HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. LTD.1. COMPANY OVERVIEW: FIGURE 1: SWAJIT ENGINEERING PVT. LTD It is a pleasure to introduce SWAJIT, as a leading 'Customized solution provider for Industrial chains. Swajit Engineering Pvt. Ltd. is based at Aurangabad (M.S), India. Swajit has evolved in as the leading Conveyor chain manufacturer, Conveyor chain supplier & Conveyor chain exporter of all type of Roller conveyor chains and any types of Link, Pin and Bush mechanism for Material handling systems. Also SWAJIT manufacturing 2", 2.5", 3" & 3.5" Simplex, Duplex & Triplex transmission chains. Since the inception in 1992;Swajit is equipped with latest technology comprising ‘state-of-art-plant’ with all Infrastructure facilities & processes, advanced metallurgical laboratory to manufacture all types Conveyor chains and Slats of finest quality. Swajit has a dedicated and technically qualified team of experienced Engineers & Metallurgists for fulfilling precisely the customer’s needs on the continuous basis. We have developed an expertise to provide a wide range of Conveyor chains and its components for diversified industry segments like Sugar, Cement, Automobile, Steel, Solvent, Boiler& Thermal power plant, Co-generation, Bakeries, Asphalt, Breweries, Chemical & Fertilizers, Bottling, Food Processing, Agriculture, Mining, Paper and Allied Industries. Excellent Quality is Swajit’s inherent strength and in a journey of two decades organization has strongly emerged as the unchallenged leaders in the ever-growing Indian Market and we are now looking beyond the boundaries to increase our business in the Global market. Organization has attained this niche position by creating the best products to exceed customer expectations, creating everlasting Customer Satisfaction with trust and service to generate repeated orders. Swajit adhere to global business practices and also an ISO 9001: 2008 company certified by TUV NORD (Germany). 1 HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. LTD. Organization has a list of valued clients and look forward to add your distinguished name into it, hence requesting you to solicit your enquiries. Swajit assures excellent solutions to specify your specified requirements supported by timely delivery. They are looking forward to build a technically proven & mutually beneficial relationship in future. (A leading Conveyor Chain Manufacturer, Supplier & Exporter of all type of Roller conveyor chains, Transmission chains & Slates since 1992) 2 HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. To check the strength. (Bulk hardening. OBJECTIVES To study production planning and control practices used during Heat Treatment processes at Swajit. recrystallization annealing) 3 . hardness and wear resistance of material. 2. (Tempering. LTD. surface hardening) To check toughness of the material. To study the shop floor management during handling heat treatment operations at swajit. 14. 07. 3. LTD.Swajit is equipped with latest technology comprising ‘state-of-art-plant’ with all Infrastructure facilities & processes. 04. Paper and Allied Industries. Asphalt. Mining. 10. Cement. 03. 05. Overseas Market 01. 12. Bottling. Bakeries. Breweries. We have developed an expertise to provide a wide range of Conveyor chains and its components for diversified industry segments like Sugar. Co-generation. Chemical & Fertilizers. Steel. 11. advanced metallurgical laboratory to manufacture all types Conveyor chains and Slats of finest quality. 02. 08. 06. Food Processing. 15. Agriculture. Swajit has a dedicated and technically qualified team of experienced Engineers & Metallurgists for fulfilling precisely the customer’s needs on the continuous basis. INTRODUCTION TO SWAJIT PLANT Since the inception in 1992. Philippines Mauritius Malaysia Uganda Kenya Tanzania Zambia Indonesia Rwanda Ethiopia Spain Jamaica Sudan Nepal Vietnam 4 .HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. Automobile. Boiler & Thermal power plant. 09. Solvent. 13. Continuous Customer Focus. 2. Ethical Business Practices. To establish as a brand associated with quality and consistency in Manufacturing all kind of chains in Asia & Europe by 2020. Be Accountable for Human resource development. MISSION 1. VISION 1. To become the first choice for the established trade. 5 . 2. occupational & Customer’s health & safety.8 to 10 weeks. 3. 2. VALUES 1. Delivery time? .HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. 3.Pitch 75 to 400 mm.Breaking Load 10 to 250 ton. . 4. Providing products as complete solutions. To become a leading name in global market by Best performance. LTD. Improving employee skills. Technology Enhancement. involvement & Quality of Life (QOL). 3. FAQs Product range? . Excellent Services. 