Summer Training Report

At
ISGEC Pvt. Ltd.
Submitted in partial fulfillment of the requirement for the award of the
Summer Training of
BACHELOR OF TECHNOLGY (Mech. Engg.)
2015-2019

Submitted To: - Submitted By:-

Mr. Ashok Garg Lokesh
(Assistant Professor) Roll No. 1511154910
Department of Mech. Engg. B.tech Mech-7th Sem.

CH. DEVILAL STATE INSTITUE OF ENGINEERING AND

TECHNOLOGY
PANNIWALA MOTA, SIRSA, HARYANA

Affiliated to Guru Jambheshwar University, Hisar

 ACKNOWLEDGEMENT
Simply put, I could not have gained this work knowledge without the lots of help I
received cheerfully from whole ISGEC Pvt. Ltd. The work culture in ISGEC Pvt.
Ltd. really motivates. Everybody is such a friendly and cheerful companion here
that work stress is never comes in way.

I am highly indebted to my HR Mr. Subash Sharma, who seemed to have to all my

problems.

At this juncture I feel deeply honored in expressing my sincere thanks to my

project guide Mr. Ashok Garg (Assistant Professor) who assisted me in compiling
the Report

Lokesh

1511154910 Date.
 Abstract
Training is an act of increasing knowledge and skills of a person for doing a
particular job more professionally. Classroom teaching helps the students by
making conceptual base clear, but on the job training is the practical way, which
helps the students get the practical knowledge about the concept.

Industrial experience is also required in this field to prosper as a professional in

future. The object of training is to get familiar with the job, fill areas of gap
between immaturity and professionalism with knowledge and skill and change
negative to positive attitude.
 CADIDATE’S DECLARATION
We here certify that the work which is being presented in the project, titled “Press
Production”, in the partial fulfillment of requirements of the award of the Degree
of Bachelor of Technology and submitted in the Mechanical Engineering
Department of CH. Devilal State Institute of Engg. & Tech. Panniwala Mota is an
authentic record of our own work carried out under the supervision of Ch. Devilal
State Institute of Engg. & Tech. Panniwala Mota. The matter presented in this
Project report has not been submitted by us for the award of any Degree of this or
any other university.

Date

Lokesh

1511154910
 Contents
Acknowledgement

Abstract

Candidate Declaration

Chapter 1 [ISGEC- A Brief Profile]

Chapter 2 [Project- Construction & Inspection of Presses]

2.2 Preparation Shop

2.3 Fabrication Shop

2.4 Machine Shop

2.5 Assembly Shop

Chapter 3 [Mechanical Press]

3.1 Principle

3.2 Advantage

3.3 Features of Mechanical Press

3.4 Problems in Mechanical Press

3.5 Inspection of Press

 Chapter 1
ISGEC-A Brief Profile
ISGEC the heavy engineering unit of Saraswati Industrial ltd. was established in
1946 and is located at Bawal (Rewari), Haryana about. The annual turnover of
ISGEC is US $ 50 million and group turnover of the Saraswati Industial Syndicate
ltd. Exceeds US $ 100 million.

 Infrastructure
 Lifting Capacity : Crane capacity- 200 MT(Hydraulic Lifting arrangement
for heavier loads up to 250 MT)
 Shop covered area: 43,000 Sq. Meter (51,427 Sq. yards)
 Total plant area: 250,000 Sq. Meter (298,998 Sq. yards)
 Forming
 Rolling : Thickness - 200 mm (8 inches)
 Welding
 Narrow Gap Welding with seam tracking
 Strip Cladding using single as well as double layer technique
 Automatic small diameter nozzle cladding.
 Twin wire and tandem head welding SAW, SMAW, TIG, and MIG etc.
Over 850 WPS and 1000PQR
  Drilling

Thickness up to 1000 mm ( 40 inches) using deep hole CNC Drilling

machine

 Heat Treatment

 Four Gas Fired Furnaces Size up to: 4500 mm x 4000 mm x 14500 mm

 Stress Relieving, Annealing, Quenching and Tempering as well as Solution

Annealing of Stainless Steels

 Local Stress Relieving by Electrical Resistance Method

 Stress Relieving by Internal Firing Method

 Stress Relieving of large jobs in Temporary Furnaces

 Radiography

Cobalt 60 for Radiography up to 200 mm (8 inches)

