information about job from supervisor.

3.2.1.5) Hydro-testing :-

1. Gather job-related information from your boss.

2. Examine the project for rust, oil, grease, or other type of dust particles.

3. Before painting, ensure that the project has been grit blasted or wire brushed in
accordance with the job drawing.

4. Using a piece of cloth, clean the task surface as needed.

5. Apply primer as directed by Quality Assurance.

6. If you have any doubts, consult with your supervisor.

7.According to supervisor’s instructions, set job’s position keeping in mind the

position of air packet.

3.2.1.6) Welding :-

1. Collect information about the job and type of welding from supervisor.
 2. Select appropriate machine and check for its calibration and connections.

3. Check WPS or shop welding record of job and check for your qualified position.

4. Collect electrode from electrode cabin as per data sheet.

5. Issue a maximum of 15 electrode and filler wire for MIG/TIG.

6. Weld according to WPS and test Route run OP of 10% part of groove size more than
10mm.

7. Return stubs of used electrodes before issuing new electrodes.

8. Self-inspect after welding and fill up check sheet.

3.2.1.7)Blast Cleaning :-
Stage I

1. Remove all grease, oil, and other contaminants from the task.

2. Blast work in accordance with SA 2 12 Swedish specification SIS055900.

Compare the surface profile to a regular full-size image.

3. If blast cleaning is not an option, clean grease using a D-slagging gun or wire
brush.

4. Have the job examined by the shop supervisor.

Stage II

Primer coating inside oil tank

1. Before applying primer, ensure that it has not been more than 8 hours since
blasting.

2. The job must be thoroughly cleaned and dried. Never ever clean with a cloth.

3. Before applying primer, keep the following points in mind: 4. Use only primer
epoxy Zinc Chromate that is less than 12 months old.

5. Make sure the primer is in two packets and mix the plate and hardener according
to the directions below.

A. To mix Zinc Chromate, use 3 parts paste and 1 part hardener, then dilute the paste
with epoxy thinner.
The pot life of such a primer is 3-4 hours. Apply primer using a brush or a spray
gun.
 B. Consider how long primer takes to dry. Touch dry takes 1 hour. Handle dry time
is 4 hours. And the hard dry time is 12 hours.

For Steel Structure

Same as for Oil tank above, except the use of Zinc Phosphate primer.

Stage III, IV & V

Painting top coat

1. Before applying Putty, check the quality of the priming covering.

2. Rough up the primered surface with emery paper and wipe it dry with a towel.

3. Apply a coating of Putt to each visible and primed exterior surface of the work.
Putty is prepared in the same manner;

4. Combine 9 parts paste to 1 part hardener. Dilute the mixture with epoxy thinner.
Stir using a stirrer or a rod. Pot life is 3-4 hours.

5. Using a knife, apply the prepared Putty. Putty can be used to fill up dents. The
drying time is 12 hours.

6. Rub the Putty with a Putty Sander as directed below.If drying time is 14-24hrs use
80 Grit Sanding disc on Putty sander. If drying time is more than 24hrs then use 60
Grit Sanding disc.

7. Wipe down with a clean towel.

8. Apply PVC tape, grease, or oil to the whole machined surface.

9. Apply a surfacer coat. Keeping the following considerations in mind;

10. Use just PU surface and 9 parts PU with 1 part Hardener and prepare only that
amount that can be used within 4-6 hours. Allow at least 4 hours after application to
dry.

Stage VI and VII

1. Apply for jobs that are ready to be dispatched.

2. Check that the work is clear of dust particles and, if necessary, wipe the surface
with a surface thinner.

3. Apply primer to the grinded surface.

4. Apply epoxy Putty to the scratched area and allow it to dry.

5. Protect all surfacers that will not be painted.

 6. Using an 80-grit sanding disc, plane the areas where putty has been placed.

7. Use a PU surface on areas where Putty has been used.

8. Paint the areas where the PU surface has been applied and allow the paint to dry.

9. Finally, add a final layer of paint.

10. Rust protection should be used on all machined surfaces.

11 .Use Zinc phosphate primer on inside parts and those parts that touch ground.

12. Uncover all the parts and clean them properly.

3.2.2 Various Welding Techniques Observed in MBD :-

3.2.2.1 Submerged Arc Welding (SAW) :-

It is a typical arc welding procedure. A constantly supplied consumable solid or tubular (flux
cored) electrode is required. The molten weld and arc zone are shielded from ambient
contamination by a blanket of granular fusible flux made up of lime, silica, manganese oxide,
calcium fluoride, and other chemicals. When the flux melts, it becomes conductive and
creates a current route between the electrode and the work. This thick coating of flux
completely covers the molten metal, preventing spatter and sparks and suppressing the
process's powerful UV light and fumes.

Fig. 3.2 (A schematic diagram of submerged arc welding )( Source – Internet)

SAWs are often used in automated or mechanised mode. Typically, the method is confined to
flat or horizontal-fillet welding locations.
 Fig. 3.3 Pieces of slag from Submerged arc welding ( Source – ISGEC)

3.2.2.1.1) Electrode :-

SAW filler material usually is a standard wire as well as other special forms. This wire
normally has a thickness of 1/16 in. to 1/4 in. (1.6 mm to 6 mm).

Factors that usually effect SAW :-

1. Wire feed speed (main factor in welding current control)

2. Arc voltage

3. Travel speed

4. Electrode stick-out (ESO) or contact tip to work (CTTW)

5. Polarity and current type (AC or DC) & variable balance AC current

Weld Layer Electrode Size Current (A) Voltage (V) Speed (IPM)

1. Root 4.00mm 140-160 22-24 16-18

2. Subsequent 4.00mm 400-500 28-32 18-24

3. Lapping 4.00mm 500-600 32-34 18-24

Table 3.2 ( Specifications as per Weld Layer )

3.2.2.1.2 ) Advantages of SAW :-

1. Mechanized applications with high operating factors.

2. Extensive weld penetration

3. It is simple to make excellent welds (with good process design and control).

4. It is able to weld thin sheet steels at speeds of up to 5 m/min (16 ft/min).

5. There is very little welding smoke or arc light emitted.

6. Almost no edge preparation is required.

7. The procedure is appropriate for both indoor and outdoor work.

8. There is substantially less distortion.

9. The welded joints are sound, homogeneous, ductile, corrosion resistant, and have a
high impact value.

Single pass welding in thick plates are possible using standard equipment.

