HERO CYCLES(C.R.

DIVISION) PLANT OVERVIEW

PRESENTED BY: P.N.MISHRA

COMPANY PROFILE

DATE OF COMISSIONING PLOT AREA BUILT UP AREA

JULY 1991 12 ACRE 9 ACRE

HERO GROUP COMPANIES

HERO CYCLES LTD. HERO HONDA LTD. MUNJAL SHOWA MUNJAL CASTINGS MUNJAL AUTO ROCKMAN CYCLE MAJESTIC AUTO HERO CYCLES - C.RD HERO MOTORS SUNBEAM CASTING

BICYCLE MOTOR BIKE SHOCK ABSORVERS NON FERROUS CASTINGS AUTO PARTS AUTO & BICYCLES CHAIN MOPED CR STEEL STRIPS HERO PUCH NON FERROUS CASTINGS

HERO GROUP COMPANIES

HERO MINDMINE HERO TECHTOUCH HERO SERVIT

TRAINING & EDUCATION ERP/SAP IT

PRODUCT

COLD ROLLED THICKNESS WIDTH GRADE FINISH SHAPE WEIGHT

STEEL STRIPS 0.15 - 5.0 MM 20 - 760 MM D/DD/EDD/IF/MC-11/12/HC BRIGHT/DULL COIL/SHEET 150-12000 KGS

LIST OF SEGMENT

BICYCLE INDUSTRIES AUTOMOTIVE INDUSTRIES ELECTRICAL INDUSTRIES CONTAINER INDUSTRIES WHITE GOODS INDUSTRIES TRACTOR INDUSTRIES PICTURE TUBES COSMETIC ITEMS

UTILITIES

CONNECTED LOAD CONTRACT DEMAND

19228.23 KW 12500KVA

H.R.SLITTER

TO CUT THE WIDE COIL INTO NARROW COILAS PER THE REQUIREMENT OF COLD ROLLING MILL TO CONTROL THE O.D. OF THE COIL AS PER THE REQUIREMENT OF MILL IN CASE OF SINGLE SLIT TO REMOVE THE CRACKED / DAMAGE EDGE

H.R.SLITTER
PINCH ROLLER FLATTNER ROLLER DEFLECTORS

GUIDE ROLLS SHEAR UNIT SCRAP WINDER UNCOILER ARBOR

RECOILER

DIRECTION OF OPERATION

DEFECTS IN H.R. COILS

SLIVERS SEAM LINES ROLLED IN SCALE PITTING LAMINATION CENTRE LOOSENESS

PICKLING MACHINE
PICKLING IS THE PROCESS OF MILL SCALE REMOVAL WITH THE HELP OF ACID H2SO4 , HCL , HF , HNO3 HCL IS USED FOR THE PICKLING OF CARBON STEEL HCL PICKLING PROVIDES SMUT FREE SURFACE SUITABLE FOR COLD ROLLING , ELECTROPLATING , ETC

PICKLING
PINCH ROLLER BREAKER UNIT STRIP DRYER SHEAR UNIT ACID TANKS FLATTNER ROLLER

RINSE TANKS BURR MESHER UNCOILER

RECOILER

ROLLING

COLD ROLLING IS THE PROCESS OF THICKNESS REDUCTION WITH THE HELP OF ROLLS AT ROOM TEMP

HEAT IS GENERATED IN THE PROCESS OF COLD ROLLING HENCE FOR THE COOLING OF ROLLS AND STRIP COOLANT IS USED

Cont....

ROLLING

THE PURPOSE OF COOLANT IS ALSO TO IMPART ANTI RUSTING PROPERTIES TO THE SHEET AND THE ROLLED ROLLING LEADS TO INCREASE OF THE STRIP HARDNESS SURFACE FINISH IMPROVES AND GAUGE VARIATION BECOME UNIFORM

4HI MILL
BACKUP ROLLS STRIP

NG

NG

WORK ROLLS DEL. TENSION REEL

PAY OFF REEL

ENTRY TENSION REEL

6HI MILL
BACKUP ROLLS I.M.R.