Testing

Tensile testing including Elevated Temperature Testing up to 800

C (1470F)

Impact Testing up to (-) 196

C (-320F)

• Insitu Alloy Analyzer

• Metallurgical Microscope X-2000 with Photography facility
• Ferrite Measurement
• Recordable/ Mechanized Ultrasonic Testing
• Magnetic particle Testing
• Liquid Penetrant Testing
• Holiday Testing for Painting
• IGC Testing
• Complete laboratory supported by spectrometer

PRODUCT RANGE
Diversity of ISGEC products range enables us to serve industry from Automobile
and ship building to oil &natural gas, defense, aeronautics and nuclear power. The
group’s product range includes for;

• Hydraulic Presses, Mechanical Presses & Press brake. ISGEC has successfully
commissioned around 100 presses built include a 3700 tones hydraulic presses for
defense and a 2500 tones mechanical press.
• Process plant equipment (pressure vessels, heat exchangers, columns, storage and
transport vessels, reactors etc.) for fertilizer refinery, petrochemical and other
industries.
• Industrial & power boilers(including pulverized fuel boilers up to 60 MW size
bubbling as well as circulating fluidized bed boilers up 200 TPH size).
• Custom made equipment for India’s nuclear establishments. ISGEC has supplied
equipment during last 15 years to Bhabha Atomic Research Center, Nuclear power
Corporation, center of advanced technology.
• Chlorine, Ammonia and other gases containers. ISGEC are the largest
manufactures of chlorine in the world.
 Chapter- 2
Project- Construction & Inspection of Presses

The step by step procedure followed during the project & explanation of the same
is as follows;

Preparation Shop

This is where the raw material for production is brought in initial stage and it is
identified as per the specification. The scope of Preparation shop is to prepare
material required by various other shops. The tentative load or the amount of
material required is set in starting of the financial year i.e. October. The quantity
depends upon the delivery date & the requirement of the customer, The raw
material is firstly identified & then is brought inside the shop where cutting
operations are performed by using manual Gas cutting & CNC machines on the
material as per requirement for its fabrication. The two main requirements for
cutting the material are drawing, and information about material. The cutting
machines are CNC which require some operator to feed the program and the
cutting is done as per the program. Most of the programs are made by the operators
while some complex programs are made by supervisors. The programs are
compiled in Auto Cad & are feed directly to CNC through Burney LCD scanner.
There are two cutting methods A)

Gas cutting A cutting torch is used to heat metal to kindling temperature. A stream
of oxygen is then trained on the metal, and metal burns in that oxygen and then
flows out of the cut as an oxide slag. B)

Plasma cutting an inert gas is blown at high speed out of a nozzle; at the same time
an electrical arc is formed through that gas from the nozzle to the surface being
cut, turning some of that gas to plasma. The plasma is sufficiently hot to melt the
metal being cut and moves sufficiently fast to blow molten metal away from the
cut.
Fabrication Shop

Fabrication shop is one of the constituents of the machine-building division.

Almost all sort of fabrication work are done here. In this shop thick sheets of mild
steel are cut, welded and bent according to the required design. For the cutting of
plates and sheets gas cutting technique is made use of. Then different cut parts
are joined together with the help of welding.

Some of the welding techniques adopted are

• Gas Metal Arc Welding (GMAW)
• Submerged Arc Welding (SAW)
• Shielded Metal Arc Welding (SMAW)
• Semi Saw
• Plasma Arc Welding
The bending of sheets is preferred in hydraulic presses. For bending, a specific
type and size of the die is kept under the plate to be bent and then hydraulic
pressure is applied above the plate. Extent of bending depends upon the radius of
curvature of arc formed by bend plate. Gouging is used for repairing faulty
weld joint.

Instructions for various works in Fabrication Shop

• Gas Cutting Instructions
1. Select the optimum plasma cutting machine as per the supervisor’s
instructions.2.

Read instructions and work method on machine.3.

If cutting is through gauging, then leave 1.5mm from marking punch & start
cutting.

