pulley 111

ABOUT THE COMPANY 1 TRF Limited

The Tata Group, founded in the last quarter of the 19th century, at a time when India had just embarked on the road to independence, is committed to aligning its business opportunities with nation building activities.

TRF Limited, established in 1962, is part of the Tata Group of Companies which consists of more than 90 enterprises operating in seven business sectors, in over 80 countries. .

The combined competencies of three companies, the erstwhile Tata Robins Fraser (established in 1962), Tata Material Handling Systems (formerly Tata Man. Ghh., established in 1978), and Tata Techno dyne (established in 1996), resulted in the formation of TRF Ltd

The company has evolved into one of the most comprehensive sources of engineering equipment, systems and services. It manufactures bulk material handling and processing equipment, bulk material handling systems, coke oven equipment, coal dust injection systems for blast furnaces, coal beneficiation systems, and port and yard equipment. It's Port and Yard Division is also equipped with the technology; EPC and EPCM services for mini blast furnace technology. TRF Ltd caters to diverse industries including power, metallurgy, chemical, mining and cement.

Over the last five decades, TRF has emerged as a pioneer in solutions for material handling equipment and processing systems required in the infrastructure development. In quest of rapid growth, TRF has also diversified into automotive applications business. It envisages growing five times in five years and becoming a Rs 2500 Crores Company by 2013 by enhancing focus on material handling business and auto applications business.

1.1 TRF Group Companies

The Company’s subsidiary, York Transport Equipment (Asia)Pvt Limited, Singapore is engaged in the business of trailer under gear, which includes axles, suspension and other components, with market presence in 27 countries. York Transport Equipment (Asia) Pte Ltd has manufacturing facilities in Singapore, Australia, China and India. TRF has also set up Adithya Automotive Applications Limited, an automotive applications unit for a fixed body truck application in India. The objective of this venture is to engage in automotive applications and provide end-to-end solutions through fabrication and machining for tippers, load bodies, refrigerated bodies, etc. TRF acquired the Dutch Lanka Trailer (DLT) Manufacturers Limited, Sri Lanka. DLT is a world class trailer manufacturing company and has

manufacturing facilities in Sri Lanka, Oman and India. It exports trailers to as many as 30 countries.

More recently TRF has acquired Hewitt Robins International Ltd (HRIL) London which has a world class reputation in bulk material handling and processing equipment. Hewitt Robins is engaged in design, manufacture of Mobile Crushing plants and Screens, and related products in the quarrying,

mining, recycling, iron and steel industries. It's proven screen and crusher brands, including the

‘Container Classic' and the ‘Super Jaw', are all setting standards by which competitors' equipment is judged.

1 | R A D H A K R I S H N A I N S T I T U T E O F T E C H N O L O G Y A N D E N G I N E E R I N G

1.2 TRF Business Units

The Company has five business units which cater to the material handling requirements of customers in the core infrastructure sectors of the economy. TRF Limited undertakes turnkey projects for infrastructure development industries such as power and steel plants, cement, ports, fertilisers and mining. TRF's material handling products and systems are well known in the market, in India and overseas, for their reliability, productivity and longevity. The Company been constantly upgrading and developing new products and systems with the help of internationally reputed enterprises having cutting edge technical expertise.

BMHE

BMHS

PORT & YARD

O & MS

BOP

1.2.1 Bulk Material Handling Equipment(BMHE) Division:-

FIG 1:- BMHE DIVISION


The Bulk Material Handling Equipment Division specialises in the design and manufacture of a wide range of material handling equipment used in the infrastructure industries, such as wagon tipplers, stacker reclaimers, ship loaders and unloaders, travelling wagon loaders, etc.

1.2.2 Bulk Material Handling Systems(BMHS) Division:-

FIG 2:- BMHS DIVISION

The Bulk Material Handling Systems Division offers a complete package of material handling and allied systems and services on a turnkey basis.

1.2.3 Port & Yard Equipment :-

FIG 3:- PORT & YARD DIVISION

TRF Ltd specialises in engineering and manufacturing of unit and bulk material handling equipment for ports, ship-yards, power plants and metallurgical units, while also providing consultancy and maintenance to those sectors.The company has carved a niche for itself in the global market, as a leading supplier to ports in India, having the potential to compete with global players. In fact, the largest luffing grab cranes and ship unloaders in India, have been supplied by TRF Ltd.


PRODUCTION PROGRAMME

Maritime Technology

– Level luffing cranes – unit handling– Level luffing cranes – grab duty– Ship and barge unloaders– Ship and barge loaders– Shipyard gantry cranes– Rail mounted quay container cranes– Rail mounted gantry container cranes- Rubber tyred gantry container cranes

Bulk Handling

– Stackers– Bucket wheel on boom reclaimers– Combined stacker reclaimers– Bridge type reclaimers

Metallurgical Cranes

– Ladle cranes– Special purpose cranes.

Operations

• Development• Engineering• Supplying• Erection and• Commissioning of the above equipment as well as related consultancy and maintenance.

The equipments are customised to the customer’s requirements and also to the unique locational characteristics, to enhance performance. The state -of-the-art technology coupled with TRF’s invaluable experience in this field, ascertains a smooth operation with minimum operator fatigue. For the customers, this feature translates into uninterrupted higher output giving it a competitive advantage.

1.2.4 O & MS:-

TRF Ltd. has set-up the Operations and Maintenance Services (O&MS) division to serve the end customer for an operational plant. This service is aims to lower total cost of maintenance and asset upkeep for the customer.


Apart from direct financial benefits, O&MS strives to provide customer with a safe and green plant, guarantee performance levels and develop trust amongst the customer of the service provided.

1.2.5 BOP:-

TRF is exploring various possibilities to diversify into new areas of growth and BoP business is one of

such opportunity. With this intent TRF has launched a new strategic business unit as BOP Division at

Kolkata. This Strategic Business Unit undertakes complete execution of BOP facilities for power

generation projects on turnkey basis. TRF has many strategic advantages which have made it a

frontrunner in this arena.