11. Because the arc is constantly coated in flux, there is no risk of weld spatter. 12.
Between 50% and 90% of the flux is recoverable.

Fig 3.4- SAW ( Source – ISGEC)

3.2.2.1.3 ) Limitations of SAW :-

1. Mechanized applications with high operating factors.

1. Only ferrous (steel or stainless steels) and some nickel-based alloys are permitted.
 2. Typically, lengthy straight seams or rotational pipes or containers are the only
options.

3. Requires relatively difficult flux handling systems.

4. Flux and slag residue might be hazardous to one's health and safety.

5. Inter-pass and post-weld slag removal are required.

3.2.2.2 Gas Metal Arc Welding :-

Metal inert gas (MIG) welding or metal active gas (MAG) welding is a semi-automatic or
automated arc welding procedure that uses a welding gun to feed a continuous and
consumable wire electrode and a shielding gas. A constant voltage, direct current power
supply is most typically utilised with GMAW, however alternating current and constant
current systems can also be employed. In GMAW, there are four basic metal transfer
methods: globular, short-circuiting, spray, and pulsed-spray, each with unique features and
benefits and limits.

Fig. 3.5 GMAW Circuit diagram. (1) Welding torch, (2) Workpiece, (3) Power source, (4)
Wire feed unit,
(5) Electrode source, (6) Shielding gas supply

 Equipment used in MIG :-

3.2.2.2.1) Welding gun :-

A control switch, a contact tip, a power cable, a gas nozzle, an electrode conduit and liner,
and a gas hose are all common components of a GMAW welding gun. When the operator
presses the control switch, or trigger, it starts the wire feed, electric power, and shielding gas
flow, resulting in an electric arc. The contact tip, which is typically constructed of copper
and is occasionally chemically treated to decrease spatter, is linked to the welding power
source through the power cable and provides electrical energy to the electrode while
directing it to the weld region. The gas nozzle is used to evenly direct the shielding gas into
the welding zone; if the flow is erratic, the protection may be insufficient of weld area.
 Fig. 3.6 GMAW torch nozzle cutaway image. (1) Torch handle, (2) Molded phenolic
dielectric (shown in white) and threaded metal nut insert (yellow), (3) Shielding gas diffuser,
(4) Contact tip, (5) Nozzle output
face

3.2.2.2.2) Wire feed unit :-

The electrode is supplied to the work via the wire feed unit, which drives it through the
conduit and onto the contact tip. The wire is typically fed at a steady rate in most models, but
more modern machines may alter the feed rate in response to the arc length and voltage.

3.2.2.2.3) Electrode :-

The composition of the metal being welded, the process variation employed, joint design,
and material surface conditions all have a role in electrode selection. To assist avoid oxygen
porosity, all commercially available electrodes contain trace amounts of deoxidizing metals
such as silicon, manganese, titanium, and aluminium. To avoid nitrogen porosity, some
incorporate denitriding metals such as titanium and zirconium. The diameters of the
electrodes utilised range from 0.7 to 2.4 mm but can be as high as 4 mm depending on the
process variation and base material being welded.

3.2.2.2.4) Shielding gas :-

Shielding gases are used in gas metal arc welding to shield the welding region from ambient
gases like nitrogen and oxygen, which can produce fusion flaws, porosity, and weld metal
embrittlement if they come into contact with the electrode, arc, or welding metal. The
selection of a shielding gas is influenced by various aspects, the most important of which are
the kind of material being welded and the process variation utilised. Pure inert gases such as
argon and helium are exclusively used for nonferrous welding since they do not offer enough
weld penetration (argon) or generate an unpredictable arc and increase spatter when used
with steel (with helium).

Pure carbon dioxide, on the other hand, allows for deep penetration welding but promotes
oxide development, which reduces the weld's mechanical qualities. Its low cost makes it an
appealing option, but due of the arc plasma's reactivity, spatter is unavoidable and welding
thin materials is challenging. As a result, argon and carbon dioxide are routinely blended in
proportions ranging from 75%/25% to 90%/10%. There are other shielding gas mixes of
three or more gases available. For welding steels, argon, carbon dioxide, and oxygen
mixtures are offered. Other mixes add a little quantity of helium to argon-oxygen
combinations, claiming better arc voltages and welding speed.

Advantages :-

1. MIG welding is substantially quicker than TIG or stick electrode welding because
of the constantly supplied electrode.

2. It is capable of producing joints with deep penetration.

3. Both thick and thin work parts may be properly welded.

4. The MIG welding method achieves high metal deposition rates.

5. The procedure is easily automatable.

6.There is no flux utilised. MIG welding provides welded surfaces that are smooth,
tidy, clean, and devoid of spatter, requiring no further cleaning. This contributes to
lower overall welding costs.

7.The higher arc travel rates associated with MIG welding significantly minimise
distortion.

Disadvantages :-

1. Compared to TIG or stick electrode welding, the method is a little more

complicated because a lot of variables (such as electrode stick out, torch angle,
welding parameters, type and size of electrode, welding torch manipulation, etc.)
must be properly regulated to provide good results.

2. Welding equipment is less portable, more expensive, and more complicated.

3. MIG welding may not perform effectively in outdoor welding situations because
air draughts might spread the shielding gas.

