TRAINING REPORT

OF
SIX WEEKS INDUSTRIAL TRAINING, UNDERTAKEN
AT
BHUSHAN POWER AND STEEL
SUBMITTED IN PARTIAL FULFILLMENT OF THE DEGREE
OF
BACHELOR OF TECHNOLOGY
IN
DEPARTMENT OF MECHANICAL ENGINEERING

Submitted By:
Name: Shivanshu Gupta
College Roll No.: UM-11910

Under the Guidance of:

Name: GIAN SABLOK
Designation: DGM

ACKNOWLEDGEMENT

First and foremost, I thank the Almighty God for sustaining the enthusiasm with which
plunged into this endeavor.
I avail this opportunity to express my profound sense of sincere and deep gratitude to
many people who are responsible for the knowledge and experience I have gain during
the Training.
I have great pleasure in expressing my deep sense of gratitude to guide Mr. Maninder
Singh & Mr. Gian Sablok (Dept. Manager, Quality Assurance) Bhushan Power and Steel
for their valuable and prompt guidance without which this project would not have been
a successful one.
I extend my overwhelming gratitude to Mr. Satinder, (Manager, Quality Assurance) & Mr.
Inderpal Singh (Senior Manager, Quality Assurance) Bhushan Power and Steel for their
valuable guidance and meticulous supervision during the preparation of this Industrial
Training Report.
My hearty and inevitable thanks to all the respondents who is helped me to bring out
the project in a successful manner.
Last but not the least I extend my gratitude towards my parents, faculties and friends
who extended their whole hearted support towards the successful completion of this
Industrial Training.

PREFACE

Training is a part and parse of professional course in engineering. Classroom study is not
enough to develop a professional mind and person. Exposure to industrial environment
is necessary to make one a good engineer. In industrial environment one comes in
contact with real practice and problems of industrial. One can see things practically
which one has studied in classroom.
This training report describes about the various departments in which I have worked and
tried to become familiar with the practical working of the machines and tried to gain
knowledge.
I went through all the departments located in steel plant. Being in the industry premises
I had an added advantage to look at the production function also. It was not possible for
me to get detailed knowledge of all the function even then I tried to grasp a few
important functions and observed others.
I am greatly thankful to the cooperative behavior of executives and the workers of the
Bhushan Power and Steel Co. Ltd., Chandigarh.

COMPANY PROFILE

BHUSHAN-The Beginning
Brij Bhushan Singal, the prime mover, a visionary entrepreneur founded the Bhushan
group than 20 years ago in Chandigarh.
Making a moderate start with manufacture of hinges rail track fasteners in early 70s
with a capital less than a lakh of rupees, the group has continuously grown by
modernizing, expanding and integrating its fascilities/ operations.
Joined by his young and dynamic sons Sanjay & Neeraj in the 80s and taking
advantage of the liberalized environment in the steel sector, Brij Bhushan Singal has
propelled the group to the success earning it a permanent place among the large
players of the steel industry, with a turnover of Rs. 2200 crore, cash profit of over
Rs. 180 crore and net worth of Rs. 500 crore

