Hindalco Industry Limited Project Report _Inplant Traning

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INDUSTRIAL TRAINING IN

HINDALCO INDUSTRY LIMITED, RENUKOOT

An In-Plant Training Report

Submitted by

BHUPENDRA SINGH

In partial fulfillment for the award of the degree of

B.TECH

In

MECHANICAL ENGINEERING

VIT U N I V E R S I T Y

(Estd. u/s 3 of UGC Act 1956)

Vellore - 632 014, Tamil Nadu, India

SCHOOL OF MECHANICAL AND BUILDING SCIENCE

NOVEMBER 2011

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Introduction

Hindalco: An industry leader in aluminium and copper

Hindalco Industries is India's largest Aluminium manufacturing Company and is a

subsidiary of the Aditya Birla Group. It is run by one of the world's youngest

billionaires, Mr. K.M. Birla.

The company has annual sales of $ 5 billion and employs 13,675 people and is listed on

Forbes 2000. A metals powerhouse with a turnover of US$ 14 billion, Hindalco is the

world's largest aluminium rolling company and one of the biggest producers of primary

aluminium in Asia.

Short overview of company

Type

Private

Industry Metals

Founded 1962

Headquarters Mumbai, India

Key people Kumar Mangalam Birla (Chairman)

Revenue ▲ US$14.87 billion (2008)

Products Aluminium and Copper

Total assets US$18.31 billion (2008)

Employees 13,675

Parent Aditya Birla Group

Website Hindalco.com

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HEAD OFFICE & WORKS:

P.O. Renukoot - 231271, Distt. Sonebhadra (U.P.), INDIA.

Phone: +91 5446 52077-9, Fax: +91 5446 52107, 52427.

E-mail: [email protected]

EXPORT OFFICE:

9/1, R. N. Mukherjee Road, Calcutta - 700 001, INDIA.

Phone: +91 33 2480949, 2200464. Fax: +91 33 2200214.

E-mail: [email protected]

Vision:

To be a premium metals major, global in size and reach, excelling in everything we do,

and creating value for its stakeholders

Mission:

To relentlessly pursue the creation of superior shareholder value, by exceeding

customer expectation profitably, unleashing employee potential, while being a

responsible corporate citizen, adhering to our values.

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Main plant of the company

Hindalco, at Renukoot, house a fully integrated plant, comprising of 3 main Plants i.e.

the Alumina, Smelter & Fabrication Plant. Each plant employs varying Technology.

With integrated facilities, output from various plants are used by others, along with

varying raw materials.

Alumina Plant

Hindalco's Alumina Plant employs the conventional Bayer’s process was

commissioned with an initial capacity of 40,000 MTPA which has now increased to

660,000 MTPA. The Company has been inducting new technology from time to time

and the most recent initiative in this regard is the adoption of Alusuisse Precipitation

Technology for energy efficiency and capacity enhancement. The major raw materials

for the Alumina Plant are Bauxite, Steam and Caustic Soda. Bauxite is procured from

the Company's Mines in Jharkhand and Chhatisgarh, as well as through market

purchases and requirement of steam is met thru Cogeneration plant at Renukoot.

Aluminium Smelter

The Company's Smelter commenced operations in 1962 with 1 Potline having a

capacity of 20,000 MTPA. The smelter now has 11 Potlines with 2038 Pots installed

with annual capacity of production of 3,42,000 MT. The Smelter employs the Hall

Heroult Electrolysis Process for the extraction of Aluminium from Alumina. Basic raw

materials for the smelter are Alumina, Power, Anodes and Aluminium Fluoride.

Alumina is produced by the Company's Alumina Refinery at Renukoot, Power is made

available from the Company's Captive Power Plant at Renusagar and Cogeneration

plant at Renukoot and Anodes are produced at the Carbon Plant located in the

Renukoot . Aluminium Fluoride is sourced from the Company’s JV, amongst other

sources.