4. When compared to methods that deposit slag on the weld metal, cooling rates for
the weld metal are faster.

3.3 ) MACHINE SHOP :-

Machine shop is the main work station. Here various machining operations are carried out to
produce different parts of presses. There are two division of machine shop

a) Machine shop-I Heavy Work Division

 b) Machine shop-II Light Work Division

3 .3.1) Various Machine Employed at Machine Shop-I :-

1. SKODA horizontal boring

HB -11, HB-3, HB-19, HB-8, HB-1

2. SWIFT Lathe
ML-14

3. H.M.T Radial Drilling Machine RD-4

4. SACEM- MSMG

3.4 ) ASSEMBLY SHOP :-

In this final step of the machine building process, the numerous parts needed to manufacture
a press are gathered, and the press's final assembly is completed.

The pit area and the outside area are the two areas that make up the store. Presses with higher
height and size are constructed in the outside region, while smaller presses are assembled in
the pit area. More competent employees and knowledgeable supervisors are needed for the
final assembly since it demands such exact labour.

Each press is put together using the customer's specifications as a guide. Two wide machine
pieces are needed for the assembling.

 Parts fabricated by ISGEC i.e. the frame and some other components.

• Parts being imported from outside that are parts like modules and brake and gear
system and oil lubrication unit.

Tie rods are used to connect the bottom head, uprights, and top head of the link frame presses
during assembly. The tie rod aids in placing them together properly. When the frame is
prepared, the slide is transported inside of it and installed using jigs, etc. All other pieces are
constructed in accordance with the drawing's specifications. Before being shipped, the press
is examined repeatedly for any form of flaw after it is finished.

The processes involved in the assembly, which is a difficult procedure that takes hours of
continuous effort, are explained below.

• Compiling all the building supplies that are needed.

• Recognizing the various components' locations.
• Examining the veracity of all the information.
• Starting the assembling process as needed.
• Each item is perforated or labelled for identification and to make site workers' jobs
easier when assembly is complete.
• Any defective materials are either removed or repaired once the presses have been
assembled. The press is disassembled and prepared for shipping when the
examination is finished.
 CHAPTER – 4) FABRICATION AND QUALITY TESTING FOR PRESSURE
VESSEL
4.1) Fabrication for Pressure Vessel :-
Before any building in an industry can begin, the primary pressure vessel's drafting design and
its components must be authorised by the customer and the inspection authority. Only then
can the manufacturer begin the construction. They also supplied the following information in
addition to the dimensions and thickness of the completely dimensioned drawing for the main
pressure vessel and its parts:

 Conditions of design
 Selection of material
 Welding details
 Heat treatments to process
 Non destructive testing
 Pressure testing
The primary goal of manufacturing is to offer a clear procedure for recognition. To ensure
that any item can be traced back to its source, building must only utilise materials that meet
the necessary specifications. The method used to shape the material sheets into elliptical head
plates and cylindrical shells through hot or cold forming entirely depends on the thickness and
dimensioning of the material that has been chosen. The standards and rules that are applied
determine the limits of acceptable assembly and shaping for cylindrical shell and end heads.
By applying these tolerance limits, the strains caused by joint misalignment and outside
roundness may be avoided. Preheating or post-welding treatments are used to complete the
welding for the weld joints depending on the material and thickness of the component..
Preheating is conducted to the weld local areas and post welding is heating the vessel in
enclosed furnace.

4.1.1) Design Conditions :-

The laws, regulations, and requirements must be followed when fabricating a pressure vessel.
Here are several codes and requirements:
 ASME BPV code, SecII partC – material specification for welding rod, electrode and
filler metals.
 ASME BPV code, SecV – Non destructive Examine (NDE)  ASME BPV code,
SecVIII, Div 1 – Rules and regulation of pressure vessel.
 ASME BPV code, Section IX – Welding and Brazing qualification
 Indian Boiler regulations (IBR) and any other specified.

4.1.2) Material Specification Processing :-

• Carbon Steel: In accordance with Table 5.3, stress relief must be applied to carbon
steel welded joints after welding. The welded joint temperature is raised to 600 C and
not lower than that utilising local stress relief. A weld with a 25mm thickness is
treated for one hour at a temperature range of 600 to 650 C. The weld region is then
 held in still air for cooling without interruption and the temperature is kept below 315
C.

• Austenitic Stainless Steel: Since solution annealing is done after the welding
process, the stainless steel welding joint does not require stress relief. The
requirements include notch toughness, fatigue strength, and fracture at elongation and
reduction zones and ageing of material and its non brittle nature at operation situation
and availability.

4.1.3) Welding Processes :-

The following welding processes shall be used

Weldin AWS Electrod Shielding Remarks

g Designatio e Gases
Process n
Gas GTAW Non Argon Clean
Tungst Consuma And Process
e n Arc ble Helium
Weldin Tungste Gas To
g n Penetrate
Electrod Weld
e
Shielde SMAW Consum Some Common
d a Shielding In The
Metal ble Stick . Gas Field And
Arc Electrod Produced In Small
Weldin e From Shops.
g Welding Produces
Rod. Excessiv
e
Fumes.
Gas GMAW Consuma Argon, From
Metal ble Wire Co2 Electrode,
Arc Electrod And Ar / Metal
Weldin e Co2 Flows To
g Workpiec
e
Flux FCAW Consuma External Same As
Core ble Gas As GMAW
 Arc Electrod Co2
Weldin e Or Gas
g Wire Generate
With d By
Core Flux
Flux
Table 4.1 – Welding Process

4.1.4) Preheating :-
1. The preheating method enhances fracture avoidance and welding precision. Preheating is
subject to the usual PWHT criteria.
2. Preheating must be used in accordance with Section VIII Division 1 of the ASME BPV
Code. The specifications set forth by IBR shall apply to all equipment falling under its
jurisdiction. The prerequisites for preheating for frequently used materials are listed in Table
9.

