PRESENTATION ON DIFFERENT SECTIONS OF METAL AND STEEL FACTORY ,ISHAPORE,(WEAT BENGAL)

1. METALAND STEELFACTORY,ISHAPORE (A METALLURGICAL
UNIT DEDICATED TO DEFENCE PRODUCTION )
OBJECTIVE : VOCATIONAL TRAINING
PROJECT : REPORT ON SECTIONS ATTENTED DURING
TRAINING
TIME PERIOD : 29/12/2014 to 24/1/2015

2. GROUP MEMBERS
1)MD FAHAD ANWAR
2)VAIBHAV KUMAR
3)MD SHAHID JAMIL
4)MINHAJ AHMAD
5)MD MODDASSIR SHAHAB

3. FACTORY PROFILE
 Metal & Steel Factory Ishapore, under Ordnance Factory Board,
Ministry of Defence, Government of India, is main producer of basic
Ferrous and Non-Ferrous raw material for military Hardwar.
 A high capacity PLC controlled 2650 T Forging Press with fully
integrate an double manipulators gives shape to the products like
gun-barrel & other components of artillery and tank guns. A CNC
controlled Radial Forging Press of 1250T for each hammer can forge
various section and profiles with degree of mechanical properties.
 The factory possesses a hot rolling mill, a high precision combination
cold rolling mill for making the thin strips of ferrous and non-ferrous
material with online X-ray and mechanical gauging system.
 Precision controlled heat treatment facilities impart high mechanical
properties in the metal, making it capable of performance under
conditions of high stress.

4. PRODUCTS OF MSF, ISHAPORE
25 mm
Barrel
20 mm AMR 23mm Schilka
Cartridge Case
Ballistic Cap
Brass Rod
Breech Block Pinaka Tube Steel Cone
Strip Railway Axel
1) Gun Barrels and Forged Gun
Components
2) Rolled Steel Bars/Rods of Ultra
Clean Steel
3) Brass Rods
4) Steel Cartridge Cases of Medium
Calibre

5. Basic processes in making the Final product.

6. MECHANICAL REPAIRING
 It is the section where the mechanical repairing is done, it may be large or
small repairing.
 Most of the machining part is done here and large repairing work including
drilling, repairing of machine tools and damaged machine parts are
restructured here.

7. The most repairing done is the gear .
The machine used for repairing are as:-
a)Milling machine
b)Boring machine
c)Lathe .

8. TOOL ROOM
A tool room is a room where tools are stored or, in a
factory, a space where tools are made and repaired
for use throughout the rest of the factory.
It consists of two sections traditional and non
traditional.
Traditional Section:-
1.Lathe Machine
2.Drilling Machine
3.Grinding Machine
4.Milling Machine
Non Traditional Section:-
1.EDM
2.Wire-Cut EDM
3.ECM etc.

9. Charpy and Izod
test
Impact is a very important phenomenon in
governing the life of a structure. For
example, in the case of an aircraft, impact
can take place by a bird hitting a plane
while it is cruising, or during take off and
landing the aircraft may be struck by
debris that is present on the runway, and
as well as other causes. It must also be
calculated for roads if speed breakers are
present, in bridge construction where
vehicles punch an impact load, etc.
Impact tests are used in studying the
toughness of material. A material's
toughness is a factor of its ability to
absorb energy during plastic deformation.

10. FORGING SHOP
Forging
Forging is a manufacturing process involving the shaping of metal using
localized compressive forces. It is the process by which metal is shaped
by plastic deformation by suitably applying compressive force. Usually the
compressive force is in the form of hammer blows using a power hammer
or a press.
PURPOSE
a)Improve mechanical properties.
Forging can produce a piece that is stronger than an equivalent
cast or machined part. As the metal is shaped during the forging
process, its internal gain deforms to follow the general shape of
the part. As a result, the gain is continuous throughout the part,
giving rise to a piece with improved strength characteristics.
b)Forming the shape
Forging is a type of forming operation. It gives the metal initial
formation that will be further machined to get the desired
formation.
FORGING AT MSF,ISHAPORE
Hot forging of 155mm BOFORS gun barrel is done in two forging
workshops in Metal & Steel Factory, Ishapore.
• RFS(Radial Forging Shop)
• NGF(New Gun Forge)

11. RAW MATERIAL :
ESR produced from methane having diameter 680-700mm is the end length 3m
almost. Maximum weight 7.05 ton.
PROCESS:
Here two types of forging is done they are hollow forging and solid forging.
SOLID FORGING:
• The job remains solid throughout the cross-section.
• After discharging from the furnace the material is immediately taken to the forging
machine.
RADIAL FORGING SHOP (an ultra-modern forging shop of this factory)

12. HOLLOW FORGING:
The most exclusive operation of radial forging machine is to be capable of making
hollow forging.
• It gives the hollow job enough support to withstand the hammering pressure.The
uniformity of the boring diameter is maintained by this process.
• The bloom is forged from temperature 110-950C to soften the metal.
• The mandle which is fitted in the boring region is not made to face such a high
temperature. To avoid this problem the inner surface of the mandle is water cooled
reducing the temperature heat about 40C
• The core region being most hot, it may attach with the mandle, so if the job is now
rotated by manipulator, there may happen twisting effects. As the mandle is
cooled, the inner surface shrinks reducing the chance of twisting.
PRODUCT: Forged barrel (length is7500mm , dia. 430 ending size, 365 initial size)
Why is it termed Radial Forging?
The word ‘radial’ comes from the word ‘radius’. After completion of forging
operation it can transfer a square bloom into a uniform cylindrical shape. This
forging process also supports hollow forging, so it is called Radial Forging.