The BOP or Balance of Plant system comprises of all the system and utilities which are required to run

thermal power plants starting from raw material input to waste output apart from the power island

which includes the generator, turbine and boiler with its auxiliaries.

1.3 TRF JAMSHEDPUR :-

The TRF Works at Jamshedpur spreads over nearly 22 acres with and this includes six covered

manufacturing bays on nearly 21,250 square metres. TRF’s skilled manpower meets the expectation of

its customers by continuously adapting new technology, upgrading skills and serving its customers on

time. They also use several process improvement tools and techniques like TOC-CCPM, quality

circles, cross functional teams, etc to attain the highest level of productivity.

TRF, with the help of advanced design and analysis software, constantly innovates, enhances

efficiency and improves reliability of its products and systems which enable it to maintain leadership

in the market.


FIG 4:- MANUFACTURED PULLEY IN TRF

Vision

We will grow five times in five years and become a Rs. 2500 crore company by 2013, by enhancing

focus on material handling business and entering new businesses as necessary. We will expand our

business on a sustainable basis by building a team that is passionate about serving all its

stakeholders and is committed to makingTrust, Respect and Fellowship, a Way of life .

Mission

To be an internationl leader in material handling equipment, processes and systems.

TRF Values

TrustRespectFellowshipExcellenceResponsibility

Business Principles

Sense of urgencyContinuous improvementConsistency and detail


1.4 Vision - 2013

TRF Ltd Launches Vision – 2013TRF Ltd new vision was ceremoniously launched by its Chairman, Jamshed J Irani, along with Managing Director, MrSudhirDeoras and President of Tata Robins Fraser Labour Union, MrRakeshwarPandey in the presence of its employees and external stakeholders in a function held on April5,2008... DrJamshed J Irani, Chairman, TRF Ltd said that while it is important to set a Vision, it was even more important to achieve them within a given time frame as vision without action was just a dream. He emphasized that the goals set in Vision-2013 must be achieved by the year 2013, if not earlier.

MrSudhirDeoras, Managing Director, TRF Ltd said that he was confident that TRF Ltd would achieve the goals laid in Vision 2013. The Company is gradually raising the bar of its performance and this indicated it had the potential to improve its performance. However, he said that the Company must now work with a sense of urgency and execute its projects and orders with the customer’s interest in mind.

The President of Tata Robins Fraser Labour Union, MrRakeshwarPandey, said that he believed that the employees of TRF Ltd had the potential to achieve the goals laid in Vision-2013. This he said had been demonstrated by them and the new vision would facilitate them to enhance their focus on and help to achieve their targets on sustainable basis.


1.5 Milestones

Pioneers & "Firsts"

It has been five decades of an uphill journey, at times easy and at times strewn with impediments. But the fortitude to deliver in the most adverse of conditions, the team spirit and respect for each other and the ability to dream and the courage to realise this dream has placed TRF in an enviable position.

Defined below are some historical moments in the TRF Ltd's voyage through these last 46 years....

1962-69 1970-79 1980-89 1990-99

2000-09 2010-2011 2012 Onwards


1.6 TRF VALUES

Any organisation is identified by its corporation culture and the manner in which it conducts business. The Tata group has since its inception been identified by its belief in responsible and ethical business practices. These values were articulated by the Founder of the Group, Jamsetji Tata. They have been reinforced and carried forward to every Tata Enterprise by successive generations of leaders. At TRF, in all communication with employees and union office bearers, MrSudhirDeoras, Managing Director, TRF continuously emphasises the need to demonstrate certain Values.

Values Appropriate Behavior

Trust State of being responsible – responsible behaviour wins trust

Respect Due regards for feeling and for rights of others

Fellowship Group of people meeting to pursue a shared interest or aim for larger benefit

Excellence Possessing good qualities of a high degree

Responsibility Ability to be responsible for our conduct and activities


HISTORY 2

YEAR EVENTS

1962 - The company was incorporated on 20th November, at Jamshedpur. The company was Ltd.,(ACC) in financial &technical collaboration with Hewitt-Robins,Inc. of U.S.A.(now known as the Hewitt-Robins Division of Litton Systems Inc., Of U.S.A.) and the General.Electric Co., Ltd., U.K

1970 - The main objective of the company is to manufacture of material Handling equipment such idler rollers, vibrating screens, sectional and mine conveyors, industrial chains, wire screen cloth, winders, tipplers, crushers, ore and coal preparation equipment, and coal cutters and undertaking Systems Contracts for such equipment including design, Manufacture,supply and installation of equipment.

1973 - 5,000 shares issued to ICICI upon conversion of loan.

1976 - 16,250 Bonus shares issued in prop. 1:3.

1978 - Shares subdivided. 5,07,500 shares of Rs. 10 each issued at A prem. of Rs. 4 Company's Indian employees, directors, etc. and 4, 42,500 shares offered for public. subscription during July

1985 - 6,90,000 No. of Equity shares issued at par in part conversion of 2,30,000-13.5% bonds. of Rs. 130 each

1986 - The Company obtained foreign technical know-how for the manufacture of extensible belt conveyors in collaboration with Kurimoto of Japan to expand the Company's range of manufacture of various types of crushers.- 11,11,672 No. of equity shares allotted (Prem. Rs. 5 per share)in part conversion of 12.5% debentures on 1.3.1989.

1987 - A substantial portion of the Company's business comprises execution of turn-key contracts which were executed over a period of two to three years depending upon the magnitude of the project. The drop in turnover was due to the fact that there were no major contracts which reached substantial completion during the year.

1988- The Company also took up the manufacture of stamping charging pushing machine and charging gas cleaning cars for Tata Steel.

1989 - A repeat order was received from Tata Steel for a stamping charging pushing machine and charging gas cleaning car forties coke oven battery No. 61990 - A portion of Rs. 60 of each debenture was to be compulsorily converted into 4 equity shares of Rs. 10 each at a premium of Rs. 5 per share as on 1st March.