BHUSHAN POWER & STEEL LIMITED

Bhushan power & steel limited, is an ISO 9002 certified company of erstwhile
Bhushan Group, is a merged entity of Bhushan Power & steel Limited, Bhushan
Mettalic Limited & Dcor Steel Limited having turnover of more than INR 2000 Crores
(USD 460 Million) is a leading manufacturer of Flat, Round and value added products
in steel. Bhushan Power & Steel Limited has by continuation up-gradation of
technology, redesigning structures, integrating & synergizing operatios made a
special place in production of various value added products in secondary Steel
segment among the steel producers in India. From production of special steel for
vehicles and white goods segment to high class steel for Exports, Bhushan has made
its mark. Bhushan Power & Steel Limited is having 7 World Class & state of art plant
at Chandigarh, Derabassi, Kolkata & Orissa in India. A completely integrated plant is
commissioned under Phase-I in Orissa and Phase-II is all set for take off. At all of
these plants, technology and equipments are procured from world-renowned
Companies like Luirgi from Germany, ABB limited, SMS Demag, Siemens etc. Bhushan
is selling its value added range of products in Secondary Steel through a large
distribution network in India ( comprising more than 25 Sales offices ) and Abroad.
Among our major and valued customers in India are Hero Honda, Honda Scooters,
Yamaha Motorcycles, JBM, BPL, HMT, GNA Group, Hero Cycles, Avon Cycles, Atlas
Cycles, Delton Cables etc. Bhushans products are being exported to China,
Singapore, Malaysia, Hong Kong, Indonesia, Philliphines, Dubai, Oman, Saudi
Arabia, South Africa, Thailand, Korea, Mayanmar, Srilanka, Nepal, Bangladesh,
Vietnam etc. and a host of African countries.

MISSION & VALUE

Our Mission is to achieve clear identiy and leadership globally in Steel production and
distribution by integration of complete chain of production starting from captive iron
ore to end user Steel Products.
Our revolution in Steel production has helped us to carve a niche unique only to
market leader. Every year passes by with new value additions and more accolades
from our customers- Locally and Globally. In pursuing our mission, we at BHUSHAN
POWER & STEEL LIMITED are guided by following values
QUALITY
To be the best in quality. We aim and achieve excellence.
TECHNOLOGY
State of art technology and product enrichment by continuous Research and
Development
CUSTOMER FRIENDLY
Our products are world class and more and more clients are appreciating and using
our products. We also undertake customized products with values addition and
enhancement.
CORPORATE GOVERNANCE
We comply with all applicable laws and regulation. We believe in maintain clean
environment and conservation of natural resources. We contribute towards
betterment of our staff and provide them with best of facilities.
ENVIROMENT PROTECTION AND PRACTICE
We are adopting and implementing pollution control measures as a matter of policy.
OUR COMMITMENTS
To improve the quality of our products and complete integration of various
stages of production.
To be conscious towards quality and pricing of our products. We strive by
continuous research and development to make our products world class,
having distinct identity and uniqueness.
To run the company profitably year after year.
To workforce motivated, skilled and well looked after.

PRODUCTS
Cable Tapes- These Tubes are widely used for Power and Industrial boilers,
Transformers, Super heaters, Automobiles and Bicycles, Railway Electrification,
Furniture and General Engineering Applications etc.
GP Coils- These Tubes are widely used for Power and Industrial boilers, Transformers,
Super heaters, Automobiles and Bicycles, Railway Electrification, Furniture and General
Engineering Applications etc.
Steel Coils- These Tubes are widely used for Power and Industrial boilers, Transformers,
Super heaters, Automobiles and Bicycles, Railway Electrification, Furniture and General
Engineering Applications etc.
GP Coils Sheets- Applications: Galvanised Coils and Sheets are used to make Boxes,
Containers, Ducting, Cooler Body, etc.

Corrugated Sheets- corrugated sheets are extensively used for Industrial sheds,
housing, temporary structures etc.
Cold Rolled Sheets-Cold Rolled Sheets are used in the manufacture of Automobiles,
White Goods, Panels, Furniture, Transformers, Oil barrels and drums and general
engineering products.
Narrow CR Coils- Narrow Cold Rolled Coils are used in the manufacture of Automobiles,
Precision Tubes, Cable Tapes, White Goods, Electrical Panels, Furniture, Transformers,
Oil barrels and drums and general engineering products.
Black Pipe- Black pipe is used for transportation of air, gas, fabrication of structure,
automobiles, cycles and general furniture industries. Varnished pipes are used for
general engineering industries.

Precision Tubes- These Tubes are widely used for Power and Industrial boilers,
Transformers, Super heaters, Automobiles and Bicycles, Railway Electrification,
Furniture and General Engineering Applications etc.

