“Industrial Training”

IN
“JAYCEE STEEL PVT LTD”

Submitted in partial fulfilment of the requirements for the award of the degree of

BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING

Submitted by
Dhruv Bhardwaj 00615608221

DEPARTMENT OF MECHANICAL ENGINEERING

Dr.AKHILESH DAS GUPTA INSTITUTE OF TECHNOLOGY

C-26, Panduk Shila Marg, Zero Pusta Rd, Shastri Park, Shahdara, New Delhi, Delhi 110053

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2
 ACKNOWLEDGEMENT

The extensive training program at Jaycee Steel was a great opportunity and an
exceptional learning experience for me. I got an opportunity to work under the
esteemed guidance of MR.LOKESH ASATI SR.Production Engineer (PRM), Mr.
A.K. Dhakite, Engineer (PRM). It was great privilege for me to work under him. I
am thankful for his extremely patient gesture, to make training program fruitful
for me and for rendering every possible help to carry out this research project.

It is great pleasure for me to acknowledge the assistance and contributions of all

the staff members of Jaycee Steel for their prompt and timely help in the official
clearances and valuable suggestions during the time of this training.

Dhruv Bhardwaj

Place: Jaycee steel

S.No Description Page No.

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1 Introduction 6

2 Plant 7

3 Press Shop Division 10

4 Product Profile 10

5 Facilities Available 13

6 Why Segmental Laminations for Stator Core? 19 -27

&major activities of prm in detailed and flow chart of
manufacturing activities of different type of
lamination in PRM

7 Critical Quality Assurance Requirements 28

8 Materials Used 28

9 Types of Press Tools 20

10 Selection of Press Tools 20
11 Major Developments Done To Improve Productivity 29

12 Future Augmentations 30
13 Conclusion 33

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JAYCEE STEELS PRIVATE LIMITED
manufacturer of Brake Parts, Engine Housing, Cast Iron Plates

Jaycee Steels Private Limited is a private limited company based in New Delhi, India and it was
incorporated officially on 10/07/1986. The corporate identification number (CIN) of this
company as per the official records is U74899DL1986PTC024781 and the company registration
number is 024781. Its email address is [email protected] and its registered office address
is 16/867,,JOSHI ROAD,New Delhi,Delhi,INDIA,110005.

Jaycee Steels Private Limited is a manufacturer company with the industrial and NIC / SIC
code of 74899 as per the official records. The company was registered in the year 1986 and its
authorized share capital is INR 35,000,000 and paid up capital is INR 25,000,000. The
company's business is based in the city of New Delhi. The company is duly registered at
Registrar of Companies, Delhi (RoC-Delhi) and is classified as the Indian Non-Government
Company.

Jaycee Steels Private Limited is one of the leading manufacturer company of high quality
products / business services such as Brake Parts, Engine Housing, Cast Iron Plates, Engine
Components, Engine

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 Fig.(i) Block II – The Press Shop Division

Fig (ii): AC motors & Alternators

Jaycee steel manufactures large AC motors and Alternators for different purposes as required
by the modern industries. These include O.D. Motors up-to 1100 mm O.D. in IMM department
and from 1100 mm to 2600 mm (O.D.) in LEM department.

Large hydro turbines are also manufactured here for power generation at different water
reservoirs .They are so humongous in size that instead of assembling them at the plant itself, is
in practice to assemble them at the site only.

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 Fig (iv): Transportation Equipment

Jaycee steel also manufactures the brakes for Indian Railways which include traction
alternators and traction motors. These are supplied to Indian Railways for their different train
engines like WDG4, WDM3D, WDP2, DEMU, EMU etc. Overall BHEL provides around 4000
machines to Railways in a year.

Fig (v): Transformer(Jaycee Steel is the largest supplier of electric transformers in India
as per the need of the industrial specifications.)

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 PRESS SHOP DIVISION

Fig (vi): Press Shop

Press Shop Division is a Feeder Division, equipped with latest & sophisticated CNC Machines
other than Conventional Presses, which are used to meet the requirement of the complete
range of laminations for manufacturing of Electrical Machines, Hydro Generators and Traction
Motors. Approximately 150 lakhs of different varieties of laminations (Punchings) are supplied
by PRM to five product divisions viz. IMM, LEM, PLM, TXM& TAM.