1991- The non-convertible portion of Rs. 100 of each debenture would be redeemed at par after the expiry of 7 years from the date of allotment of the debentures.1992 - Drop in Company's turnover was due to the fact that there were no major contracts Which reached substantial completion during the year.

1993 - As a part of its diversification plans, the first phase of the steel service centre was implemented. - 15, 60,108 shares allotted on rights basis.

1994 - Company has been awarded Iso 9001 certification during the year.

1995- During February the Company made a Rights Issue of 15,60,836 equity shares of Rs. 10 each at a premium of Rs. 15 per share in the ratio of 1:2 (only 15,60, 148 shares were taken up). The remaining 688 shares were reserved for allotment as per approval of Regional Stock Exchange, Patna

1996 - The expansion plans for putting up a composite steel service centre at Bara near Agnrio Jamshedpur made satisfactory progress.

1997- Tata-Ryerson Ltd. was formed to provide value added steel service centre Facilities throughout the country. In addition, the company's steel service centre at Bara with all its plants machineries and buildings etc. were to be sold by negotiation to Tata Ryerson Ltd.

1998 - The Company had sold its steel service centre assets and Barafora consideration of Rs. 14 cores to Tata-Ryerson Ltd.

1999 - As a part of its ongoing technology up gradation and innovation programme the company has signed an MOU with M/s. Tip-TopSaarGmbH, Germany for acquiring state-of-the-art know-how for conveyor belt reconditioning plant.

2000 - The Company successfully commissioned the projects of Stamp Charging machine for Tata Steel's Battery No.8, Coal Dust Injection Systems for SAIL, Coal Handling Plant for Rajasthan and Andhra Pradesh.

1999 - Amalgamation of M/s. Tata Material Handling Systems Ltd.,(TMHS) and Tata Techno dyne Ltd. (TTDL), with the Company effective1stApril was approved in The Board Meeting held on 30th March, 1990.

2007 - TRF Ltd has appointed Mr. Sudhir L Deoras as an Additional Director of the Company with effect from January 22, 2007.

TRF Ltd products have established their own brand and a demand for themselves in the Indian infrastructure sector, such as power, steel, mining, cement and port, to mention a few.


Among its other activities are, implementation of projects on an EPC (engineering, procurement and

construction) basis or providing EPCM (engineering, procurement, construction management) services

towards the setting up of small and medium size plants, such as blast furnaces, sinter plants and coal

washeries.


PRODUCTS MANUFUCTURE 3

3.1 The products manufactured in TRF LTD. can be listed as follows:-

Wagon Tippler & Side Arm Charger

Rotary Breakers

Ring Granulators

Screens: Vibro Pulse, Truflo, Ultra flo, Unbalanced Motor, Washery Screens

Impactors, Jaw Crushers, Roll Crushers, Cone Crushers & Hammer Wheel

Rotary Plough Feeders, Belt Feeders

Vibrating Feeders

Shuttle Conveyors

Apron Feeders

Stacker & Barrel Reclaimers

Level Lufffing Cranes & Ladle Cranes

Side Discharge Loaders

Travelling Tippers

Idlers & Pulley

3.1 Some of the noteworthy projects executed by TRF LTD. includes:-

Downhill regenerative conveyor systemfor an iron ore mine at Bailadilla.

Coal Handling Plant for India’s first super thermal power station at Singrauli.

High speed vibrating screen for iron ore concentrators of Kudremukh Iron Ore Company.

Automatic mobile wagon loader for coal and iron ore for Tata Steel.

Circular stock piling, blending and reclaiming system for cement factory.

Coal washery.

Coal dust injection system for blast furnace.

Stamping-charging-pushing machine for coke oven.


3.3 Some big customers of TRF LTD. are:-

Tata Power

Tata Steel

National Thermal Power Corporation

Bharat Heavy Engineering Limited

Jindal Steel & Power Limited

Damodar Vailey Corporation

Indian Iron and Steel Company Limited

Shaheed Iron and Steel Limited

South Thermal Power Corporation Limited

Rajasthan Rajya Utpadan Nigam Limited

Aravali Power

Tata Project Bhuwal

M.P. Power

3.4 Name of the competitor:-

Those companies which are producing the same products as TRF Ltd. and are giving healthy competition in the world market are:-

THYSSEN KRUPP

BEEKAY ENGG

LARSEN AND TOUBRO

ELECON

MCNALLY BHARAT

MECON

HEC

PROMAC

TECPRO


INTRODUCTION OF PULLEY 4

4.1 INTRODUCTION

Pulleys are the heart of the Belt Conveyor Systems, which hardly can be resisted by an industry to use them. TRF Ltd. Is one among the prime manufacturers of pulley in India.

Pulleys are generally specified by their types (as drive or non-drive), type of fit, and their purpose and area of use and these are also important in the decision of the type of manufacturing processes to be employed.

In the following report, an effort has been implied to “reduce the manufacturing time of the pulley”.

A pulley can be considered to be made of four main parts namely shaft, hub, flange and shell. This proves helpful in the study of the manufacturing process of pulley and generating the idea of parallel machining of each part.

The observation of time involved in machining, transportation, loading, unloading etc. and their application to the operation tools such as Gantt chart, reveals the scope of reduction of manufacturing time. The deductions from the chart are then used to establish relationship between different cells using the concept of Activity-Relationship chart & activity relationship diagram. This concept is then combined with quantitative techniques, like CRAFT to develop the layouts for manufacturing of pulley. The possible layouts are then checked for minimum transportation distance between different cells, using from-to chart.

The report concludes by list of some suggestions related to design of pulley, these when employed may improve the life of the pulley.

FIG 5:- MANUFACTURED PULLEY


4.2Types of Pulleys:

I. Based on use: The following gives an account of the types of Pulleys based on use –

1. Drive Pulley – It is one which has to drive the conveyor belt system and hence it involves more Torque transmission.

2. Non-Drive Pulley – It just facilitates supporting a belt conveyor system on the other side of a drive pulley. Obviously, it involves less torque transmission.