Pig Iron- A product in solid (lumpy) form obtained upon solidification of hot metal in
pig casting machine. Pig Iron is used for production of cast iron casting and steel

Wire Rod and Bar Mill- With the introduction of most technologically advanced
special and alloy steel long product rolling complex for manufacture of value added
bars and coils, a new dimension has been added in BPSL's long history in the steel
business.

The Long Product Rolling Complex consists of a most modern 0.5 million tpa
multiproduct Wire Rod and Bar Mill (18 pass Horizontal & Vertical Continuous Mill)
supplied by Danieli Morgardshammar, Italy and KOCKS, Germany (4 pass mill).
The state of the art Wire Rod & Bar Mill, one of the most modern plants of this type
in the world, will produce:

Straight Bars
Bar in Coil form
Wire rods

Mill Product RangeProduct *

Size Range

Round Bars

16mm to 90 mm

Round Corner Square

16 mm to 75 mm

Hexagonal Bars

16 to 50 mm

Wire Rods

5mm to 22 mm

Bar in Coil

16 mm to 60 mm

Finished Product Bundle Characteristics

SL

LENGTH

WEIGHT

MAX DIA.

END CUTS

(Meters)

Kg

mm

Cold Shear Metallic Saw & Abrasive Cut

2000

300

12

4000

300

Wire Rod Coil Characteristics

Item

Outside Dia

Inside dia

No & Type of ties

Weight

Approx. mm

Approx mm

No - type

Kg

1250

900

4-flat knot

2100,2400,3000

1 MANUFACTURING OF TUBES ON PRECISION TUBE MILL

1.1

PROCEDURE-

JIB CRANE

UNCOILER SECTION

TIG WELDER

ACCUMULATOR

FORMING SECTION

WELDING ZONE

COOLING ZONE

SIZING ZONE

ALPHA CUT OFF

RUN OUT TABLE

JIB CRANE-

A jib crane is a type of crane where a horizontal member (jib or boom), supporting a
moveable hoist, is fixed to a wall or to a floor-mounted pillar. Jib cranes are used in
industrial premises and on military vehicles. The jib may swing through an arc, to give
additional lateral movement, or be fixed. Similar cranes, often known simply as hoists,
were fitted on the top floor of warehouse buildings to enable goods to be lifted to all
floors.

 UNCOILER SECTION-

The slitted coil is loaded on the uncoiler with the help of JIB CRANE which can weigh a
load of 5 H.P. motor which puts the slitted coil in the support of uncoiler. The support
can be enlarged or shortened in dia according to inner dia of coil There are two big
wheels in the uncoiler to support the slitted coil from the side. The wheels can be
rotated due to bearing on wheel shaft. There are two types of uncoiler, one which can
be stopped by hydraulic mechanism and other in which brakes or speed can be lowered
by the applying force on the roll by tightening it, on the moving shaft. The uncoiler can
be rotated if one coil ends. In hydraulic mechanism both supporting and rotating of
uncoiler is automatic.
It is the facility to uncoil the coil to make it stable by equipping the drum of widened
coil inside diameter and applying the back tension during the line operation.
The frame is of welding structure type and the top frame is supported by slewing
bearing on the bottom frame while it is revolving by Slewing Ring Gear and pinion.
The drum has 4-segment structure of toggle link system, which is possible to reduce
and to enlarge.
The main shaft is of Tube Type and the load goes up and down inside to enlarge and
reduce the segment and hydraulic cylinder is connected to the back of the load

 TIG WELDER
On TIG welder, for continuous running of the mill, the tail end of the running coil is
welded with the leading end of the next coil with the help of TIG welder. The two ends
of the first cut off to have straight edges to weld. As a compound system of shear and
welder, this shear & welder make it possible to cut and center the line and end of the
strip and to weld it inside of this facility not moving it. The operation of this facility is
semi-automatic and it is classified into fedding of a strip, shearing, gap adjustment and
welding. It is designed to automatically work by section.

