`

PARUL INSTITUTE OF ENGINEERING AND

TECHNOLOGY (PIET)

MECHANICAL ENGINEERING
DEPARTMENT

STUDENTS EXTERNAL
ATTACHMENT LOG-BOOK

DURATION: 3 WEEKS
(10.06.2013 to
30.06.2013)

THE LOG
BOOK
1. INTRODUCTION
This log book is to assist the student to keep a record of the training. It
will show the departments and sections in which the student has
worked and the periods of time spent in each.
2. DAILY REPORT
The daily work carried out during the periods of training is to be
recorded clearly with sketches and diagrams where applicable.
3. WEEKLY REPORT
This is a summary of work done in a week and should cover
theory/practical report on the work covered.
Students are required to present the log-book weekly to the industry
based supervisor for assessment of content and progress. The
Supervisor can use any page for his comments where necessary.
4. COLLEGE SUPERVISOR'S VISIT
The Training Supervisor of the PIET will check the log-book when
he/she visits the industry/project to ensure that the proper training is
being carried out, and record his/her comment on the page provided for
this purpose, towards the end of the book.
5. SPECIAL REQUEST FOR THE INDUSTRY- MENTOR
Please assess the student as per assessment
form provided.
6. REPORT WRITING
In addition to the daily and weekly record the student should submit
a summary report of the work done during the training period.
The report should contain a summary of activities of the
organization, manufacturing/services processes the student was
involved in. The report has to be in the proper format as prescribed
by the project head. (Report Format will be mailed to you by the
Project Head during your first week of training).
7. REPORT SUBMISSION
The log-book and report
departmental Project
Head on or before 3rd July
2013.

must

be

submitted

to

the

relevant

STUDENTS PARTICULARS
Name of Student :

t e

a n d

a k

a n

Enrolment No.:

1
9

0
4

0
2

3
9

7 0 1
3

1 9
5

setupatel6116@gmail.com

Name of Student :

a t

a m I

m na

r a

k u

N G

Enrolment No.:
1 0 0 3
Contact No.
8

7
1

0
8

1
9

1
5

9
1

4
Email ID

samirpatel1437@gmail.com
Name of Student :

P
ma

a
r

e l

h a n

a n

Enrolment No.:
1 0 0 3
Contact No.

1
8

S
G.

A N G H V
L. T. D.

9
Email ID

patelshashank12@gmail.com
Name of Company

O R G I

N G

&

Address of Company

2 4 4/ 6, 7, G I D C
I N DUS T I A L
E S T A T E,
E
W A G H O 77
DI A
V A D O D A R A- 3 9 1 7 6 0
O
Name of Industry Mentor
R
A K E
Contact No.

2 2

H B

6 0

H A

8 9 2

P A T
Email ID

Name of Faculty Mentor

Contact No.

Email ID

Training Duration: From: 10/6/2013

To: 30/6/2013
2

The student could draw the organization chart of industry attached

hereunder.

ATTACHMENT TIME-PLAN
(The student should draw a time-table indicating time to be sent on each
task/section).

WEEK

1ST

ND

RD

DATE

DEPARTMEN
T

TIME

10/6/2013

INTORUCTION

10 AM -4 PM

11/6/2013

ROW
MATERIAL

10 AM -4 PM

12/6/2013

CUTTING SHOP

10 AM -4 PM

13/6/2013

OPEN DIE
FORGING

10 AM -4 PM

14/6/2013

OPEN DIE
FORGING

10 AM -4 PM

15/6/2013

CLOSED DIE
FORGING

10 AM -4 PM

17/6/2013

CLOSED DIE
FORGING

10 AM -4 PM

18/6/2013

HEAT
TREATMENT

10 AM -4 PM

19/6/2013

HEAT
TREATMENT

10 AM -4 PM

20/6/2013

MACHINING

10 AM -4 PM

21/6/2013

MACHINING

10 AM -4 PM

22/6/2013

CNC SHOP

10 AM -4 PM

24/6/2013

CNC SHOP

10 AM -4 PM

25/6/2013

Q.C.

10 AM -4 PM

26/6/2013

Q.C.