3. Snub Pulley – It is an idler pulley so mounted as to increase the arc of contact between a belt and a drive pulley.

4. Bend Pulley – It is an idler pulley that is used solely for the purpose of changing the direction of travel of the belt other than at the terminals of the conveyor.

5. Take-Up Pulley – It is an adjustable idler pulley to accommodate changes in the length of a conveyor belt to maintain proper belt tension.

So, basically, pulleys are of just two types – Drive and Non-Drive. Snub, bent, and take-up are all Non-drive pulleys.

II. Based on construction: The types of pulleys manufactured here in TRF Ltd. are -

1. Non-Replaceable type Press Fit – The shaft and the hole are press-fitted to each other, and hence this is usually used with requirements of less torque transmission.

2. Non-Replaceable type Key-Fit – Once fitted using key, the shaft cannot be taken out from the system, hence called non-replaceable type.

3. Replaceable type Key-Fit – It has different diameters of shaft at the two ends, and hence it can be taken out of the hub at a later stage, hence replaceable. The fit used is using a key.

4. Ring Feeder Type – Ring feeders are used to employ the connection of shaft and hub. Ring-feeders are heavy-duty locking elements and can be tightened as per the requirements of the torque transmission. It is the most costly but the most advanced in Pulley construction design as well.

Thus we see that there is a wide variety of Pulleys manufactured here in TRF Pvt. Ltd, and a particular industry when ordering, orders all the different kinds of Pulleys needed to it, at different places in the industry based on its use.


PROCESS FOR MANUFUCTURING 5

5.1 Process chart:-

1. Planning :- Material Instruction sheet Process chart Progress cum H/O sheet

2. Preparation:- Marking and cutting

3. Fabrication :- Drilling, Bending, Rolling, Straightening4. Fitting5. Welding6. Assembly (Dressing, Cleaning, Painting)7. Inspection8. Cost centre

5.2 Stages of Manufacturing:

For manufacturing of a certain product, the process takes the following route:

1. Order from the customer: The customer requiring a certain number of certain types of products issues the order to TRF.

2. Issue of SODS (Sales Order Data-Sheet): The marketing department of the company releases SODS and sends it to the departments of Planning and Design.

3. Drawing of the product: The design department makes a detailed drawing of the product to be made and sends APL (Advanced Procurement List) along with it to the Planning department.

4. Purchase Requisition: The above is sent to MMD (Material Management Division) and a Purchase Requisition (PR) is prepared involving the details of the materials to be purchased keeping in view of the inventory already existing, and the capacity of it.

5. Instruction– Sheet: Planning department sends an IS (Instruction Sheet) to the work-shop, which involves the details of the various units to be assembled in the final product, and acts as a guide to the Shop Engineers to manufacture the required product.

6. Purchase Order: The MMD then releases a PO (Purchase Order) which is sent to the various raw-material making companies. After the procurement of the raw-goods, the manufacturing is started in the work-shop.


Forged Bar/Rolled Round

Shaft Centering:25

Shaft Turning:700

Keyway M

arking:30

Steel PlateShell Cutti

ng:150

Shell Rolling:350

Shell Extra Matl.

Cutting:100

Shell Fitting:80

Shell Welding:230

Re-rolling:170

Shaft Keyw

ay Cutting:200

Forged Blank/round Bar

Hub Turning:180

Hub M

arking:15

Hub Keyw

ay cutting:90

Hub w

ith flange fitting:90

Hub w

ith Flange w

elding:250

Shell with m

iddle flange welding:100

Middle-flange cutti

ng

Rawm

atl. for mid-flange

End Flange Cutting

Steel plate

Shaft Key fitti

ng

Pressing:180Fitti

ng of Pulley:420W

elding of Pulley:540M

achining:610Balancing:60

Pulley M

anufacturedLagging

FIG 6:- OVER ALL FLOW CHART


PRO

CESS

FL

OW

CH

ART

OF

PULL

EY

5.3 Details of the operations:

The manufacturing process of pulley can be subdivided into that of its main parts namely shaft, hub and shell and then their assembly. Various operations involved require different machines and equipments and finished or unfinished components are to be transferred to the respective. The required transportation is executed by EOTC (Electric Overhead Travel Crane). The EOTC facilitates movement of a work piece by hanging it by the means of iron-ropes and hooks. For the machines placed closer, jib cranes are used for transportation. For transportation of smaller components, special vehicles called ‘Forklift’ are used more often.

SHAFT

1. Raw material for shaft can either be Forged Steel Bar/Blank or Rolled Steel bar, depending upon the diameter of Pulley, applications, cost and preferences. (Typical Ultimate Tensile Strength 60-65 N/mm2).

2. Centering: Centering of shaft is essential to eliminate any possible eccentricity (caused due to eccentric turning of shaft on lathe) that can lead to appreciable amount of vibration in the pulley. The purpose of centering is accomplished by the use of centering machine, incorporated with the arrangements that easily locate the center of the shaft. Two V-jaws are employed for locating centers. Centers are drilled into the ends of the shafts. (25 minutes)

3. Turning: Turning for the shaft of pulley under study is performed on Conventional lathe. At first turning is performed on one side of the shaft as per the dimensions required, then the shaft is reversed to turn the unmachined part of the shaft (part under the chuck) it is required that the shaft be unloaded, the chuck be set according to the new diameter, the program required for the machining of the other side be entered, etc. These all take some 200 minutes. (800 minutes)

4. Key way marking: After the turning of the shaft is finished, shaft is transferred to the marking table.keyway is marked manually. (33 minutes)

5. Key way cutting: The marked keyway is transferred to the milling machine. Two different tools are employed to cut the slots having round end. First the round end is machined using two flute slot drill and then key slot is extended along the length by slot cutter.The keys are then fitted into the two middle slots. (197 minutes)

This makes the shaft ready for assembly.

