INTRODUCTION

H eavy Mechanical Complex (Private) Limited is a leading engineering goods

manufacturing enterprise in Pakistan located at Taxila about 30 Kilometers north of
capital Islamabad. It is a professionally managed progressive organization with over 160,000 sq.
meters covered facilities and 1,100 employees.

HMC have the resources to handle large projects with demanding delivery schedules. Being the
largest and most extensive fabrication and machining facility equipped with state of the art
technology. HMC provide manufacturing services both on our own or customers design.

HMC have gained rich experience in designing and manufacturing of large projects through
collaboration with internationally reputed engineering organizations. All its processing facilities
are in-house including Designing, Fabrication, Machining, Iron and Steel Castings, Forgings,
Heat Treatment, Assembly, Sand Blasting, Painting and Galvanizing etc.

HMC is ISO 9001 certified and is authorized to use 4 ASME stamps U, U2, S & PP for
equipment manufactured according to ASME code. The manufacturing is backed by excellent
quality control and testing facilities to meet the product and customer quality requirements. 3rd
party inspection facilities are also available, where required.

Heavy Mechanical Complex Ltd. (HMC), Taxila is a major heavy engineering subsidiary of the
State Engineering Corporation (SEC) under the Ministry of Industries & Production,
Government of Pakistan.

HMC defines itself as “A technical institute in which all types of machines including Sugar
plants, Cement Plants, Road rollers, Over Head Cranes ranging from 0.5 to 50 tons Heat
Exchanger boilers, Special Defense parts (i.e., NDC works), Special Vibratory Rollers (which
can bear statistically 10 to 12 tons vibratory load) and Pakistan steel

works. Some other processes that are also done by HMC are Designing and manufacturing and
assembling and installation with the certification of ISO – 9001.

The Heavy Mechanical Complex (HMC), the biggest undertaking of its type in Pakistan, was
established in 1979 with Chinese assistance. The Heavy Forge Factory (HFF) at this complex has

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proved crucial for Pakistan's defense production needs. HMC has the capability for designing,
engineering and manufacturing of industrial plants and machinery. HMC has the largest
fabrication and machining facilities in the country equipped with Computer Aided Designing
(CAD) and can undertake a variety of fabrication / machining jobs on sub-contracting basis.
HMC manufactures equipment for hydro-electric power plants, thermal power plants, sulphuric
acid plants, industrial alcohol plants, oil & gas processing plants, and chemical & petro-chemical
plants, etc. Boilers, cranes, construction machinery, material handling equipment, steel structure,
railway equipment, etc. are some of the other products which are produced on regular basis. The
company's capabilities include engineering and manufacturing of Sugar Mills ranging between
1,500 - 12,000 TCD (tons of cane crushing capacity per day), Portland Cement Plants of 700-
5,500 TPD (tons per day) module and White Cement Plant of 50 - 1,000 TPD.

WORKING STAFF
HMC is a professionally managed progressive organization with 1,100 employees.

HMC has a total covered area of 160,000 square feet.

FACTORIES AT HEAVY MECHANICAL COMPLEX

 Heavy mechanical complex I (HMC I)

 Heavy forge and foundry works (HMC II)

 Heavy mechanical complex III (HMC III)

Of these the last one is directly under the ministry of defense while the former two are governed
by ministry of production.

QUALITY POLICY OF HMC

HMC states its quality policy as follows:

“Quality performance is committed to excellence by each company employee. It is

achieved by team work and through a process of continuous improvement.”

“We are dedicated to being seen as an organization which provides quality products and
services which meet or exceed the expectations of our customers.”

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FACILITIES AT HMC
There are several shops in HMC industry.

✔ Design department
✔ Production planning and control (PPC)
✔ Sales department /(PMD i.e. Project Management Department)
✔ Accounts Finance and Administration
✔ Machine shop
✔ Heat treatment shop
✔ Fabrication shop
✔ Forging shop
✔ Hydraulic press shop
✔ Steel foundry
✔ Cast iron foundry
✔ Pattern shop
✔ Maintenance shop
✔ Quality control

PRODUCTION CAPACITY
Machining capacity = 500ton *12 months
Fabrication and Machining capacity= 1000ton *12months
Total = 500*12 + 1000*12 = 6000 tons per annum
This production capacity can be increased time to time with the extension of man power and
other sources subjecting to sub contractors.