NG

NG
W.R.

E.T.R P.O.R

D.T.R.

SKIN PASS 2HI MILL

SKINPASS: IT HELPS IN IMPARTING FLLATNESS TO THE COIL DECREASE HARDNESS OF COIL. REMOVES WRINKLES OF COIL REMOVES STRESSES FROM WITHIN THE COIL.

2HI MILL

COIL STRIP

SHEAR UNIT

RECOILER

WORK ROLLS UNCOILER

ANNEALING
Cold rolling of strip is a work hardening process and renders the strip hard and brittle. There are very few uses of the cold rolled strip in this condition. Annealing is a process of heating, soaking and controlled cooling of coil in a nonoxidizing atmosphere. Metallurgically, the annealing process relieves the stresses developed by Cold Rolling and renders the strip soft and restores its ductility Cont.. and formability.

TYPES OF ANNEALING

We have two types of Annealing based on the atmospheres used

HNX (95% N2+5%H2) HPH (100% Hydrogen)

100% Hydrogen are the latest built furnaces and the strip that comes out of the furnace is extremely bright in appearance

ANNEALING BASE AND FURNACE

ANNEALING BASE AND FURNACE

ANNEALING BASE AND FURNACE

C.R. SLITTER

C.R.S. unit (1,2,3) is employed for cutting rolled sheet to desired width & length as req. by the customer. It has a number of cutters with spacers in between them so that the desired width of sheet can be obtained. The rolled sheet is mounted on one side of the unit i.e. the uncoiler & is collected on the coiler side with the req. widths.

CUT TO LENGTH (CTL)

Cut to length unit (1,2,3) is req. for cutting the sheet to desired lengths. A cutter that works under pressure does cutting. This is a programmable m/c, which cuts the sheet when it reaches the desired length with pressure. Pressure application capacity is 0-7 Kg/cm^2. Pressure applied is hydraulically controlled. The maximum length cut is 2500mm. The capacity of the machine is 62 Tones / Shift

QUALITY SYSTEM CERTIFICATION

ISO-9001 2000 ISO-14001

PRODUCT SPECIFICATIONS

IS 513 IS 7226 JIS 1641 JIS 3141 DIN 1623 BS 1449 AS PER CUSTOMERS SPECIFICATIONS

PROPERTIES OF VARIOUS GRADES

Stand. Grade Equiv. Grade JIS-3141 SPCC D SPCD DD SPCE EDD Chemical composition C% Mn% Si% S% P% 0.12 max 0.50 max. ----- 0.045 max. 0.04 max. 0.10 max 0.45 max. ----- 0.035 max. 0.035 max. 0.08 max 0.40 max. ----- 0.03 max. 0.03 max.

Al% -------------

Stand. JIS-3141

Grade Equiv. Grade SPCC D SPCD DD SPCE EDD

Mechanical properties Hard (RB) ECV UTS YS 65 max. As 28 min. ---------per 28 min. ---------chart 28 min. -----

Elong. 32 min. 34 min. 36 min.

PROPERTIES OF VARIOUS GRADES

Stand. IS-513 Grade Equiv. Grade D DD EDD Chemical composition C% Mn% Si% S% P% 0.12 max 0.50 max. ----- 0.04 max. 0.04 max. 0.10 max 0.45 max. ----- 0.035 max. 0.035 max. 0.08 max 0.40 max. ----- 0.03 max. 0.03 max.

Al% -------------

Stand. IS-513

Grade Equiv. Grade D DD EDD

Mechanical properties Hard (RB) ECV UTS YS Elong. 65 max. As 27-41 28 max.28 min. 57 max. per 27-37 25 max.32 min. 50 max. chart 27-35 22 max.36 min.