General Instructions
1. Clean the surface before cut.
2. Cut in down hand position only.
3. Use guide in case of round cutting (whenever possible).
4. Use cookie machine during straight cut.
5. Avoid under cuts during cutting.
6. Ask supervisor in case of any doubt.

• Cold Bending

1. Check machine and dye as per requirement.

2. Check material size and mark bend line as per layout.
3. Set dye as per the material size.
4. After setting up machine, set bend marking and bend degree.
5. Bend the job slowly and on completion check the size with the help of template.
6. Check the completed piece and get it passed by supervisor.

• Fitting via Welding

1. Check material according to BOM.
2. Collect drawing from supervisor and required material from BOM.
3. Check the material for straightness.
4. Straight material as per supervisor’s instructions.
5. Prepare layout for fitting as per drawing and supervisor.
6. Set priorities for fitting as per supervisor’s instructions and drawing or ND table
given by Quality Assurance.

7. Fit job as per drawing or layout.

8. Mark job no., drawing no., mark no., serial no., and fabrication weight which
must not exceed 5tons,
9. Self-inspect for next operation.

• Painting a Job
1. Collect required information about job from supervisor.
2. Check for rust, oil or grease or any kind of dust material on job.
3. Before painting, check that job is grit blast or wire brushed as per job drawing.
4. Clean job surface as required by piece of cloth.
5. Apply primer as per Quality Assurance or instructions.
6. Ask supervisor in case of any doubt.

• Hydro-testing

1. According to supervisor’s instructions, set job’s position keeping in mind the

position of air packet.
2. Collect at least 2 pressure gauges as per the test pressure given in job drawing,
3. Range of pressure gauge must be between 1.5-4 times the test pressures.
4. Gauges must be calibrated.
5. Gauge must be placed at a place from where its reading is easy to read.
6. Tight all gauges and close all job openings before applying pressure.
7. Apply test pressure as per supervisor’s instructions and check for leakage and
report the same.
8. Remove pressure slowly and remove water from job completely.
9. If there is a difference of more than 30PSI, than report to the supervisor.

• Welding

1. Collect information about the job and type of welding from supervisor.
2. Select appropriate machine and check for its calibration and connections.
3. Check WPS or shop welding record of job and check for your qualified position.
4. Collect electrode from electrode cabin as per data sheet.
5. Issue a maximum of 15 electrode and filler wire for MIG/TIG.
6. Weld according to WPS and test Route run OP of 10% part of groove size more
than 10mm.
7. Return stubs of used electrodes before issuing new electrodes.
8. Self-inspect after welding and fill up check sheet.

• Blast Cleaning Stage I

1. Clean job from grease, oil, etc.

2. Blast job as per SA 2 ½ Swedish standard SIS055900. Check surface profile by
comparing it with standard full size photograph.
3. If blast cleaning is not possible, clean grease with the help of D-slagging gun or
Wire brush.
4. Get the job checked by Shop supervisor,

Stage II Primer coating inside oil tank

1. Before applying primer check that it has been not more than 8hrs after blasting.
2. Job must be properly cleaned and dry. Never clean with the help of a cloth.
3. Keep in mind following things before applying primer;
4. Use primer epoxy Zinc Chromate only, and ensure that it’s not more than 12
months old.
5. Ensure primer is in 2 packs and mix its plate and hardener as per instructions
below.
A. For mixing Zinc Chromate use 3 parts of paste and 1 part of hardener, use
epoxy thinner to dilute the paste. Pot life for such a primer is 3-4hrs use brush or
spray gun to apply primer.
B. Keep in mind the time required by primer to dry. For Touch dry it is 1hr. For
Handle dry is 4hrs.And hard dry is 12hrs.

For Steel Structure

Same as for Oil tank above, except the use of Zinc Phosphate primer.