ACCUMULATORIn tube mill operations, a supply coil is positioned in the coil holding device, the end of
the coil is fed into the tube mill, and the mill operates until the supply coil is depleted.
The total operation then stops until a new supply coil is positioned and the leading end
is again fed into the mill. Line operation is intermittent, possibly running 60 percent of
the time. This is not an ideal situation, as a tube mill line represents a significant
capital investment that produces a high-value product. Because of these factors, many
companies place a great deal of emphasis on the continuous operation of the mill.
Most tube mills can justify the added cost of entry-end equipment that will permit them
to operate continuously. Non continuous operation resulting from intermittent strip

supply to the mill can be eliminated by the addition of a strip accumulator and a coil
joining machine. This coil accumulator has the special device called the internal pinch
roll simultaneously carrying out the revolution and rotation inside of the machine to
reduce the damage to the strip and the noise so the proper tension is always applied to
the strip and as no pushing force is applied, it is saved in a stable condition.
The Accumulator's Role
A strip accumulator provides a continuous line of strip to a tube mill from a supply of
non-continuous coils of strip. It does this by accumulating or temporarily storing strip in
a manner that permits the strip to be withdrawn to a mill line from the accumulator,
while strip is simultaneously added to the accumulator at a higher speed.

FORMING SECTION-

After accumulator it comes forming section, in it the coil is formed to take circular
shape. They are three to four in number forming rolls, placed next to each other. The

first roll forms the inner portion of the coil. The second roll bigger than the first. The
third roll of smaller profile concentrates more on the inner portion of the coil and
hence the cupping shape is formed of the coil.
Then through these rolls circular shape is formed. They are two to three in number. It
has two outer rolls on one thin roll surrounded by the two outer edges of the coil. The
third roll of smaller profile concentrates more on the inner portion of the coil and
hence the cupping shape is formed of the coil.
Then comes the fin rolls, through these rolls, circular shape is formed. They are two to
three in number. It has two outer rolls on one thin roll surrounded by the two outer
rolls. It is provided to straighten the outer edges of the coil. The cluster rolls are
provided in the alternate position. The extra metal is taken off from the above or from
inside as per customer requirement. It is composed of forming part, welding part,
cooling part and sizing part. At first, the forming part has the breakdown, side cluster
and fin-pass to consecutively form the strip and the formed strip is melted by H.F.
welder at the welding part. The melted part is pressurized by squeeze roll stand to
shape the pipe. The pipe is cooled down as passing through the cooling zone and it
becomes a round pipe or angular pipe at the sizing part

WELDING ZONE(HIGH FREQUENCY WELDER)

There are two types of welder:

C.F.I(Current fed welder)

V.F.I.(Voltage fed welder)

In High Frequency Welded (HFW) pipe production process, hot rolled steel coils are fed
with a high capacity accumulator in order to achieve continuous welding. Coil edges are
milled using carbide cutters in order to assure a high quality weld. Coils are then
formed by cold forming method using a set of cage rolls and fin passes, and then joined
using high frequency currents using induction or alternatively conduction methods.
The coil edges, which reach welding temperature through the resistance shown by steel
to the applied electrical current, are butted together and welded. This method does
not use any filler material for the weld to take place. Immediately subsequent to
welding, internal and external burrs are removed in order to achieve a uniform surface.

Post weld heat treatment facilities are used in order to temper martensitic structure
created by the welding process. As a result of applied controlled normalization process,
the weld area achieves a fine grain structure with required ductility.
The pipe string is brought to the exact required and precise outside diameter and
straightness by passing through a set of sizing rolls. The pipe string is finally cut-tolength by a flying cut-off operating at the same speed as the pipe. Following beveling,
hydrostatic testing, non-destructive testing, the pipes are subject to final inspection for
the compliance to customer requirements.
Starting from incoming control up to the final inspection stage; entire process is
monitored and supported by computerized system. Traceability is achieved by input
controls and barcodes through entire production lines.