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Fabrication Plant

The Fabrication Plant at Renukoot comprises of 4 Main Sections:

� Remelt Shop

� Cast House

� Rolling Mills

� Extrusion & Conform

The Remelt Shop houses 3 Properzi Mills for the production of Wirerods and Feedstock

to Conform Machine.

Cast House is comprised of a state of the art Pig Ingot casting, Rolling Ingot (slab)

casting and Extrusion Billet casting facilities. Product of Pig Ingot Casting is directly

sold to customer and product of slab casting and billet casting are the feedstock to

Rolling Mills and Extrusion presses respectively.

The Company has a Hot Rolling Mill and 2 Cold Rolling Mills. The Rolling Mill

facilities also include a Continuous Strip Caster, which contributes substantially to

Energy efficiency since it eliminates numerous intermediate operations.

The Company’s 3 Extrusion presses and one Conform Machine are well supported by a

well-equipped Die Shop.

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Products

Aluminium:

Hindalco is Asia's largest integrated primary producer of aluminium and among the most

cost-efficient producers globally. Our aluminium units across India encompass the entire

gamut of operations, from bauxite mining, alumina refining, aluminium smelting to

downstream rolling, extrusions and recycling

Product Uses

Aluminium Ingots Remelted and used in the form of Castings, Consumer Durables, Powders & Chemicals, Redraw Rods etc.

Aluminium Billets Supplied to Secondary Extruders for the production of Extruded Profiles

Aluminium Wirerods Drawn to smaller Diameter for applications - largely in Conductors & Cables.

Aluminium Sheet Products Transport, Electrical & Electronics, Consumer Durables, Architectural Applications

Aluminium Extrusions Major consumption in Architectural applications. Others include Transport, Computer Hardware, Textile Machinery, Strategic Applications

Aluminium Foils Packing of Food and Pharmaceuticals

Aluminium Alloy Wheels Cars

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About Workshop

Need:

• To repair the regular job e.g. valve body, mise casing, impeller, pot room tool, and dc

casting tool to meat day to day maintence need.

• To fabricate new spare for the entire plant & carry out insitu machining.

• To meet the emergency and break down of whole plant. Workshops provide all type

of repairing at the completive prise in minimum time.

mission and vision:

Vision: “To achieve total customer satisfaction.”

Mission: “to deliver value for customer through protective, timely, flexibly & and

Cost effective service.”

equipment, which can machine up to:

1. 1250 mm dia on vertical boring machine.

2. 1000 mm dia x and 3000 mm long on lathe.

3. 30” dia and 30’ long job on lathe.

4. Grinding of Loma saw blade and many more type job depending on

requirement.

Central mechanical workshop is divided into five sections:

1. Machine shop & fabrication ( plant repair section)

2. Spare part section ( plant spare section)

3. Black smithy & press area

4. Air tool & machine maintenance

5. Tool room

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Machine shop & fabrication (plant repair section):

Work orders are received for repairing of any job from plant and outside parties. It is

processed as per their requirement e.g. turnine, milling, slotting etc.

Spare part section (plant spare section):

P.R’s are received to make spare for the plant. The job in this section is made new.

Black smithy & press area:

Different tool of reduction plant & dc casting are repaired. Bending, shearing, sling

and press operation are also performed in this section.

Air tool & machine maintenance:

In air tool section mise pneumatic tool like rock drill, air motors, jack hammers, &

coke clamps etc are required. Through mechanical maintenance section the

maintenance of all workshop machines are done by PM, OH & daily maintenance.

Tool room:

For economic machining and other processes tool room play major role. As the name

indicates tool room supplies tooling for workshop as per Ned.

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LAYOUT OF WORKSHOP

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Detail about centre lathe NH 26

In the workshop many type lathe machine like beco lathe, hagorian lathe, blue chip lathe,

H.M.T. lathe. All the machine come under same category i.e. centre lathe. But among the lathe

machine I found that there is 10 H.M.T. lathe machine (NH 26).

Parts of NH 26.