Stage III, IV & V Painting top coat

1. Ensure condition of primer coating before applying Putty.
2. Rough the prime red surface with emery paper and clean dry with the help of
cloth.
3. Each outer surface of job that is visible and is prime red is coated with a layer of
Putt. For the same, Putty is prepared as below;
4. Take 9 parts paste and 1 part hardener. Use epoxy thinner to dilute the mixture.
Stir a rod or stirrer. Pot life is of 3-4hrs.
5. Apply the prepared Putty with the help of knife. Dents are filled up with the help
of Putty. It takes12 hrs to dry.
6. Use Putty Sander for rubbing of Putty as per given below;
7. If drying time is 14-24hrs use 80 Grit Sanding disc on Putty sander. If drying
time is more than 24hrs then use 60 Grit Sanding disc.
8. Clean with a clean cloth.
9. Cover the entire machined surface with PVC tape, Grease, Oil, etc.
10. Apply a coat of surface. Keeping in mind the following points;
11. Use PU surface only and use 9 parts with 1parts Hardener and prepare that
much only which can be utilized within 4-6hrs. Give at least 4hrs after applying to
dry.

Stage VI and VII

1. Apply on jobs ready to be dispatch.
2. Ensure the job free from any kind of dust particles, if so, clean the surface with
help of surface thinner,
3. Use primer on grinded surface.
4. Use epoxy Putty on scratched surface and give time to dry.
5. Cover all those surfaces that are not to be painted.
6. Use 80 Grit Sanding disc in sander and plane those surfaces where putty is
applied.
7. Use PU surface on surfaces where Putty is applied.
8. Use paint where PU surface has been applied and give paint time to dry.
9. Now apply a fixed coat of paint.
10. Use rust guard on all machined surfaces.
11. Use Zinc phosphate primer on inside parts and those parts that touch ground.
12. Uncover all the parts and clean them properly.

Welding Techniques Observed

Submerged Arc Welding (SAW)

It is a common arc welding process. It requires a continuously fed consumable

solid or tubular (flux cored) electrode. The molten weld and the arc zone are
protected from atmospheric contamination by being submerged under a blanket of
granular fusible flux consisting of lime, silica, manganese oxide, calcium fluoride,
and other compounds. When molten, the flux becomes conductive, and provides a
current path between the electrode and the work. This thick layer of flux
completely covers the molten metal thus preventing spatter and sparks as well as
suppressing the intense ultraviolet radiation and fumes that are a part of the
process.

SAW is normally operated in the automatic or mechanized mode. The process is

normally limited to the flat or horizontal-fillet welding positions.

Electrode

SAW filler material usually is a standard wire as well as other special forms.
This wire normally has a thickness of 1/16 in. to 1/4 in. (1.6 mm to 6 mm).
Factors that usually effect SAW
1. Wire feed speed (main factor in welding current control)
2. Arc voltage
3. Travel speed
4. Electrode stick-out (ESO) or contact tip to work (CTTW)
5. Polarity and current type (AC or DC) & variable balance AC current

Advantages
1. High operating factors in mechanized applications.
2. Deep weld penetration.
3. Sound welds are readily made (with good process design and control).
4. High speed welding of thin sheet steels up to 5 m/min (16 ft/min) is possible.
5. Minimal welding fume or arc light is emitted.
6. Practically no edge preparation is necessary.
7. The process is suitable for both indoor and outdoor works.
8. Distortion is much less.
9. Welds produced are sound, uniform, ductile, corrosion resistant and have good
impact value.
10. Single pass welds can be made in thick plates with normal equipment.
11. The arc is always covered under a blanket of flux, thus there is no chance of
spatter of weld.
12. 50% to 90% of the flux is recoverable

Limitations
1. Limited to ferrous (steel or stainless steels) and some nickel based alloys.
2. Normally limited to long straight seams or rotated pipes or vessels.
3. Requires relatively troublesome flux handling systems.
4. Flux and slag residue can present a health & safety concern.
5. Requires inter-pass and post weld slag removal.

Gas Metal Arc Welding

Sometimes referred to by its subtypes metal inert gas (MIG) welding or

metal active gas (MAG) welding, is a semi-automatic or automatic arc welding
process in which a continuous and consumable wire electrode and a shielding gas
are fed through a welding gun. A constant voltage, direct current power source is
most commonly used with GMAW, but constant current systems, as well as
alternating current, can be used. There are four primary methods of metal transfer
in GMAW, called globular, short-circuiting, spray, and pulsed-spray, each of
which has distinct properties and corresponding advantages and limitations.

