Training Report

Industrial Training of Automobile Engineering

Department of Automobile Engineering

Chandigarh university

Submitted by: -
Sahil Verma
15BAM1114
7AME-1
Acknowledgement

The six weeks of industrial training project is a golden opportunity for learning and self-
development. I consider myself very lucky and honoured to have so many wonderful
people, lead me through in completion of this project.
I am highly grateful to Chandigarh University for providing this opportunity to carry out
the six weeks Industrial Training at Acme Pipe Industries, Ludhiana, Punjab.
My grateful thanks to Mr. Varinder Singh, training coordinator at Acme Pipe Industries,
Ludhiana, Punjab, who in spite of being extraordinarily busy with his duties, took time out
to hear, guide and keep us on correct path.
The author expresses gratitude to other faculty members of Automobile department of
Chandigarh University for their intellectual support throughout the course of this work.
Scope of Training
Steel industry is one of the fastest growing and fastest changing industry in world since
ages just because of vast applications of steel products and steel tube or pipe is one of
them. Steel tube is basic structural element in most industries without steel tubes its
hard to imagine manufacturing industry and making precise products out of steel tubes
according to various industry needs and with high accuracy and precision
RAW MATERIAL USED IN ACME FOR MANUFACTURING DIFFERENT
PRODUCTS:

1) ERW: ERW (Electric Resistance Welded) pipes are welded longitudinally, manufactured
from Strip / Coil and can be manufactured up to 24” OD. ERW pipe cold formed from a ribbon of
steel pulled through a series of rollers and formed into a tube which is fused through a electric
charge. It is mainly used for low/ medium pressure applications such as transportation of water /
oil. Pearlites steel is one of the leading ERW Stainless Steel Pipes Manufacturer and exporter from
India. Contact us for product details. ERW pipes means Electric Resistance Welded Pipes. ERW
steel pipes and tubes are used. ERW steel pipes and tubes are used in various engineering purposes,
fencing, scaffolding, line pipes etc. ERW steel pipes and tube are available in various qualities,
wall thicknesses, and diameters of the finished pipes.
Common sizes for ERW Steel Pipe range from 2 3/8-inch OD to 24-inch OD in a variety of lengths
to over 100 feet. Surface finishes are available in bare and coated formats and processing can be
handled on site to customer specifications.

2) DOM: DOM (Drawn Over Mandrel) pipe is basically the same pipe with a seam weld but
weld line is removed with the help of mandrel and different processes like buffing and grinding.
DOM tubing is created from flat sheets of raw material, rolled on a weld mill to produce mother
hollow. The material is subjected to a normalizing heat treatment to produce suitable tube for cold
working. The cold drawn process provides the tube with better dimensional tolerances, improved
surface finish and the strongest weld strength achievable. DOM is often incorrectly referenced as
“seamless tube” when it actually does have a seam (although it is almost invisible). Drawn Over
Mandrel. Technically, DOM is not a type of steel tube, but rather the process in which the tube is
finished. The cold drawn process provides the tube with better dimensional tolerances, improved
surface finish and the strongest weld strength achievable.
3) CEW: - In CEW process the welded tubes (ERW Tubes) are used as parent hollow. After
Normalizing & Surface Treatment (Conventional & Oil route) the tubing is cold drawn through a
Die and over a Mandrel to reduce diameter & wall thickness to required dimension. Acme has an
Oil Draw facility to produce extremely smooth ID finish with close tube tolerance for Cylinder
bore tubes where piston moves freely repeated under severe conditions. The tooling & process is
well designed to achieve close ID tolerances with ID finish. Such close tolerances & finish enable
customer to use oil draw tube directly without additional operations.
4) HRC: There are many types of steel out there, with various shapes, grades, specifications,
finishes, and other processing considerations. One key distinction among prefabricated steel
products is the difference between hot rolled versus cold rolled steel. To process hot rolled steel,
manufacturers start with a large, rectangular billet. The billet gets heated and sent for pre-
processing, where it is flattened into a large roll. From there, it is kept at a high temperature, and
the glowing white-hot steel is run through a series of compression rollers to achieve its finished
dimensions. For sheet metal, manufacturers spin the rolled steel into coils and leave it to cool. For
other forms, such as bars and plates, materials are sectioned and package