COOLING ZONE-

In cooling section, the tube after being weld and extra metal removed by the tool , is
fed into a cooling tank in which the tube is completely dipped into the coolant, so that
the temperature raised by the welding of the tube is lowered down and at the same
time tool hardness also increased.

SIZING SECTION-

The sizing the tube is fed into sizing rolls from where the tube gets its final size. It
consists of four sizing rolls and three truck head roll in which tubes are given final size.
In truck head other attachments are fitted to get sectioned tubes. The right size tubing
limits fluid-friction losses that cause pressure drop, heat generation and, in case of
suction lines, pump-damaging cavitations.
A tube that is too small raises fluid velocity, which has many detrimental effects. In
suction lines, it leads to cavitation that starves and damages pumps. In pressure lines, it
causes excessive friction losses and turbulence, both resulting in high pressure drops and
heat generation. High heat, in turn, accelerates wear in moving parts and ages seals and
hoses. The end results are shorter component life and wasted energy and, therefore,
low levels of efficiency.
On the other hand, tubing thats too large unnecessarily increases costs. It can also
consume valuable real estate that makes it more difficult to fit tubing into confined
spaces and restricts engineers in configuring adjacent equipment and components. And
oversized tubing can simply be harder and more time consuming to install. It also weighs
more than necessary, and that hurts fuel consumption on mobile equipment. Matching
tubing to an application involves selecting the right material and determining optimum
OD and wall thickness.

ALPHA CUT OFF-

After passed through sizing rolls the tube passes through the cutting machine in which
alpha shaped cutter is used On another mill simple plain cutter is used which is placed
on the trolley. The trolley moves to and motion by rack and worm gear attached at
bottom of the trolley. The limit switches control the trolley travel. The tube is cut off
by the cutter in which cutting action is controlled by air pressure cylinder.
In an alpha cutting, there is an encoder behind the truck head rolls whose number of
rpm is counted to know how much length of tube is passed off from it and required
length to cut off is fed into the computer. The alpha cutter travel is controlled by the
limit switches. The cutting stroke and return stroke happens when the clutch engages
with flywheel return stroke when it disengages from flywheel after brakes are applied
to stop the alpha cutter at rest. It is the facility to automatically cut the pipe to have
the desirable length according to the instruction from D.D.S system.
The carriage of the cut off machine travels on the rail of the top of the bed and
the drive is cut off by pinion and the rack passing through A.C servo motor and the
gear box.
The travelling wheel and the supplementary wheel to prevent conduction are
assembled in the carriage of the cut off machine.
The clamp operates up and down by the hydraulic cylinder and it is designed for
simple disassembling and easy repair by manufacturing the clamp assembly on the top
to complement the existing repair problem.

The ascent and descent of the saw minimizes the wearing of the saw and bug
generation by applying the hydraulic valve system to perform the operation of quick
forward movement - quick cut off - slow cut off - quick return.

RUN OUT TABLE-

The tube after being cut out as per demand is collected at the run out table. For
inspection if there is defect in the tube such as welding defect due to joining of strip end
on the TIG welder or the tube which is drilled to see the weld on the TIG welder.