Product Profile:

 For Industrial Machine Management (IMM Division): Stator and Rotor laminations
including Vent spacers and End Plates for Medium and small Electrical Machines (150
KW to 2 MW).

Fig (vii):Stator PunchingFig (viii):Rotor Punching

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 For Large Electric Machines (LEM Division): Stator, Rotor laminations including Vent
spacers and End Plates for Large Electrical Machines (300 KW to 17.5 MW). Also, main-
pole laminations in few cases.

Fig (ix):Rotor Spacer PlateFig (x):Segmental Stator Laminations

 For Plant Manufacturing (PLM Division): Stator laminations including spacer plates, Rim
and Pole laminations for Hydro Generators (2 MW to 200 MW).

Fig (xi):Stator LaminationFig (xii):Stator Spacer Plate

Fig (xiii):Rim LaminationFig (xiv):Pole Lamination

 For Traction Motors (TXM Division):

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 o For AC Motors- Stator and Rotor laminations including end plates (200 KW to
1150 KW).
o For DC Motors- Armature, Main Pole and Com-pole laminations including end
plates (45 KW to 630 KW).

Fig (xv): Armature and Main Pole Lamination Fig (xvi): Stator and Rotor Laminations
For Dc Motors for Ac Motors (6 FRA)

 For Traction Alternators (TAM Division):

o For Traction Alternators (TA) - Stator and Main Pole laminations including End
Plates and rim laminations in few cases.

Fig (xvii): TA Rim Fig (xviii): TA Main Pole Fig (xix): Exciter Stator &Exciter Rotor

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 Fig (xx): TA/ OA Stator Fig (xxi):TA Stator Segment

o For Auxiliary Machines- Armature and Main Pole laminations including end
plates (2 KW to 2.5 MW).

o For Exciter Motors - Stator and Rotor laminations including End Plates.

Facilities Available:

o 250 Ton CNC Blanking Line Press

o 16 Ton CNC Segmental Notching Press.

Fig (xxii):250 T CNC Blanking Line & Notching Press

These machines are fully automatic Computer Numeric Controlled (CNC) lamination production
machines which house the process of producing stator or rotor lamination.

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They are manufactured by German company SCHULER. And are based on the concepts of
Programmable Logic Controller (PLC).

Fig (xxiii): Inside view of CNC Notching machine

Fig (xxiv): Stator Punching Stack Fig (xxv):Stator Segmental Punching Stack

The figures show the stator lamination stack and stator segmental lamination stack which were
made in 3hrs respectively by a fully automatic CNC machine for the IMM division.

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The process that takes place in a fully automatic CNC machine is as follows –

BLANK STATOR
ID PRESS
PICKUP STALKING

KEYWAY NOTCHING
ROTOR
STALKING

This process makes laminations of thickness 0.65 mm each and it takes these machines 8hrs to
complete a core of thickness 40 cm which is composed of these laminations

 8 Ton and 16 Ton 6 Station CNC Auto Notch Press

 8 Ton 8 Station CNC Auto Notch Press.

Fig (xxvi): Conventional CNC Notching Presses

These are used to make the laminations (Punching) manually.

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  32 Ton CNC Segmental Notching
 12.5 Ton Notching Presses (4 No.)

Fig (xxvii):16 T Segmental Notching Press

 Heavy conventional Blanking Presses

 1600 T, 500 T, 300 T, 200 T one each

Fig (xxviii):1600T Press

Used for the maintenance purposes of the Cutting and machining tools which are used to make
the laminations conventionally.

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  Medium and Light Blanking Presses ( 40 T to 150 T)
 Shearing Machines
 Conventional Notching Presses ( 6 Ton )
 Large Vertical Spindle Surface Grinding Machine

Fig (xxix): Vertical Spindle Surface Grinder

 Surface Grinding Machines

 Varnishing Plant

Fig (xxx): Varnishing Plant

Varnishing is done to increase the insulation thickness. The total varnish thickness required is 5
to 9 microns per side.

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The process for varnishing of the laminations is –

PRE HEAT ZONE: HEATING: 400 to

COOLING VARNISHING COOLING
200 to 400 C 500 C

 De-burring Machine / Belt Burr Grinder

 Projection welding Machines
 Spot Welding Machines

Fig (xxxi): Spacer Plates after Spot Welding

These machines are used for removing the burr that might occur during the manufacturing
process and also from the old raw materials. Projection welding and spot welding is done to
make the spacer plates (ventilating plates).

