INTRODUCTION:

“The Sitara Engineers” was conceived and formulated in 1984 with its Head Office in Faisalabad
and Branch Offices in Lahore, Karachi & Dhaka-Bangladesh. In the beginning we started
manufacture of “Heat Transfer Units” & “Engraving Units” which used in dyeing, Printing and
finishing sector. From 1986 we started manufacturing textile machinery in Faisalabad-Pakistan
for local sector and also in international textile sector like Bangladesh, Egypt, Tanzania etc

“The Sitara Engineers” has earned national and international recognition as major manufacture
in textile machinery like Engraving Unit, Heat Transfer Unit, Drying Cylinders, Washing Tanks,
Curing Machine, Caustic Soda Recovery Plant, Flat Bed Engraving, Sampling Machine, Vacuum
Filtration, Screen Washer, Singing Machine, and we also so do some projects in chemical
sectors for the last 25 years, specializing in Dyeing, Printing & Finishing units. “The Sitara
Engineers” services on the flexibility to meet the demand of constantly changing market
requirement by dealing in large range of modern machines.

“The Sitara Engineers” has revised its usual model of management to serve our customers
according to modern needs. They have demonstrated remarkable gradual progress and have
earned good trade-good will in national and foreign market during these periods and are now
well positional to capitalize on this platform and look forward to the future with firm
commitment to success with standard service to Textile Sector.
They also work as facilitator between buyer and seller for new, used and recondition

machineries on commission basis. In case a company has any kind of machinery or equipment

for sale, They can outsource buyers for you. They have a very qualified team for services.
 CH # 1

MECHANICAL ENGINEERING WORKSHOP

1. Introduction:

Mechanical Engineering Workshop is a place where students acquire knowledge on the

operation of various processes involved in manufacturing and production. The Workshop
Practice course makes students competent in handling practical work in engineering
environment. Mechanical Engineering Workshop is also involved in different
maintenance/repair works for University.

Workshop technology has increasingly important to the engineer, supervisor or worker

engaged in the production of various types of machines or tools. The study of workshop has,
therefore, been made compulsory these days.

2. Mechanical Working of Metals:

The mechanical working of metals is defined as an intentional deformation of metals plastically

under the action of external applied force. It may be described as hot working and cold working
depending upon whether the metal is worked above or below the recrystallization
temperature.

The metal is subjected to mechanical working for the following purposes;

1) To reduce the original block or ingot into the desired shapes.

2) To refine grain size
3) To control the direction of flow lines.

3. Hot Working:
Hot working process metals are plastically deformed above their recrystallization temperature.
Being above the recrystallization temperature allows the material to recrystallize during
deformation. This is important because recrystallization keeps the materials from strain
hardening, which ultimately keeps the yield strength and hardness low and ductility high.

Many kinds of working, including rolling, forging, extrusion, and drawing, can be done with hot
metal.

4. Advantages:

1. The porosity of the metal is largely eliminated

2. Decrease in yield strength, therefore it is easier to work and uses less energy or force
3. Increase in ductility
4. Elevated temperatures increase diffusion which can remove or reduce chemical in
homogeneities
5. Pores may reduce in size or close completely during deformation
6. In steel, the weak, ductile, face-centered-cubic austenite microstructure is deformed
instead of the strong body-centered-cubic ferrite microstructure found at lower
temperatures
5. Disadvantages:

1. Undesirable reactions between the metal and the surrounding atmosphere (scaling or
rapid oxidation of the work-piece)
2. Less precise tolerances due to thermal contraction and warping from uneven cooling
3. Grain structure may vary throughout the metal for various reasons
4. Requires a heating unit of some kind such as a gas or diesel furnace or an induction
heater, which can be very expensive
5. It requires expensive tools.
6. The correct temperature range for working is difficult to maintain.
 7. Hot Working Processes:

7.1 Rolling:

Hot rolling is a mill process which involves rolling the steel at a high temperature (typically at a
temperature over 1700° F), which is above the steel's recrystallization temperature.

Rolling usually is the first step in converting cast material (ingot) into finished wrought
products. Hot rolled products, such as sheets, plates, bars, and strips, serve as input material
for further processes, such as cold forming or machining. Basically hot rolling consists of passing
heated metal between two rolls that revolve in opposite directions, the size of the gap between
the rolls being somewhat less than the thickness of the entering metal.
7.2 Forging;

Forging is a manufacturing process involving the shaping of metal using localized compressive
forces. The blows are delivered with a hammer (often a power hammer) or a die

Is the plastic working of metal by means of localized compressive forces exerted by manual or
power hammers, presses, or special forging machines. It may be done either hot or cold.

In forging, three types of deformations are observed.

1. Draw out

In which length is increased and cross section is decreased.