Like the pats of other lathe machine NH26 heaving the same parts which i described

before. But the parts of NH 26 are given below.....

Leg: leg is mounted on the surface it gives the saport to entire lathe machine

Bed:

• Base of the machine

• Head stock and tail stock are located at either end of the bed

• Carriage rests over the lathe bed and slides on it

• Bed material should have high compressive strength should be wear resistant

and absorb vibration

• Cast iron alloyed with nickel & Chromium

Head stock:

• Secured / fixed permanently on the left hand side of the lathe bed

• Provides the mechanical means of rotating the work at multiple speeds

• Comprises a hallow spindle & mechanism for driving & altering the spindle

speed

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Main pats of head stock:

The headstock (H1) houses the main spindle (H4), speed change mechanism (H2, H3),

and change gears (H10). It is made by cast iron.

Tail stock:

• It has a provision to slide and facilitate operations at different locations

• Supports longer blanks and often accommodates tools like drills, reamers etc for

hole making

Main pats of tail stock:

The tailstock is a toolholder directly mounted on the spindle axis, opposite the

headstock. The spindle (T5) does not rotate but does travel longitudinally under the

action of a leadscrew and handwheel (T1). The tailstock can be positioned along the

bed and clamped (T6) in position as required. There is also provision to offset the

tailstock (T4) from the spindles axis; this is useful for turning small tapers, reduction

gear box (T2) between the handwheel and spindle.

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Carriage:

• Contains certain parts such as Apron, Saddle, cross slide, compound rest and

tool post

• Tool post accommodates the tool

Main parts of carriage:

carriage holds the tool bit and moves it longitudinally (turning) or perpendicularly

(facing) under the control of the operator. The operator moves the carriage manually

via the handwheel (5a) or automatically by engaging the feed shaft with the carriage

feed mechanism (5c). This provides some relief for the operator as the movement of the

carriage becomes power assisted. The handwheels (2a, 3b, 5a) on the carriage and its

related slides are usually calibrated, both for ease of use and to assist in making

reproducible cuts. The carriage typically comprises a top casting, known as the saddle

(4), and a side casting, known as the apron (5).

Cross-slide:

The cross-slide (3) rides on the carriage and has a feedscrew that travels perpendicular

to the main spindle axis. This permits facing operations to be performed, and the depth

of cut to be adjusted. This feedscrew can be engaged, through a gear train, to the feed

shaft (mentioned previously) to provide automated 'power feed' movement to the cross-

slide. On most lathes, only one direction can be engaged at a time as an interlock

mechanism will shut out the second gear train.

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Compound rest:

The compound rest (or top slide) (2) is usually where the tool post is mounted. It

provides a smaller amount of movement (less than the cross-slide) along its axis via

another feedscrew. The compound rest axis can be adjusted independently of the

carriage or cross-slide.

Tool post:

The tool bit is mounted in the toolpost (1) which may be of the American lantern style,

traditional four-sided square style, or a quick-change style such as the multifix

arrangement pictured.

Feed rod and lead screws:

The feedscrew (H8) is a long driveshaft that allows a series of gears to drive the

carriage mechanisms. These gears are located in the apron of the carriage. Both the

feedscrew and leadscrew (H7) are driven by either the change gears (on the quadrant)

or an intermediate gearbox known as a quick change gearbox (H6) or Norton gearbox.

These intermediate gears allow the correct ratio and direction to be set for cutting

threads or worm gears.

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Specification of NH 26

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Lubrication system of the NH 26

We use servo 68 as a coolest combining with water in ratio of (oil:water :: 1:15)

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LUBRICATION POINT IN NH 26:

Cutting Fluid & Lubricant:

The aims in metal cutting are to retain accuracy, to get a good surface finish on the

workpiece and at the same time to have a longer tool life.

However during the metal cutting process heat is generated due to:

• The deformation of the material ahead of the tool

• Friction at the tool point

Heat generated due to friction can readily be reduced by using a lubricant. Heat caused

by deformation cannot be reduced and yet it can be carried away by a fluid. Thus the

use of a cutting fluid will serve to reduce the tool wear, give better surface finish and a

tighter dimensional control.