FLANGES

Flanges are disc-shaped structures made from weldable quality structural steel plate. In End-flanges, OD is matching to Shell and ID is matching to Hub, to support the hub against shell, while in middle flanges, OD is matching to shell and ID is kept with some clearance between it and shaft. End Flanges are supported to the hub using ribs. Chamfer is provided at the inner periphery of the end flange.Cutting of Flanges from Steel plates is performed using Super Plasma Cutting System, from Koike Sanso Kogyo Company Ltd., Japan. It is reputed to be the world’s fastest precision plasma cutting system, with a maximum speed of 6000 mm/min.


HUB

1. The raw hubs are hollow round bar or Forged Steel blank or weld able steel casting, depending upon quality and preferences.

2. Turning of the outside diameters of the Hub as well as boring of the inner diameter is performed on CNC lathe. (185 minutes)

3. The Hub is marked for keyway cutting. (16 minutes)

4. The keyway is cut using Slotting Machine. (92 minutes)

5. Fitting End-Flange: Flanges are cut using Plasma Cutting Machine. End-flanges are fitted with the hub using Tack-Welding. (89 minutes)

6. Welding End-Flange – Then it is welded with the hub, using CO2 welding. (255 minutes)

Thus the hub with end-diaphragms is ready for assembly.

SHELL

1. Raw material for shell is large weldable quality structural Steel Plate.

2. The large plate is cut into smaller sheets of sizes corresponding to the dimension of the shell. This cutting is executed by using Plasma Cutting machine.

3. The plate is bent into cylindrical from using 3-Roll Bending Machine. (350 minutes). The three rolls are so placed that their centers form the three corners of a triangle. Initially, one end of the plate is inserted between first two rolls and the plate is then withdrawn spontaneously due to rotating roll pressure. The bending of the sheet is obtained by the vertical translation of two lower rolls required to increase the roll pressure. The open shell is obtained as a result of this process.

FIG 7:- MANUFACTURING OF SHELL


4. More commonly, the portion of the metal at the ends of the rolled sheet remain unrolled. This

makes it difficult to join the ends to form the shell. Thus, it is required to remove these portions

of the rolled sheet. This is executed by the gas cutting. In general, the width of this portion is

6mm approximately at both ends.

5. The shell is then fitted. Tack welding is performed at intermittent points. (81 minutes)

6. The two ends are then joined together by welding. The welding process used is submerged arc

welding. (231 minutes)

7. The welded shell is again processed by the 3-Roll Bending Machine to make it more uniform.

(173 minutes)

8. The Middle-flanges (also called Diaphragms) are welded in between the shell. This is done to

provide extra constraint to the shell expansion and keep the shell intact even in severe cases.(97

minutes)

9. The Shell is ready for assembly.

ASSEMBLY

After making all the parts ready, they are assembled through the following sequence of operations:

1. Pressing: One Hub with flange is pressed to one side of the shaft using the type of fit

incorporated (here, it is key fitting). The shaft is then carefully inserted into the shell to

properly match the central line of shaft and shell. The second hub is then pressed into the shell

using Horizontal Pressing machine. (180 minutes)

2. Fitting: It involves performing tack welding at areas where shell and end-flange join and

making the pulley ready for welding. The distance of shaft and shell is checked in four (or

eight) different radial directions, and made equal before tack welding is performed.

3. Welding: The above areas are now welded using CO2 welding on both the sides of the pulley.

(537 minutes) Horizontal welding is employed by putting the assembly into a pit. First flange is

welded , assembly is reversed and then the second end is welded.(420 minutes)

4. Returning : Finally, pulley is machined by mounting it on its shaft centers. (612 minutes) this

is done to obtain more uniform cylindrical surface.


5. Balancing: It is performed to make the pulley balanced in terms of weight along all radial

directions. (60 minutes)

Method of checking: For checking, whether the pulley is balanced or not, it is mounted on the

Balancing Machine, and rolled to a particular direction. When it stops, it should not roll back

by more than 5o.

If the pulley is not balanced, counter-weights are welded to the outer periphery of end-flange

inside the shell at appropriate positions.

6. Lagging: It is the operation of providing Rubber Lagging on external face of the shell, which

comes in contact with the belt. It is performed due to following reasons:

(i) To increase friction: The friction co-efficient between rubber and rubber is higher

compared to rubber and steel. Thus rubber lagging permits transmission of higher

tractive pull to belt, reduction in belt tensions and consequent economy.

(ii) To prevent material build-up: Rubber lagging prevents wear of shell against wear by

abrasive and corrosive materials.

Lagging is not performed here in TRF, and Pulleys are sent outside for the same. It is done

using Hot Vulcanising Process. The Non-Drive pulleys usually have plain lagging, while two

types of lagging grooving patterns are usually provided on the Drive-Pulleys:

(a) Herring Bone pattern – The grooves are inclined at approximately 60o to the belt-axis. This

type is ideal for unidirectional conveyor, and the groove apex allows escape of material

trapped between belt and pulley.

(b) Diamond pattern – This is used for conveyors operating in both the directions.

In this way, a Pulley is manufactured.


5.4 FLOW CHARTS OF PROCESSES

FLOW CHART FOR MANUFACTURE OF SHAFT

TEMPORARY STROAGE

CM-1, SW-2

CL-1, 16, 18, 20,

CL-21, 22, 24

YES NO

UM-2


START

CENTERI-NG & CUTTING

TURNING & FACING

KEYWA-Y YES/

KEY PROCESS

INSPECTION

SHAFT

FLOWCHART FOR MANUFACTURE OF DIAPHRM OR E.F

TEMPRORAY STORAGE

PC-2

PC-2


START

CUTTING & PREPRARION OF

BEVELLIN-G OF E.F

INSPECTION

DIAPHRAM OR E.F(2 NOS.)