HMC PRODUCTS RANGE

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HMC specializes in Engineering, Designing, Manufacturing, Installation and Commissioning of
plants and machinery including;

Cement Plant and Spares: 600-5000 TPD

Sugar Plant and Spares: 500-12000 TCD
Process Plant Equipment: Pressure Vessels, Columns, Heat Exchangers, Drums, Storage Tanks
and Kilns
Chemical & Petro-Chemical Plants: Sulphuric Acid Plant, Basic Chromium Sulphate Plant,
Industrial Alcohol distillery, Gas Dehydration, LPG/LNG, Gas Purification & Sulphur Recovery
Plants.
Industrial Boilers: Fire tube Package units, water tube package units, heat recovery boilers,
begasse fire boilers (capacity up to 200 T/hr
Thermal Power Plants: Equipment for utility boilers, membrane wall, turbine/generator parts.
Hydral Power Plants: Gates, penstocks, wicket gates, head covers, turbine/generator parts
Cranes: Electric overhead travelling crane, portal & mobile cranes.
Road Construction Machinery: Static & vibratory road rollers, asphalt mixing plant.
Steel Structures: For thermal power plants, process plants etc.
Railways Equipment: Railway axles, surface troverser, screw coupling & screw jack.
Castings: Iron & steel castings as per specifications
Forgings: Shafts, rings and others as per specifications
Automotive Forging: For tractors and other automobile

• PRODUCTION PLANNING & CONTROL

The PPC department has been organized with the objective of improving company’s
performance. The dept is headed by a Dy. GM incharge PPC and comprises of the following
sections:

 Core planning / Data processing

 Project planning

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  Material management
A. Material management section (MMG)
B. General store
 Production technology
A. Feasibility / quantitative detail
B. Process planning
C. Tool designing
 Dispatch cell / Material handling
A. Material handling store (MHC)
B. Dispatch cell
 Income tax custom rebate (ICR)

1. SALES ORDER NUMBERING SYSTEM

The sales order numbering system allocates a unique identification system to each order acquired
by the sales and marketing department. This sales order consists of six digits. The first two of
these numbers designate the product group number of the products to be manufactured or
services to be provided by the organization. The next two digits specify the fiscal year in which
the order is received and the last two digits give the number of similar orders already received in
the same fiscal year.
For example, a job order given as 11-10-04 is read as follows
11_______ product group no for sugar spares
10_______represents 2010 as the fiscal year
04_______specifies the fourth order for the current year

That is fourth order of sugar spares in 2010.

2. CORE PLANNING SECTION

 Master schedule planning

 Order activity planning

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  Monitoring all schedules / shop scheduling
 Preparing various reports for MIS
 Maintenance of balance order position.
 Monthly sales and production reports
 Sales / production budget.
 Project review. Meeting and follow up.
 Data entry, loading data and processing data

3. PROJECT PLANNING SECTION

 To ensure receipts of all drawings and documentation from design as per contact
and accelerate the schedule for production and procurement.
 To issue “material purchase requirement” to MMG.
 To prepare “bill of material” to be purchased.
 To co ordinate with the production technology for preparation of necessary
documents for production.
 To prepare and issue job orders and follow up.
 To suggest alternate materials from stock to design.
 To prepare data and reports for ICR and for survey by CBR.

4. MATERIAL MANAGEMENT

A. MMG Section:
 Material requirement planning.
 Indenting and follow up of indents.
 To keep update purchase status for all the project demands.
 Establish stock levels for general consumable items and raw materials.
 Issuance of materials to the appropriate job.
 To keep and maintain update levels for the store items.
 To look after stores and related things.

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B. General Store:

 To receive, issue all the materials, and equipment in stotes as per laid down
procedure.
 Maintain detailed record of store movements.
 Maintain stock location system.
 Maintain daily submission of issue and receipt statement to concerned dept.to keep
store areas secure and organized.

5. PRODUCTION TECHNOLOGY

Feasibility/Quantitative Detail:
 Feasibility study and quantitative details of clients requirements for cost estimate.

Process Planning:
 Prepare details per list, route cards, cutting plans, time sheets and process maps for
all the processes.

