PRESENTATION ON

INDUSTRIAL TRAINING
AT
INDIA METALS
SUBMITTED BY-:
TRIPAT SINGH
ROLL NO 1325555




COMPANY PROFILE
India Metals, was established in 1967 for manufacturing
Track Fitting items, started in own premisesin industrial
area
The business practice of M/s INDIA METALS, is to
improve the quality of its products up to the entire
satisfaction of customer.
Quality Objective
To give better quality at lower rates
To increase on time delivery by 90% to 95%

RAW MATERIAL TESTING
1. VISUAL AND SURFACE DEFECT TEST

2. CHEMICAL TEST

3. TENSILE, BEND & YIELD TEST

4. DIMENSIONAL TEST

PROCESS TREE

RAW MATERIAL CUTTING OPERATION

SLOTTING OPERATION

KNOTCHING OPERATION

ATAMPING & COINING OPERATION

PUNCHING OF LOT NO

PARTING OPERATION

GRINDING

GAUGING

HARDNESS TEST

INSPECTION

CALIBRATION AND
INSPECTION OF TESTING
EWUIPMENTS

CALIBRATION OF TESTING EQUIPMENTS
Up to date calibration of testing equipment i.e Computerised
UTM Machine, Computerised Hardness Testing Machine
&Vernier Cliper is maintained at a frequency of 1 year,
calibration is pasted on respective equipments.
GUAGES AND ITS CALIBRATION
We have 3 sets of guages fror each Drg. i.e for metal liner to
Drg. No.. Two set of each Drg.This is sent to RDSO for
approval and 1 sets of each Drg are for internal use. These
guages are hardened by heat treatment to have minimum
wear & tear while using it. The guages approved by RDSo is
kept for inspection as advised by RDSO

INCOMING RAW MATERIAL
For procuring Raw Material section of metal liners it is
ensured that billets for rolling of section raw material has
been procured from RDSO approved sources integrated
Steel Plant.
Raw material received at work premises is identified and
checked bymatching the details provided in the original
invoice.
After proper identification of raw material , the raw material
unloaded at the work premises
The unloaded raw material is stacked in raw material stock
yard heatwise/ section wise.
CHECKING OF RAW MATERIAL

VISUAL

DIMENSIONS

CHEMICAL COMPOSITION

PHYSICAL PROPPERTIES(Bend test, yield , tensile strength)



MANUFACTURING PROCESSES
CUTTING OPERATION
Cutting of raw material is done with Power Press of
sufficient capacity. The die work is done with the help of
stoppers engraved for dimension control. The prescribed
length for all types of metal liners is 107.5 to 109. To check
taper while cutting angle guage is used. The dies are
checked at regular intervals and faces are sharpened at
surface grinding machine if bluntness occurs.
SLOTING OPERATION
After cutting the material undergoes slotting operation at
power press of sufficient capacity. Air also dies are
operated with stopper engraved as per prescribed limit.
These stoppers are made of tank plates having very low
wear and tear . The slotting operation is very important
operation with tolerance is only 0.5 mm . This tolerance is
as per area available between insert and tracks while lying
of metal liners at railway track.


NOTCHING OPERATION
In this operation notching/ V cutting is done with the help
of die guided plates and stoppers. Notching is done in such
a manner that the upper dimensions is maintained
equivalent to inner dimensions of 77.5 to 79mm. This
operation is done on power press. The compound die
operation is suck that it cuts two pieces from two sides in
single stroke.


STAMPING AND COINING OPERATION
As the whole process of manufacturing of metal liner is cold
process and the cutting are done with power presses with
single strokes hence some times after slotting and notching
operation there is a slight twist in the material . In coining
operation dies are made in such a manner that the metal
liner became straight line and all twists are removed by
press stroke i.e. coining operation.



PARTING OPERATION
As the raw material is rolled in such a way that two pieces of
liners are rolled together. Parting is done in such a way that
the vertical strome of the Power Press parts the product into
two liners of equal dimension. Here also the total operation is
gided by the guide, if the cutting edges become blunt then
the edges are sgarpened at surface grinding machine.

GRINDING OPERATION
To remove the burs & sharp edges of liners each metal liner
grinded on bench grinders as per the requirement of
respective drawing.

SCREEN PRINTING
Screen printing as per Drg. Shall be done to differentiate GS
and NGS liners . Incase the purchaser desires to dispense
with the screen printing on This aspect shall have to
specifically mentioned in the purchase order.

GUAGING & INTERNAL TESTING OF FINISHED PRODUCTS
After metal liner is manufactured, guaging is done with the
help of RDSO approved guages from Guage no G 1 to G 9, G
! Is for to check the thickness of the rib , G 2 guages is for
check the thickness of liner, G 3 Guage is for to check the
length of horns, G4 is to check the length between two
hors, G5 to check the total length of liner, g6 is to check the
internal width, g7 is to check the overall width of the liner,
G8 and G9 are to check the over all fitting and sitting of
liner. Sampling Plan IS 2500 Part 1

CHEMICAL COMPOSITION
Chemical composition from the finished material is done on
smal pieces cut & prepared as specified with the help of
shaper & surface grinding machine as described in clause . It
shall be tested after manufacturing One sampler per lot from
each section is drawn for chemical test.

MACRO EXAMINATION & HARNDNESS TEST
If the material is within acceptance range of sampling Plan IS
2500 Part-1,GIL II , AQL 2.5% then 5% liners or minimum 6
No.s are taken for Hardness Test. In the macro examination
test liners are examined for surface flaws , laminations, rough
& imperfect edges etc. The other Harmful defects arechecked
by etching process in hot acid. If the Liners are found OK &
free from all defects than the lot is considered as accepted lot
in terms of maxro examination . Samples drawn for hardness
test are tested for hardness on the middle portion of the liner
in axxordance with IS 1500-2005. If the Macro examination is
satisfied as per Annexure- XI & Hardness test is not less than
115 BHW as per annexure-XII , then said lot is axxepted and
offered for final inspection after oiking ans packing.


OILING AND PACKAGING
After the material is found satisfactory the materials send for
packing, before screen printing or oiling is done with rust
preventive oil as specified or as required by the purchasing agency.
After oiling, packing of liner is done in old gunny bags, Stacking is
done in heat for final inspection the authorized inspecting authority
, inspection is done in our own premises and and the sampling plan
used by the inspecting agency is as per inspection level II and AQL
2.5% shall be as per IS 2500 Part I 1992
THANK
YOU