Sl. Base Nominal Minimu Minimu

No Materia Wall m m Temp.
. l Thicknes Tensile °C
s mm Strength
MPa
1. Carbon  25 490 10
steel
2. Carbon  25 490 100
steel

Table 4.2 – Preheating

4.1.5 ) Post weld Heat Treatment :-

After welding, a heat treatment procedure called PWHT is used to enhance the weld's
characteristics. The ASME BPVC Sec.VIII Div.1 codes are followed. The PWHT
requirements for frequently used materials are listed in Table 10. PWHT is in accordance with
IBR for equipment in that range.

Sl. Base Nominal Metal

No material wall temp.
thickness range ° c
mm
1. Carbon steel  32 None
2. Carbon steel > 32 600 to
650
3. Austenitic All -
 stainless
steels
TABLE 4.3 Post weld Heat Treatment Requirements (For Commonly Used
Steel Materials)

4.1.6) Efficiencies of Welded Joints :-

The efficiency of weld joints subjected to tension depends upon the welding type and the test
process. Double welded butt joint is a strong joint. Joint efficiency of weld joint is

Join Full Spot No

t Radiograp Radiograp Radiograp
Typ h h h
e
1 1.0 0.85 0.7
2 0.9 0.8 0.65
Table 4.4 – Efficiency of Welding joint

4.1.7) Construction Process :-

General procedure for construction of a pressure vessel is explained in detail below along
with the assembly of the parts to complete equipment. The construction of pressure vessel is
according to ASME codes and standards.

• Shell Construction: Using a forging technique, chosen raw materials are moulded into
thin shell plates with the necessary thickness and length. As seen in Figure 3, these shell
plates are being sent to the rolling operation to be rolled into cylindrical shell shape. After
bending, the shells are now attached to their ends using a technique known as longitudinal
seam welding, or Lseam welding. It is a full penetration butt weld, and the steel electrode
utilised is E7018, a low alloy steel electrode with great tensile strength. Through a welding
process, the two ends are joined. The welding procedure removes uneven edges. The
cylindrical shell is made in accordance with the given specifications.
• Producing Dished Ends: Selected raw materials are shaped into thin sheets with the
necessary cross section thickness and radius. The pressing machine is loaded with this
flat material. The machine's master cylinder piston rod oscillates up and down in
order to operate the top tool that presses the raw sheet metal into the necessary
concave form. This concave-shaped plate is used for load edging. In order to produce
dish ends on the end blank, the pressure wheel must move in accordance with a
specific round arc, which is the purpose of the clamping frame as seen in Figure 4.
The dished end's edges are unevenly trimmed by the edge trimmer. The dished end is
produced in accordance with the criteria given.

• The production of nozzles: a block of chosen raw material is sent for forging. Heat
is applied to the raw material. Compressive force is exerted once the heated block has
been put between the die. After collecting the necessary forms, drilling is done to
create holes in the nozzles so they can fit over the pressure vessel as the process
continues.
4.1.8) Assembly of Pressure Vessel :-
4.1.8.1) Shell to Dish End Assembly :-

For joining the shell to dish ends, first the shell axis is too pointed and then the four
circumferential points on dish end head are too pointed. The process of aligning is:

• To find the four centre points and keep your face straight, examine the outside
circumference and divide the perimeter into four equal pieces.
• Placing the dish ends on the thick, levelled plates in the opposite direction. Find the
opposing centre points using two tri squares. To get a sense of the dish's topmost point,
mark it with chalk. With the initial point, repeat this at a 90-degree angle to get the dish's
end point.
• Join the four centre points, which stand for 0°, 90°, 180°, and 270°, to the dish end's
centre.
• To find the nozzles or other attachments, follow the same approach.
According to the design, accurate assembly can only be achieved by measuring the shell's
diameter and the dish's circumference., assembly get done.

4.1.8.1). Fitting of Subassemblies :-

The necessary attachments for the pressure vessels, such as nozzles, flanges, manholes, and
valves, are fitted up and correctly situated simultaneously with the pressure vessel setup. If
there are any errors with these connected pieces, they may be checked and repaired at the
welded seam. Referencing the orientation plan or an elevated perspective of a horizontal
pressure vessel is taken into consideration for inspection. Locate the nozzles' centre by using
the tangent line as a guide. The pressure vessel has all of the schedule attachments.

4.2) . Quality Test for Pressure Vessel :-

After welding, the pressure vessel is submitted for inspection. Under inspection authority, the
pressure vessel that was built using ASME codes will be inspected. The guidelines for the
examination and inspection are provided by an ASME BPV code. Ultrasonic (UT),
Radiographic (RT), Magnetic Particle (MT), and Dye Penetration investigation techniques
(PT).

4.2.1) Code Standards :-

Levels of acceptance of defects in welds shall be based on ASME BPVC Sec.VIII Div.1. For
equipment under the preview of IBR, the levels of acceptable defects shall be as per IBR. For
the inspection and testing code specifications are:

• UG 90 – General
• UG 93 – Inspection of materials
• UG 97 – Inspection during fabrication  UG 103 – Nondestructive testing
4.2.2) Non Destructive Testing :-
Non-destructive testing techniques can be used to assess the vessel's completeness without
engaging in negotiations. The material and thickness are the foundation for NDT.
Discontinuities and flaws on the open surface or to near surface are examined using visual
examination, dye penetration, and magnetic particle testing. They are referred to as surface
inspection procedures for this reason. Ultrasonic testing investigates the faults within the
component, as opposed to radiography. As a result, they are known as volumetric approaches.

The easiest examination method is visual, which looks for surface flaws or fissures. This
approach is highly helpful for assessing the equipment's general condition. This test can
identify issues including corrosion, erosion, and hydro blistering.