Tool Designing:
 Designing of all types of press tools, dies, templates, jigs and fixtures.
 Prepare drawings for machinery components, cutting planes, marking templates for
shops etc.

6. DISPACH CELL
 To receive finished jobs from shops.
 To draw standard items from store for dispatch to customer.
 To organize packing etc.
 To organize transportation.
 Ensure complete accurate documentation with each product.

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 ______________________________________________

• MACHINE SHOP
Machine shop at HMC has following machines

 Gear shaper machine

 Straight bevel machine
 Gear hobbing machine
 Vertical turret lathe machine
 Horizontal lathe machine
 Horizontal vertical slope type boring and milling machine.
 Universal boring, milling, facing, threading, taping machine.
 Plano milling machine.
 Horizontal boring machine.
 Redial drilling machine.
 Column drilling machine.

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  Gear shaper tool machine
 Slotting machine
 BVT boring vertical turret machine
 Face plat lathe machine.
 Double housing planne
 Vertical milling machine.

Gear Shaper
A gear shaper is a machine tool for cutting the teeth of internal or external gears. The name
shaper relates to the fact that the cutter engages the part on the forward stroke and pulls away
from the part on the return stroke, just like the clapper box on a planer shaper. To cut external
teeth, a different machine called a hobbing machine can be used.

Spur Gears
They connect parallel shafts, have involute teeth that are parallel to the shaft and can have
internal or external teeth. They cause no external thrust between gears. They are inexpensive to
manufacture. They give lower but satisfactory performance. They are used when shaft rotates in
the same plane.

Helical Gears
Helical gears connect parallel shifts but the involute teeth are cut at an angle to the axis of
rotation. Two mating helical gears must have equal helix angle but opposite hand. They run
smoother and more quietly. They have higher load capacity, are more expensive to manufacture
and create axial thrust. They have longer and strong teeth. They can carry heavy load because of
the greater surface contact with the teeth. The efficiency is also reduced because of longer
surface contact. The gearing is quieter with less vibration.

Internal Gears
Internal gears are hollow. The properties and teeth shape is similar as of external gears except
that the internal gear had different addendum and dedendum values modified to prevent

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interference in internal meshes. They are designed to accommodate a wide range of equipment.
These are ideal and cost effective. The teeth are cut into the inside diameter while the outside
diameter is smooth. These gears are available only in brass. Internal gear offers low sliding and
high stress loading. They are used in planetary gears to produce large reduction ratios.

When choosing a mating gear the difference between the number of teeth of girth gear and the
pinion should not be less than 15. Their non-binding tooth design ensures smooth, quiet
operation. They are used to transmit rotary motion between parallel shafts, the shaft rotating in
the same direction as the arrangement.

Worm Gears
The Worm gear is the heart of most mills and kiln drive system. They can't be used in spare parts
inventory. They are also used in steel industry, sugar industry, paper and pulp industry. The girth
gear has been preferred over the gearless drives due to their lower initial cost, simplicity to
install, operate and maintain.

Hobbing
Hobbing is a machining process for making gears, on a hobbing machine, which is a special type
of milling machine .The teeth or spines are progressively cut into the workpiece by a series of
cuts made by a cutting tools called a hob. Compared to other gear forming processes it is
relatively inexpensive but still quite accurate, thus it is used for a broad range of parts and
quantities.

It is the most widely used gear cutting process for creating spur and helical gears and more gears
are cut by hobbing than any other process since it is relatively quick and inexpensive.

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 • HEAT TREATMENT AND TTC (TECHNICAL
TRAINING CELL)

Heat Treatment – The Processes

• Annealing
• Normalizing
• Hardening
 Surface
 Full
 Case
• Tempering
• Stress releasing
• Carburizing
 Gas
 Pack
• Phosphating

Heat treatment

“Heat Treatment is the controlled heating and cooling of metals to alter their physical and
mechanical properties without changing the product shape.”

Annealing
Annealing, in metallurgy and materials science, is a heat treatment wherein a material is altered,
causing changes in its properties such as strength and hardness. It is a process that produces
conditions by heating to above the re-crystallization temperature and maintaining a suitable
temperature, and then cooling. Annealing is used to induce ductility, soften material, relieve
internal stresses, refine the structure by making it homogeneous, and improve cold working
properties.

