Get the idea of writing an Internship report. It's preferred with respect to fonts writing style and other basic parameters.

1. 1
(Internship Program Report)
MOIZ STEEL, DERA ISMAIL KHAN, KPK, PAKISTAN
Submitted by:
Name Muhammad Anas Baloch
Roll No 16ME78
Designation Internee
Department Mechanical
University Mehran University of Engineering & Technology

2. 2
Contents
Introduction to Moiz Steel...................................................................................................................3
Products.............................................................................................................................................3
Introduction To Steel Rebars...............................................................................................................3
History Of Steel..................................................................................................................................3
Types Of Steel....................................................................................................................................4
Process Flow Diagram of Moiz Steel Plant ..........................................................................................5
1. Machine Shop.............................................................................................................................6
(i) Lathe Machine.....................................................................................................................6
(ii) Shaper Machine ...............................................................................................................8
(iii) Milling Machine...............................................................................................................9
(iv) Drilling Machine ............................................................................................................11
2. Drilling.....................................................................................................................................12
Imported Crap in Moiz Steel Industry ................................................................................................12
Melt Shop in Moiz Steel Industry ......................................................................................................13
Continious Casting Machine..............................................................................................................13
Rolling Mill .....................................................................................................................................13
Cold Bar Shearing Machine...............................................................................................................15
Quality Inspection ............................................................................................................................16
ii. UTM Machine ..........................................................................................................................17
Figure: Universal Testing machine.....................................................................................................17
iii. CNC Machine .......................................................................................................................18
Dealing with Environment.................................................................................................................18
Conclusion.......................................................................................................................................18

3. 3
Introduction to Moiz Steel
Moiz Steel industry is located in Dera Ismail Khan, KPK region. It is Pakistan’s most
technologically advanced high speed rebar rolling mill having an annual production capacity of
200,000 MT.
Moiz Steel manufacture grade 60 quality steel rebars with sizes ranging from 10mm to
36mm. Their rebars comply with international standards such as ASTM, BS, DIN, which are
preferred globally for the development of high quality infrastructure.
Moiz Steel has a highly responsive and flexible production capability that can produce
customized solutions. Moiz Steel aim to become the most preferred supplier of quality rebars to
the key customers in the region.
Products
Moiz steel industry produces deformed grade 60 steel rebars.
Introduction To Steel Rebars
Steel is an alloy made from iron and carbon. There are several distinct grades of steel that
have unique chemical compositions based on the different amounts of carbon and added alloys.
Steel is considered one of the major materials used for infrastructure development
throughout the world. Moiz Steel rebars are designed for high strength, high precision and high
surface quality. These rebars have superior bend ability and have better bonding with concrete.
History Of Steel
One of the earliest forms of steel, blister steel, began production in Germany and England
in the 17th century and was produced by increasing the carbon content in molten pig iron using a
process known as cementation. In this process, bars of wrought iron were layered with powdered
charcoal in stone boxes and heated.

4. 4
Types Of Steel
i. Corbon Steel
Carbon steel is dull and matte in appearance and is vulnerable to corrosion. Carbon steel
can contain other alloys, such as manganese, silicon, and copper. There are three main types of
carbon steel: low carbon steel, medium carbon steel and high carbon steel. Low carbon steel is
the most common and typically contains less than .30% of carbon. Medium carbon steel contains
up to .60% of carbon as well as manganese and is much stronger than low carbon steel. High
carbon steel contains up to 1.5% carbon steel and is the strongest of the categories and can often
be hard to work with.
ii. Alloy Steel
Alloy steels are a mixture of several metals, including nickel, copper, and aluminum. Alloy
steels tend to be cheaper and are used in mechanical work, car parts, pipelines, and motors. The
strength and property of alloy steels depends on the concentration of elements they contain.
iii. Stainless Steel
Stainless steels are shiny, corrosion resistant, and used in many products, including home
appliances, backsplashes and cooking utensils. It has a low carbon content Stainless steel
contains the alloy chromium and can also include nickel or molybdenum. Stainless steel is strong
and can withstand high temperatures. There are more than 100 grades of stainless steel, making it
an extremely versatile material that is customizable depending on your purpose.
iv. Tool Steel
Tool steels are hard and heat and scrape-resistant. They are named tool steels because they
are often used to make metal tools, such as stamping, cutting, and mold-making tools. They are
also commonly used to make hammers. There are several different grades of steel that can be
used for distinct applications.