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Following are the major activities of PRM in Detailed

1. BLANKING, NOTCHING: These are main activities of PRM .by using a press tool on press
machines blanks are made and then notching is done on blanks. During blanking noise is
generated which depends on the cutting area sheet material, cutting load of the lamination
however noise level during notching etc. Is low compare to blanking .250 ton cnc blanking line
press and all the cnc nothing presses are provide with sound enclosure? However all the
conventional blanking presses are without sound enclosure? Sometimes level of noise
generated during blanking presses beyond the permissible limit. But as precautionary measure
all operators working on large blanking use earmuffs while rest of employees use earplug, since
Noise generation during notching and other press operation is much low compare to the
blanking operation.

2. VARNISHING: to increase the insulation thickness varnish coating on the hydro generator’s
stator punching prior to assembly required .this is done on varnishing plant which involves the
following process
A.)DEBURRING: To remove the burr from the laminations.

B.) PRE HEATING: To remove the oil, lubricant, dust etc. Lamination are heated in the pre
heating zone by forced hot air circulation to the temp. Of 200 to 400 c

C.)COOLING: Lamination are air cooled on the chain conveyor.

D.)VARNISING: Required varnish is coated on lamination in the range of 5 to 9 micron.

E.)HEATING: After varnishing laminations are again heated by forced hot air circulation to the
temp. Of 400 to 500 c.

F.)COOLING: Lamination are again air cooled on the chain conveyor after varnishing.

G.)Collection of punching

3. GRINDING: Every press tools have to ground/reshaped regularly to reduce the burr level
and to sustain the life .Small tools are re sharpened on surface grinder and large press tool are
sharpened on the spindle HOMA and LUMSDON grinding machine. All the grinding machine use
coolant during grinding.
The hazards involved in this process are due to high speed rotating grinding wheels and
adopters, which may come out during the operation .the in built guards on the grinders take

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care of this hazard. Other hazards involves are noise and dust generation.to reduce the impact
of this use earplug and face mask regularly.
4.)MATERIAL HANDELING: Eot cranes with the help of lifting trackless do the majority of
material handling .here the failure of lifting tackles, limit switches and brakes of eot cranes
Can lead falloff heavy material from a considerable height which may fall on other component,
material, men and also can lead to domino effect (chain of events)

HOWEVER Safe practice are followed to avoid such occurrence. They are
A.)Use of lifting tackles of swl well above the load to be lifted.

B.)Periodic inspection of lifting tackles by safety steward as per WMI1003.

C.)Regular preventive maintenance and gantry check-up of cranes.

5.) MAINTAINENCE: maintenance takes care of the periodic .preventive and breakdown
maintenance of the machines and other facilities.it uses various grades of lubricating oils for
different purpose on machines .it is responsible for maintenance of electrical and mechanical
system in good condition.

6.)DEBURRING:PRM has two nos. of deburring machine .lamination up to 1mm thickness are
de burred in the se de burr machines by passing the lamination through two opposite rotating
belt burr remover rollers.
Hazard involved one machine are
A) Laminations may tangled during de-burring may lead to an accident

B.)Fingers may come between the rollers due to casual approach of operators during material
feeding.
7.) SPOT WELDING; PROJECTION WELDING: FOR manufacturing the end plates for
Rotor /Armature core, stator core for electrical motors and spacer plate for hydro generators
are made on spot welding Machines .4-5 LAMINATION ARE SPOT WELDED TOGETHER TO MAKE
THE END PLATE WHEREAS Spacers are spot welded on uncoated laminations to made spacer
plate assembly .In projection welding spacers are welded on the uncoated sheet to make vent
punching.
Basic hazards involved by these operation are:
1) Fumes generation leads to air pollutions
2) Leaking of water may cause electrical shock
3) Spreading of welding spark
Operators use the Safety goggles, Apron and face mask.
Note: All machines are equipped with Emergency switches

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Flow chart of manufacturing activities of different type of LAMINATION IN PRM
1. FOR A.C. MACHINES
STATOR LAMINATION