TOOL ROOM

VARIOUS MACHINES

SHAPER MACHINE

MILLING MACHINE

LATHE MACHINE

HOBBING MACHINE
SHAPER MACHINE-

A shaper is a type of machine tool that uses linear relative motion between the work piece
and a single point cutting tool to machine a linear tool path. Its cut is analogous to that of
a lathe, except that it is (archetypally) linear instead of helical. (Adding axes of motion
can yield helical tool paths, as also done in helical planing.) A shaper is analogous to a
planer, but smaller, and with the cutter riding a ram that moves above a stationary work
piece, rather than the entire work piece moving beneath the cutter. The ram is moved
back and forth typically by a crank inside the column; hydraulically actuated shapers also
exist.
Small shapers have been successfully made to operate by hand power. As size increases,
the mass of the machine and its power requirements increase, and it becomes necessary to
use a motor or other supply of mechanical power. This motor drives a mechanical
arrangement (using a pinion gear, bull gear, and crank, or a chain over sprockets) or a
hydraulic motor that supplies the necessary movement via hydraulic cylinders.
A shaper operates by moving a hardened cutting tool backwards and forwards across the
work piece. On the return stroke of the ram the tool is lifted clear of the work piece,
reducing the cutting action to one direction only.
The work piece mounts on a rigid, box-shaped table in front of the machine. The height of
the table can be adjusted to suit this work piece, and the table can traverse sideways
underneath the reciprocating tool, which is mounted on the ram. Table motion may be
controlled manually, but is usually advanced by automatic feed mechanism acting on the
feed screw. The ram slides back and forth above the work. At the front end of the ram is a
vertical tool slide that may be adjusted to either side of the vertical plane along the stroke
axis. This tool-slide holds the clapper box and tool post, from which the tool can be

positioned to cut a straight, flat surface on the top of the work piece. The tool-slide
permits feeding the tool downwards to deepen a cut. This adjustability, coupled with the
use of specialized cutters and tool holders, enable the operator to cut internal and
external gear tooth profiles, splines, dovetails, and keyways.
The ram is adjustable for stroke and, due to the geometry of the linkage, it moves faster
on the return (non-cutting) stroke than on the forward, cutting stroke. This action is via a
slotted link or Whitworth link.

MILLING MACHINEA milling machine is a machine tool used to machine solid materials. Milling machines are
often classed in two basic forms, horizontal and vertical, which refer to the orientation of
the main spindle. Both types range in size from small, bench-mounted devices to roomsized machines. Unlike a drill press, which holds the work piece stationary as the drill
moves axially to penetrate the material, milling machines also move the work piece radially
against the rotating milling cutter, which cuts on its sides as well as its tip. Work piece and
cutter movement are precisely controlled to less than 0.001 in (0.025 mm), usually by

means of precision ground slides and leadscrews or analogous technology. Milling machines
may be manually operated, mechanically automated, or digitally automated via computer
numerical control.
Milling machines can perform a vast number of operations, from simple (e.g., slot and
keyway cutting, planing, drilling) to complex (e.g., contouring, die sinking). Cutting fluid is
often pumped to the cutting site to cool and lubricate the cut and to wash away the
resulting swarf.
Mill orientationVertical milling machine. 1: milling cutter 2: spindle 3: top slide or over arm 4: column 5:
table 6: Y-axis slide 7: knee 8: base
In the vertical mill the spindle axis is vertically oriented. Milling cutters are held in the
spindle and rotate on its axis. The spindle can generally be extended (or the table can be
raised/lowered, giving the same effect), allowing plunge cuts and drilling. There are two
subcategories of vertical mills: the bed mill and the turret mill.
A turret mill has a stationary spindle and the table is moved both perpendicular and parallel
to the spindle axis to accomplish cutting. The most common example of this type is the
Bridgeport, described below. Turret mills often have a quill which allows the milling cutter
to be raised and lowered in a manner similar to a drill press. This type of machine provides
two methods of cutting in the vertical (Z) direction: by raising or lowering the quill, and by
moving the knee.
In the bed mill, however, the table moves only perpendicular to the spindle's axis, while the
spindle itself moves parallel to its own axis.
Turret mills are generally considered by some to be more versatile of the two designs.
However, turret mills are only practical as long as the machine remains relatively small. As
machine size increases, moving the knee up and down requires considerable effort and it
also becomes difficult to reach the quill feed handle (if equipped). Therefore, larger milling
machines are usually of the bed type.
Also of note is a lighter machine, called a mill-drill. It is quite popular with hobbyists, due
to its small size and lower price. A mill-drill is similar to a small drill press but equipped
with an X-Y table. These are frequently of lower quality than other types of machines.
Horizontal milling machine. 1: base 2: column 3: knee 4 & 5: table (x-axis slide is integral)
6: over arm 7: arbor (attached to spindle)
A horizontal mill has the same sort of xy table, but the cutters are mounted on a
horizontal arbor (see Arbor milling) across the table. Many horizontal mills also feature a
built-in rotary table that allows milling at various angles; this feature is called a universal