5. 5
Process Flow Diagram of Moiz Steel Plant

6. 6
Mechanical Engineering Workshop
Mechanical workshop is very important in any industry. It ensures the smooth working of
the industry by manufacturing the parts which breaks in the operations of machines, like the
gears, shafts, nut and bolts and many other things. In the Moiz Steel, it has the machine shop,
welding area and grinding area. Machine shop includes the lathe machines, drilling machine,
shaper and drilling machine.
1. Machine Shop
Machining is one of the most important material removal methods in the technology of
manufacturing. It is basically a collection of material working processes that involves other
processes such as drilling, shaping, sawing, planning, reaming, and grinding among others.
Machining is practically a part of the manufacture of all metals and other materials such as
plastics, and wood as well. An important machine that is useful in machining is the lathe
machine.
(i) Lathe Machine
The lathe machine is an important tool used in the machining process, which is an integral
process in the manufacturing technology. A lathe machine is generally used in metalworking,
metal spinning, woodturning, and glass working. The various operations that it can perform
include the following: sanding, cutting, knurling, drilling, and deforming of tools that are
employed in creating objects which have symmetry about the axis of rotation. Some of the most
common products of the lathe machine are crankshafts, camshafts, table legs, bowls, and
candlestick holders.
Bed:
This is usually a horizontal beam that holds the chips.
Headstock:
The headstock contains the high precision bearings which hold the horizontal axle, more
commonly known as the spindle.

7. 7
Spindle:
This is a hollow horizontal axle with interior and exterior threads on the inboard by
which the woodworking pieces can be mounted on.
Tailstock:
This is the counterpart of the headstock which contains a non-rotating barrel that can
slide in and out directly in line with headstock spindle parallel to the axis of the bed.
Carriage:
This is composed of a saddle and an apron and is used as a mount to the cross-slide.
Cross-slide:
This is a flat piece that sits crosswise on the bed which can be cranked at right angles
with the bed.
Tool Post:
Sits on top of the cross-slide and holds the cutting tool in place.

8. 8
Tool Rest:
A horizontal area in line with the spindle and the tailstock from which hand tools are braced
against and levered into the work pieces.
(ii) Shaper Machine
The shaper is a machine tool used primarily for:
1. Producing a flat or plane surface which may be in a horizontal, a vertical or an angular plane.
2. Making slots, grooves and keyways
3. Producing contour of concave/convex or a combination of these
Working Principle:
The job is rigidly fixed on the machine table. The single point cutting tool held properly
in the tool post is mounted on a reciprocating ram. The reciprocating motion of the ram is
obtained by a quick return motion mechanism. As the ram reciprocates, the tool cuts the material
during its forward stroke. During return, there is no cutting action and this stroke is called the
idle stroke. The forward and return strokes constitute one operating cycle of the shaper.
Construction:
The main parts of the Shaper machine is Base, Body (Pillar, Frame, Column), Cross rail,
Ram and tool head (Tool
Post, Tool Slide, Clamper
Box Block).
Base:
The base is a heavy
cast iron casting which is
fixed to the shop floor. It
supports the body frame

9. 9
and the entire load of the machine. The base absorbs and withstands vibrations and other forces
which are likely to be induced during the shaping operations.
Body (Pillar, Frame, and Column):
It is mounted on the base and houses the drive mechanism compressing the main drives,
the gear box and the quick return mechanism for the ram movement. The top of the body
provides guide ways for the ram and its front provides the guide ways for the cross rail.
Cross rail:
The cross rail is mounted on the front of the body frame and can be moved up and down.
The vertical movement of the cross rail permits jobs of different heights to be accommodated
below the tool. Sliding along the cross rail is a saddle which carries the work table.
Ram and tool head:
The ram is driven back and forth in its slides by the slotted link mechanism. The back and
forth movement of ram is called stroke and it can be adjusted according to the length of the work
piece to be-machined.
(iii) Milling Machine
Milling is the machining process of using rotary cutters to remove material from a work
piece by advancing (or feeding) in a direction at an angle with the axis of the tool. It covers a
wide variety of different operations and machines, on scales from small individual parts to large,
heavy-duty gang milling operations.
Milling machines are tools designed to machine metal, wood, and other solid materials.
Milling machines can be positioned in either vertical or horizontal orientation to carve out
materials based on a pre-existing design. Milling machines are capable of dynamic movement;
both of the tool and the work piece, and many milling machines can perform multi-axis
machining. Because of variations in orientation, operation and application, milling machines
have varying functions and different operating principles.
The different tooling used in milling machines is based on material and desired shape.
Because materials like wood and steel have different physical properties, different tool bits are
needed to properly machine the materials. If a milling machine uses a tool bit that is not strong
enough to machine steel, the tooling and even the machine itself can be damaged. Tooling that is
too strong for softer materials can damage the work piece.