10 AM -4 PM

27/6/2013

Q.C

10 AM -4 PM

28/6/2013

STORAGE

10 AM -4 PM

29/6/2013

PACKEGING

10 AM -4 PM

WEEKLY PROGRESS CHART

ENDING 15/6/2013
)
DAY

Monday

(FIRST WEEK)

(WEEK

DESCRIPTION OF WORK DONE

First we visited the company & got overview of plant &

product & in which sequence
the worksdone in the company.

We observed the raw material shop. There is different types

of steel is used to produce flanges,albow,tee etc. there is
Tuesday mainly
Two types of steel is used 1. Austenitic stainless steel 2.
Carbon
Steel .
We observed cutting m/c which are used for primary cutting
of
Wednesda The raw material. There is mainly four m/c having different
y
capacity .

Thursday

Friday

Saturday

We visited the open die forging shop, in that there are two
steam hammers. Especially we observed open die forging for
Large size jobs & its furnace & punching press for removing
of excessive material.
We observed two steam hammers operated by horizontal fire
tube boiler & its material handling equipments like overhead
crane,tongs . we saw oil fired furnace .

we visited & observed the close die forging shop. Especially

we observed close die forging for small sized jobs. We
observed friction hammer, pneumatic hammer & its furnace
& punching press for removing of excessive material.

TRAINEE'S WEEKLY REPORT

1.INSTITUTION PROFILE & LAYOUT

SANGHVI FORGING & ENGINEERING LTD

Sanghvi Forging & Engg. Ltd. is the manufacturer of various

forging and machined components for process and heavy industrial
application.
Company has always focused on state of the art technology for
delivering better products year after year.
Superior industry experience commitment to quality and strong
management vision defines the ground on which SFEL is placed today.
MILESTONE

1992: Set up existing factory at Vadodara with an installed capacity of

300 MTPA for close die forging.
1996: Obtained first major approval from the TDC of India.
2006: Establishment of new open die forging plan an installed capacity
2400 MTPA.
2009: Obtained approval from GE, PDIL, EIL etc.
2010: Placed firm order for import of forging press and manipulator for
the current capacity expansion.
2011: IPO
2012: Commencement of new heavy forging.

PRODUCTS

TYPES OF FLANGES
WNRF- weld neck race flange
SORF-slip on race flange
SWRF-socket weld race flange
BLRF- blind race flange
WNRTJ-weld neck ring tongue joint
Spectacle type flange
T , ALBOW ,LONG WELD NECK etc.

OPEN DIE FORGINGS

Size: Up to 1600 Dia.
Weight: 0.5 kg to 2500 kg
Material:
Carbon steel: A-105, A-350,LF2,[NACE+HIC] etc.
Alloy steel: F-5,F-9,F-11,F-22,F-91 etc.
Stainless steel: 304,304 L, 316, 316 L,317 L,321,347,347 H etc.
Duplex S.S.:F51, F-55
Products: Tube sheets, Rings, Valve bodies, Discs, Shafts, Barred
tees, Blocks, Special flanges, Nozzles, Long weld neck, reducing
flanges etc.

Dimensions: As per customer drawings

FORGED FLANGES

Size: 1/2 to 54
Pressure Rating: 150#,300#,600#,900#,1500#,2500#
Material:
Carbon steel: A-105, A-350, LF2, [NACE+HIC] etc.
Alloy steel: F-5, F-9, F-11,F-91 etc.
Stainless steel: 304, 304L, 316, 316L, 316Ti, 304H, 317L, 347H etc.
Duplex S.S.: F-51, F-55
High Strength steel: A694Gr52,60, 65, 70, AISI 4130, AISI 4140

CLOSED DIE FORGING

Instrument forging
Material: A-105,A-350,F 304L,F 316L,316Ti,F-321,F-51,F-55 & Nickel
alloy etc.
Valves: Needle valves, Gate valves, Globe valves, Double block &
bleed valves
Dimensions: As per customer drawing