RAW
MATERIAL
COIL

BLANK
STATOR OD
PM 250 T

CUT K’WAY
NOTCH SLOT
WITH AIR GAP

VENT/END
FINISHED
LAMINATION
STATOR MAIN
FOR
LAMINATIONS
PROJECTION/SP
OT WELD

DRESS &CLEAN
LAMINATION

STATOR CORE
PAINT
END/VENT
LAMINATIONS
SNN

DISPATCH
PRODUCT DIV
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 ROTAR BLANKS IN
ROTAR LAMINATION CUT OF STATOR
LAMINATION

CUT K’WAY NOTCH

SLOT AND PUNCH
ID/ NA16 NA 8

VENT/END FINISHED
LAMINATION ROTAR MAIN
CORE LAMINATION
PROJECTION/S M

DRESS
&CLEAN
LAMINATIO

ROTAR CORE

PAINT
END/VENT
LAMINATION

DISPATCH
PRODUCT DIV

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FOR HYDRO MACHINES RAW MATERIAL
COIL

BLANK STATOR
COMPLETE PM 250 T

VARNISH VENT/END
MAIN LAMINATION FOR
LAMINATIO SPOT WELD SPACERS
N

DRESS&CLEAN
LAMINATION

PAINT END STATOR CORE

/VENT
LAMINATION

DISPATCH
PRODUCT DIV

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 POLE LAMINATIONS

RAW BLANK COMPLETE PUNCH DESPATCH

MATERIAL POLE LAMINATION SLOTS PM TO SITE
SHEET PM 500TON 500 TON

RIM LAMINATION

RAW BLANKS PUNCH DESPATCH

MATERIAL COMPLETE SLOTS PM TO SITE
SHEET POLE 500 TON

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 2. FOR DC MACHINES
ARMATURE LAMINATIONS

RAW MATERIAL
COIL

BLANK OD ,VENT HOLES ,PILOT HOLE & KEY WAY PM 250 TON

FINISHED VENT /END

ARMATURE MAIN LAMINATIONS FOR
LAMINATIONS PROJECTIONS /SPOT
WELD

DRESS AND CLEAN

LAMINATIONS
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ARMATURE CORE
PAINT END / VENT
LAMINATIONS

PRODUCT DISPATCH
DIVISION

MAIN POLE LAMINATIONS

BLANK &PIERCE PM 120

VENT /SPOT LAMINATIONS FINISHED POLE MAIN

FOR SPOT WELD LAMINATIONS

ASSAY .END LAMINATIONS, STACKED

DRESS AND CLEAN
MAIN LAMINATIONS TAPPING BAR
LAMINATIONS
&PIVOT COMPLETE

WELD BOTH
ENDS OF
TAPPING BAR

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 DRESS AND
CLEAN POLE
COMPLETE

DRILL AND
C’SK TAP
HOLES IN POLE

DISPATCH DRESS AND

The precautions that must be taken during spot DIV
PRODUCT welding include: CLEAN SHARP
CORNERS
 Check for parallel surface of the spacers.
 Set machine for correct current setting as permachine parameters.
 Check the assembly through drop test (from 1 meter height).
Why Segmental Laminations for Stator Core?

 OD exceeds 3.5 m and may reach up-to 18.0 m.

 Core is split into segments.
 Maximum width of available magnetic sheet steel is about 1.0 m.
 Single core might be heavy and bulky for handling.
 To facilitate the handling of laminations inside the factory.
 Smooth transport by rail or road.

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 Fig (xxxii): Segmental Laminations for Stator Core

Critical Quality Assurance Requirements:

 Low tolerance on I/D & O/D dimensions

 Very low tolerance on pitch variation of dovetails on O/D.
 Variation in position of Key way on stator O/D w.r.t. dovetail and slots to be within limit
 Variation in position of Key way on rotor I/D w.r.t. slots & Bolt/Vent holes to be within
limit
 Pitch variation between slots to be within very small tolerance to avoid slot roughness
while core building
 Burr level to be controlled during all operations of O/D & I/D blanking, Key way on stator
O/D & Rotor I/D, Stator & Rotor notching, bolt/vent hole notching, trimming etc.
 Thickness variation after core building to be within 2mm ( for TPTN ) to 5 mm ( EM ).
 Strength of Projection welding of vent spacers to be such as to withstand hammer test.
 Spot welding of End plates and spacer plates to withstand destructive testing.
 Coating thickness of varnish to be maintained within a very low tolerance limit.