PROPERTIES OF VARIOUS GRADES

Stand. Grade Equiv. Grade BS-1449 CS4 D CS3 DD CS2 EDD Chemical composition C% Mn% Si% S% P% 0.12 max 0.60 max. ----- 0.05 max. 0.05 max. 0.10 max 0.50 max. ----- 0.04 max. 0.04 max. 0.08 max 0.45 max. ----- 0.035 max. 0.03 max.

Al% -------------

Stand. BS-1449

Grade Equiv. Grade CS4 D CS3 DD CS2 EDD

Mechanical properties Hard (RB) ECV UTS YS Elong. 65 max. As 28 min. 14 min. 34 min. 62 max. per 28 min. 14 min. 36 min. 55 max. chart 28 min. 14 min. 38 min.

PROPERTIES OF VARIOUS GRADES

Stand. Grade Equiv. Grade DIN-1623 ST12 D ST13 DD ST14 EDD Chemical composition C% Mn% Si% S% P% 0.10 max --------- --------0.10 max --------- --------0.08 max --------- ---------

Al% -------------

Stand.

Grade Equiv. Grade DIN-1623 ST12 D ST13 DD ST14 EDD

Mechanical properties Hard (RB) ECV UTS YS Elong. 65 max. As 27-41 28 max.28 min. 57 max. per 27-37 25 max.32 min. 50 max. chart 27-35 21 max.38 min.

PROPERTIES OF VARIOUS GRADES

Stand. IS-7226 Grade Equiv. Grade C40 MC-11 C55 MC-12 C70 C80 HC-14 Chemical composition Mn% Si% S% 0.60-0.90 0.15-0.35 0.04 max. 0.50-0.80 0.15-0.35 0.04 max. 0.50-0.80 0.10-0.35 0.04 max. 0.50-0.80 0.10-0.35 0.04 max.

C% 0.35-0.45 0.50-0.60 0.65-0.75 0.75-0.85

P% 0.04 max. 0.04 max. 0.04 max. 0.04 max.

Al% -----------------

Stand. IS-7226

Grade Equiv. Grade C40 MC-11 C55 MC-12 C70 C80 HC-14

Mechanical properties Hard (RB) ECV UTS YS 83 max. ------------85 max. ------------88 max. ------------92 max. -------------

Elong. -----------------

PROPERTIES OF VARIOUS GRADES

Stand.

Grade Equiv. Chemical composition Grade C% Mn% Si% S% P% IF 0.01 max. 0.20 max. ----- 0.02 max. 0.02 max.

Al% -----

Stand.

Grade Equiv. Mechanical properties Grade Hard (RB) ECV UTS YS Elong. IF 50 max. ----25-30 15 - 20 44 min.

THICKNESS TOL. AS PER JIS-3141

Width Thickness (mm) Under 0.25 0.25 - 0.40 0.40 - 0.60 0.60 - 0.80 0.80 - 1.00 1.00 - 1.25 1.25 - 1.60 1.60 - 2.00 2.00 - 2.50 2.50 - 3.15 3.15 & over Under 160 160 - 250 250 - 400 400 - 630 +/- 0.02 +/- 0.025 +/- 0.035 +/- 0.04 +/- 0.04 +/- 0.05 +/- 0.05 +/- 0.06 +/- 0.07 +/- 0.08 +/- 0.09 +/- 0.025 +/- 0.03 +/- 0.04 +/- 0.045 +/- 0.05 +/- 0.05 +/- 0.06 +/- 0.07 +/- 0.08 +/- 0.09 +/- 0.10 +/- 0.03 +/- 0.035 +/- 0.04 +/- 0.045 +/- 0.05 +/- 0.05 +/- 0.06 +/- 0.08 +/- 0.08 +/- 0.09 +/- 0.10 +/- 0.03 +/- 0.035 +/- 0.04 +/- 0.045 +/- 0.05 +/- 0.06 +/- 0.06 +/- 0.08 +/- 0.09 +/- 0.10 +/- 0.11

PERMISSIBLE DEVIATION IN PRODUCT ANALYSIS (IS 513)

C% Mn % Si % S% P%

0.02 0.03 0.02 0.005 0.005

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