Dye penetrant testing looks for surface faults in the weld. In order to check for any
interruptions, a specially designed liquid (penetrant) is sent into the machinery. The confined
liquids are found using a developing agent. The penetrant employed to find the developed
indicators is fluoresce under black (ultraviolet) light. Opened, spotless, and unaltered
equipment is required.

The surface faults and subsurface imperfections of the weld are examined using magnetic
particle detection. The ferro magnetic material's surface discontinuities are detected by the
magnetic flux. Electric current is used to generate this magnetic flux between the area and the
contact prods. Due to the need for ferro magnetic materials, MT use is restricted for carbon
and low alloy steels. Disturbances are seen when ferromagnetic dry powder or wet suspension
particles are introduced into the magnetic lines; these particles are then said to glow under
black light.

To check for internal welding errors and subsurface fractures and defects, radiography testing
is employed. The same X-ray testing methodology is utilised in this test in medical
radiography. Any surface flaws, such as holes, gaps, or discontinuities, will block more light
from reaching the negative film, which will limit the depletion rays. When employing the RT
approach, voids on exposed surfaces are more easily found than cracks that are firmly sealed.

During the operation, ultrasonic detection is utilised to check the wall thickness and weld any
interior faults. In the same way that radar or scanning systems are tested, so is ultrasonic
equipment. This technique looks for foreign particles using electromagnetic and acoustic
waves. In order to study a material, UT sends waves into it, and the reflected waves reveal
any discontinuities that may have occurred during the receiving mode. The electrical
recording signals used to transmit the fault information.

4.2.3). Inspection of Pressure Vessel :-

The objective of inspection program for pressure vessel is to make sure the vessel is safely
operated and maintained. The purpose of regular inspection of pressure vessels is:  To
improve the reliability

• To reduce operation and maintenance costs

• To reduce liability
• To minimize unscheduled outages
• To prevent damage to environment
• To improve facility, personal and public safety

 External Inspection for the Pressure Vessel :- The external inspection for pressure
vessel is the overall inspection of pressure vessel. It provides information concerning:

• Vessel attachments: Any expansion or contraction of the structural attachments put on the
pressure vessel is extensively examined. For unopposed saddle foundation and slotted bolt
holes, enough tolerances are required. The welds on these attachments are carefully inspected
for any fractures or deformities.

• Connections to the vessel: Nozzles, manholes, flanges, valves, and reinforced plates are
vessel connections that are rigorously inspected for any fractures, flaws, or deformations. It is
important to check bolts and nuts for corrosion or other flaws. The weep holes in the case of
reinforcing plates are meant to be opened for the visual inspection of leaks and to shield the
vessel and reinforcing plates from accumulating pressure. To ensure that the gasket is in the
proper place and to check for distortion in flanges, the
• Insulation or Other Coverings: When the vessel is coated with an external covering
such as insulation or corrosion resistance, a small section of the covering is removed
and the material and vessel conditions are examined. • Additional conditions: Erosion
on the vessel surface is checked for. Vessel dents are the consequence of surface
deformation brought on by contact with a blunt item, with no metal being harmed.
Some dents can be mechanically repaired by being pressed out. Whenever a defect is
noticed, the whole vessel must be checked. Wall thickness is decreased and large
stress concentrations are produced via cuts and grooves. The region must be repaired,
either by patching or welding, after determining the extent of the fault. Grinding is a
technique used to get rid of certain minor
• Surface inspection: Surfaces of vessels must be examined to see if they have cracks,
bulging, bulges, or other dislocations. The heads and shells should all be checked, as well as
the saddle supports.
• Welded Joint: Cracks and other flaws should be checked for in the weldment as well as any
nearby heat-damaged regions. Exams using magnetic particles and liquid penetrant are more
beneficial for this aim.
• Leak Test: The vessel must be carefully examined for any liquid or gas leaks. Any prior
leakage must be carefully checked if one develops after the insulating covers of the vessel
supports. Until the source is turned on, the covering may need to be removed.

 Internal Inspection for the Pressure Vessel :- Internal pressure vessel inspections are
performed only when ultrasonic inspection testing results of wall thickness state that
some wall thin happens or when the equipment is not approved to show true thickness
of walls for shell and dished ends. Cracks, corrosion, degradation, lamination, and
hydrogen blistering are all checked on all parts.
• Vessel Connection: All external fittings and controls welded to any aperture must be
thoroughly examined to ensure they are free of obstructions. Thread connections are
inspected to ensure that enough threads are given.
• Vessel closure: For significant decontamination closures, quick opening closures that are
utilised to operate the pressure vessel are rigorously tested for wear and sufficiency. Cracks
are also looked for in areas of significant stress concentration.

• Corrosion: There are a few severe corrosion spots in a pressure vessel, such as the liquid
level, the bottom area, and the shell area near the input nozzles. Aside from them, the welded
seam, nozzles, and weld regions are frequently affected by elevated corrosion levels.
It would be helpful if data is collected for vessels of similar functioning to locate and analyze
corrosion in the equipment for inspection.

4.2.6) Inspection and Test Record :-

The document, which must be attached to the reports of the inspection and testing, attests to
the completion of all necessary tests and inspections. The document in Fig. 4 is in accordance
with the particular form used by the third party inspectors. After the procedure is complete,
the document has to be signed while all parties are present for an inspection.

4.2.7) Methyl Chloride Rundown Tank Installation :- Processed is the pressure vessel that
will hold the liquid form of methyl chloride. The pressure vessel is created and developed in
accordance with ASME standards. According to the ASME code's criteria for quality testing,
the pressure vessel passes all of its tests. The vessel has a process certification.