Normalizing
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Annealing, in metallurgy and materials science, is a heat treatment wherein a material is altered,
causing changes in its properties such as strength and hardness. It is a process that produces
conditions by heating to above the re-crystallization temperature and maintaining a suitable
temperature, and then cooling. Annealing is used to induce ductility, soften material, relieve
internal stresses, refine the structure by making it homogeneous, and improve cold working
properties.

In the cases of copper, steel, silver, and brass this process is performed by substantially heating
the material (generally until glowing) for a while and allowing it to cool slowly. In this fashion
the metal is softened and prepared for further work such as shaping, stamping, or forming.

Hardening

Flame Hardening:
A high intensity oxy-acetylene flame is applied to the selective region. The temperature is raised
high. The "right" temperature is determined by the operator based on experience by watching the
color of the steel. The overall heat transfer is limited by the torch and thus the interior never
reaches the high temperature. The heated region is quenched to achieve the desired hardness.
Tempering can be done to eliminate brittleness.

Induction Hardening:
In Induction hardening, the steel part is placed inside a electrical coil which has alternating
current through it. This energizes the steel part and heats it up. Depending on the frequency and
amperage, the rate of heating as well as the depth of heating can be controlled. Hence, this is
well suited for surface heat treatment. The Induction and flame hardening processes protect areas
exposed to excessive wear.

Items that we induction harden include Spur Gears and Spur Pinions ,Helical Gears and Helical
Pinions ,Sprockets ,Internal Gears ,Bevel Gears ,Shafts and Pins ,Rails and Racks ,Wheels and
Rollers Sheave Wheels ,Links ,Axle Boxes and Bushes ,

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Tempering:
Tempering is a heat treatment technique for metals, alloys and glass. In steels, tempering is done
to "toughen" the metal by transforming brittle martensite into bainite or a combination of ferrite
and cementite. Precipitation hardening alloys, like many grades of aluminum and superalloys,
are tempered to precipitate intermetallic particles which strengthen the metal. Tempering is
accomplished by a controlled reheating of the work piece to a temperature below its lower
critical temperature.

The brittle martensite becomes strong and ductile after it is tempered. Carbon atoms were
trapped in the austenite when it was rapidly cooled, typically by oil or water quenching, forming
the martensite. The martensite becomes strong after being tempered because when reheated, the
microstructure can rearrange and the carbon atoms can diffuse out of the distorted BCT structure.
After the carbon diffuses, the result is nearly pure ferrite.

Stress Releasing:
stress releasing is used to reduce residual stresses in large castings, welded parts and cold-
formed parts. Such parts tend to have stresses due to thermal cycling or work hardening. Parts
are heated to temperatures of up to 600 - 650 ºC (1112 - 1202 ºF), and held for an extended time
(about 1 hour or more) and then slowly cooled in still air

Carburizing:
Carburizing, also known as carburization, is a heat treatment process in which iron or steel is
heated in the presence of another material (but below the metal's melting point) which liberates
carbon as it decomposes. The outer surface or case will have higher carbon content than the
original material. When the iron or steel is cooled rapidly by quenching, the higher carbon
content on the outer surface becomes hard, while the core remains soft and tough.[1]

This manufacturing process can be characterized by the following key points: It is applied to
low-carbon workpieces; workpieces are in contact with a high-carbon gas, liquid or solid; it
produces a hard workpiece surface; workpiece cores largely retain their toughness and ductility;
and it produces case hardness depths of up to 0.25 inches (6.4 mm).

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Phosphating:
Phosphate coatings are used on steel parts for corrosion resistance, lubricity, or as a foundation
for subsequent coatings or painting. It serves as a conversion coating in which a dilute solution
of phosphoric acid and phosphate salts is applied via spraying or immersion, chemically reacts
with the surface of the part being coated to form a layer of insoluble, crystalline phosphates.
Phosphate conversion coatings can also be used on aluminium, zinc, cadmium, silver and tin.

The main types of phosphate coatings are manganese, iron and zinc. Manganese phosphates are
used both for corrosion resistance and lubricity and are applied only by immersion. Iron
phosphates are typically used as a base for further coatings or painting and are applied by
immersion or by spraying. Zinc phosphates are used for rust proofing (P&O), a lubricant base
layer, and as a paint/coating base and can also be applied by immersion or spraying.