Equipment
Welding gun

The typical GMAW welding gun has a number of key parts—a control switch,
a contact tip, a power cable, a gas nozzle, an electrode conduit and liner, and a gas
hose. The control switch, or trigger, when pressed by the operator, initiates the
wire feed, electric power, and the shielding gas flow, causing an electric arc to be
struck. The contact tip, normally made of copper and sometimes chemically treated
to reduce spatter, is connected to the welding power source through the power
cable and transmits the electrical energy to the electrode while directing it to the
weld area. The gas nozzle is used to evenly direct the shielding gas into the
welding zone—if the flow is inconsistent, it may not provide adequate protection
of the weld area.

Wire feed unit

The wire feed unit supplies the electrode to the work, driving it through the conduit
and on to the contact tip. Most models provide the wire at a constant feed rate, but
more advanced machines can vary the feed rate in response to the arc length and
voltage.

Electrode
Electrode selection is based primarily on the composition of the metal being
welded, the process variation being used, joint design and the material surface
conditions. All commercially available electrodes contain deoxidizing metals such
as silicon, manganese, titanium and aluminum in small percentages to help prevent
oxygen porosity. Some contain denitriding metals such as titanium and zirconium
to avoid nitrogen porosity. De pending on the process variation and base material
being welded the diameters of the electrodes used range from 0.7 to 2.4 mm but
can be as large as 4 mm.
Shielding gas

Shielding gases are necessary for gas metal arc welding to protect the welding area
from atmospheric gases such as nitrogen and oxygen, which can cause fusion
defects, porosity, and weld metal embrittlement if they come in contact with the
electrode, the arc, or the welding metal. The choice of a shielding gas depends on
several factors, most importantly the type of material being welded and the process
variation being used. Pure inert gases such as argon and helium are only used for
nonferrous welding; with steel they do not provide adequate weld penetration
(argon) or cause an erratic arc and encourage spatter (with helium).Pure carbon
dioxide, on the other hand, allows for deep penetration welds but encourages oxide
formation, which adversely affect the mechanical properties of the weld. Its low
cost makes it an attractive choice, but because of the reactivity of the arc plasma,
spatter is unavoidable and welding thin materials is difficult. As a result, argon and
carbon dioxide are frequently mixed in a 75%/25% to 90%/10% mixture. Shielding
gas mixtures of three or more gases are also available. Mixtures of argon, carbon
dioxide and oxygen are marketed for welding steels. Other mixtures add a small
amount of helium to argon-oxygen combinations, these mixtures are claimed to
allow higher arc voltages and welding speed.

Advantages
1. Because of continuously fed electrode, MIG welding process is much faster as
compared to TIG or stick electrode welding.
2. It can produce joints with deep penetration.
3. Thick and thin, both types of work pieces can be welded effectively.
4. Large metal deposition rates are achieved by MIG welding process.
5. The process can be easily mechanized.
6. No flux is used. MIG welding produces smooth, neat, clean and spatter free
welded surfaces which require no further cleaning. This helps reducing total
welding cost.
7. Higher arc travel speeds associated with MIG welding reduce distortion
considerably.

Disadvantages
1. The process is slightly more complex as compared to TIG or stick electrode
welding because a number of variables (like electrode stick out, torch angle,
welding parameters, type and size of electrode, welding torch manipulation, etc.)
are required to be controlled effectively to achieve good results.
2. Welding equipment is more complex, more costly and less portable.
3. Since air drafts may disperse the shielding gas, MIG welding may not work well
in outdoor welding applications.
4. Weld metal cooling rates are higher than with the processes that deposit slag
over the weld metal.