The proper selection, mixing and application of cutting fluids is however often

misunderstood and frequently neglected in machining practice. In order that the cutting

fluid performs its functions properly it is necessary to ensure that the cutting fluid be

applied directly to the cutting zone so that it can form a film at the sliding surfaces of

the tool.

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Tool Materials and Tools used in Lathe Machine

High Carbon Steel

Contains 1 - 1.4% carbon with some addition of chromium and tungsten to improve

wear resistance. The steel begins to lose its hardness at about 250° C, and is not

favoured for modern machining operations where high speeds and heavy cuts are

usually employed.

High Speed Steel (H.S.S.)

Steel, which has a hot hardness value of about 600° C, possesses good strength and

shock resistant properties. It is commonly used for single point lathe cutting tools and

multi point cutting tools such as drills, reamers and milling cutters.

Cemented Carbides

An extremely hard material made from tungsten powder. Carbide tools are usually used

in the form of brazed or clamped tips. High cutting speeds may be used and materials

difficult to cut with HSS may be readily machined using carbide tipped tool.

Tool life:

As a general rule the relationship between the tool life and cutting speed is

V*T*n = C

Where;

V = cutting speed in m/min

T = tool life in min

C = a constant

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Tool geometry:

For cutting tools, geometry depends mainly on the properties of the tool material and

the work material. For single point tools, the most important angles are the rake angles

and the end and side relief angles.

FUNCTION OF THE ANGLES:

Radial Rake Angle (Milling) - Side Rake Angle (Single Point Tool).

This angle has a major effect on power efficiency and tool life.

Axial Rake Angle (Milling) - Back Rake Angle (Single Point Tool).

This angle controls the chip flow, and thrust force (into spindle or away from) of the cut

and the strength of the cutting edges. If the back rake angle is too large, the strength of

the tool is reduced as well as its capacity to conduct heat. In machining hard work

materials, the back rake angle must be small, even negative for carbide and diamond

tools. The higher the hardness, the smaller the back rake angle. For high-speed steels,

back rake angle is normally chosen in the positive range.

Corner (Chamfer) Angle - Side Cutting Edge Angle (Single Point Tool).

This angle reduces the thickness of the chip. Shock is absorbed behind the cutting

point, adding strength that influences tool life.

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True Rake Angle (Milling - True Rake Angle (Single Point Tool).

The combination of radial rake, axial rake, and corner angle determines the chip

formation shear angle, the power requirements, tool force and temperature. True rake

angle is the most significant angle in the metal removal process. The higher the positive

true rake angle, the lower the force, the power requirements and the heat generated. The

cutting tool material, machine rigidity and other variables determine the positive or

negative values that can be used.

Inclination Angle (Same in Milling and Turning).

This has a significant effect on the direction of the chip. Positive inclination directs the

chip outward and negative inclination directs the chip toward the center of the cutter.

The inclination angle is perpendicular to the direction of tool travel. Any change in

axial rake angle, radial rake angle or chamfer angle can change the inclination and

therefore the direction of the chip flow:

Dish Angle (Milling) - End Cutting Edge Angle (Single Point Tool).

This provides clearance between the cutter and the finished surface of the work which

blends into the radius or chamfer of the tool. All angles close to zero adds strength but

causes rubbing and generates heat. Too large an angle weakens the tool. Flats parallel

to the finished surface are often ground on the end cutting edge or dish angle to produce

good surface finishes.

Nose Radius (Milling and Single Point)

This strengthens the culting edge, improves finish and influences tool life. Too large a

radius increases radial forces and induces chalter. Too small a nose radius may result.

in premature chipping or prevent proper distribution of the heat and break down the

properties of the cutting tool material.

Clearance Angles (Milling and Single Point).