LIST OF APPARATUS

Electric Furnaces:-

1. Car bottom furnace

Max. temp = 950oC
Size =900 x 700 x 1800

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 Plotter and temperature indicator is attached with it.

2. Box type air furnace

It is small and large.
Max. temp = 950oC
Size =600 x 500 x 1200

Max. temp = 950oC

Size =450 x 450 x 950

3. Pit type tempering furnace

Max. temp = 950oC

4. Salt bath furnace

Small, medium, large
Temp = 550-650oC
Size =300 x 400 x 500

Temp = 700-900oC
Size =300 x 400 x 800

Temp = 1050-1270oC
Size =200 x 300 x 800

5. Flame quenching plant

Vertical : φ1200 x 600
Horizontal : φ 450 x 2400

6.High frequency induction machine

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 It is in isolated room, it uses 10,000 volts. It have a copper ring that induct heat to the
component’s external part, it have a mechanism of movement of job and quenching. Room is
provided with oil and water drum for the purpose of quenching.

7. Cleaner
It is use to wash salt from metal surface after sand bathing.

8.Manual Straightening Press

It is used to straight long and thin metallic sheets.

9. Electric gas carburizing furnace

Temp = 950oC
Size =φ 300 x 600

10. Electric tempering furnace

Temp = 650oC
Size =φ950 x 1220
11. Salt bath
Size =2000 x 2000 x 1400

12. Water quenching tank

Size =1500 x 3000 x 3000

• CTC Fabrication Shop

CTC stands for Central Technical Cell. Basically it is a drawing and planning section of
fabrication shop, in this section different drawings are analyzed and then sent to different
sections of fabrication shop depending upon the job and capacity of the shop.
The main jobs of CTC fabrication are

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  Job feeding to shop
 Planning
 Material check
 Observation from manufacturing till sale.

• FABRICATION SHOP

Basically Fabrication Shop is divided into four sections:

 Heavy bay section,
 Medium bay section,
 Small bay section
 Marking and layout section

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LIST OF APPARATUS AND MACHINES

The machines in the fabrication shop and their capacities are given below:

SMALL BAY
 2.5 ton press
 5 ton bending machine

MEDIUM BAY
 Shaft cutting Circular saw
Cutting Dia 1350mm

 Shaft welding machine

Height of beam 450mm
HEAVY BAY
 3000 ton press
 1000 ton rolling machine
 50 ton capacity cranes

MARKING LAYOUT AND CUTTING SECTION

 Photo cell cutting machine

Electromagnetic or paper templates are used
 CNC cutting machine
A German CNC cutting machine is used for cutting accurate and complex
parts
 Plasma arc cutting machine for non ferrous metals
 Semi automatic cutting machine

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 Oxygen and natural gas are used for cutting
 Mechanical cutting machine(shearing machine)
 Parallel cutting machine
 Trennjaeger machine
 Nine roller
 Straightening machine

Welding

Mainly welding is done in all bays of fabrication shop. The type of welding used in fabrication
shop is as follows:

1. Arc Welding:

Arc welding uses a welding power supply to create an electric arc between an electrode and
the base material to melt the metals at the welding point. They can use either direct (DC) or
alternating (AC) current, and consumable or non-consumable electrodes. The welding region
is sometimes protected by some type of inert or semi-inert gas, known as a shielding gas,
and/or an evaporating filler material. The process of arc welding is widely used because of its
low capital and running costs.

2. Shielded Metal Arc Welding (SMW):

Shielded metal arc welding (SMAW), also known as manual metal arc (MMA) welding or
informally as stick welding, is a manual arc welding process that uses a consumable
electrode coated in flux to lay the weld. An electric current, in the form of either alternating
current or direct current from a welding power supply, is used to form an electric arc between
the electrode and the metals to be joined. As the weld is laid, the flux coating of the electrode
disintegrates, giving off vapors that serve as a shielding gas and providing a layer of slag,
both of which protect the weld area from atmospheric contamination.

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 Because of the versatility of the process and the simplicity of its equipment and operation,
shielded metal arc welding is one of the world's most popular welding processes. It
dominates other welding processes in the maintenance and repair industry, and though flux-
cored arc welding is growing in popularity, SMAW continues to be used extensively in the
construction of steel structures and in industrial fabrication. The process is used primarily to
weld iron and steels (including stainless steel) but aluminum, nickel and copper alloys can
also be welded with this method.