MACHINED COMPONENT

Size: Up to Dia.700 mm
Carbon steel: A-105, A-350, LF2, [NACE+HIC] etc.
Alloy steel: F-5, F-9, F-11, F-22, F-91 etc.
Stainless steel: 304, 304 L, 316, 316 L, 317 L, 321, 347, 347 H etc.
Duplex steel: F-51. F55 etc.
Items: Nuts, Nipples, Special hardware, stub, Valve pan
Weight: Up to 1000 kg

HEAVY FORGINGS

TUBE FORGINGS
RINGS
BLOCKS & PLATES
TUBE SHEETS
SHAFTS & STEP SHAFTS
FORGED BARS
COMPANY HAS INSTALLED FOLLOWING EQUIPMENTS
Open die hydraulic forging press- 4500 tons
Rail bound manipulator -60 tons
Gas fired reheating furnace-60 tons
Two fired heating furnace
Gas fired slow cooling furnace
Quenching tank-water
Quenching tank-polymer

Cutting bandsaw-2000mm
2 Nos. EOT -80/20 tons
SANGHVI FORGING COLOUR CODING
AUSTENITIC STAINLESS STEELS
304-Light brown
304 L-Light blue
1.4 307-Yellow
316-Dark brown
316 L-Orange
1.4 404-Purple
1.4 571-Dark grey
1.4 541-Light grey
321-Dark green
EN_19-White/Orange
CARBON & LOW ALLOY STEELS

A_105-White
LF2-Crme
F_11-Light green
F_22-Dark blue
F_51-Pink
F_65-Black
347-Black/Light green
304_H-Orange/Light green
316_H-Brown/Crme

FLOW CHART OF COMPANY

P.O.DEPTT.

MARKETING
DEPT.

Q.A.

DIRECTOR

RAW MAT. INSPECTION

CUTTING DEPTT.

FORGING
DEPTT.

MAT. SHOP

HEAT TREATMENT DEPTT.

MACHINING
DEPTT.

Q.C. & Q.A.

DISPATCH
DEPT.

2.PRACTICAL TRAINING
RAW MATERIAL INTRODUCTION & INSPECTION

The basic raw materials for further forging are ingot, bar, concast
etc.
A Forging quality ingot has:
Fully killed steel,
No piping, Shrinkage or cracks,
Concave, clean, hot top surface,
No scabs, sand inclusion, seams blisters, blow holes, fish scale,
Smooth, clean surface,
Very law level of inclusions & segregation.
o Raw material is firstly inspected by PMI GUN.
o First breakdown of ingot is called bloom, C.S. Area >230 cm 2
o Further reduction of bloom is called billet minimum C.S. 40 by 40.
o Plate and sheet, plate thickness >6mm, sheet & strip <6mm, strip
width <600mm, sheet width>600mm.
o PMI - POSITIVE MATERIAL IDENTIFICATION
o Raw mat. is checked by engineer.
o Then material is taken by Cutting Deptt. for cutting into various
parts.

CUTTING DEPARTMENT
o The basic purpose of cutting is for produce proper size
material for forging.
o SFEL has 5 cutting machines.
o H-460HA, S-250HA, DCA-160, INDTOOLS.
o Each machine has cutting capacity according to their no.
o INDTOOLS has capacity of 1200mm that mean it can be
cut 1200mm height /width sample.
o EVERISING cutting machines are used in SFEL.
o For smooth cutting, flowing of cutting oil is constantly done.

3.CONCLUSION
In fact my training in SFEL was very useful to me in
acquiring new engineering skills that I had not had before.
These learned skills prove being very valuable by signifying
an impact in solving problem.
Skills of team work and planning are universally desired
since; they increase the efficiency of any project in terms of
time & money

FORGING DEPARTMENT
Forging is the working of metal into a useful shape by
hammering or pressing. It is the oldest of the metalworking
arts, having its origin with the primitive blacksmith of Biblical
times.
Most forging operations are carried out hot, although certain
metals may be cold forged. Two major classes of equipment
are used for forging operations. The forging hammer or drop
hammer, delivers rapid impact blows to the surface of the
metal, while forging press subjects the metal to a slow
speed compressive force.
The two broad categories of forging are open die forging &
closed die forging.
Open die forging is carried out between flat dies of very
simple shape. The process is used mostly for large objects
or when the number of parts produced is small.
In closed die forging the work piece is deformed between
two die halves which carry the impression of the desired
final shape. The work piece is deformed under high
pressure in a closed cavity, and thus precision forging with
close dimensional tolerances can be produced.
The simplest open die operation is the upsetting of a
cylindrical billet between two flat dies. The sides of the

upset cylinder become barreled. As a general rule , metal

will flow most easily toward the nearest free surface
because this represents the lowest frictional path.
Edging dies are used to shape the ends of the bars and to
gather metal.
Fullering is used to reduce the cross sectional area of a
portion of the stock.