10. 10
The basic tooling bit on a milling machine is called the cutter. A cutter is a shaped bar
that has saw teeth. The cutter rotates rapidly to cut down and shape materials. The cutter is
attached to an arbor, which is sometimes called a mandrel or mandrill, a shaped bar that varies in
size, length and ending, and is used to hold the cutter firmly. Knee is an adjustable vertical
casting. The knee supports a saddle and can be adjusted to allow for a customizable workspace.
Fig 3. Milling Machine
A milling cutter’s saw ending can be spaced, sized and oriented in many ways. Generally,
the teeth are either positioned in a straight up-and-down orientation, or angled in a helical
orientation. Straight teeth are preferable in operations on denser materials, while helical teeth can
create very smooth cuts on softer materials. There are a variety of cutters within these categories,
including dense end cutters, t-slot cutters, and angle cutters.

11. 11
(iv) Drilling Machine
The drilling machine is intended for drilling medium to large and heavy work pieces. The
machine consists of a heavy, round, vertical column mounted on a large base. The column
supports a radial arm which can be raised and lowered to accommodate work pieces of different
height. The arm may be swung around at any position over the work bed. The drill head
containing mechanism for rotating and feeding the drill is mounted on a radial arm and can be
moved horizontally on the guide ways and can be clamped at any desired position. These three
movements in a drilling machine can be combined together to permit the drill to be located at
any desired point on the work piece for drilling the hole.
When several holes are drilled on a large work piece, the position of the arm and drill
head is altered so that the drill spindle may be moved from one position to the other after drilling
the hole without altering the setting of the work. This versatility of the machine allows it to work
on large work pieces. The work may be mounted on the table or when the job is large it may be
placed on the floor or in a pit. The figure illustrates a radial drilling machine with its principal
parts.

12. 12
2. Drilling
Drilling is a cutting process that uses a drill bit to cut a hole of circular cross-section in
solid materials. The drill bit is usually a rotary cutting tool, often multi-point. The bit
is pressed against the work-piece and rotated at rates from hundreds to thousands of revolutions
per minute. This forces the cutting edge against the work-piece, cutting off chips from the hole as
it is drilled.
Under normal usage, swarf is carried up and away from the tip of the drill bit by the
fluting of the drill bit. The cutting edges produce more chips which continue the movement of
the chips outwards from the hole. This is successful until the chips pack too tightly, either
because of deeper than normal holes or insufficient backing off (removing the drill slightly or
totally from the hole while drilling).
Cutting fluid is sometimes used to ease this problem and to prolong the tool's life by
cooling and lubricating the tip and chip flow. Coolant may be introduced via holes through the
drill shank, which is common when using a gun drill. When cutting aluminum in particular,
cutting fluid helps ensure a smooth and accurate hole while preventing the metal from grabbing
the drill bit in the process of drilling the hole.
When cutting brass, and other soft metals that can grab the drill bit and causes "chatter", a
face of approx. 1-2 millimeters can be ground on the cutting edge to create an obtuse angle of 91
to 93 degrees. This prevents "chatter" during which the drill tears rather than cuts the metal.
However, with that shape of bit cutting edge, the drill is pushing the metal away, rather than
grabbing the metal. This creates high friction and very hot swarf.
Imported Crap in Moiz Steel Industry
Steel scrap consists of discarded steel or steel products, generally segregated by composition
and size or ‘grade’ suitable for melting. The following are the facts associated with steel scrap
and its recycling.
 Almost 40 % of the global steel production is made from steel scrap. Around 500 million
tons of steel scrap is being used annually for the production of steel.
 Recycling of one ton of steel saves 1.4 tons of iron ore, 0.40 tons of coal, and 0.055 tons
of limestone.
 CO2 emissions are reduced by 58 % through the use of steel scrap.
 Recycling one ton of steel scrap saves 2.3 Cu m of landfill space.
 Recycling of steel scrap uses 75 % less energy compared to creating steel from raw
materials.