Materials Used:

 Coated CRNGO (Cold rolled non-grain oriented) SILICON STEEL Sheet.

 Coated Material (4 to 7.5 MICRONSTABOLITE 40 VARNISH).
 Coating Material (Varnish & Thinner).
 Major Supplier - RSP Raurkela, TKESNASIK, ALLOVERGY – Germany.
 MATERIAL Thickness –
o 0.35mm TO 0.75mm (Stator & Rotor).
o 1 to 2.25mm (Pole Punchings).
o 1.6 To 4.5mm (Rim Laminations).
 Uncoated CRNGO STEEL Sheet.
 CRCS (cold rolled carbon steel) Sheet.
 Stainless steel Bar.

Types of Press Tools:

 Single Notch Tools:

Produce single notch in a stroke and used when the required quantities are less.
E.g. Notching, Venting, Trimming etc.

 Compound Tools:

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 Two or more than two cutting operations are completed in a stroke, used for mass
production.

 COMBINATIONS TOOL:
Cutting & non-cutting operations like bending, forming are performed in a stroke.

 PROGRESSIVE TOOLS:
It performs a series of fundamental sheet metal operations at two or more stations
during each stroke.

Selection of Press Tools:

 Quantity of laminations.
 Design/Profile of laminations.
 Cutting Load (of available Presses).
 Machine Delivery time.
Major Developments Done To Improve Productivity:

Technology:

 Stator and rotor laminations are manufactured in one pass using state-of-the-art
technology of circular multi-station notching press (8 ton 8 station CNC notching press).

 Modification of Gear train assembly of 12.5 Ton Impact make notching press resulted in
enabling notching of 200 slots in place of rated 192 slots.

 Installation of regular/irregular skip-notch slot programming on Impact Notching Press

for making LEM Rotor punching.

 Manufacturing of 2600 mm dia. LEM range segmental lamination for M/s KBL Mundra.

 Manufacturing of stator laminations for 1250 mm dia. LEM range motors on the 12.5
Ton notching press.

 Manufacturing of large size Rim punching of 4.5mm thickness using a four stage
compound tool for Koldam Hydro-generator project.

 Development of LASER cutting technology for manufacturing of laminations.

 Online Production Monitoring system developed involving storage of required

information like work order wise customer name, component drawing nos., tool nos.,

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 material, core height, dispatch status, user requirement etc. to facilitate easy retrieval
of information.

Cycle-Time Reduction:

 Development of compound tools for stator and rotor laminations.

 Development of compound tools for armatures of Traction Motors in maximum possible

varieties.

 Manufacturing of Gang-slot Tools to reduce load on 16 Ton segmental notching press

and reduce cycle time.

 Carbide notching tools developed with M/s Kennametal to reduce machine idle time
caused by tool re-sharpening.

 Manufacturing of end laminations of TM4907 armature, TM4507 stator & rotor etc.
through LASER cutting.

 Development of compound tools of various ID, OD combination along with bolt holes to
reduce cycle time by eliminating separate operations for ID and for bolt hole.

 Development of notching tools which also have the vent hole punch to reduce cycle
time by eliminating separate operation of vent hole in case wherever possible.

Cost Reduction:

 Use of old Bolster plates for new compound tools to reduce cost of compound press
tools.

 Indigenization of lightweight notching die shoes for CNC notching press. Earlier these
were imported from OEM supplier M/s Schuler, Germany.

 Import substitution of HRNGO with 1.0mm thick CR sheet for manufacturing of hydro-
generator pole laminations.

 Manufacturing of TM4303 armature, Main Pole & Com-pole punching for TPTN from the
off cuts of IMM and LEM laminations.

 Manufacturing of small size stator and rotor laminations for 700mm, 620mm and
550mm dia. IMM frame using large size shaft-hole in-cuts of LEM rotors.

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  Saving in material cost by reducing width of the CRNGO coils used for stator lamination
of IMM motors.

Future Augmentations:

 Establishing of LASER cut of end laminations for more traction motors.

 Renovation of 32 Ton segmental notching press to manufacture stator segments.

 Development of more compound tools to eliminate multiple operations.

 Development of more gang-slot tools to reduce load on 16 Ton segmental press and also
reduce cycle time.

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