5) Seamless pipe: Seamless pipe does not have any joint in its cross-section through-out
its length. In Seamless pipe, there are no welding or joints and is manufactured from solid round
billets. The seamless pipe is finished to dimensional and wall thickness specifications in sizes from
1/8 inch to 26-inch OD. Applicable in for High-pressure applications such as Hydrocarbon
Industries & Refineries, Oil & Gas Exploration & Drilling, Oil & Gas Transportation and Air and
Hydraulic cylinders, Bearings, Boilers, Automobiles etc.
6) CDS: Cold Drawn Seamless Tubing (CDS) is a cold drawn steel tube. Produced
from piercing hot rolled bar stock, the cold drawing process increases the tube's physical
properties reducing the cost of machine time. Cold drawn seamless tubing provides a better
uniformed OD and ID, enhanced machinability, increased strength, and tighter tolerances
compared to hot finish seamless products .
Manufacturing Process:

1) Pickling: In stainless steel production process oxides are formed on the stainless-steel
surface during annealing and hot rolling. Under these oxides’ layers chromium is depleted and the
steel has lost a significant amount of corrosion resistance. Thus, removal of the oxide scale is
necessary. Best performance and quality are reached by using chemical cleaning of the surface.
This is done with an acid pickling process, where mixtures of hydrofluoric acid (HF) and nitric
acid (HNO3) are used to remove the oxides and to enrich the chromium depleted areas again. This
site should give an overview of the chemical reactions during pickling process. The pickling
process is used to remove a thin layer of metal off of the stainless-steel part. This is different from
the descaling process, which removes visibly thick oxide scale from the stainless-steel part. Our
pickling solutions for stainless steel are mixtures of nitric acid and hydrofluoric acid. Corrosion
on the contacted part can occur if the process is not done by a pickling specialist. To match our
state-of-the-art facility, this is our “one-step” process which removes heat tint and weld scale while
simultaneously passivating the surface of the parts being processed. Most of our new customers
are surprised to find out that stainless steel pickling also accomplishes passivation. In summary,
Pickling passivates, Passivating passivates and Electropolishing passivates.
The next most common application for stainless steel pickling is as a surface pre-
treatment step prior to electropolishing. When a part has heat tint and weld scale, recommends
pickling prior to electropolishing to achieve the best results.

2) Pointing: Pointing, sometimes called tagging or swaging, is a method of reducing a tube's