FLOWCHART FOR MANUFACTURE OF HUB

TEMPRORAY STORAGE

SB CNC –CL-23(CL-22, 18, 21, 24)

SB CNC –CL-23(CL-22, 18, 21, 24)

SB CNC –CL-23(CL-22, 18, 21, 24)

KEYWAY DRILLTAPING

YES NO


START

TURNIN-G PROCE

BORINGPROCES-S

FACINGPROCES-S

KEYWAY OR DRILLTA-

KEYWAY YES/N

KEYWA-Y PROCE

INSPECTIO-N

DRILLIN-G PROCESS

HUB

FLOWCHART FOR MANUFACTURE OF SHELL

TEMPORARY STORAGE

PC-2

PR-3

BAY-3(SAAW-1)

MIG-2/3

PR-3


START

CUTTING & PREPRATIO-N

ROLLING OF SHELL

WELDING OF SHELL (INSIDE/OU-TSIDE)

GRINDING(WELD SPOT UPON SHELL

REROLLI-NG

MF-WELDIN-G

INSPECTION

SHELL

PULLEY LAGGING 6

Conveyor pulleys can be covered with some form of rubber fabrics or other material. One use of lagging is to increase the coefficient of friction between belt and drive pulley. Another purpose is to reduce wear on the pulley face and to effect a self cleaning action on surface pulley.

6.1 Lagging thickness and attachment :

Lagging thickness varies from a few thousandths of an inch as with a sprayed-on coating to a considerable thickness as with some solid rubber vulcanized coatings.

The normal methods of attachment are bolting, painting, cementing and vulcanizing. Vulcanized lagging is generally preferred for the heavy or severe service applications. Bolted-on lagging has the advantage of being replaceable in the field. It can be obtained in various grooved and the specialized surface finished types. Bolted lagging generally consists of a rubber cover reinforced with multiple ply fabric construction similar to conveyor belting. The fabric insert is required to reinforce the bolt holding strength. Painted-on and cemented lagging are generally limited to lighter conditions and are normally not used where grooving and imbedability characteristics are needed.

6.2 Lagging hardness :

Rubber lagging used on drive pulleys normally has a durometer hardness of 55 to 65 shore A scale. The lagging on snub or send pulley, which contacts the carrying side of belt, normally has a specified hardness from 35-45 shore A scale. This cover rubber tends to the build up of material on the pulley face and allows solid objects to imbed in the rubber lagging rather than to damage the belt.

6.3 Grooving of lagging:

Drive pulley which perform in wet or damp condition are often grooved, these grooves commonly take the shape of herringbone or chevron shaped pattern cut into the lagging. Generally the dimensions of the groove are ¼ in. wide X ¼ in. deep with 1/8 in. minimum thickness of material under the bottom of the groove. These grooves are usually spaced on 5/4 to 7/4 in. centers. Their purpose is to improve the traction between the belt and pulley by removing water from belt. The apex of pattern points is in the direction of belt travel.


CURRENT LAYOUT OF TRF 7

7.1 SUPPLY RANGE FOR TRF:

DIA.OF PULLEY(mm): 200,219,273,324,400,500,630,800,1000,1250,1600

BELT WIDTH(mm): 400,500,650,800,1000,1200,1460,1600&1800


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Die

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.

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Se

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ity

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Path

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ay

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eria

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agem

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ivis

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(MM

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rag

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on

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Fab

rica

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Acc

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ept.

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Fi

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St

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Bay

1Ba

y 2

Bay

3Ba

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Bay

6

BAY

5

Cur

rent

layo

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f T

RF

LT

D.

TIME OF OPERATION 8

8.1 Time involved in each operation :

Component Name : ShaftOp. no. Operation Name

Time(Min)

M/C used

1 Centering 25 Centering Machine2 Turning one side 400 CNC Lathe3 Set up time 2004 Turning other side 300 CNC Lathe5 Keyway Marking 30 Manual6 Keyway Cutting 200 Milling Machine

Total time for one piece 1155

Component Name : Hub (with end flange)Op. no. Operation Name

Time(Min) M/C used

1 Turning one side 100 CNC Lathe2 Set up time 2003 Turning other side 80 CNC Lathe4 Keyway Marking 15 Manual

5 Keyway Cutting 90Slotting Machine

6 Hub with flange fitting 90 Welding7 Hub with flange welding 250 Welding


Component Name : ShellOp. no. Operation Name

Time(Min)

M/C used

1 Shell Cutting 150 Plasma Arc Cutting2 Shell Rolling 250 Plate Bending Machine3 Extra Material Cutting 100 Gas Cutting4 Shell Fitting 80 Welding5 Shell Welding 200 Welding6 Re-rolling 10 0 Plate Bending Machine7 Middle-flange Welding 100 Welding



CAPACITY ANALYSIS OF MACHINES

MACHINE

SHIFT REST REMAINING HOUR

75% (ACTUAL EFFICIENCY)

CAPACITY

CM-1,SW-2 3 3hrs 21hrs 15.75hrs 350*3000mm

CL-21 2 2hrs 14hrs 10.5hrs Hgt of center-260mmDist. Of center-1500mm


CL-24 3 3hrs 21hrs 15.75hrs SHAFT SPEED-1800MAX. 600MIN.


CL-1 3 3hrs 21hrs 15.75hrs Hgt of center-762mmDist. Of center-812mm,RPM-1800MAX.

CL-20 3 3hrs 21hrs 15.75hrs Hgt of center-1mDist. Of center-7m

CL-16 3 3hrs 21hrs 15.75hrs 400*4000mm

UM-2 3 3hrs 21hrs 15.75hrs 630mm(width),1410mm(long)

SL-1 3 3hrs 21hrs 15.75hrs R.P.M-11.2Length of stroke-7.3

SL-2 3 3hrs 21hrs 15.75hrs R.P.M-18Length of stroke-11.8

PC-2 3 3hrs 21hrs 15.75hrs 6 to 32mm(thick),27m(long),3m(width)

PR-3 2 2hrs 14hrs 10.5hrs 3000mm(width)25 to 32mm(bend thickness) ,550 to 1200mm(dia.)