4. Perfect Implementation of Occupational Health and Safety Management System (OHSAS). Bucket Elevator chain 4. Reclaimerstaker chain 6. Gate chain 4. Deep bucket conveyor chain 7.HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. Travelling Grate chain 3 Cement Industry 1. Coal Handling chain 3. Cooling bed conveyor chain 2. LTD. Conveyor chain for cold draw bench 4. Bucket elevator chain for Fertilizer 5 Solvent Industry 1. Bucket elevator chain 2. Drag & Flow conveyor chain 2. Pan Conveyor chain 5. Extractor chain 6 Steel Industry 1. Slat conveyor chain 2 Boiler and Thermal Power plant 1. Feeder breaker chain for Collieries 3. Transfer bed conveyor chain 3. Drag chain 3. Enemas conveyor chain 4 Chemical and Fertilizer 1. Ash handling chain 2. Mandrill insert chain 6 . Conveyor chain for coal feeding 2. Customer Segments:Type of chain 1 Automobile 1. Paul retarder & retarder chain 3. Baggase carrier chain 2. LTD.HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. All types of conveyor chain 7 Sugar Industry 1.3. Amusement park FIG. Sugar elevator chain 6. Bakeries 4. Sugar bag staker chain 7. Home Appliances 5. Shell pusher chain 6. Feeder table chain 5.1 VARIOUS CONVAYER CHAINS 7 . Block type & inter carrier chain 3. Paper mill 6. Cane carrier chain 4. Food Processing 3. Agriculture 2. 5. Slates and fabricated rake 8 Other Applications 1. nitriding. Cast irons White. bainite and martensite. copper. Temper designations for aluminum and magnesium alloys. Processes Annealing. 8 . Dimensional and compositional changes during heat treatment. LTD. its measurement and control. Homogenization. HEAT TREATMENT Heat treatment is an operation or combination of operations involving heating at a specific rate. induction and flame hardening processes. Recovery. Residual stresses and decarburisation. The aim is to obtain a desired microstructure to achieve certain predetermined properties (physical. Special Grade Steels Stainless steels. quenching media. soaking at a temperature for a period of time and cooling at some specified rate. Controlled Atmospheres Oxidizing. magnetic or electrical). maraging steels. gray and spheroidal graphitic cast irons Nonferrous Metals Annealing of cold worked metals. magnesium. mechanical. Heat treatment of aluminum. high speed tool steels. reducing and neutral atmospheres.HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. high strength low alloy steels. titanium and nickel alloys. tempering. Surface Hardening Case carburising. Isothermal and continuous cooling transformation diagrams for plain carbon and alloy steels. Microstructure and mechanical properties of pearlite. Austenitic grain size. normalizing and hardening of steels. 4. Fundamentals Fe-C equilibrium diagram. recrystallisation and grain growth. carbonitriding. Hardenability. Steel is heated up to austenitic region and held there until its carbon is dissolved. and cooling it rapidly. 4. LTD. remove residual stresses. molten salt. The selection of heat treatment operations is strongly influenced by the carbon content in the steel. In this process. and then cooled rapidly. the carbon does not get sufficient time to escape and get dissipated in the lattice structure.1 Hardening Hardening is performed to impart strength and hardness to alloys by heating up to a certain temperature. oil. austenite is decomposed in ferrite and carbide at relatively lower temperature and fine pearlite is produced. Residual stresses are removed by another process called annealing. This helps in locking the dislocation movements when stresses are applied. 9 . Heat treatments on phase diagram of steel. improve toughness.HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. Cooling rate is very slow around 10oC per hour. In normalization variation in properties of different sections of apart is achieved. Partial annealing is incomplete annealing and there is partial phase transformation however in sub-critical annealing there is no phase transformation.3 Normalizing The process is similar to annealing and is carried out to avoid excessive softness in the material. depending on the material. and to alter various mechanical. Quenching sets up residual stresses in the workpiece and sometimes results in cracks. 4. The material is heated above austenitic phase and then cooled in air. Normalizing is less expensive than annealing. water. electrical or magnetic properties of material trough refinement of grains.2 Annealing Annealing is performed to reduce hardness. restore ductility. Process is carried out in a controlled atmosphere of inert gas to avoid oxidation. Used to achieve ductility in work hardened steels. Quenching is performed to cool hot metal rapidly by immersing it in brine (salt water). air or gas. This gives relatively faster cooing and hence enhance hardness and less ductility. 4. 5 Surface Hardening Heat treatment methods in general change the properties of entire material. strength and wear resistance marginally. FIG. the steel is heated to lower critical temperature keeping it there for about one hour and then cooled slowly at prescribed rate. Increase in tempering temperature lowers the hardness. LTD. Hardening improves wear resistance of material but lowers impact resistance and fatigue life. and second is thermo-chemical treatment. and toughness and relieve stresses in martensite structure.4. This process increases ductility and toughness but also reduces hardness.1 HEAT TREATMENT FURNACE 10 . . Tempering is applied to hardened steel to reduce brittleness. Induction heating Flame hardening High frequency resistance heating Laser beam hardening Electron beam hardening Carburizing Nitriding Cyanding. 