Closed die forging uses carefully machined matching die

blocks to produce forgings to close dimensional tolerances.
Large production runs are generally required to justify the
expensive dies.

In close die forging the forging billet is usually first fullered

and edged to place the metal in the correct place for
subsequent forging.

The preshaped billet is then placed in the cavity o the

blocking die and rough forged to close to final shape.

It is then transferred to the finished die, where it is forged to

final shape and dimensions.

It is important to use enough metal in the forging billet so

that die cavity is completely filled. When the dies come
together for the finished step, the excess metal squirts out
of the cavity as a thin ribbon of metal called flash. In order
to prevent the formation of a very wide flash, a ridge known
as a flash gutter

SFEL FORGING
FORGING OF C.S. & S.S.
o First of all the material is taking for flange
forging. The material cutting ratio is 3:1.That
mean material is taking for forging is 3 times
higher from main pieces.
o Then material is going in forging yard ,here two
process is done 1.PRE HEATING 2.FORGING
o The temp. for preheating is maintain above
1000 C.
o Here for preheating oil fired furnace is used.
o Drop hammer type is steam drop hammer
capacity of hammer is 3 ton & 5ton for open die
forging & 1 ton for close die forging.
o For drop hammer steam pressure is 150 kg/cm2.
o In forging step first remove the piping from
preheat pieces.
o Closed die forging m/c is HUTA ZYGMUNT and
another NKH.

MATERIAL : [ASME/ASTM] STAINLESS STEEL

AUSTENITIC S.S.
GRADE

FORGING TEMP.

QUENCHING
MEDIUM

F 316/F
1100-1200 0
316L/316H

WATER

F 304/
1100-12000
304L/304H

WATER

F 321/
321H

1100-12000

WATER

F 347/
347H

1100-12000

WATER

F 51

1150-12200

WATER

CARBON STEELS & LOW ALLOY STEELS

GRADE

FORGING TEMP.

QUENCHING MEDIUM

A 105

1000-11500

AIR

A 694 F 65

1000-11500

AIR

A 694 F52

1000-11500

AIR

A 350 LF 2

1000-11500

AIR

F 11/CL 1,2,3

1000-11500

STILL AIR

F 22

1000-11500

STILL AIR

F5

1000-11500

SLOW AIR

F9

1000-11500

SLOW AIR

FOR SKETCHES,
DIAGRAMS AND GRAPHS
DATE:
(Additional drawings, may
be attached where
necessary)
The student may also use

this space for

additional
reports.

Date:

Student's
Signature:
Comments by Industry Mentor:

Name:
Signature:

Date:

WEEKLY PROGRESS CHART

ENDING 22/6/2013
)
DAY

Monday

Tuesday

(SECOND WEEK)

(WEEK

DESCRIPTION OF WORK DONE

We got information about how the row material is heated in

the oil fired furnace and how the row material is converted
into require size and shape of flanges by friction hammer and
pneumatic hammer and remove excessive material by
punching press.
We visited the heat treatment shop and we observed the
different equipment of heat treatment process. We observed
different type of furnace for heat treatment process like oil
fire furnace, gas fire furnace and muffle furnace

We observed the different process of heat treatment for

different material like
Wednesda normalizing,anneling,hardening,temparing and solution
y
anneling.

Thursday

Friday

Saturday

We visited the machining shop and observed different type of

lathe machine, grinding machine,drill machine . we also
observed material handeling equipment like crane.

We visited the die shop here company making die for the
forging. In this shop there were two lathe. We take
information about different type of die which was used by the
company.
We visited the CNC machine shop. In which there is 6 CNC
and 2 VMC machine heaving different capacity and
specification.

