Get Presentation of Summer Training In Durgapur Steel Plant ( SAIL). Special focus on Wheel and Axle Plant

1. STEELAUTHORITY OF INDIA LIMITED
PRESENTATION OF INDUSTRIAL TRAINING AT
DURGAPUR STEEL PLANT
DURATION: 26TH MAY TO 26TH JUNE
BY
RITAM BHATTACHARJEE
DEPARTMENT OF MECHANICAL ENGINEERING
SURESH GYAN VIHAR UNIVERSITY

2. WHAT I LEARNT IN DURGAPUR STEEL
PLANT……
1. DIFFERENT MANUFACTURING PROCESSES INVOLVED IN INDUSTRY.
2. HOW DIFFERENT TYPE OF WHEELS ARE MADE IN WHEEL AND AXLE PLANT.
3. PRACTICAL EXPERIENCE OF THE PROCESSES STUDIED IN BOOKS.
4. MANAGEMENT ABILITIES.

6. USES OF STEEL
A. USED IN BUILDING.
B. BUSES AND CARS.
C. BRIDGES AND FLY-
OVERS.
D. AIRCRAFT.
E. WHEELS AND AXLES.
F. ALL TYPES OF
MACHINERY

19. WHEELAND AXLE PLANT

20. PLANT DESCRIPTION
 Set up in late 50’s.
 Initial annual capacity of 1 million tons of crude steel per year, the capacity of Durgapur
Steel plant (DSP) was later expanded to 1.6 million tons in the 70's.
 Enhanced the capacity of the plant to 2.088 million tons of hot metal.
 1.8 million tons crude steel .
 1.586 million tons saleable steel.
 The entire plant is covered under ISO 9001: 2000 quality management system.
 DSP’s Steel Making complex and the entire mills zone, comprising its Blooming & Billet
Mill, Merchant Mill, Skelp Mill, Section Mill and Wheel & Axle Plant, are covered under
ISO: 9002 quality assurance certification.
 Plant covering an area 6.4 km.
 It is situated at a distance of 158 km from Calcutta, It is situated on the banks of the
Damodar river.
 It is The only plant in all over India which manufacture Forge Railway Wheels for Indian
Railway

21. RAILWAY WHEELS
 Wheels are most critical part of rolling stock. Utmost care is taken right from the
manufacture to its last use on the trains. Wheels are most stressed components of
railway vehicles.
 Different functional parts of the wheel (as shown in Fig 1 below) such as flange (4), rim
(3), centre (2) or hub (1) fulfill different task and have therefore different material
properties.
 Railway wheels are usually made of unalloyed or low alloyed steels with a high degree
of purity. Tight tolerances for the single alloying elements are desired in order to assure
a low variation of material properties from heat to heat.
 European standard EN 13262 defines four different steel grades which mainly consist of
up to 0.6wt% of carbon, up to 0.8 wt% of manganese and up to 0.4wt% silicon. National
and international standards such as UIC 812-3V, GOST 10791, AAR M107-84, EN
13262 define the wheel steel grades and partly their manufacturing.

22. MANUFACTURING PROCESS
• STEEL MAKING PROCESS:-Steel
for the production of railway wheels is
melted in the electric furnace at
3200deg F with the charge of 250
tonnes and tapping in two ladles. High
quality characteristic of steel is
provided by the subsequent processing
at the out of furnace complex of steel
treatment.
• WHEEL MANUFACTURING:-
From electric furnace molten metal is
transferred to ladle which pours metal
in graphite moulds to make ingots.
Each ingot is approximately 20 feet
long. Ingots are then cut into small
pieces called billets. Each weight
around about 1000 pounds. Billets are
then transferred to rotary furnace
where they are heated to 2400 deg F.

23. The Technology of the Production of Railway Wheels

25. TESTING
DESTRUCTIVE
TESTING
• BRINELL HARDNESS TEST
NON DESTRUCTIVE
TESTING
• ULTA-SOUND TEST
• MPT METHOD

26. MAJOR DEFECTS IN
WHEELS
1. WEAR
2. HOLLOW WHEEL OR DEEP
FLANGE
3. RADIUS TOO SMALL AT THE
FOOT OF THE FLANGE
4. THIN FLANGE
5. THIN WHEEL
6. SHARP FLANGE
7. FLAT WHEEL
8. ROLLING CONTACT FATIGUE

27. FACTORS AFFECTING WHEEL LIFE
Static stress in the wheel treads
Maximum train speed
Braking requirements
Track conditions
Design and condition of equipment

32. THANK YOU