As seen in fig. 5, the pressure vessel is set up at the SRAAC Company facility of
chloromethane as a rundown tank for methyl chloride storage. The dilapidated tank is
positioned atop a 4.5-inch-high base foundation.
 CHAPTER – 5 MECHANICAL PRESS :-

5.1 ) PRINCIPLE :-

Flat or V-belts are used to transfer power from the engine to the flywheel. V-belts are used
the most frequently because flat belts might slip and cause losses. The flywheel drive shaft
does not revolve when the clutch is not engaged. The clutch-brake liner interacts with the
flywheel when air is given to the clutch brake assembly at a specific air pressure, which
causes the drive shafts to begin rotating. The eccentric shaft's opposite end has teeth cut into
it that mesh with a bigger gear installed on it. Therefore, when the pinion shaft rotates, the
connecting rod or pitman, which is positioned on the eccentric part of the shaft, transfers the
motion to the eccentric shaft.. In this way, rotating motion of the motor is converted in to
reciprocation motion of the slide.

Fig, 5.1 Mechanical presses at ISGEC ( Source – ISGEC )

5.2 ) ADVANTAGES :-
 • More rapid manufacturing than a hydraulic press.

• Simple upkeep.

• Fit for operations like punching, blanking, and trimming when the load is suddenly
released at the conclusion of the cutting stroke.

• Simple integration with robotic material handling equipment.

 Press overload is a possibility. There must be a safeguard against overload.

5.3 ) STEPS TO INSTALL MECHANICAL PRESS :- ( H – frame Mechanical press)

STEP 1 :- Constructing foundation as per press manufacturer Drawing :-

Fig 5.2 Drawing of Foundation ( Source – ISGEC )

STEP 2:- Fixing of base plate :-

Purpose of Base Plate: - Using base plates, the press may be installed on the cast pillars
on a level, flat surface. It has 5 centre holes to fill the GP2 (Grout in Powder Non
Shrinkable Type) which function and 4 holes on the corners to level it.

Fig. 5.3 Base Plate ( Source – ISGEC )

bonding agent between the base plate and the cast pillars. The base plate should be
made of MS. In the figure above, there is a second hole for the foundation bolt that is
used to secure the press using foundation bolts. This hole serves no use if we are
utilising an anti-vibration mount. Before placing the weight on the base plate, wait 48
hours.

STEP 3 :- Positioning of AVM ( Anti- vibration Mount) :-

Before installing the AVM, clean the upper face of the base plate well. To maintain the
centre distance between the anti-vibration mounts, mark the base plates according to
the picture. Keep a gap (about 100mm) on the base plate where a jack may be placed
for the press's final levelling and future maintenance. Use an adhesive pad on the
AVM's bottom and top faces.
 Fig. 5.4 – AVM ( Source – ISGEC )

STEP 4 :- Placing of Lubrication and Air Tanks:

Place the pit material in the pit before installing the bed on foundation i.e. lubrication
and air tanks as per the foundation drawing.

STEP 5 :- Placing and levelling of bed :-

Before installation, carefully unload and clean the Bed. Use the appropriate slings and clamps
for the load. As the foundation arrangement, place the Bed on the AVMs. Before putting the
die cushion, make sure the bed is level. (That is, within 0.1 mm.)

STEP 6 :- Installation of die cushion :-

Fig. 5.5 – Die Cushion ( Source – ISGEC )

Die cushion was put from the top after the bed had been placed. This design differs from the
ones we employ in our other mechanical presses in that the die cushion is positioned before
the bed. Die Cushion is equipped with a damper at the bottom to dissipate vibration and
lessen noise caused by metal contact.

STEP 7 :- Placing of Moving bolster :-

Moving Bolster is used to place the Die on it and is capable of moving Left to Right for
loading and unloading of Die. The no. of MB is two to reduce Die change over time.

Fig. 5.6 – Moving Bolster ( Source – ISGEC )

STEP 8 :- Fixing of tie rod and columns :-

The crane placed each of the four tie rods into the bed one at a time. The press's components
(Bed, Column, and Crown) are tied together into a single unit using tie rods. Tie rods are
made of a material type that can bear vibrational loads. To lubricate and run the press,
uprights have pneumatic and electrical pipework, electrical wiring, an HMI, and a push-
button control station. Additionally, it has slide guiding mechanisms that regulate how
parallel and perpendicular the slide is to the bolster plate.

Fig. 5.7 – Tie Rod ( Source – ISGEC )

STEP 9 :- Placing of slide :-

Upper Die is held in position by a slide, which also transfers power from the eccentric gear to
the lower Die, which is resting on the bolster plate. It has a motor that allows the slide to be
adjusted using worm gears and universal joints, enabling the use of Dies with various shut
heights. Additionally, it has a hydraulic over load component that is useful when a die jams
and when there is an excessive load on the die. Oil at the bottom of H.O.L. returns to the oil
tank when it is overloaded by the Haskell pump and dump valve, assisting the slide's upward
motion (20 – 30 mm). There are hydraulic clamps in the slide to clamp the upper die.

Fig. 5.8 Slide of mech. Press ( SOURCE – ISGEC )

STEP 10 :- Placing of counter balance weight cylinder :-

If the press break fails, the slide weight is counterbalanced with counter balancer cylinders to
prevent a fall. It contains that much air pressure in order to balance the top die weight and
slide weight. Additionally, less air causes the clutch to wear out faster since the clutch has to
work harder to raise the slide. has to work more in lifting the slide.

STEP 11 :- Placing of Crown :-

The crown is the very top of the press. It delivers the motor's power to the slide where the
upper die is mounted. Crown functions like a gearbox with several gears that convey motion
and power. Additionally, it slows down motion. The flywheel is connected to the primary
motor, which is situated on top of the crown, by pulleys and belts.

On the main shaft, the flywheel is placed. Because of its link to the motor, the flywheel is
continually rotating. Breaks are constantly in contact with the main shaft when this
circumstance exists. When the clutch is engaged, the break releases, allowing the main shaft
to send power to the idler gear and one intermediate gear.

The idler gear powers the second intermediate. The power is then further transmitted to the
eccentric gear via the pinions on the intermediate gear. The connecting rod that slides through
is attached to the eccentric gear. As a result, the reciprocating motion of the slide is created
from the eccentric gear's rotating motion.

