The document summarizes the casting, forging, heat treatment, and machining processes at Heavy Engineering Corporation's Foundry Forge Plant, Heavy Machine Building Plant, and Heavy Machine Tool Plant. It describes the key areas like the foundry, forge shop, machine shop, and their core processes. It also provides details on melting, furnaces like electric arc and vacuum arc degassing, heat treatment techniques like annealing and normalizing, and machining operations. The overall document gives an overview of the different production areas and manufacturing processes at Heavy Engineering Corporation.

1. HEAVY ENGINEERING
CORPORATION
PROJECT REPORT ON
CASTING, FORGING, HEAT TREATMENT & MACHINING
Name- Ashish Ranjan
Admn No - 2012JE1013
6th Semester

2. Heavy Engineering Corporation
Foundry Forge Plant
(FFP)
Heavy Machine Building Plant
(HMBP)
Heavy Machine Tool Plant
(HMTP)
Pattern
Shop
Grey Iron
Foundry
Steel
Foundry
Fettling Shop
Forge Shop
Machine
Shop
Turning, Boring, Facing,
Grinding, Threading etc.
Milling, Grinding,
Gear Hobbing, Heat
Treatment
CNC gas cutting,
Sheet metal work,
Welding
Fabrication & Assembly
Machining
Operations
Assembly of
Machine Tools like
CNC machine

3. Product
Requirement
Flow Chart of Casting
Method
Pattern Allowance,
Gating System,
Machining Allowance etc.
Moulding &
Core Making
Pattern Making
Mould & Core
Painting
Mould & core
assembly and
Closing of
Mould
Drying in oven
Clamping &
Loading
Pouring of
Liquid Metal
Cooling & Shake
out
Cleaning &
Fettling
Stress RelievingMachining ShopFinal Product

4. Melting Section
Charging Unit Melting Unit Die and pit Unit
• Preparation of metal
scraps mainly for
Plane carbon steel,
Alloy Steel and Cast
Iron Materials.
• Basic components of
melt contains C, Si,
Mn, P etc.
• Metal is alloyed with
different alloying
elements Cr, Ni,Mo,V
etc.
• Electric Arc Furnace,
Induction Furnace and
Vacuum Arc Degassing
Furnace.
• Molten metal
is poured into
mold cavity for
casting using
ladle furnace
with the help
of E.O.T.
crane.

5. Furnaces
Induction Furnace
Electric Arc Furnace
Vacuum Arc Degasing Furnace (VAD)
Vacuum Degasing Furnace (VD)

6. ELECTRIC ARC FURNACE
• It is powered by a 3 phase electrical system and has three electrodes.
• Arc is formed between the charged metal and the electrode.
• The charge is heated both by current passing through the charge and by the
radiant energy evolved by the arc.
• Electrodes can move up and down automatically for regulation of the arc.
• To protect the transformer from heat, it is installed in a vault.
• It is cooled via pumped oil exchanging heat with the plants water cooling
systems.
• It is built on a tilting platform to pour molten metal into another vessel for
transport.

7. Ladle
• It is not used for metal melting, metal addition & degassing purpose.
• This Furnace is used to reserve molten metal for pouring and degasing
process.
• It is of three type.
a) Casting Ladle: For pouring of molten metal into mold.
b) Transfer Ladle: Transfer of molten metal from one process to other.
c) Treatment Ladle: Process to take place within the ladle to change some
aspect of molten metal

8. VACUUM ARC DEGASING FURNACE
• The VAD is used for
purification of molten
metal.
• It is equipped with
bottom plugs for argon
bubbling.
• To achieve a
homogeneous bath
temperature and
composition, the steel in
the ladle is often stirred
by means of argon gas
bubbling.
• Hydrogen and oxygen
gas is removed.

9. Fettling Shop
• Process of cleaning of casting object from sand & gating
elements i.e. Runner, riser, Sprue basin & gates.
• Maximum sand is removed by pneumatic chipping hammer
(operating press. 4 to 7 kg/cm2 ).
• Runner, Riser, Sprue basin and other extra metal is removed by
gas cutting (Lancing).
• Some extra metal is removed by Fettle Torch.( Graphite
electrode for steel & general purpose electrode is used for cast
iron).

10. Heat Treatment Process
• Annealing
• Normalising
• Quenching
• Induction
Hardening
Controlled heating &
cooling of materials
for the purpose of
altering their
structures and
properties

12. Annealing
• In this process, hypoeutectoid steels (less than 0.77 % C) are heated to 30o
to 60oC above the upper recrystallization temperature held for sufficient
time to convert the structure to homogeneous single phase austonite of
uniform composition and slowly cooled at a controlled rate through the
lower crystallization tem.
• Cooling is done in the furnace by decreasing the tem by 10oC to 30oC per
hour to at least 30oc below 727oC.
• After that metal can be cooled at room tem.
• Annealing produce softer material.

13. Normalizing
• The steel is heated to 60°C (100°F) above the upper recrystallization
Temp (hypoeutectoid) or lower recrystallization Temp
(hypereutectoid) , held at this temperature to produce uniform
austenite.
• It is removed from the furnace and allowed to cool in still air.
• The resultant structures and properties will depend on the subsequent
cooling rate.

14. HMBP
Machining Processes
• Turning
• Boring
• Facing
• Grinding
• Vertical & Horizontal
Milling
• Planning
• Grooving
• Threading
• Parting
• Slotting
• Trepanning
• Gear Hobbing,
• Heat Treatment

15. Thank
You