Machine Shop
Machine shop is the main work station. Here various machining operations are
carried out to produce different parts of presses. There are two division of machine
shopa) Machine shop-I Heavy Work Divisionb) Machine shop-
II Light Work DivisionVarious Machine Employed at Machine Shop-I
1. SKODA horizontal boring HB -11, HB-3, HB-19, HB-8, HB-1
2. SWIFT LatheML-143. H.M.T Radial Drilling Machine RD-44. SACEM-
MSMG

Assembly Shop
The last stage in the machine building division, the various components for
the construction of a press is collected here and the final assembly of the press is
done. The shop is divided in two zones of area one is the pit area and the other is
outer area. Presses greater in size and height are assembled in the outer area and
those normal in size in the pit area. The final assembly involves very precise work
and therefore requires more skilled workers and experienced supervisors. Each
press is assembled according to the requirement of the customer. The assembly
requires two broad machine parts

• Parts fabricated by ISGEC i.e. the frame and some other components.
• Parts being imported from outside that are parts like modules and brake and
gear system and oil lubrication unit. The link frame presses are assembled with the
help of tie rods which join the bottom head, uprights and top head together. The tie
rod helps to assemble them in proper positions. When the frame is ready the slide
is moved inside it and placed with the help of jigs etc. all other parts are assembled
as per requirement with the help of drawing. Once the press is complete it is tested
again and again for any kind of defect before it is dispatched. The assembly is a
complex process and involves hours of continues work the steps involved are
discussed below
1. Gathering all the required material for the construction.
2. Identifying the various parts and their layout.
3. Inspecting all material and its reliability.
4. Starting the assembly work as per the requirement.
5. After the assembly is over each part is punched of marked for identification and
for making the work of site workers easy.
6. After assembly the presses are tested for any fault and any faulty material is
either removed or corrected.
7. After the inspection is over the press is dismantled and is ready to be dispatched.
 Chapter- 3
MECHANICAL PRESS

Principle

The power is transmitted from motor to flywheel with the help of flat or V-belt.
Most commonly V-belt is used because in case of flat belt, losses due to slip are
present. When clutch are not engaged with the flywheel drive shaft does no rotate.
When air is supplied to the clutch brake assembly then at a particular pressure of
air, the liner of clutch-brake engages with flywheel and drive shafts starts rotating.
There are teeth cut on the other end of the shaft, which mesh with the larger gear
mounted on the eccentric shaft. So when pinion shaft rotates, the motion is
transferred to the eccentric shaft through connecting rod or pitman, which is
mounted on the eccentric part of the shaft. In this way, rotating motion of the
motor is converted into reciprocation motion of the slide.

Advantages

• Faster production rate than hydraulic press.

• Ease of maintenance.
• Suitable for operation viz. punching, blanking and trimming in which there
is sudden release of load at the end of cutting stroke.
• Ease of interfacing with automatically material handling systems.
• Press over loading is possible. Safe guard against over load is required.

Features of Mechanical Press

Die Cushion

A large pressurized cylinder located in or under a die block or bolster to provide

additional pressure or motion for stamping.

Need for a Die Cushion

1. To prevent slip and wrinkling during forming from a blank.
2. Uniform pressure over entire blank.
3. Uniform pressure throughout entire stroke.
4. Easy adjustment with changing jobs. Two kinds of die cushions are used
Pneumatic Hydro-Pneumatic The pneumatic die cushion is mostly widely
used. Standard air pressure in a pneumatic die cushion is 4-5kg/cm
2. When it is necessary to raise the pressure in a pneumatic die cushion up to three
cylinders can be used in tandem. A hydro-pneumatic die cushion can only be used
for a single stage. The blank holder pressure and knock out pressure are the same
in the pneumatic die cushion; however, in a hydro pneumatic die cushion the
knock out pressure is only about one sixth of the blank holder pressure.

Clutches and Brakes

Mechanical press uses clutch and brake assembly. Electric brake and clutch
assemblies are equipment drive components that consist of electric brakes for
slowing or stopping shafts and electric clutches for connecting or disconnecting
shafts. Engaging the clutch transfers power from an engine to devices such as a
transmission and drive wheels. Disengaging the clutch stops the power transfer, but
allows the engine to continue turning. Braking slows or stops the movement of the
coupled shafts by using permanent magnets, hysteresis, and eddy current or
magnetic particles. All the mechanical presses are provided with a flywheel to
store energy. During the idle position of the stroke, flywheel rotates continuously
on the main shaft and power to slide is transmitted through a clutch. Clutches are
of positive friction and eddy current types. A brake is an important part of a press.
It assists the clutch thereby ensuring positive and safe operation of the press. A
faulty brake can cause a major break down of the press. When the press starts the
clutch must engage only after the brake has been released and conversely, when
the press stops the brake must operate only after the clutch has been disengaged,
the time lapse in each case is called time lag. The control of provided clutches is
usually limited to stop and start only. Mechanical controls are available so that the
press cycle may be either continuous. This clutch has many other special features
to be designed in to the system to suit almost any circumstances.