table. While end mills and the other types of tools available to a vertical mill may be used
in a horizontal mill, their real advantage lies in arbor-mounted cutters, called side and
face mills, which have a cross section rather like a circular saw, but are generally wider
and smaller in diameter. Because the cutters have good support from the arbor and have a
larger cross-sectional area than an end mill, quite heavy cuts can be taken enabling rapid
material removal rates. These are used to mill grooves and slots. Plain mills are used to
shape flat surfaces. Several cutters may be ganged together on the arbor to mill a complex
shape of slots and planes. Special cutters can also cut grooves, bevels, radii, or indeed any
section desired. These specialty cutters tend to be expensive. Simplex mills have one
spindle, and duplex mills have two. It is also easier to cut gears on a horizontal mill. Some
horizontal milling machines are equipped with a power-take-off provision on the table.
This allows the table feed to be synchronized to a rotary fixture, enabling the milling of
spiral features such as hypoid gears.

 LATHE MACHINEA lathe is a machine tool which rotates the work piece on its axis to perform various
operations such as cutting, sanding, knurling, drilling, or deformation with tools that are
applied to the work piece to create an object which has symmetry about an axis of
rotation.
Lathes are used in woodturning, metalworking, metal spinning, Thermal spraying/ parts
reclamation, and glass-working. Lathes can be used to shape pottery, the best-known
design being the potter's wheel. Most suitably equipped metalworking lathes can also be
used to produce most solids of revolution, plane surfaces and screw threads or helices.
Ornamental lathes can produce three-dimensional solids of incredible complexity. The
material can be held in place by either one or two centers, at least one of which can be
moved horizontally to accommodate varying material lengths. Other work-holding methods
include clamping the work about the axis of rotation using a chuck or collet, or to a
faceplate, using clamps or dogs.
Examples of objects that can be produced on a lathe include candlestick holders, gun
barrels, cue sticks, table legs, bowls, baseball bats, musical instruments (especially
woodwind instruments), crankshafts, and camshafts.
Parts of a wood latheA lathe may or may not have a stand (or legs), which sits on the floor and elevates the
lathe bed to a working height. Some lathes are small and sit on a workbench or table,
and do not have a stand.
Almost all lathes have a bed, which is (almost always) a horizontal beam (although CNC
lathes commonly have an inclined or vertical beam for a bed to ensure that swarf, or
chips, falls free of the bed). Woodturning lathes specialized for turning large bowls often
have no bed or tail stock, merely a free-standing headstock and a cantilevered tool rest.
At one end of the bed (almost always the left, as the operator faces the lathe) is a
headstock. The headstock contains high-precision spinning bearings. Rotating within the
bearings is a horizontal axle, with an axis parallel to the bed, called the spindle. Spindles
are often hollow, and have exterior threads and/or an interior Morse taper on the
"inboard" (i.e., facing to the right / towards the bed) by which work-holding accessories
may be mounted to the spindle. Spindles may also have exterior threads and/or an
interior taper at their "outboard" (i.e., facing away from the bed) end, and/or may have
a hand-wheel or other accessory mechanism on their outboard end. Spindles are
powered, and impart motion to the work piece.