2. Upset:
In which cross section is increased and length is decreased,

3. Squeeze:
In which multidirectional flow is produced in closed impression dies.

7.4 Extrusion:

It is a process used to create objects of a fixed cross-sectional profile. A material is pushed

through a die of the desired cross-section. The two main advantages of this process over other
manufacturing processes are its ability to create very complex cross-sections, and to work
materials that are brittle, because the material only encounters compressive and shear
stresses. It also forms parts with an excellent surface finish.
Extrusion may be continuous (theoretically producing indefinitely long material) or semi-
continuous (producing many pieces). The extrusion process can be done with the material hot
or cold. Commonly extruded materials include metals, polymers, ceramics, concrete, modelling
clay, and foodstuffs.

8. Cold Working:

The working if metals below their recrystallization temperature is known as cold working most
of cold processes are performed at room temperature. The cold working distorts the grain
structure and does not provide an appreciable reduction in size. It requires much higher
pressures then hot working. The increase in hardness due to cold working is called work-
hardening.

Cold working produces the following effects:

1) The stresses are set up in the metal which remain in the metal.
2) A distortion of grain structure is created.
 3) The strength and hardness of the metal are increase with a corresponding loss in
ductility.
4) The re-crystalline temperature for steel is increased.
5) The surface finish is improved.

8.1 Cold Rolling:

It is generally employed for bars of all shapes, rods, sheets and strips, in order to provide a
smooth and bright surface finish. It is also used to finish the hot rolled components to close
tolerance and improve their hardness and toughness.

8.2 Cold Forging:

It is also called swaging. During this method of cold working, the metal is allowed to flow in
some pro-determined shape according to design of dies, by a compressive force or impact. It is
widely used in forming ductile metals.
8.3 Cold Bending:
The bars, rods, wires, tubes, structural shapes and sheet metal may be bent to many shapes in
cold conditions through dies.
 CH# 2

MANUFACTURING UNIT

2. TEXTILE CURING MACHINE:

Curing consists of baking a garment or garment section in a heated chamber to either set
creases in the fabric permanently or to decompose auxiliary media used as a sewing aid. For
example, curing permanently sets previously pressed creases in certain permanent press,
durable press, and wash and wear garments. Curing decomposes the backing material used for
facilitating the embroidering in certain embroidered garments.

There are different sizes of curing machine are available. Each machine of standard of size has
125 roller in it. Garment enters the machine and travels in zig zag position. A tray is placed in
curing to collect the garment. Heaters are there to warm the air circulated by the blowers.

It also used to starch or press the garment with help of warm air. After passing through the
curing garment is warped on the rollers and ready to supply in market.

The machine is essentially built on a steel frame with insulation panels containing min wool.
Inside the machine, centrifugal blowers are mounted this blowers sucks surrounding air and
blow into the machine chamber. This blowing is done from the bottom, underneath the
heaters. In this way the fresh air is first heated and then mixed with the circulation air.
The eventual oil condenses or hydrocarbons, which develop during fixation, are removed
through an exhaust fan partially and partially re-circulated air to air heat recovery within the
chamber.

The fabric transports on free loops, quantity of fabric contain from 50 meters to 250 meters
and working fabric width available from 1250mm to 3650mm.

Some special de-ionization bars are installed at the inlet and outlet to reduce the fabric
electrification phenomena.

The air heating can be reached with battery fed by thermic oil or may also be achieve by direct
gas burner.

The machine is usually equipped with electric control panel and on request it is possible to
supply a logic programmer.
2.1 CLIMATIZER ( OWEN):

Basically climatizer is owen type machine used to dry the chemical coated screen. This is a
single heater drying machine made of wood. Having a heavey capacity blower to circulate air in
the chamber of climatizer machine.

At the bottom of climatizer there 8 plastic grills are placed to hold the chemical coated screen.
Usually size of this machine Is 4×12 feets in which having 4 feets width and 12 feets of height.
Also having walls made of wood sheets and are coated with thick layer of paint.

After screen coming out from the coating machine, Placed in climatizer to dry the chemical
layer on the surface of of screen. At the top of climatizer, Provided with a blower which
circulates air across the chamber of machine. At the back side a heavey duty heater is placed.
Air cieculated by the blower is warmed with the help of this heater which dryes the chemical
coated screen.
2.2 COATING MACHINE:

Coating machine has become a very important technique for addihg value to textile. It
enhances and extends the range of funtional performance properties of textile. The use of this
technique is growing rapidly as the application for technical textile material has become more
diverse.

Now we have also know about the definition of coating, coating is an application of an
appropriate chemical system to form a layer of a coating compound on the substrate. Coating is
process in which a polymeric layer is applied directly on one or both surfaces of the screen.