Various Modes of Run Inch mode

Inch controls is mainly used for setting up the tools and allows the press to run
only when inch button is pressed. When inch button is released press stops. It is the
most common mode of operation.

Single auto mode

In this mode press run one complete cycle.

Continuous mode

In this mode press run for predefined number of cycles. The press must be
equipped with automatic feeder.

Slide Adjuster
A slide adjuster is used to adjust the position of the bottom face of the slide
to change the die height. Adjustments are made by turning the threaded coupling
part between the connecting rod and slide. Generally on small capacity presses
adjustments are made manually with a turning rod and other suitable tool. For
medium and large capacity presses, however, this is done with an electric and air
motor.
Counter Balance Cylinders

The weight of the slide is generally 5-20 tones, which is acting in downward
directing, so during the upward motion of the press the weight is against the
mechanical force. So, power requirement during downward stroke is very low
and during the upward stroke the power requirement is very high. So motor with
large range is required which is impractical. To avoid this difficulty the slide is
kept in equilibrium position i.e. weight of slide is required to zero. For this purpose
counter balance cylinders are used. The counter balance cylinders are mounted on
both sides of the slide. Each cylinder consists of a piston fitted with a piston rod.
The other end of the piston rod is connected to slide. As the area of cylinder is
fixed the pressure of air inside the cylinder is changed to meet the equilibrium
condition. The air is supplied to the cylinder is changed through an air tank
whereas air tank receives air at high pressure by a pneumatic pump. The counter
balance cylinder is fitted with a spring loaded valve and a pressure switch. When
counter balance tank exceeds certain permissible value then the valve opens and
excess air leaves the tank. Similarly pressure switch also protects the tank from
over pressure. When pressure exceeds permissible value pressure switches controls
and press stops working.

Various Modes of Run Inch mode

Inch controls is mainly used for setting up the tools and allows the press to run
only when inch button is pressed. When inch button is released press stops. It is the
most common mode of operation.

Single auto mode

In this mode press run one complete cycle.

Continuous mode

In this mode press run for predefined number of cycles. The press must be
equipped with automatic feeder.

Slide Adjuster
A slide adjuster is used to adjust the position of the bottom face of the slide
to change the die height. Adjustments are made by turning the threaded coupling
part between the connecting rod and slide. Generally on small capacity presses
adjustments are made manually with a turning rod and other suitable tool. For
medium and large capacity presses, however, this is done with an electric and air
motor.

Counter Balance Cylinders

The weight of the slide is generally 5-20 tones, which is acting in downward
directing, so during the upward motion of the press the weight is against the
mechanical force. So, power requirement during downward stroke is very low
and during the upward stroke the power requirement is very high. So motor with
large range is required which is impractical. To avoid this difficulty the slide is
kept in equilibrium position i.e. weight of slide is required to zero. For this purpose
counter balance cylinders are used. The counter balance cylinders are mounted on
both sides of the slide. Each cylinder consists of a piston fitted with a piston rod.
The other end of the piston rod is connected to slide. As the area of cylinder is
fixed the pressure of air inside the cylinder is changed to meet the equilibrium
condition. The air is supplied to the cylinder is changed through an air tank
whereas air tank receives air at high pressure by a pneumatic pump. The counter
balance cylinder is fitted with a spring loaded valve and a pressures witch. When
counter balance tank exceeds certain permissible value then the valve opens and
excess air leaves the tank. Similarly pressure switch also protects the tank from
over pressure. When pressure exceeds permissible value pressure switches controls
and press stops working.

Knockout Device

A knockout device is used at the conclusion of a forming process to separate the

formed product from the die. There are three types of knockout devices
Mechanical
Pneumatic
Hydraulic
A knockout device is normally fitted to the slide of the press, however, in a forging
press it is fitted to the head size.