Primary clearance is directly below the cutting edge and is selected for the material

being machined. It prevents the cutter or tool from rubbing on the workpiece. It also

affects the strength of the tool. The secondary clearance is on the tooth form of the

cutter or the shank of the single point tool.

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Operations performed on Lathe Machine

i. Turning

ii. Thread cutting

iii. Chamfering

iv. Facing

v. Knurling

vi. Grooving

vii. Drilling

viii. Reaming

ix. Boring & Counter boring

Turning:

Removal of excess material from the w/p to produce a cone-shaped or a cylindrical

surface

• Straight turning: Rough turning & Finish turning

• Shoulder turning

• Taper turning

• Straight turning:

Removing material along the axis of the w/p

Produces cylindrical surface by removing excess metal

Rough turning: Process of removal of excess material in a minimu time by applying

High rate of feed (0.3 to 1.5 mm/rev) and heavy depth of cut (2 to 5 mm)

Finish turning: Obtain good surface finish, requires high cutting speed, small feed

(0.1 to 0.3 mm/rev) and small depth of cut (0.5 to 1 mm)

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Shoulder turning:

When a w/p having different diameters is turned, the surface forming the step from one

diameter to the other is called as shoulder

Four types, viz., Square shoulder, angular or beveled shoulder, radius shoulder and

undercut shoulder

Taper turning:

Taper may be defined as a uniform increase or decrease in diameter of a piece of work

measured along its length

Producing a conical surface by gradual reduction in diameter from a cylindrical w/p

Thread cutting:

A thread is a uniform helical groove cut on or in a cylinder or cone. Thread cutting on a

lathe is one of the most exacting lathe operations. It requires a thorough knowledge of

the principles and procedures of thread cutting. It ties together a number of operations

and dimensions in such a way that accuracy must be maintained to achieve a proper

working thread.

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Position of the gear in thread cutting:

Facing:

Facing is the process of removing metal from the end of a work piece to produce a flat

surface. Most often, the work piece is cylindrical.

Facing part of the turning process. It involves moving the cutting tool at right angles to

the axis of rotation of the rotating work piece. This can be performed by the operation

of the cross-slide, if one is fitted, as distinct from the longitudinal feed (turning). It is

frequently the first operation performed in the production of the work piece, and often

the last- hence the phrase "ending up".

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Knurling:

Knurling is a manufacturing process, typically conducted on a lathe, whereby a

visually-attractive diamond-shaped (criss-cross) pattern is cut or rolled into metal. This

pattern allows hands or fingers to get a better grip on the knurled object than would be

provided by the originally-smooth metal surface. Occasionally, the knurled pattern is a

series of straight ridges or a helix of "straight" ridges rather than the more-usual criss-

cross pattern.

Grooving:

A turning operation in which a single-point tool moves radially, into the side of the

workpiece, cutting a groove equal in width to the cutting tool. If the desired groove

width is larger than the tool width, multiple adjacent grooves will be cut. A profiling

cut can be performed to smooth the surface of multiple grooves. Special form tools can

also be used to create grooves of varying geometries.

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Drilling:

Operation of the portable electric and pneumatic drills differs from recommended

operating procedures for the upright drilling machine. The portable drill is hand

supported for most operations, and the cutting speed of the drill is fixed or dependent

upon the operator to control.

When metal is to be drilled with the portable drill, the work piece must be prepared by

locating the center position of the potential hole and marking the location with a center

punch.

Reaming:

An operation in which a reamer enters the workpiece axially and enlarges an existing

hole to the diameter of the tool. Reaming removes a minimal amount of material and is

often performed after drilling to obtain both a more accurate diameter and a smoother

internal finish. A finish reaming operation will use a slower cutting feed and cutting

speed to provide an even better finish.

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Boring & counter boring:

Boring:

An operation in which a boring tool enters the work piece axially and cuts along an

internal surface to form different features. The boring tool is a single-point cutting tool,

which can be set to cut the desired diameter by using an adjustable boring head. Boring

is commonly performed after drilling a hole in order to enlarge the diameter or obtain

more precise dimensions.