end to permit it to pass through a draw die before a drawing operation. After the tube end goes
through the draw die, gripper jaws converge on the point to begin the draw operation. Draw
operations are performed on drawbenches or bull blocks.
Push pointing is accomplished by gripping a tube and advancing pointing dies over the end,
resulting in a reduced end diameter, usually 6 inches to 8 in. long. The push-pointing operation
usually is performed cold. It can be performed warm or hot, but this is rare.
Although push pointing is an auxiliary operation, the quality of the point has a big impact on the
proficiency of the following drawbench operation. For example, a crooked point can cause two
significant problems: The gripper jaws might miss the point when they converge or the point might
break, both of which have a negative effect on drawbench productivity.
3) Tube drawing: Tube drawing is a process to size a tube by shrinking a large diameter
tube into a smaller one, by drawing the tube through a die. This process produces high-quality
tubing with precise dimensions, good surface finish, and the added strength of cold working.[1] For
this reason this process is established for many materials, mainly metalworking but also glass.
Because it is so versatile, tube drawing is suitable for both large- and small-scale production.[2] The
large-scale production of glass typically uses a one step process where glass is directly drawn into
a tube from a melting tank.
There are five types of tube drawing: tube sinking, mandrel drawing, stationary mandrel, moving
mandrel, and floating mandrel. A mandrel is used in many of the types to prevent buckling or
wrinkling in the workpiece. Tube Drawing Processes When a hollow tube is drawn through a die,
generally a mandrel or plug is used to support the inside diameter of the tube, this process is called
tube drawing. The function of the plug is to effect wall reduction and to control the size of the
hole. However, the mandrel may be omitted if it is not necessary to make a reduction in the wall
thickness, or if the dimensions and surface of the inside are not important. The process to draw a
pipe without any mandrel is known as tube sinking. In drawing tubes over a stationary mandrel,
the maximum practical sectional area reduction does not exceed 40 per cent per pass the increased
friction from the mandrel. If a carefully matched mandrel floats in the die throat of the die, it is
possible to achieve a reduction in area of 45 percent, and for the same reduction the drawing loads
are lower than for drawing with a fixed plug. This style is called the drawing with floating plug.
To be mentioned is that in this style, tool design and lubrication can be very critical. Problems with
friction in tube drawing are minimized in drawing with a long mandrel. The mandrel consists of
along hard rod or wire that extends over the entire length of the tube and is drawn through the die
with the tube. In this design, the area reduction can be 50 per cent. However, after drawing, the
mandrel must be removed from the tube by rolling (reeling), which increases the tube diameter
slightly and disturbs the dimensional tolerances. The drawing process discussed above can be
illustrated in the figure.

4) Manual straightening:
Rotary tube straightening machines are called rotary because the tube rotates as it passes through
the machine. The rolls grip the tube and rotate it while feeding it through the machine until the
entire length has been straightened. While passing through the machine, the tube is subjected to
two specific straightening forces: pressure straightening and bend (or offset) straightening.
1. Pressure straightening. Each pair of rolls can be adjusted so that the gap between them is slightly
smaller than the outside diameter of the tube. As the tube passes through this restricted gap, it is
subjected to pressure which, if sufficient, will cause the tube walls to be strained past their elastic
limit, thereby causing some straightening of the tube. If this ability to squeeze the tube is used
correctly, the tube will be "rounded up," removing some or all of its ovality.
 2. Bend, or offset, straightening. One or more pairs of rolls can be adjusted to cause the tube to
follow a curved path through the machine. Bending the tube in this manner is the main
straightening action.
The amount of bend must be carefully controlled so that it has enough force to take the tube past
its elastic limit to achieve straightness, but not so much that it causes excessive work hardening.

5) Cutting: Pipe cutting, or pipe profiling, is a mechanized industrial process that removes
material from pipe or tube to create a desired profile. Typical profiles include straight cuts, miters,
saddles and midsection holes. These complex cuts are usually required to allow a tight fit between
two parts that are to be joined via arc welding.
Hot cutting
Hot cutting is performed by means of a thermal torch (plasma or oxyfuel) and is mounted to the
last axis of a multi-axis machine. The axes of the multi-axis machine are powered by electric
motors and are synchronized to create a path for the torch and pipe that yield a desired profile.
The synchronization of axes is accomplished either mechanically, via cams, levers and gears, or
electronically, via microprocessors and controllers.

Cold cutting
Where the high temperatures and sources of ignition required by hot cutting are not desirable, air-
or hydraulically-powered pipe cutting machines are used. These comprise a clamshell or chain-
mounted cutting head holding a tool steel and feed mechanism which advances the tool a set
amount per revolution round the pipe. Tools may be styled to cut and/or prepare the bevel for
welding in a single or multiple pass.
Popular in offshore, pipe processing, ship building, pressure vessel, structural and mechanical
contracting manufacturing because of the complex cuts and profiles typical required in their
respective industries. Some common pipe cutting applications are: pipe work, offshore jackets,
industrial steel structures, stadiums, cranes, nozzles, and pipe laying stingers.