4. In this process. increase ductility.4 Tempering Martensite is very hard and brittle.HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. Therefore sometimes there is requirement of surface hardening Two methods are used. 4. first is heating and cooling to get required phase. 2 ROTARY FURNACE 11 .HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT.4. FIG. LTD. Vickers. usually by penetration. abrasion or cutting. Hardness of materials has probably long been assessed by resistance to scratching or cutting. but not material A. the term hardness may also refer to resistance to bending. HARDNESS TESTING 5.1What is Hardness? Hardness is the property of a material that enables it to resist plastic deformation. Relative hardness of minerals can be assessed by reference to the Moh's Scale that ranks the ability of materials to resist scratching by another material. A hardness property value is the result of a defined measurement procedure. The above relative hardness tests are limited in practical use and do not provide accurate numeric data or scales particularly for modern day metals and materials. If the file bites or marks the surface. 5. scratching. Alternatively. length and time. The usual method to achieve a hardness value is to measure the depth or area of an indentation left by an indenter of a specific shape. Similar methods of relative hardness assessment are still commonly used today. There are three principal standard test methods for expressing the relationship between hardness and the size of the impression. with a specific force applied for a specific time. For practical and calibration reasons. If the file slides without biting or marking the surface.HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. the test material would be considered softer than the file. An example is the file test where a file tempered to a desired hardness is rubbed on the test material surface. 5. However. LTD. defined by a combination of applied load and indenter geometry 12 . and Rockwell.2 Measurement of Hardness: Hardness is not an intrinsic material property dictated by precise definitions in terms of fundamental units of mass. material A scratches material B slightly and scratches material C heavily. the test material would be considered harder than the file. An example would be material B scratches material C. each of these methods is divided into a range of scales. these being Brinell. 3 Hardness Test Methods: Rockwell Hardness Test Rockwell Superficial Hardness Test Brinell Hardness Test Vickers Hardness Test Microhardness Test Moh's Hardness Test Scleroscope and other hardness test methodS 13 . 5. LTD.HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. the additional major load is removed but the preliminary minor load is still maintained. which follows the movements of the indenter and so responds to changes in depth of penetration of the indenter is set to a datum position. While the preliminary minor load is still applied an additional major load is applied with resulting increase in penetration.e e = permanent increase in depth of penetration due to major load F1 measured in units of 0. 14 . D = diameter of steel ball.002 mm. E = a constant depending on form of indenter: 100 units for diamond indenter. so reducing the depth of penetration. The indenter is forced into the test material under a preliminary minor load F0 usually 10 kgf.HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. HR = E . 130 units for steel ball indenter. When equilibrium has again been reach. When equilibrium has been reached. Removal of the additional major load allows a partial recovery. HR = Rockwell hardness number. The permanent increase in depth of penetration. LTD. resulting from the application and removal of the additional major load is used to calculate the Rockwell hardness number. an indicating device. Rockwell Hardness Test The Rockwell hardness test method consists of indenting the test material with a diamond cone or hardened steel ball indenter. HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. LTD. FIG.5.1 ROCKWELL HARDNESS TESTING MACHINE 15 . The Brinell Hardness Test The Brinell hardness test method consists of indenting the test material with a 10 mm diameter hardened steel or carbide ball subjected to a load of 3000 kg. The diameter of the indentation left in the test material is measured with a low powered microscope. A well-structured Brinell hardness number reveals the test conditions.2 BRINELL HARDNESS TESTING MACHINE 16 . "75 HB 10/500/30" which means that a Brinell Hardness of 75 was obtained using a 10mm diameter hardened steel with a 500 kilogram load applied for a period of 30 seconds. and looks like this. LTD. which will more accurately account for multiple grain structures and any irregularities in the uniformity of the material. This method is the best for achieving the bulk or macro-hardness of a material.5. FIG. The