Fig. 5.9 Crown Placed ( Source – ISGEC )

STEP 12 :- Fixing of connecting rod , flywheel , brakes and clutches.:-

When necessary, the flywheel may provide the gear throw clutch with stored energy by
rotating via rubber belts and motor power. Today, we use a single clutch and brake unit that
is powered by hydraulic oil.
5.4 ) FUNCTIONS OF VARIOUS COMPONENTS :-

5.4.1 Die Cushion :-

A large pressurized cylinder located in or under a die block or bolster to provide
additional pressure or motion for stamping.

5.4.1.1 ) Need for a Die Cushion :-

1. To prevent slip and wrinkling during forming from a blank.

2. Uniform pressure over entire blank.

3. Uniform pressure throughout entire stroke.

4. Easy adjustment with changing jobs.

Two kinds of die cushions are used

Pneumatic
Hydro-Pneumatic

Most people utilise pneumatic die cushions. A pneumatic die cushion has a standard air
pressure of 45 kg/cm2. Up to three cylinders can be used in tandem to increase the pressure
in a pneumatic die when necessary.

You can only use a hydro-pneumatic die cushion for one step. In a pneumatic die cushion,
the blank holder pressure and knock out pressure are the same; however, in a hydro
pneumatic die cushion, the knock out pressure is only around one sixth of the blank holder
pressure.

5.4.2 Clutches and Brakes

Clutch and brake assembly are used in mechanical presses. Electric brake and clutch
assemblies are equipment drive parts that combine electric brakes and electric clutches to
slow or stop shafts and connect or detach shafts, respectively. Power is transferred from
an engine to components like a gearbox and drive wheels when the clutch is engaged.
Clutch disengagement halts power transfer but permits the engine to keep running. The
connected shafts' motion is slowed or stopped by braking utilising permanent magnets,
hysteresis, eddy current, or magnetic particles.

A flywheel is included with each mechanical press to store energy. A clutch transmits power
to the slide while the flywheel rotates continuously on the main shaft at the idle position of
the stroke. Positive friction and eddy current clutches are available.

An essential component of a press is a brake. It helps the clutch, ensuring the press operates
safely and effectively. A press might experience a serious breakdown due to a broken brake.
The time delay in either scenario is referred to as the time lag. When the press starts, the
clutch must engage only after the brake has been released, and when the press ends, the
brake must act only after the clutch has been disengaged.
Usually, the only controls available for the clutches are stop and start. There are mechanical
controls so that the press cycle may either be continuous or intermittent. Numerous
additional unique features have been incorporated into the design of this clutch so that it can
adapt to almost any situation.

5.4.3 Various Modes of Run :-

5.4.3.1) Inch mode :-

Inch controls is mainly used for setting up the tools and allows the press to run only when
inch button is pressed. When inch button is released press stops. It is the most common mode
of operation.

5.4.3.2) Single auto mode :-

In this mode press run one complete cycle.

5.4.3.2) Continuous mode :-

In this mode press run for predefined number of cycles. The press must be equipped with
automatic feeder.

5.4.4 Slide Adjuster :-

To vary the die height, the bottom face of the slide is moved using a slide adjuster. The
threaded coupling component between the connecting rod and slide is turned to make
adjustments. On presses with a modest capacity, adjustments are often made manually
using a turning rod and other appropriate tools. However, an electric and air motor is
used to do this for presses with medium and big capacity.

5.4.5 Counter Balance Cylinders :-

The slide typically weighs 5 to 20 tonnes and acts in a downward direction, so as the
press moves higher, the weight is opposing the mechanical force. As a result, the power
demand is relatively low during the downward stroke and very high during the upward
stroke. Therefore, a motor with a big range is needed, which is not feasible. The slide is
kept in equilibrium, meaning that the weight of the slide must be zero, to prevent this
problem. Counterbalance cylinders are employed for this purpose.
On both sides of the slide, the counterbalance cylinders are placed. An individual piston
and piston rod make up each cylinder. The piston rod's opposite end is attached to a
slide.

The air pressure within the cylinder changes as the cylinder's area is fixed to achieve
balance. An air tank is used to replace the air that is delivered to the cylinder, and a
pneumatic pump is used to bring high pressure air into the air tank. The counterbalance
cylinder is equipped with a pressure switch and a spring-loaded valve. The valve opens
when the counterbalance tank reaches a particular acceptable value, allowing extra air to
escape. In a similar manner, the pressure switch shields the tank from excessive pressure.
Pressure switches controls when it exceeds the allowable value, and the press ceases to
function.
5.4.6 Knockout Device
A knockout device is used at the conclusion of a forming process to separate the formed
product from the die. There are three types of knockout devices
Mechanical
Pneumatic
Hydraulic

A knockout device is normally fitted to the slide of the press, however, in a forging press
it is fitted to the head size.

5.4.7 Flywheel Brake

When the main motor power of a medium or a large capacity press is cut off, the
flywheel continues to turn for a considerable time under its own inertia. To stop the
flywheel the brake is engaged directly to flywheel rim.

5.5 ) INSPECTION OF PRESSES :-

To maintain the quality of presses, its inspection is very strictly performed. The common test
performed is Dye penetrant inspection (DPI). Skilled high level supervisors are employed to
maintain the quality of the product,

 Dye Penetrant Inspection :-

A popular and inexpensive inspection technique used to find surface-breaking flaws in all
non-porous materials is dye penetrant inspection, also known as liquid penetrant inspection
or penetrant testing (metals, plastics, or ceramics). Both ferrous and non-ferrous materials
can be penetrated by the penetrant, while magnetic-particle examination is frequently utilised
for ferrous components due to its capacity to identify subsurface materials. LPI is used to
find surface flaws in casting, forging, and welding, including hairline cracks, surface
porosity, leaks in fresh products, and fatigue cracks in components already in use.