TRAINEE'S WEEKLY REPOR

HEAT TREATMENT DEPARTMENT

o The area of application for any metal or alloy is limited by its
properties. Heat treatment plays an important role in such a
wide acceptance of steel as an engineering material.
o Properties of steel can be controlled and varied over a wide
range by H.T. Heat treatment affects mechanical properties
either allotropic transformation or changing relative
solubilities of element in the base metal.

ANNEALING
Annealing , in general involves heating to predetermined temp.,
holding at this temp. And finally cooling at a very slow rate. The
temp. to which steel is heated and holding time are determined
by various factors such as chemical composition of steel , size
and shape of steel component, and final properties desired.
Annealing is performed for
1.Relieve internal stresses
developed during solidification ,machining, forging, rolling,
welding 2.Improve ductility and toughness
3.Enhance
machinability 4.Eliminate chemical non uniformity 5.Refine
grain size.
On the basis annealing temp. it can be classified as FULL
ANNEALING,
PARTIAL
ANNEALING,
SUBCRITICAL
ANNEALING.
According to phase transformation it can be further classified as
FIRST ORDER & SECOND ORDER ANNEALING.
Full annealing is employed for hypoeutectoid steels and not for
hypereutectoid steels.

 Homogenizing annealing is known as diffusion annealing, other

classification
are
PROCESS
ANNEALING,
RECRYSTALLIZATION ANNEALING, PROCESS ANNEALING.

NORMALIZING
Normalizing is a process oh heating steel to about 40-50 C 0 above
upper critical temp. holding for proper time, then cooling in still air
or slightly agitated air.
More homogeneous austenite is formed, to improve mechanical
properties.

NORMALIZING VERSUS ANNEALING

Normalized steels are harder than annealed
ones.
Higher degree
normalizing.

of

super

cooling

in

Annealing improves machinability of medium

carbon
steels,
whereas
normalizing
improves machinability of low low carbon
steels.
Prolonged heat treatment time and high
energy consumption make annealing more
expensive.
Normalized improver strength & hardness,
whereas annealing improves ductility.
Normalized steel has lower impact transition
temp.

 HARDENING
o Certain applications demand high tensile strength and
hardness value, it can be obtained by a process known as
hardening.
o Hardening treatment consists of heating to predetermined
temp., holding at that temp. And followed by rapid cooling such
as quenching in water, oil or salt bath.
o The product of low temp. transformation of austenite is
martensite which is a hard micro constituent of steel.
o Hypoeutectoid steels are heated about 30-50 0 C above the
upper critical temp.

FACTORS AFFECTING HARDENING

o Chemical composition of steel
o Size & shape of steel
o Hardening cycle
o Quenching media
o Surface condition of steel parts

HARDENING METHODS
Conventional or direct quenching
Quenching in stages in different media
Spray quenching
Austempering & Mar tempering

 TEMPERING
Tempering treatment lowers the hardness, strength and
wear resistant, however this marginal loss adequately
compensated by advantages gained by relieving internal
stresses.
Hardening followed by tempering is the only conventional
heat treatment process for improving elastic limit of steel.

SFEL HEAT TREATMENT

o Annealing
o Solution annealing
o Normalizing
o Tempering
o Hardening
SFEL has total 4 furnaces for heat treatment.
Two muffle f/c for R&D.
Annealed furnace with capacity 1 ton, and another solution
annealing gas fired f/c with capacity 4 ton.
Shot blasting machine is also placed in H/T department.
Normalizing air cooling, Annealing furnace cooling,
Hardening-fan cooling or quenching.

 MAIN HEAT TREATMENT IN SFEL

SAMPLE

TEMP.