SAAW-1 (WELD)

2 2hrs 14hrs 10.5hrs Man power=4

MIG-2/3 13hrs 1hr 12hrs 9hrs Man power=4

HP-3 3 3hrs 21hrs 15.75hrs MAX. TONS OF RAM-150


X


8.2 Deduction from the Gantt chart:-

1. The time involved in machining of a shaft is maximum; therefore the machining of shaft must not be delayed as this would delay the overall manufacturing time of the pulley.

2. During the time, a shaft is manufactured, the shell welded with mid-flanges, two hubs and two end flanges have already been completed. Thus operation of assembly can be started without losing any time in waiting for the parts.

3. Since, Plasma Arc Cutting Machine is employed for cutting both flanges and sheets for shells, sheets are first to be cut since they involve longer operation time and then flanges are cut. Delaying the operation on flange doesn’t influences the overall manufacturing time.

4. As there is sufficient time available for welding the middle flange with the shell, so it can be transported to the welding section (assembly) and a common welding section can be employed.

5. If, the machining time, loading, unloading, and setting time are kept constant, the total manufacturing time is reduced by an hour approximately when new layout is employed.

6. In long run, when large numbers of pulley are to be manufactured, the manufacturing time reduces significantly.

8.3 ACTIVITY- RELATIOSHIP CHART


A

B

C

D

E

F

Here, the symbols in italic form signify the different sections as:-

A Plasma arc cutting m/c Symbols Meaning

B Shaft section I Important

C Shell section E Essentially important

D Hub section A Absolutely necessary

E Assembly section

F Storage

Form of layout on the basis of activity relationship chart:

ACTIVITY RELATIONSHIP DIAGRAM

CLOSENESS RATING INDICATION( NUMBER OF LINES)

A 4 E 2 I 1


A

B

C D E

F

8.4 BEST POSSIBLE LAYOUT

Probable cellular layouts of the pulley section can be obtained on the basis of the activity-relationship chart. Here, some are some attempts to find the best possible layout:-

1. 9 m 9 m 13.5 m

9 m 13.5 m 9 m


35

m

9 m

4.5

m

8 m

2 m

A

B

C

D

E

F

9 m

PLASMA ARC CUTTING M/C

SAW

PRESS ROLL

CNC LATHE

SL

UM + MARKING TABLE

CL

CM

WELDING SECTION

BALANCING M/C

HORIZONTAL PRESS

CL

STORAGE

From-To chart for the above layout (assuming center to center transportation b/w cells) is:-

Other alternative layout can be:-

9 m 9 m 7 m 5 m

19 m


A B C D E F

A

B

C

D

E

F

17.5 16.5

12.4

16

16.8

19.7

98.9

34

12.4

16

16.8

19.7

19.761.717.5

35 m

9 m

9 m

A

B

CD

E

F

PRESS ROLL

SAW

CNC LATHE

SL

WELDING PRES

SIN

G

M

/C

BALA

NCI

NG

M

/C

CL

UNIVERSAL MILLING + MARKING TABLE

CL

CEN

TERI

NG

M

/C

STORAGE

PLASMA ARC CUTTING M/C

X X

X X

X

X

X

X

X

0

From-To chart for the above layout (assuming center to center transportation b/w cells) is:-

Thus, from the above two alternatives for the layout of the pulley section designed as per the activity-relationship chart, it can be deduced that the transportation distance of the material is lesser for the second layout and therefore involves less transport cost. Thus it can be concluded that the second layout is better than the first one.

There can be more alternatives for these layouts for the same activity relationship chart. For each of them From-To chart is prepared and total distance covered by the material during the manufacturing process is calculated. The layout corresponding to the minimum value of the distance will be the best layout.


A B C D E F

A

B

C

D

E

F

18 18

9

18

16

14.7

18 61 14.7 93.7

36

9

18

16

14.7

X XX

X X X

X

X

X

0

CONCEPT OF SHAFT DESIGN & PULLEY 9

9.1 CONCEPT OF SHAFT DESIGN IN PULLEY

The basic concept of forces, torque and bending moment can be shown by a schematic representation of pulley.

F F

E D C B A

F F

FIG 8:- DESIGN OF SHAFT

The above figure shows the schematic view of a drive pulley. Point B and point E are bearing support centerlines. Point C and point D are the diaphragm centerlines. Torque TQis applied at point A. Shaft section AC will be transmitting this full value of torque. The portion of this torque TQCwill be absorbed by diaphragm at C and the balance portion TQDis absorbed by the diaphragm at D such that TQC + TQD = T. the shaft portion AC is carrying full value of torque and thus becomes the criterion for design of shaft.The torque being applied has following characteristics:-

The torque during steady state operation is less, but is applicable for most of the time. The torque at the starting phase is more but duration is short. The torque is not alternating but remains unidirectional. Therefore, endurance strength is not

applicable. Maximum torsion stress is at shaft periphery.

Other major force acting on the pulley shaft is in radial direction. Total radial force F’= T1 + T2 + weight of the pulley. The force F’ can be considered acting at the center. Thus force exerted by each will be F’/2. A multiplier 1.05 is included to compensate for the other factors.

Thus F = 1.05 X F’/2. The bending moment has following characteristics:-

Bending moment is more during starting phase. Bending moment is less during steady phase operation. The shaft is rotating. Therefore, each element in the shaft will be subjected to alternating

compressive and tensile stress. Thus endurance strength is applicable here. Maximum bending stress is at periphery.


In addition, there will be radial compressive stress within hub due to fitting between shaft and hub. This compressive force is uniformly spread across width when there is no tension in the belt. However, in actual installation, a couple force acts on shaft at hub, which arises as a result of the shaft deflection. The pulley assembly tends to prevent shaft deflection but shaft tends to create deflection in pulley assembly.

