Department: MECHANICAL ENGINEERING INDUSTRIAL TRAINING ON Al foil Prepared by Subhash kumar

Training experience at India Foils Limited has been truly a fulfilling and rewarding one. Many people have contributed towards making this project a success. The text below is my humble & heartfelt expression of gratitude to all those who have contributed to this project by their valuable suggestions, inspiration, support and co-operation. I would like to thank Mr. Debashis Halder, Manager-Human resource department whose encouraging cooperation have made a great success to fulfill our project and providing all kind of supports. I would also be thankful to Mr. Pranab Basu Roy for giving effortless guidance at our training .

Characteristics of Aluminium
Aluminium is a soft, durable, lightweight, ductile and

malleable metal with appearance ranging from silvery to dull gray, depending on the surface roughness. Aluminium is non-magnetic and non sparking. It is also insoluble in alcohol, though it can be soluble in water in certain forms. The yield strength of pure aluminium is 711MPa, while aluminium alloys have yield strengths ranging from 200MPa to 600MPa

USE OF GRAPHITE IN ALUMINIUM FOILS PRODUCTION

Graphite is the most stable form of carbon under

standard conditions. Therefore, it is used in thermochemistry as the standard state for defining the heat of formation of carbon compounds. Graphite spray is used in the time of casting and formation of sheet metal of aluminium.

Formation of Al sheet from Ingot

Molten material of Al are

send to the the Holding furnace. It solidifed and start rolling for convertion into sheet form(width 1490mm and thickness 7.2 mm). Casting speed is about 0.82 m/min.

Rolling Aluminum Metal

the metal passes through a series of rolling mills with a gauge reduction of 50% or more for each pass through each mill.

Reduction of thickness in ACHENBACH MACHINE are formed in six pass.

Rolling mill
Rewinding machine: raw materials

coming to the industry are aluminium rolls of thickness 300-600 microns. It comes on cardboard spool rolled and packed. But cardboard spool cannot be mounted on the machines because it cannot be hold by the chuck. so a rewinding machine is used to roll it on a spool of diameter 660 mm. ACHENBACH MACHINE: It is a 4 high universal rolling machine.

Aluminium Foil Separator

The Aluminium Foil

separator machine is used to open/separate the paired foils into two rolls of maximum 600 mm diameter. A side slitting system is also to provided with the machine for final material at re-winder.

Aluminium foil conversion

VMCH Coating Machine: It is three roll coating

system V.M.C.H coating is done on Aluminium foil. High velocity VMCH drying system equipped with insulated drying tunnel of 10000 mm length. VMCH tunnel is distributed in 8 Heating zones & 2 cooling zones having individual air blower for better temperature control.

Finished products.
The finished products can be classified into..
Light gauge(L.G) 0.009 to 0.012mm Ultra light gauge(U.L.G) -- 0.005 to 0.007mm Medium gauge (M.G) --.02mm

CONCLUSION
From this project we have come to know that how aluminium foils of low thickness are made. More specifically how a rolling mill works. The different steps to reduce the thickness as written earlier are clearly understood. As this is a very vast industry and only 1 month is not enough to understand it fully we have tried our level best to get valued information in this span of time. This company as a great heritage and it has contributed a lot in the upcoming of Aluminium foils business in India.