Flywheel Brake

When the main motor power of a medium or a large capacity press is cut off, the
flywheel continues to turn for a considerable time under its own inertia. To stop the
flywheel the brake is engaged directly to flywheel rim.

Problems in Mechanical Press

Bottom Head

The common problem is with leveling, and can be cured by using a calibrated
master level. Self-calibration of Master level is done as follows; Place on any
surface such that bubble is in between two braces. Rotate through 1800, & check it
again. If the reading is same then its accurate.

Slide

• Pump taking continuous stroke, check for;

leakage from any pipe.
Porosity during welding.
Internal leakage.
• Adjustment motor drawing high current.
• Abnormal sound during adjustment.

Upright
• Sitting problem occur due to machining inaccuracy.
• Taper matching problem.

Gear Train
• Key way mismatching.
• Geometrical inaccuracy in bores.
• Timing error
• Fouling of connecting rod.
• Noise level is high.
• Backlash, Back biting & abnormal heating.

Crown

• Abnormal heating of motor.

• Uneven tension in belt.
• Leakage from flywheel.

Power pack

• Abnormal sound.
• No pumping.
• Less pumping pressure.

Inspection of Presses

To maintain the quality of presses, its inspection is very strictly performed.

The common test performed is Dye penetrant inspection (DPI). Skilled high
level supervisors are employed to maintain the quality of the product,

Dye Penetrant Inspection

Dye penetrant inspection (DPI), also called liquid penetrant inspection (LPI) or
penetrant testing (PT), is a widely applied and low-cost inspection method used to
locate surface-breaking defects in all non-porous materials (metals, plastics, or
ceramics). The penetrant may be applied to all non-ferrous materials and ferrous
materials; although for ferrous components magnetic-particle inspection is often
used instead for its subsurface detection capability. LPI is used to detect casting,
forging and welding surface defects such as hairline cracks, surface porosity, leaks
in new products, and fatigue cracks on in-service components.

Principles

DPI is based upon capillary action, where surface tension fluid low penetrates into
clean and dry surface-breaking discontinuities. Penetrant may be applied to the test
component by dipping, spraying, or brushing. After adequate penetration time has
been allowed, the excess penetrant is removed, a developer is applied. The
developer helps to draw penetrant out of the flaw where an invisible indication
becomes visible to the inspector. Inspection is performed under ultraviolet or white
light, depending upon the type of dye used - fluorescent or non-fluorescent
(visible).
4.5.2

Inspection steps

1. Pre-cleaning

The test surface is cleaned to remove any dirt, paint, oil, grease or any loose scale
that could either keep penetrant out of a defect, or cause irrelevant or false
indications. Cleaning methods may include solvents, alkaline cleaning steps, vapor
degreasing, or media blasting. The end goal of this step is a clean surface where
any defects present are open to the surface, dry, and free of contamination.

2. Application of Penetrant
The penetrant is then applied to the surface of the item being tested. The penetrant
is allowed dwell time to soak into any flaws (generally 5 to 30 minutes). The dwell
time mainly depends upon the penetrant being used, material being testing and the
size of flaws sought. As expected, smaller flaws require a longer penetration time.
Due to their incompatible nature one must be careful not to apply solvent-based
penetrant to a surface which is to be inspected with a water-washable penetrant.

3. Excess Penetrant Removal

The excess penetrant is then removed from the surface. The removal method is
controlled by the type of penetrant used. Water-washable, solvent-removable,
lipophilic post- emulsifiable, or hydrophilic post-emulsifiable are the common
choices. Emulsifiers represent the highest sensitivity level, and chemically interact
with the oily penetrant to make it removable with a water spray. When using
solvent remover and lint-free cloth it is important to not spray the solvent on the
test surface directly, because this can remove the penetrant from the flaws. If
excess penetrant is not properly removed, once the developer is applied, it may
leave a background in the developed area that can mask indications or defects. In
addition, this may also produce false indications severely hindering your ability to
do a proper inspection.

4. Application of Developer
After excess penetrant has been removed a white developer is applied to the
sample. Several developer