Depending upon the end-ues, heavey duty technical textile coating may be applied.
Formulation contains a wide range of chemicals depending upon:

 Nature of polymer
 Necessary additives for the specific end-ues
 Wether coating has to be foamed prior to application.
The tecnique that is selected for any given product will be depends upon following factors:

 Required coat-weight
 Direct coating
 Transfer coating
 Crushed foam coating
 The nature of compound to be applied
 The degree of penetration required into the substrate

A coating machine consists of 2 motors that are attached at the bottom of machine. These
motors are connectedwith super gears each motor has one gear. Over the gears a chain is
mounted that holds the trays in which chemical is filled. With the help of motors trays are move
up and down and coat the screen.

2.3 EXPOSING MACHINE:

Exposing machine is used to epose the printed design marked over the screen. It also marks
straight lines over the screen to keep this screen in line. Exposing machine may be a laser light
mounted or ink injector type machine.

Over the heads of this machine a long shaft is placed. On this shaft a move able box having ink
injector or a laser light is fitted. This box moves in linear motion when the light stricks ths
surface of screen it removes the chemical coat of the screen and expose the printed design.

A gear mechanism is uesd to move box over the shaft. Two heads are placed on both ends of
the machine to hold and keep the screen in line. Limit switches are use to control the
movement of the ink injector box.

2.4 HEAT RECOVERY BOILER:

Waste Heat Recovery boilers are designed to recover heat from waste flue gases from DG
exhaust, Furnace exhaust, Kiln exhaust, incinerator exhaust etc. To produce steam or hot water
based on the application requirements of the plant.
As the name suggests, the heat going waste from the process like flue gases of Diesel Generator
sets is utilized in these boilers to generate hot water or steam. Since no fuel is fired, whatever
heat we recover in the boiler is free of cost.

Heat Recovery boilers are versatile as steam or hot water applications and are designed for
operating in conjunction with a wide range of heat generating equipment, such as gas turbines,
reciprocating engines, incinerators, gasifiers and other process heat plant.

The boiler is supplied complete with inlet and outlet ducts, control panel and all necessary
valves and fittings for safe operation.

The boiler is designed to maximize the output from the waste heat source, be that a turbine,
engine .When output in excess of that available from the waste gas source is required the boiler
can be fitted with supplementary firing equipment.

Benefits:

 Highly Reliable in operation and robust in construction.

 Quick Payback Returns are achieved.
 One time investment with lifetime returns.
  No combustion, No emission hence Eco-friendly.
 Energy being put to use, which was getting wasted anyway.

2.5 Centrifugal pump:

Centrifugal pumps are used to transport fluids by the conversion of rotational kinetic energy to
the hydrodynamic energy of the fluid flow. The rotational energy typically comes from an
engine or electric motor. The fluid enters the pump impeller along or near to the rotating axis
and is accelerated by the impeller, flowing radially outward into a diffuser or volute chamber
(casing), from where it exits.

Common uses include water, sewage, petroleum and petrochemical pumping. A centrifugal fan
is commonly used to implement a vacuum cleaner. The reverse function of the centrifugal
pump is a water turbine converting potential energy of water pressure into mechanical
rotational energy.
Components of Centrifugal pump:

There are a few components that virtually every centrifugal pump has in common. These
components include:

 Impeller

 Volute or diffuser style casing

 Shaft

 Shaft sleeves

 Bearings
  Sealing arrangement

 Inlet & outlet flange

 Coupling

 Water body

Pump Shaft:

The impeller is mounted on a shaft. The shaft is usually made of steel or stainless steel and is
sized to support the impeller. Shafts have to be sized carefully. An undersized shaft can result in
increased pump vibration, shorter bearing life, the potential for shaft breakage, and an overall
reduced pump life. However, an oversize shaft can increase the cost of the pump unnecessarily.

Shaft Sleeve:

In most pumps, the portion of the shaft that is under the sealing arrangement is covered with a
shaft sleeve. The shaft sleeve is a sleeve of metal, usually bronze or stainless steel, that is
designed to either slide or thread onto the shaft. The shaft sleeve is used to position the
impeller correctly on the shaft, and it also protects the shaft.

Sealing Arrangement:

The location where the shaft passes through the casing is called the stuffing box. A sealing
arrangement must be used to seal the gap between the shaft and the wall of the stuffing box.
Either packing or a mechanical seal may be used to seal this area.

Pump Bearings:

The final part of the mechanical end is the bearing arrangement. Generally speaking, centrifugal
pumps are equipped with standard ball-type anti-friction bearings. These are the same bearings
used in everything from electric motors, to roller skates, to automobiles, and they are
lubricated by grease or oil.