Counter boring:

An operation in which a counterbore tool enters the workpiece axially and enlarges the

top portion of an existing hole to the diameter of the tool. Counterboring is often

performed after drilling to provide space for the head of a fastener, such as a bolt, to sit

below the surface of a part. The counterboring tool has a pilot on the end to guide it

straight into the existing hole.

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Formula for calculation of cutting speed and reed rate:

Cutting speed:

Formula in British system:

�. �. =� × � ×

12 � ./��

Formula in metric system:

�. �. = � × � ×

1000 �� /��

Cutting time:

�� = �� ℎ �� × ��. ��

�� × ��./��

Feed rate:

Is decided according to the job material and speed of spindle as per the chart by setting

the lever.

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Job Performed:

Exercise:

Making of shaft as per the given dimension heaving the length 537mm. And bigger dia.

53.5 mm. And give the all the processes detail and step of final finishing.

Material Used: EN 24

Steps on Job:

Step 1: Fix the job on the lathe machine with the help of four jaw chuck

(Independent chuck) and center.

Step 2: After this we make centre on both side of job one by one with an angle 60°.

Step 3: After this turning the dia. 38mm. From the side of tail stock up to distance

66mm. by taking........

• Cutting speed = 38.79 m/min

• Spindle speed = 325 RPM

• Feed rate = 0.12 mm./rev.

Step 4: After this turning the dia. 40mm.up to length 18mm starting from 66mm from

tail stock. By taking..........




Step 5: Making the dia 45mm up to length 51mm. starting from the 84mm from tail

Stock. By teaking.........




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Step 6: Making the thread on the dia. 45mm heaving the pitch 1.5mm by seating

The thread cutting lever, according to thread cutting chart.

Step 7: After this making the dia. 53.5mm up to length 139mm starting from

135mm from the tail stock. By taking....




Step 8: Then reverse the position of the job fro head stock to tail stock.

Step 9: Making the dia 45mm up to distance 43 mm with starting point 274mm from

Tail stock. By taking.......




Step 10: Making the dia 38 mm up to distance 132 mm srating from 317mm from

Tail stock. By teaking........

• Cutting speed = 38.79 m/min.



Step 11: Making the dia. 28mm up to distance 69mm from starting point 449mm from

Tail stock. By taking......




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Step 12: Making the dia 16mm with distance 19mm starting point 518mm from

Tail stock. By taking.......




Step 13: Making the thread on the dia 16mm heaving the pitch 2mm by seating the

Lever, according to thread cutting chart.

Step 14: Making the chamfer on all the outer dia. Of shaft as per given dimension.

i.e. On 38dia 2x45° and on 40, 45, 28, and 16 mm dia 1x45° and on 53.5mm

dia. 1.5x45°.

Step 15: Making the groove at given position in the dimension 2x2mm i.e. 2’U’cut.

Step 16: After this giving the surface finishing of the entire surface with the help of

Emery Seat of different gread.like 1200, 1000, 800 etc. By teaking.....

• Cutting speed = as per our convenience



Step 17: After this marker mark the position on the job for key way cutting.

Step 18: after this key way cutting is performed on the milling machine by using the

Suitable milling cutter.

RESULT:

And at last we made the shaft of length 537mm.

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CONCLUSION

It was a great privilege to undergo vocational training at Hindalco Industry Limited,

Renukoot. Working in such an encouraging atmosphere with people dealing with latest

technology working in tight schedule, dedicated to help was a privilege. While carrying out

the industrial training I received tremendous support from all the staffs of the various

departments. Working in different shops provided a real time experience of engineering and

technology being used currently in manufacturing industry. The training helped me in great

deal as I came to know and explore more information and gained invaluable knowledge about

the subject. The training also helped me to gain knowledge about the industrial environment.

This invaluable experience will help me further to adapt quickly in the environment of the

company in future when I will have to join any company.

Hindalco Industry Limited Project Report _Inplant Traning

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