PROCESS

A-105

9300

NORMALIZING

A-182,F-304/304L

10600

SOLUTION
ANNEALING

A-182,F-316/316L

10600

SOLUTION
ANNEALING

F-5

9700

ANNEALING[450]

F-9

9700

ANNEALING450[]

A-68 GR.70

9300

NORMALIZING

F-22

9800

ANNEALING

F-53

10600

SOL .ANNEALING

SS-420

9800-9800-6350

ANNEALING,
HARDENING,
TEMPERING

A-6,GR.70

8800-6900

QHENCHIN &
TEMPERING

 MACHINING DEPARTMENT
o Machining process produced the required shape by removal
of selected areas of work piece through a machining
process.
o Most machining is accomplished by straining a local region
of work piece to fracture by the relative motion of the tool &
work piece.
o Machining usually is employed to produce shapes with high
dimensional tolerance, good surface finish, and often with
complex geometry.
o Machining is secondary processing operation since it
usually conducted on a work piece that was produced by a
primary process such as hot rolling, forging or casting.
SFEL MACHINING
TYPES OF MACHINING
o Facing Reduce thickness.
o Turning Reduce O.D.
o Drilling For creating holes.
o Boring For enlarging holes.
o Milling For cutting slot.
o Chamfering For smooth edges
o Reaming For smoothing hole.

 TYPES OF CUTTING TOOL

Single point turning tool
Multi point drill, milling cutter/ grinding tool
In SFEL CNC shop & Heavy m/c shop are there.
In CNC shop VMC- vertical machining centre,
VTL- vertical turning lathe, radial drilling
machine.
CNC-computerized numetic control
CNC SHOP LAYOUT
CNC- 4
CNC-8

CNC-3

CHAMF.
M/C

LATHE1

LATHE-2

CNC-7
ITEM UNDER INSPECTION

MATERIAL
STORAGE
VMC-2
CHAMFERING
M/C
CNC-5

VTL
CNC-6

VMC-1

In heavy machine shop different type of machining is carried out

with different capacity.

FOR SKETCHES, DIAGRAMS AND GRAPHS

DATE:
(Additional drawings, may be attached where necessary)
The student may also use this space for additional reports.

Student's
Signature:

Date:

Comments by Industry Mentor:

Name:
Signature:

Date:

10

WEEKLY PROGRESS CHART

ENDING 29/6/2013
)
DAY

(THIRD WEEK)

(WEEK

DESCRIPTION OF WORK DONE

Monday

We observed the process and work done on the CNC

machine. We had deeply observed and learn how to operate
the CNC machine for different operation.

Tuesday

We visited the quality control department and observed

process of quality control and inspection. We show the
different equipment for quality check by company.

We observed how to quality check by company. We observed

different type of test like NDT, Distructive test and
Wednesda metallurgy test .we show different type of test.
y

Thursday

We observed the testing of test pieces. We take some

important information about quality control from q.c
engineer.

We visited the m.s.store and s.s.store where the product

stored by the company and dispatched as per order.
Friday

Saturday

We visited the product packing shop and in this shop the

product is packed in the wooden box manually made as per
requirement.

11

TRAINEE'S WEEKLY REPORT

Q.C. & Q.A. DEPARTMENT

Quality control department
o Visual inspection like crack, burn, dent, stub, forging defects etc.
o Sampling inspection & dimensional inspection, 10% that mean
10 samples are taken from 100 samples.
o Mechanical testing- UTM: Universal tensile m/c, Hardness testRockwell hardness tester, Impact test.
o NDT- UT: ultrasonic testing, DP: die penetration test, MPImagnetic particle inspection, RT- radiographic testing
o PMI GUN-positive material identification, chemical analysis go to
MET-HEAT, macro & micro test, grain size measurement &
analysis, corrosion test.S
o Dynamic hardness tester, spectrographic for chemical analysis,
hydraulic tester.

 MEASURING EQUIPMENTS
Calipers
Mechanical vernier calipers
Digital vernier calipers
Micrometer [O.D.]
Slip gauge [thickness]
Plain plug gauge
Bevel protector [angular measurement]
Pitch gauge
Radius gauge
Thread gauge
Degree protector
Bore gauge[I.D.]
Roughness tester
Magnification glass

QUALITY ASSURANCE DEPARTRMENT

Documentation
o Heat no., Item description, order & offer quality
Third party handling
QAP- quality assurance plan

 DISPATCH DEPARTMENT

Rust prevention by colored products

Packing products
Cap for prevent damaging
Transportation by road & railway

Student's
Signature:

Date:

Comments by Industry Mentor:

Name:
Signature:

Date:

13