CH # 3
PRODUCTION ENGINEERING
3.INTRODUCTION

The PRODUCTION ENGINEERING deal with the metal cutting or machining ,cutting tools
measurement of cutting forces, grinding, boring, gear, manufacturing ,jigs and fixtures ets

3.1 Mechanics of metal cutting

There are two methods of metal cutting orthogonal cutting or two dimensional cutting oblique
cutting or three dimensional cutting.

i. Orthogonal cutting

The cutting edge of the tool is perpendicular to the direction of the tool travel. The
cutting edge clears the widths of the work piece on either end. The chips flows over the
tool face and direction of the chip flow velocity is normal to the cutting edge. The
maximum chip thickness occurs at the middle
ii. Oblique cutting.

The cutting edge of the tool is inclined at an angle less than 90 degree to the direction of
tool travel. Frequently, more than one cutting edge in action. The cutting edge may not
clear the width of the work piece.

3.2 Metal cutting tool (single point cutting tool)

A single point cutting tool is mostly used on lathe, shaper and planer while a multipoint
cutting tool is used on milling machine and broaching machine. A single point cutting
tool either on left or right hand cut tool depending upon the direction of the feed. The
following definition may be clearly understood:
 i. Shank. It is main body of the tool.
ii. Face. It is the surface on which the chip slides.

iii. Flank. It is the surface below and adjacent to the cutting edge.
iv. Nose. It is the intersection of the side cutting edge and end cutting edge.
v. Cutting edge. It is the edge on the face of the tool which remove the material from
the work piece.
vi. Heel. It is the intersection of flank and the base of the tool.
vii. Lip angle. It is the angle between tool face and ground end surface of flank. The lip
angle of the single point is usually 60 to 80 degree.
viii. Cutting angle. It is the angle between the face of the tool and a line tangent to the
machine surface at the cutting point.
ix. Rack angle. The angle made by the face of the tool and the plane parallel to base of
the cutting tool the strength of the tool depend upon this angle.
x. End relief angle. It is the angle between the surface of the flank immediately below
the point and a line draw from the point perpendicular to the base.
xi. Side relief angle. It is the angle between the surface of the flank immediately below
the point and a plan at right angle to the center line of the point of tool.

3.3 Chips.

There are three types of chips produced during metal cutting or machining.
i. Discontinuous chips.

These types of chips are usually produced during machining of brittle material like cast
iron. The low cutting speed and low rack angle of the tool are responsible for the
formation of discontinuous chips.
ii. Continuous chips.

These types of chips produced during the machining of ductile material like mild steel.
The high speed and large rack angle of the tool will result in the formation of the
continuous chips. These chips are in the form of coil having the same thickness
throughout.

iii. Continuous chips with built up edge.

These types of chips are also produced during the machining of ductile material. The
speed and small rack angle of the tool will result in the formation of the continuous
chips with built up edge. These chips are also formed when the edge of the tool is dull.
3.4 Tool wear.

The tool wear or tool failure may be due to following;

i. Cracking at the cutting edge due to thermal stress,

ii. Chipping of the cutting edge,
iii. Plastic deformation of the cutting edge, and
iv. Flank and crater wear

a) Difference between flank wear and crater wear.

Flank wear is due to the abrasive action of hard miss-constituents including debris from
built up edge at the work material rubs the work surface.it depends upon the amount
and distribution of hard constituents of work material.
b) The flank wear occurs main:

On the nose part,

Front relief face and side relief face of the cutting tool.
The crater wear is usually found while machining brittle material. It occurs mainly due to
diffusion of metals. It leads to increase cutting temperature, weakening of tool, friction
and cutting forces. The crater wear occurs mainly on the face of cutting tool at a short
distance from the cutting edge only.
3.5 Tool life.

Tool life may be defined as tools useful life which has been expended when it can no
longer produce satisfactory parts. The tool life is said to be over if poor surface finish is
obtained and there is sudden increase in cutting forces and power consumption. The
tool life also said o be over if overheating and fuming due to heat of friction starts. The
various factor which affects the tool life are tool geometry, cutting sped, feed, feed rate,
depth of cut microstructure and chip thickness. The relation between tool life (T) in
minutes and cutting speed (v) in m/min

3.6 Tool material.

The tool material for the fast machining, should have wear resistance, red hardness and
toughness. The principle materials used in cutting tools are as follows;
i. High carbon steel.

The tools made up of the high carbon steel have low heat and wear resistance,
since this tools lose hardness at about 300C. Therefore they are for high cutting
speed and heavy duty work. Such tool may be used on soft material such as
wood.
ii. HIGH SPEED STEEL.

The high speed steel containing 18% tungsten, 4% chromium and 1% vanadium is
consider to be one of the best for all purpose tool steel. They retain their
hardness up to a temperature of 900C.

iii. Carbide.

A carbide is suitable for the steel machining consist of 82% tungsten carbide,
10% titanium carbide and 8% cobalt. The carbide tools operating at very cutting
speed below (30m/min) reduces tool life.
iv. Ceramic.

The ceramic tools are fixed to a tool body for brazing. These tools have greater
tool life then carbide tools.