3. Tungsten Inert Gas Welding:

Gas tungsten arc welding (GTAW), also known as tungsten inert gas (TIG) welding, is an arc
welding process that uses a no consumable tungsten electrode to produce the weld. The weld
area is protected from atmospheric contamination by a shielding gas (usually an inert gas
such as argon), and a filler metal is normally used, though some welds, known as autogenous
welds, do not require it. A constant-current welding power supply produces energy which is
conducted across the arc through a column of highly ionized gas and metal vapors known as
plasma.

GTAW is most commonly used to weld thin sections of stainless steel and light metals such
as aluminum, magnesium, and copper alloys. The process grants the operator greater control
over the weld than competing procedures such as shielded metal arc welding and gas metal
arc welding, allowing for stronger, higher quality welds. However, GTAW is comparatively
more complex and difficult to master, and furthermore, it is significantly slower than most
other welding techniques. A related process, plasma arc welding, uses a slightly different
welding torch to create a more focused welding arc and as a result is often automated.

4. Metal Inert Gas Welding:

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 Gas metal arc welding (GMAW), sometimes referred to by its subtypes metal inert gas
(MIG) welding or metal active gas (MAG) welding, is a semi-automatic or automatic arc
welding process in which a continuous and consumable wire electrode and a shielding gas
are fed through a welding gun. A constant voltage, direct current power source is most
commonly used with GMAW, but constant current systems, as well as alternating current,
can be used. There are four primary methods of metal transfer in GMAW, called globular,
short-circuiting, spray, and pulsed-spray, each of which has distinct properties and
corresponding advantages and limitations.

WELDING DEFECTS

Defect found in the welding are

• Cracks Blow holes
• Crack Spatter
• Lack of penetration Undercut
• Pipes Tungsten inclusion
• Porosity Restart of welding
• Lack of fusion
 Slag inclusions

• NON DESTRUCTIVE TESTING LAB

Non destructive test is used to identify the defects in welding joints in the NDT lab of HMC

NON DESTRUCTIVE EXAMINATION FACILITIES

• x-ray radiography
• Gamma ray radiography
• Ultrasonic
• Magnetic particle
• Liquid penetrant

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 • Eddy current
• Spectroscopy

RADIOGRAPHY TECHNIQUES

Following Radiography techniques are possible, but only three type of radiography are used
mostly X-ray, ultrasonic, and gamma ray radiography because other radiography are expensive.
A list of available radiographic methods is given below:
• X-ray Radiography
• Gamma Ray Radiography
• Neutron Radiography
• Proton Radiography
• Xero Radiography
• Fluoroscopy
• Micro Radiography
• Flash Radiography
• Auto Radiography
• Electron transmit Radiography

NDT METHDS APPLICATION AND LIMITATIONS

 Radiography testing Method.

1. Radiography is the most universally used NDT method for detection of gas porosity
in the weldments.

2. The radiography image of a “Round Porosity” will appear as oval shaped spots with
smooth edges, while “elongated porosity” will appear as oval shaped spots with major
axis. Sometimes several time longer then minor axis.

3. Foreign material such as loose scale, flux or splatter will affect validity of test results.

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  Ultrasonic Testing Method

1. Ultrasonic testing equipments are highly sensitive, capable of detecting micro

separations.
2. Surface finishing and grain size will affect the validity of the test.

 Eddy current Testing Method

1. Normally confined to thin wall welded pipes and tube.

2. Penetration restricts testing to a depth of more than one quarter inch.

 Liquid Penetrant Testing Method

a. Normally confined to in processes control of ferrous and non ferrous welds.

b. Liquid penetrant testing is like magnetic particle is restricted to surface
evaluation.
c. Extreme condition must be exercised to prevent any cleaning material and
liquid penetrant materials from becoming entrapped and contaminating the
rewelding operation.

 Magnetic particle Testing Method

Normally used to detect gas porosity .Only surface porosity would be evident. Near
surface porosity would not be clearly defined, since indications are neither strong nor
pronounced.

_________________________________________

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 • FORGING SHOP

“Forging is the term for shaping metal by using localized compressive forces.”