The spindle is driven, either by foot power from a treadle and flywheel or by a belt or
gear drive to a power source. In most modern lathes this power source is an integral
electric motor, often either in the headstock, to the left of the headstock, or beneath
the headstock, concealed in the stand.
In addition to the spindle and its bearings, the headstock often contains parts to convert
the motor speed into various spindle speeds. Various types of speed-changing mechanism
achieve this, from a cone pulley or step pulley, to a cone pulley with back gear (which is
essentially a low range, similar in net effect to the two-speed rear of a truck), to an
entire gear train similar to that of a manual-shift auto transmission. Some motors have
electronic rheostat-type speed controls, which obviates cone pulleys or gears.
The counterpoint to the headstock is the tailstock, sometimes referred to as the loose
head, as it can be positioned at any convenient point on the bed, by undoing a locking
nut, sliding it to the required area, and then re-locking it. The tail-stock contains a
barrel which does not rotate, but can slide in and out parallel to the axis of the bed, and
directly in line with the headstock spindle.
The barrel is hollow, and usually contains a taper to facilitate the gripping of various
type of tooling. Its most common uses are to hold a hardened steel center, which is used
to support long thin shafts while turning, or to hold drill bits for drilling axial holes in the
work piece. Many other uses are possible.[1]
Metalworking lathes have a carriage (comprising a saddle and apron) topped with a crossslide, which is a flat piece that sits crosswise on the bed, and can be cranked at right
angles to the bed. Sitting atop the cross slide is usually another slide called a compound
rest, which provides 2 additional axes of motion, rotary and linear. Atop that sits a tool
post, which holds a cutting tool which removes material from the work piece.
Woodturning and metal spinning lathes do not have cross-slides, but rather have banjos,
which are flat pieces that sit crosswise on the bed. The position of a banjo can be
adjusted by hand; no gearing is involved. Ascending vertically from the banjo is a toolpost, at the top of which is a horizontal tool rest.
In woodturning, hand tools are braced against the tool rest and levered into the work
piece. In metal spinning, the further pin ascends vertically from the tool rest, and serves
as a fulcrum against which tools may be levered into the work piece.

 HOBBING MACHINE-

Hobbing is a machining process for making gears, splines, and sprockets on a hobbing
machine, which is a special type of milling machine. The teeth or splines are progressively
cut into the work piece by a series of cuts made by a cutting tool called a hob. Compared
to other gear forming processes it is relatively inexpensive but still quite accurate, thus it
is used for a broad range of parts and quantities.
It is the most widely used gear cutting process for creating spur and helical gears and more
gears are cut by hobbing than any other process since it is relatively quick and inexpensive.
Hobbing uses a hobbing machine with two skew spindles, one mounted with a blank work
piece and the other with the hob. The angle between the hob's spindle and the work
piece's spindle varies, depending on the type of product being produced. For example, if a
spur gear is being produced, then the hob is angled equal to the helix angle of the hob; if a
helical gear is being produced then the angle must be increased by the same amount as the
helix angle of the helical gear. The two shafts are rotated at a proportional ratio, which
determines the number of teeth on the blank; for example, if the gear ratio is 40:1 the hob
rotates 40 times to each turn of the blank, which produces 40 teeth in the blank. Note that
the previous example only holds true for a single threaded hob; if the hob has multiple
threads then the speed ratio must be multiplied by the number of threads on the hob. The
hob is then fed up into work piece until the correct tooth depth is obtained. Finally the
hob is fed into the work piece parallel to the blank's axis of rotation.

Up to five teeth can be cut into the work piece at the same time. Oftentimes multiple
gears are cut at the same time. For larger gears the blank is usually gashed to the rough
shape to make hobbing easier.
HOBThe hob is the cutter used to cut the teeth into the work piece. It is cylindrical in shape
with helical cutting teeth. These teeth have grooves that run the length of the hob, which
aid in cutting and chip removal. There are also special hobs designed for special gears such
as the spline and sprocket gears.
The cross-sectional shape of the hob teeth are almost the same shape as teeth of a rack
gear that would be used with the finished product. There are slight changes to the shape
for generating purposes, such as extending the hob's tooth length to create a clearance in
the gear's roots. Each hob tooth is relieved on the back side to reduce friction.
Most hobs are single-thread hobs, but double-, and triple-thread hobs increase production
rates. The downside is that they are not as accurate as single-thread hobs. Depending on
type of gear teeth to be cut, there are custom made hobs and general purpose hobs.
Custom made hobs are different from other hobs as they are suited to make gears with
modified tooth profile. The tooth profile is modified to add strength and reduce size and
noise of gears.