6) Chamfering: Pipe chamfering means machining a pipe in order to get a preparation.

The chamfer tool on our chamfering machine is cutting the steel material from the pipe end to get
the chamfer. Especially in the oil and gas industry with high pressure pipelines the welding
preparation has to be done very accurate in order to get a good base to start with before welding
the pipes together. Tolerances on the chamfering process are getting tighter and more important in
the industry, with our stable and accurate machine it is easy to offer quality and accurate bevels to
your customers. An extra option is our Inside copying system to follow the inside diameter of the
pipe to keep track of out of round pipes to always get an equal bevel all around the pipe.
Products: -
Bush Bushings, also known as “Plain Bearings” or "Sleeve Bearings," are designed for use in
numerous applications and offer features and benefits unavailable with many rolling-element
bearings. Bushings (plain bearings) are distinguished from rolling-element bearings primarily by
the fact that they consist of only one part. That one part may be built up of different materials,
layered and combined into a load carrying system. Depending on the application, bushings are
available for operation with supplemental lubrication or to run “dry”, with no additional
lubrication. Bushings are available impregnated with lubricant, with lubricant “plug” inserts, or
with inherently low coefficients of friction. Bushing materials include cast or machined metals,
stabilized polymers (“plastics”), fiber-wound composites, and combinations of different types of
materials. Selecting the right bushing for each project requires detailed knowledge of the
application requirements and experience with bushing technology.
Industrial Uses:
USES FOR STEEL PIPE
Steel pipes are extremely versatile. That’s why they’re commonly used in many industries, from
gas to sewage. They also come in a variety of types and sizes, and they can easily be customized
to fit the needs of a particular project, adding even more to its versatility. Truth be told, it’s near
impossible to find an industry that does not use steel pipe in some capacity.

MOST COMMON STEEL PIPE USES IN VARIOUS INDUSTRIES

Construction, in particular, has benefited from the fact that steel is a more practical alternative to
other metals, like iron. Steel is corrosion resistant, making them more durable and cost-effective.
It also means that you can use these pipes in areas constantly exposed to the elements because it’s
able to withstand them. Given all these benefits, here are some of the common uses of steel pipes.

DOMESTIC
Steel pipes are a common choice for many homes because they are more durable, meaning you
won’t have to change them every couple of seasons. Any plumber will recommend a stainless-
steel pipe for your shower, tap and the rest of the house, especially exposed pipes because they’re
more enduring of the elements. They’re also known to be more durable. Its wide use is proven by
how commonly you see it in hardware stores and DIY showrooms.
MEDICAL
If doctors use it, it must be safe, so that’s another tick for steel. Steel pipes are so popular in the
medical field that they have used them for everything, including supporting fractured bones,
medical machinery, surgical tools, dental procedures and even in pharmaceutical. Steel’s varied
application is a testament to its durability, safety, and versatility.

FACTORIES
Because factories have to ensure the safety of what they are producing, they have to make sure
that they’re equipment are of top calibre. That’s why most of them use steel pipes, from assembly
lines and water treatment facilities to dairy and food processing and the refineries themselves.
CONSTRUCTION
This is one of the most obvious uses of steel pipes. They are the go-to for many construction
companies because they’re malleable and sturdy, at the same time. Steel pipes are used as
construction piling, to support the weight of heavy buildings when the soil is too weak. It’s also
used on the building itself and even its architectural design.
Steel pipes are also used to construct ships, the ship yard where they’re kept, oil refineries and
even space stations. Whether the construction is on land, over the water, or in space, steel pipes
are a quality choice.

AUTOMOBILES
Automobile industry also uses steel pipes in manufacturing majority of auto parts because
numerous parts that are used to make a car involve steel tubes in one or another way but a lot of
post processing is required to achieve required quality and standard but it easy to make them with
use od steel tubes as compare to any other raw material.