full load is normally applied for 10 to 15 seconds in the case of iron and steel and for at least 30 seconds in the case of other metals. For softer materials the load can be reduced to 1500 kg or 500 kg to avoid excessive indentation. On tests of extremely hard metals a tungsten carbide ball is substituted for the steel ball. the Brinell ball makes the deepest and widest indentation. so the test averages the hardness over a wider amount of material. The Brinell harness number is calculated by dividing the load applied by the surface area of the indentation. The diameter of the impression is the average of two readings at right angles and the use of a Brinell hardness number table can simplify the determination of the Brinell hardness.HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. Compared to the other hardness test methods. particularly those materials with heterogeneous structures. for a given length of time. LTD. that have a small load capacity. a Brinell test will use 3000 kgf load with a 10mm ball. The test standard specifies a time of 10 to 15 seconds. There are other conditions that must be met for testing on a round specimen.HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. Brinell test loads can range from 3000 kgf down to 1 kgf. Most typically. If the sample material is aluminum. Test Method Illustration D = Ball diameter d = impression diameter F = load HB = Brinell result 17 . A Brinell hardness result measures the permanent width of indentation produced by a carbide indenter applied to a test specimen at a given load. an indentation is made with a Brinell hardness testing machine and then measured for indentation diameter in a second step with a specially designed Brinell microscope or optical system. like Rockwell units. spacing of indentations. Typically. Generally. The resulting measurement is converted to a Brinell value using the Brinell formula or a conversion chart based on the formula. etc. the lower loads and ball diameters are used for convenience in “combination” testers. minimum thickness of test specimens. Ball indenter diameters can range from 10mm to 1mm. although shorter times can be used if it is known that the shorter time does not affect the result. the test is most frequently performed with a 500 kgf load and 10mm ball. computation of manpower and capacity requirements. fixing time standards. Preparations of design drawings. Designing and ensuring availability of tools. 3. 3. 18 . 6. INDUSTRIAL ENGINEERING 1. 2. 5. 5. Testing of new design prototype or design verification. technologies and process based upon the product and design requirements. Set up manufacturing facilities. Selection of machines. 2. 4. LTD. PRODUCT DEVELOPMENT 1. 4. VARIOUS DEPARTMENTS OF SWAJIT ENGINEERING 1. Modify old products to suit new market norms. Assemble and make new design in development shop. 2. Planning related to manufacturing methods. jigs and fixtures. Industrial engineering.HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. Laying down standards and acceptable norms. ASSEMBLY The final product is assembled in the well laid out and balanced lines. 2. 4. 3. Overall co-ordination between marketing. Dispatch of complete consignments. MANUFACTURING 1. Management of stores. client. PRE-ASSEMBLY This consist of various processes such as riveting. Receipt and processing of orders placed by sales division. spot welding. Pre manufacturing – manufacture of components and brazing of parts. 19 . 6.HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. LTD. The product is thoroughly tested and packed before dispatch. 3. 4. Scheduling . Assembly of manufactured and bought out components.involving assignment of priorities based on urgency and material availability. LOGISTICS 1. 5. Procurement and administration of raw materials. soldering through which various in-house and bought out parts are assembled to form subgroups which are fed to the main product assembly line after testing. 2. excise etc. Planning and budgeting 8.HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. 3. 5. Verification of standards of finished goods. Markets product made by factories. LTD. 5. COMMERCIAL 1. Cost accounting & control 7. Source customers. Inspection during stages of manufacturing and assembly processes. 5. Product cost calculation 6. 2. 4. 3. 2. Inputs for company’s balance sheets. Verify compliance with client requirements. Collaborates with the technical and manufacturing sections. QUALITY ASSURANCE 1. 6. 20 . 4. Financial accounting 9. Studies the requirements of the customers. Inspection of incoming materials. Routine testing after the products is ready. sub assembly or equipment as whole. LTD.HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. replacement of same part or periodic check up or inspection. 21 . MAINTENANCE Maintenance has been defined as a combination of any action carried out to retain any item or to restore to it an acceptable condition. In other words Maintenance may be defined as an application of an assembly of man and machine to keep the plant running at maximum efficiency and profitability to keep it in maximum availability of plant and conserve the life of plant and equipment. over hauling of parts. repair work. This action may be some major adjustment. periodic lubrication. 