5.5.1 ) Principles :-

DPI is based on capillary action, in which fluid with low surface tension permeates
through spotlessly dry and clean surface-breaking discontinuities. Applying penetrant to
the test component can be done by dipping, spraying, or brushing. The surplus penetrant
is removed once enough time has passed for penetration, and then a developer is used.
The developer assists in drawing penetrant from the fault where an inspector may see an
unseen indication. Depending on the type of dye used—fluorescent or not—inspection is
conducted under ultraviolet or white light (visible).
 Fig.5.10 1. Section of material with a surface-breaking crack that is not visible to
the naked eye.
2. Penetrant is applied to the surface. 3. Excess penetrant is removed.
4. Developer is applied, rendering the crack visible.

5.5.2 ) Inspection steps :-

5.5.2.1.) . Pre-cleaning :-
Any debris, paint, oil, grease, or loose scale that might either prevent penetrant from reaching
a fault or result in irrelevant or erroneous signals is removed from the test surface. Solvents,
alkaline cleaning procedures, vapour degreasing, or media blasting are some cleaning
techniques that can be used. The outcome of this phase should be a clean surface that is dry,
devoid of contaminants, and where any faults are visible on the surface.

5.5.2.2) Application of Penetrant :-

The surface of the object being tested is then covered with the penetrant. The penetrant is
given time to linger so it can penetrate any defects (generally 5 to 30 minutes). The material
being tested, the penetrant being employed, and the magnitude of the sought-after faults are
the key determinants of dwell time. Smaller faults necessitate a longer penetration time, as
predicted. One must be careful not to apply a solvent-based penetrant to a surface that will be
examined with a water-washable penetrant due to their incompatibility.

5.5.2.3) Excess Penetrant Removal :-

The surface is then cleaned of the extra penetrant. The kind of penetrant employed
determines the removal technique. Common options include those that are water-washable,
solvent-removable, lipophilic post-emulsifiable, or hydrophilic post-emulsifiable. The most
sensitive substances are emulsifiers, which work chemically with the oily penetrant to make
it sprayable with water. It's crucial to avoid immediately spraying the solvent on the test
surface while using a lint-free cloth and solvent remover since doing so might wash away the
penetrant from the defects. Once the developer is applied, if the excess penetrant is not
thoroughly removed, it may leave a background in the developed region that might conceal
signs or flaws. Additionally, this can result in erroneous indicators that seriously impair your
capacity to do an adequate inspection.
5.5.2.4) Application of Developer :-

A white developer is then put to the sample after any extra penetrant has been cleaned off.
There are several developer types available, including dry powder, non-aqueous wet
developer, water suspendable developer, and water soluble developer. Developer selection is
influenced by both inspection requirements and penetrant compatibility (water-soluble or
suspendable developers cannot be used with water-washable penetrants). In contrast to
soluble and suspendable developers, which may be applied with the portion still damp from
the preceding phase, nonaqueous wet developers and dry powder require that the sample be
dried before application. On the surface, the developer should create an even, semi-
transparent layer.

Developers create bleed-out, or visual indications, by drawing penetrant from flaws out onto
the surface. Any regions that leak out can reveal the position, direction, and potential nature
of surface flaws. The indication size is not the same as the real size of the defect, thus it may
need some training or expertise to interpret the data and characterise flaws based on the
indications obtained.

5.5.2.5). Inspection :-

For visible dye penetrant, the inspector will use visible light with a sufficient intensity (100
foot-candles). Low ambient light levels (less than 2 foot-candles) and sufficient ultraviolet
(UV-A) radiation with an intensity of 1,000 microwatts/cm2 or more are required for
fluorescent penetrant tests. The test surface should be examined following a 10-minute
development period. The blotting action is made possible by this delay in time. When
utilising visible dye, the inspector may examine the sample to look for indicator
development. It is also a good idea to keep an eye out for signs as they emerge since the
features of the bleed out have a big role in how defects are interpreted and characterised.

5.5.2.6) Post Cleaning :-

The test surface is often cleaned after inspection and recording of defects, especially if post-
inspection coating processes are scheduled.

5.5.3 Advantages and Disadvantages :-

• The main advantages of DPI are the speed of the test and the low cost.
 • The main disadvantages are that it only detects surface flaws and it does not work on
very rough surfaces. Also, on certain surfaces a great enough color contrast cannot be
achieved or the dye will stain the work piece

Fig. 5.11 – DPI Schematic diagram ( Source – Internet)

5.5.4 Standards for DPI :-

International Organization for Standardization (ISO)

• ISO 3059, Non-destructive testing - Penetrant testing and magnetic particle testing -
Viewing conditions

• ISO 3452-1, Non-destructive testing. Penetrant testing. Part 1. General principles

• ISO 3452-2, Non-destructive testing - Penetrant testing - Part 2: Testing of penetrant

materials

• ISO 3452-3, Non-destructive testing - Penetrant testing - Part 3: Reference test blocks

• ISO 3452-4, Non-destructive testing - Penetrant testing - Part 4: Equipment

• ISO 3452-5, Non-destructive testing - Penetrant testing - Part 5: Penetrant testing at

temperatures higher than 50 °C

• ISO 3452-6, Non-destructive testing - Penetrant testing - Part 6: Penetrant testing at

temperatures lower than 10 °C

• ISO 12706, Non-destructive testing - Penetrant testing – Vocabulary

• ISO 23277, Non-destructive testing of welds - Penetrant testing of welds -

Acceptance levels
American Society of Mechanical Engineers (ASME)

• ASME Boiler and Pressure Vessel Code, Section V, Art. 6, Liquid Penetrant
Examination

• ASME Boiler and Pressure Vessel Code, Section V, Art. 24 Standard Test Method for
Liquid Penetrant Examination SE-165 (identical with ASTM E-165)
RESULT
REFERENCES