Cold forging is done at room temperature or near room temperature. Hot forging is done at a
high temperature, which makes metal easier to shape and less likely to fracture. Warm forging is
done at intermediate temperature between room temperature and hot forging temperatures.
Forged parts can range in weight from less than a kilogram to 170 metric tons. Forged parts
usually require further processing to achieve a finished part.

PROCESSES OF FORGING

 Open-die drop-hammer forging

 Impression-die drop-hammer forging
 Press forging

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  Upset forging
 Automatic hot forging
 Net-shape and near-net-shape forging
 Induction forging

Of these the first three methods are commonly used in HMC

FUNCTIONS OF FORGE SHOP

 Production of large and medium size forgings.

 Mostly forged parts include railway axles, draw hooks, screw couplings, cement and
sugar plant parts, boiler components, road rollers parts, cranes and drop tank equipments.
 Its annual production is 4500 tons.

FORGING EQUIPMENT
HAMMERS:
 150kg pneumatic hammer
 400kg pneumatic hammer
 750kg pneumatic hammer
HYDRAULIC PRESSES:
 800 ton drawdown type press along with pump, accumulator station and forging
manipulator.
DIE FORGING PRESSES:
 60 ton power press
 160 ton friction press
 400 ton power press
 1250 ton friction press.
CRANES:
 1 ton stationary stewing crane
 5 ton quenching overhead crane

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  12.5 ton overhead crane
 20.5 ton forging crane
OTHER APPLIANCESL
 Shot blasting machine
 Pedestal grinder
 Quenching tanks_____ 2 oil and water (5m* 3m* 5m each)
FURNACES
 Heating furnaces ________ 10
4.84m* 2.08m* 1.5m
Max temp 1300 degree Celsius
 Heat treatment furnace ________ 5
15m* 4m* 6m
Max temp 1050 degree Celsius

• PATTERN SHOP

The purpose of pattern shop is to make wooden or metallic components for casting process.

TYPES OF PATTERN

 One piece or solid pattern

 Two piece or split pattern
 Three piece pattern
 Loose piece pattern.
 Self core pattern.
 Sweep pattern.
 Skeleton pattern.
 Match plate pattern.
 Connecting pattern.
 Master pattern

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TYPES OF CORE PRINTS

 Top print.
 Bottom print.
 Side print.
 Tail print.
 Hang print.
 Balancing print.

TYPES OF CORE BOX

 Box type core box.

 Shake out type core box.
 Gang type core box

MACHINES IN PATTERN SHOP

 Band saw.
 Joint planner.
 Thickness planner.
 Disc and spindle sander.
 Wooden lathe machine.
 Wooden milling machine.

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 • MATERIAL TESTING LABORATORY

The objective of material testing laboratory is to check the chemical composition of different
alloys of iron, copper as well as other non metallic elements. The facility contains the following
laboratories:

 Quick response section.

 Mechanical testing section
 Heat treatment section
 Microscope section
 Wet test laboratory

QUICK RESPONSE SECTION

The quick response section is situated near the steel foundry and it helps the foundry men to melt
different alloys in exact element ratios to get specific allows. It has the facility to inspect the
molten metal from the furnace at intervals and provide the feedback within a few minutes. The
facility has the following apparatus:

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  Emission spectrometer.
 Spectrophotometer.
 Carbon furnace.
 Titration apparatus.

EMISSION SPECTROMETER
This instrument vaporizes the metal by producing an electric spark and then analyses the
spectrum of the resulting vapors to identify the percentage of 26 different metals in the given
alloy. It has the capability to detect both iron based and copper based metals. The elements that
are detected by it include the following:

Carbon, silicon, manganese, phosphorus, sulphur, chromium, molybdenum, aluminum, copper,

cobalt, titanium, vanadium, tungsten, lead, boron, tin, zinc, arsenic, bismuth, calcium, cesium,
zirconium, and iron.

MECHANICAL TESTING SECTION

This testing section includes the following machines:

 Universal testing machine
 Impact test machine
 Brinnel hardness testing machine
 Rockwell hardness tester and Vickers
 Wear testing machine

WET TEST LABORATORY

In the wet test laboratory, we use the element analysis to measure the moisture contents in any
material or a specimen or element.

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