7. LTD. While carrying out production process. When these material arrive from source those are given to vendor to slash them into required size. for their dimensions and other quality parameters. Then those are moved to storage areas present near each punching press.HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. These materials are then inspected at arrival area of department.1 QUALITY TESTS In case of material treatment 2 types of tests are performed to check quality of those. 7. 1. Hardness test For contacts quality test are performed using microscopic check for its shape and vernier caliper is used to measure the dimensions. at the beginning of each production cycle few samples are produced and given for quality check if they are passed then only further production is carried out. Metal sheet and bars are the primary raw material used in production department. QUALITY INSPECTION AND QUALITY REPORTS In Swajit first preference is always given to the quality though it might come at higher cost but no chance is taken against the quality. 7.Grinding test 2. 22 . else necessary action is taken with help of tool maintenance department. if the no of rejection from that entire lot are exceeding that limit of 2% then the concerned department is required to prepare second report.2 QUALITY REPORTS Report is prepared by quality assurance department. 7. If any defects are observed in quality of those samples then that person prepares I – report and submits that report to concerned department. The concerned department to which report is issued prepares second report. from which those samples were collected which got rejected. Inspector from this department draws samples of each product by predetermined method and inspect its quality. This report contains details of the incident and justification for the same. LTD. This department inspects the entire lot. 23 . For each department there is 2% tolerance level allowed.HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. Fig:7.1 ISO certification of Swajit Engineering 24 . LTD.HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. This generated scrap is categorized mainly into hazardous waste. These records contains amount or quantity of waste (weight). ferrous scrap and non ferrous scrap. being non hazardous and also not having much re-sell value record of such is not maintained and is directly sold to vendors.HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. this scrap is sold to vendor from which that raw material was bought. along with these waste form 3 and form 12 are attached which helps in identify that its hazardous waste and proper procedure is followed while it`s disposal. originator. Being a non-ferrous material it is very expensive and hence waste of such material also gives good value. any other). packed in which container (plastic. In case of both i. While disposing hazardous wastes like grinding dust. metal. disposal of hazardous and non-ferrous waste records are maintained. While in case of ferrous scrap. LTD. 8. araldite waste etc. DISPOSAL OF SCRAP The scrap generated while production process is required to be disposed using some proper guidelines. 25 . In case of non-ferrous scrap. vendor details etc.e. Production targets are met on regular basis. HT and Production department are able to keep low levels of inventory while also achieving high inventory turnover. LTD. 26 . Capacity utilization is very effective and efficient.2% of total production.HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. what all activities are taking place on floor at that movement and also helps in keeping track of various performance parameters like additional cost. CONCLUSION Production planning and control practices used in Heat treatment department are very efficient. Also the number of defects or numbers of rejections are very less. It has helped in establishing proper chain of command and proper channel for communication. quality issues. safety etc. It also helps in understanding. Shop floor management system implemented in Heat treatment department is very effective. With help of FOCUS ( ERP software) and scientific techniques of inventory management. even less than 4. 9. E. That will give more accuracy and minimize errors.g. 3) Inspection record of daily as well as monthly production should be maintain as per the ISO standards.HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. 10. 27 . Digital Vernier caliper should be used. 2) Quality inspection should be carried out after every stages of during Heat treatment operations. LTD. RECOMMENDATIONS 1) Conventional instrument should be replaced by the Digital instrument. can-eng.HEAT TREATMENT PROCESS AT SWAJIT ENGINEERING PVT. LTD.swajit.com www.wikipediya. 11.org https://en.com/HeatTreatment 28 .osti.org/iso/about/iso_members.anvilfire.iso.htm www.htm www. Bibliography https://en.gov/servlets/purl/836878/ www.com/FAQs/Heattreating.com www.thermotreatedwood.