13. 13
 Steel scrap recycling uses 90 % less virgin materials and 40 % less water. It also
produces 76 % fewer water pollutants, 86 % fewer air pollutants and 97 % less mining
waste.
 Steel automobile frames contain at least 25 % recycled steel scrap and a typical electrical
appliance will usually be made of 75 % recycled steel scrap. Steel cans consist of at least
25 % recycled steel scrap.
Moiz Steel import best quality scrap (HMS 1, Shredded 211, and CRC Bundle Scrap) from
Europe, US, Middle East, Australia and African regions to provide superior quality rebars to
their customers.
Melt Shop in Moiz Steel Industry
State of the art steel melt shop is equipped with latest Induction Melting Furnaces and
providing the customers with the complete metallurgical solutions. Its melting process is
facilitated by scrap vibratory feeders and air pollution control system to achieve efficient and
safe melting. To achieve the highest quality of molten metal from the furnaces, quality imported
scrap/materials are being used.
Moiz Steel manufactures its own steel billets through a state-of-the-art steel melt shop
having a production capacity of 180 MT per day of billets sizes ranging from 100mm X 100mm
to 150mm X 150mm. The melt shop comprises of a 15 MT induction furnace and a two stand
6/11 radius continuous casting machine.
Continious Casting Machine
Continuous casting of steel is a process in which liquid steel is continuously solidified
into a strand of metal. Depending on the dimensions of the strand, these semi-finished products
are called slabs, blooms or billets. Steel billet has a square cross section with one side normally
150 mm or less. It is a feed material for rolling of steel in light section mills, bar mills, and wire
rod mills. Steel billets are also used in forging of certain products. A very wide range of billet
continuous casting machines are now available. These machines have different bending radiuses,
are of single strand to eight strands and have casting speeds up to 6 m/minute.
The automatic continuous casting machine at Moiz Steel has a two stand 6/11 radius for a
smooth production process.
Rolling Mill
In rolling mills, intermediate steel products are given their final shape and dimension in a
series of shaping and finishing operations. Most of the slabs are heated in reheating furnaces and
rolled into final shape in hot– or cold–rolling or finishing mills. While some products (e.g.
reinforcement bars, steel plates) only require hot-rolling, some others may require both hot– and
cold–rolling (steel for cars and white-goods). Mechanical forces for cold rolling will create much
more force and energy needs, while hot rolling happens much faster with less forces; however,
there are significant energy costs to heat the metal to near eutectic temperatures.

14. 14
Moiz Steel has a fully automatic high-speed continuous rolling mill line with an annual
capacity of 200,000 MT rebars. This twenty one stand rebar mill is based on single path rolling
with a speed of 14 m/s. The technologically advanced configuration of the rebar mill ensures
final production of high surface quality, precision in size, and high strength.
Cooling Bed
A cooling bed is part of a rolling mill, at the end of the rolling mill that supports and
permits the hot rolled products from the hot mill to cool hot rolled and cast steel products. A
walking beam cooling bed is the most common type of cooling bed. What one wants to happen is
for all the temperature of the bar to all cool at the same time. If not, it develops stresses in the
bar. If part of the bar stays continually in touch with the metal supports, then it will cool at a
different rate than the parts of the bar that is continually open to the ambient air. A walking beam
cooling bed consists of moving and stationery skids which lift, traverse and lower the product
numerous times so that where it touches continually changes permitting all the bar to cool at the
same rate.
The bar walks its way to the end of the bed where it is placed on a set of roller tables.
Walking beam cooling beds have a saw tooth pattern which is why it is also known as a rake
type cooling bed. When cooling billets, walking beam turn over cooling beds have a feature that
continually rotates the billet so that where it touches the bed changes continuously, thus the billet
does not distort its shape in the cooling process. Cooling beds that are used for blooms and plate
do not have a rake pattern, but may use a chain transfer as the traversing method. Cooling beds
are sized so that the product will cool within a particular cycle time.