13. GUN MACHINE SHOP
PROCESS: The machining operation includes
INPUT: Barrels are taken to GMS after forging to make machining operation on it.
Turning operation:
The forged metal contains some scales of oxides. With the help of CNC operated
turning machine these scales are removed. Moreover the forged barrel remains
eccentric. Turning operation also makes the barrel perfect cylindrical.
Boring operation:
After turning the barrel is placed to boring machine. Boring means making hollow
cavity throughout centre axis.

14. Two types of boring operations are done in MSF, Ishapore :
they are :
Tipping :
A hollow rod is produced after boring
Solid:
Only chips are produced after boring
Centering:
A centre is made on the centre axis to hold the barrel while boring
Parting: The parting machine cuts test pieces from two ends of the barrel.
OUTPUT:
BARREL of boring diameter 140mm and length 7061mm.
NOTE:-
As the BARREL is tremendous heavy with a long length, is a need to give
supports in between head tail and bottom tail. These supports are called
rests.
High fluid pressure is maintained to remove chips.

15. GUN HEAT TREATMENT
Heat treatment is a process by which mechanical properties of a material
can be altered. It comprises ‘Heating & ‘Cooling’.
INPUT : Barrel received from GMS

16. PROCESS :
OUTPUT : Heat treated barrel.

17. TESTS
SPECTRO TEST :
INPUT :
Small segment of metal brought from SMR shop.
PROCESS :
1.Take the sample from the SMS.
2.Before test,the samples surface is made smooth by Al oxide paper
3.Spectro test done by spectro machine, manufactured in SWITHERLAND.
OUTPUT-
Chemical composition report of metal.

18. NEW GUN FORGE
INPUT
Ingot or ESR slag
Process
a) At first the raw material that is ingot or slag has to be transferred
into Birlic Furnaces (electric furnace ) or oil fired furnace that is
WES forge II ,Bigbogi ,Tatakorf depending on the condition.
b)After completing 25 or 26 hour heating cycle the raw material
ingot or slag is placed to oil pressed (2650 ton) and there
partially forging process takes place and then the partial forged
material again transferred into oil furnace for near 4-5 hour and
later the material again placed to press for final forging process.
The final product is transferred to the annealing furnace for
releasing its internal stress.
OUTPUT :
Forged barrel

19. CARTRIDGE CASE SHOP
A type of ammunition packing a bullet or shot.
A propellant substance and a primer within
a metallic paper or plastic case.
Used in military forces
Chemical and composition of various cartg. case
Type %C %Mn %S %P %Ni %Cr %Cu %Si %Al
30m
m
.9-
.13
.13M
ax
.3-
.5
.025
Ma
x
.025
Max
.15M
ax
.20M
ax
.20
Ma
x
.03-
.09
23m
m
.18-
.22
.15M
ax
.4-
.6
.02
Ma
x
.02M
ax
.10M
ax
15Ma
x
.15
Ma
x
.03-
.08
20m
m
.15
Ma
x
.4-.6 .02
Ma
x
.02
Ma
x
.10M
ax
15M
ax
.15M
ax
.03-
.08

20. NEW ROD MILL
 In metal working,rolling is a metal forming process in which
one or more rolls metal stock is passed to reduce the
thickness and makes thickness uniform.
 Machines used during process
a) Reeling (straightning) Sheet
b) Peeling (cutting) Sheet

21. MACHINES WHICH ARE USED IN NRM FOR MAKING THE
PRODUCTS ARE:-
• 1.REELING(STRAIGHTNING) SHEET:-This machine is
used for removal of ovality and making straightning of the
rods.
• 2.PEELING (CUTTING) SHEET:-This machine is used for
removal of ovality and making final size of bright rods are
required.

22.  STEELS WITH THEIR ROLLING TEMP.
PRODUCTS:
Rods of dia 20,30,40,50,70 are
obtained.
STEELS ROLLING
TEMP.(Degree Celsius)
1)Low carbon steels 1200-950
2)Medium carbon steels 1200-900
3)High carbon steels 1150-850
4)Tools steels (carbon) 1150-900
5)Tools steels (Alloyed) 1200-900
6)Chromium Molybdenum
steel
1180-850

23. CONCLUSION
MSF DEALS WITH THE PRODUCTION OF BOTH FERROUS
AND
NON FERROUS FERROUS PRODUCTS.
THE FACTORY BELIEVES IN MAKING QUALITY PRODUCTS
IN 5-S
JAPANESE WAY
THE IMPORTANCE OF STEEL IN FUTURE AND DIFFERENT
PRODUCTION WHICH ARE MADE BY STEEL.