Schematic view of the shaft under action of forces:-

A B C D

Bending moment diagram of the shaft when free to deflect :-

Bending moment diagram of the shaft when shaft is constrained at hub:-

Pulley behavior under load:- Pulley is a composite structure, which is subjected to radial and tangential

forces. The source of the radial force is the belt and the tangential force originates at the end of the

drive pulley. Pulley composite structure deflects under these forces; creating certain value of deflection

in each component. The deflection of each component is dependent on its stiffness as well as rigidity

of its connection with other components.

The element in the shaft is subjected to usual bending stress, polar shear stress and radial compression

due to hub. It has been observed that the diaphragm joints at rim and particularly at hub are the zones

of stress concentration between hub and shaft. One side of the hub is hard pressed to the shaft whereas

the other side of the hub is less pressed to the shaft. This situation reverses in every revolution and is

critical for hub and shaft. The sudden change of load resisting area from hub to diaphragm and welded

joint at hub outer diameter and rim are prone to failure.


9.2 Suggestions for design of pulley:-

1. Use of simple taper bush at Hub :- The taper bush hub sheave is subjected to torque and radial force but stress due to shaft deflection is virtually non-existent within Hub because it is free to deflect within shaft. Simple taper bush when used for belt conveyor pulley, is subjected to different kind of stress pattern due to widely spaced two rigid units subjected to shaft defletion.

FIG 9:- SCHEMATIC LAYOUT OF PULLEY

2. Shifting of hub joint radially outwards:- The sudden change of load resisting area from hub to diaphragm and welded joint at hub outer dia. and rim are prone to failure. So, design can be improved by shifting the hub joint radially outwards. This is economically possible by using forged or cast steel hubs with extension on the hub outer radius.

3. Changing the position of the keyways in shaft : Keyways are one of the prime sources of raising stress concentration. Here, there are four keyways machined in the same line in shaft. This is certainly going to raise the stress concentration. Therefore, it may be suggested that two of the keyways required for fitting hub should be in one line and other two should be machined at angular offset of 900 to them. Although, it will increase the machining time and cost, it will definitely enhance the quality and life of the product.

4. Removing the sharp edge in keyways :- Usually, this is taken care of by the engineers in their design. But workers often used to neglect this important point. The sharp edge in the inner surface of the keyways, experiences drastic rise in the stress. This can be avoided by rounding /filleting the edge using the form tools after slot has been made using slot drill and slot cutter.


Taper bush

Shaft

Hub

ANNUAL REPORT 10

Rupees in lac

2013-14 2012-13 2011-12 2010-11 2009-10

Consolidated Consolidated Consolidated Consolidated Consolidated

Sales & Services (Net) 117,453.39 111,482.43 132,740.63 111,355.70 86,591.86

Other Income 1,443.58 817.73 659.03 1,254.42 1,237.10

Exceptional Item 2,972.50 — — — —

Employee Costs 10,889.36 11,787.43 10,306.89 8,302.18 6,914.10

Depreciation 1,233.98 1,214.57 1,077.89 849.17 611.60

Interest & brokerage 5,886.38 5,493.99 4,036.85 1,755.21 1,250.76

Profit/(Loss) before taxes (5,644.35) (8,778.03) 2,718.45 711.86 7,386.77

Provision for taxes (net) 149.01 355.11 1,375.99 522.84 2,509.91

Profit/(Loss) after taxes (2,820.86) (9,133.14) 1,342.46 189.02 4,876.86

Dividend (%) — — 40 20 75

Work Production 26,450.34 30,713.00 28037.00 24,910.00 20,009.86

Progress billings 50,522.96 59,952.88 65,612.31 64,014.87 54,046.79

As on As on As on As on As on

31.03.2014 31.03.2013 31.03.2012 31.03.2011 31.03.2010

Net fixed assets 10,973.75 11,151.99 11,166.11 8,390.78 6,170.29

Share Capital 1,100.44 1,100.44 1,100.44 1,100.44 1,100.44*

Reserves and Surplus 4,746.87 6,570.60 15,017.56 13,380.05 13,616.54

Net worth 5,647.31 7,671.04 16,118.00 14,480.49 14,716.98

Borrowings 59,907.76 57,561.64 50,315.02 32,776.87 21,661.95

Net worth per share (Rs.) 53.14 69.71 146.47 131.59 133.74

Debt: Equity ratio 10.61:1 7.50:1 3.12:1 2.26:1 1.47:1

Number of employees 1390 — 1579 1556 1336

CONCLUSION 11


From the case study on the TRF LTD.,we got the brief knowledge about the company, its management, its marketing stratergy etc. About the products which is manufactured in the TRF. Pulley is also one of the product which is manufactured in this company. A basic idea is highlighted for the manufacturing of the Pulley, its type, parts which is used in the pulley. There is also need of some improvement in the process of manufacturing to reduce the time taken by the machines and to increase the the rate of production. Basic design concept of shaft is essential to make a balanced pulley. After the completion of the product.i.e- pulley, a process called lagging is needed to increase the life of the pulley, lagging reduces the wear and tear of the pulley surface from the belt.


REFERENCES.

1. http://www.tatasteel.com/UserNewsRoom/usershowcontent.aspx?

id=30&type=Awards&REFERER=http://www.tatasteel.com/media/awards-and-

recognitions.asp

2. http://www.tatasteel.com/corporate/operations/indian-operations.asp

3. http://www.tatatinplate.com/hospital.shtm

4. http://www.telcon.co.in/html/SubIndex.asp?sMainPage=plants

5. http://www.tata.com/company/profile.aspx?sectid=4c4BdnkPpOQ

6. http://www.tatagrowthshop.com/corporate/profile.asp

7. http://www.myjamshedpur.com/iswp-launch-wire-unit-expansion-plans-jamshedpur

8. http://www.aiada.in/web/profile/facts.php


http://www.tatasteel.com/corporate/operations/indian-operations.asp

http://www.tatasteel.com/UserNewsRoom/usershowcontent.aspx?id=30&type=Awards&REFERER=http://www.tatasteel.com/media/awards-and-recognitions.asp



pulley 111

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