15. 15
Fig: Cooling Bed
Cold Bar Shearing Machine
Cold Bar Shearing Machine offered is made available by us in precision designed and
constructed finish so as to provide desirable support to the process of cutting bundle of bars after
cooling process on cooling bed up to 800 mm blade length and 150 mm stroke
(hydraulic/mechanical). Further, all internal parts of the offered machine come hardened as well
as grinded with the outer body made available in fabricated or casted finish so as to provide
optimum functional support. Some of the features these machines are recognized for include
superior finish quality, robust construction support, corrosion resistant finish as well as
delivering precision support in cutting finished product into desired lengths.

16. 16
Stocking
The rebars then move on to a series of conveyers that monitor them to workers, who
organize bundles on the basis of number of rebars given in each bundle.
After weighting and proper inspection, these are lifted through a magnetic crane that
stores them to the stockings.
Quality Inspection
The absolute last thing we want in a fabrication project is for a steel structure to fatigue
and fail. Quality steel could be the secret to successfully avoiding this. However, quality steel is
much more than meets the eye. For this purpose Moiz Steel Industry uses several advance
equipments to meet the standards of its motto.

17. 17
i. Spectro Lab
The Spectro lab (stationary metal analyzer) is used mainly for material testing in
foundries and for incoming and outgoing inspections in the metal industry around the world. It
determines all of the elements used in the metal industry, including metal analysis of carbon,
phosphorous, sulfur and nitrogen.
In Moiz Steel Industry chemical lab at the melt shop is equipped with a highly
sophisticated German origin spectro-chemical analysis machine that ensures billets adhere to the
standard grade 60 chemical composition.
ii. UTM Machine
A Universal Testing Machine (UTM) is used to test both the tensile and compressive
strength of materials. Universal Testing Machines are named as such because they can perform
many different varieties of tests on an equally diverse range of materials, components, and
structures. Most UTM models are modular, and can be adapted to fit the customer’s needs.
Universal Testing Machines can accommodate many kinds of materials, ranging from
hard samples, such as metals and concrete, to flexible samples, such as rubber and textiles. This
diversity makes the Universal Testing Machine equally applicable to virtually any manufacturing
industry.
The UTM is a versatile and valuable piece of testing equipment that can evaluate
materials properties such as tensile strength, elasticity, compression, yield strength, elastic and
plastic deformation, bend compression, and strain hardening. Different models of Universal
Testing Machines have different load capacities, some as low as 5kN and others as high as
2,000kN.
Figure: Universal Testing machine

18. 18
iii. CNC Machine
CNC Machining is a process used in the manufacturing sector that involves the use of
computers to control machine tools. Tools that can be controlled in this manner include lathes,
mills, routers and grinders. The CNC in CNC Machining stands for Computer Numerical
Control.
Under CNC Machining, machine tools function through numerical control. A computer
program is customized for an object and the machines are programmed with CNC machining
language (called G-code) that essentially controls all features like feed rate, coordination,
location and speeds. With CNC machining, the computer can control exact positioning and
velocity. CNC machining is used in manufacturing both metal and plastic parts.
Dealing with Environment
Moiz Steel aspires to be the leading name in the steel industry with regard to its focus on
health, safety and environment. An air pollution control plant (APC) is installed in its melt shop
that captures the emissions of the furnace and clean it, thus safeguarding employees, protecting
environment and making the steel making process more eco-friendly.
Moiz Steel has a comprehensive quality, environmental and safety management program
that complies with international standards: ISO 9001, ISO 14001 and 18001 respectively.
Conclusion
This internship was a useful experience. I have gained new knowledge, skills and met
many new people. I achieved several of my learning goals, got insight into professional practice
and learn practical knowledge.
Finally, I would like thanks all the staff of the Moiz Steel plant for such a kindness, each
and every person at the site help me in every possible way without any hesitation.