Final Int RPT RV

VISVESVARAYA TECHNOLOGICAL UNIVERSITY
JNANA SANGAMA, BELAGAVI – 590018, KARNATAKA, INDIA
Internship Report
“Study on manufacturing of furnaces and commercial heat treatment”

Submitted in fulfilment of the requirements for the award of degree of
BACHELOR OF ENGINEERING
in
MECHANICAL ENGINEERING
Submitted by
RUDHRAVEENA C
1PE16ME115
Internship carried out
at
Hightemp Furnaces Limited
1C, 2nd Phase, Phase -1, Peenya, Bengaluru, Karnataka 560058
Internal Guide External Guide
Mr. Naveen H E Mr. Ravi M
Assistant professor, Deputy Manager, Quality Dept
PESIT Bangalore South Campus, Hightemp Furnaces Ltd,
Bengaluru – 560100 Bengaluru – 560058
Department of Mechanical Engineering
PESIT BANGALORE SOUTH CAMPUS

HOSUR ROAD, BENGALURU-560100
2019-2020
PESIT BANGALORE SOUTH CAMPUS
Hosur Road, Bengaluru-560100
DEPARTMENT OF MECHANICAL ENGINEERING
Certificate
This is to certify that the Internship work entitled “Study on manufacturing of furnaces
and commercial heat treatment” is carried out by RUDHRAVEENA C bearing USN
1PE16ME115, a bonafide student of PESIT Bangalore South Campus, Bengaluru in
fulfilment for the award of Degree of Bachelor of Engineering in Mechanical
Engineering of Visvesvaraya Technological University, Belagavi during the academic
year 2019-2020. It is certified that all corrections/suggestions indicated for internal
assessment have been incorporated in the report deposited in the department library. The
Internship report has been approved as it satisfies the academic requirements in respect of
Internship work prescribed for the said degree.
Signature of the guide Signature of the guide Signature of the HOD

Internal Guide External Guide Head of the Department
Mr .Naveen H E Mr. Ravi M Dr. Subrahmanya S.Katte
Assistant Professor, Professor & Head,
Deputy Manager,
Dept. of ME, Quality Department, Dept. of ME,
PESIT-BSC. Hightemp Furnaces Ltd PESIT-BSC.
External Viva
Name of the Examiner Signature with Date

1.
2.
DECLARATION
I, RUDHRAVEENA C bearing USN 1PE16ME115 student of 8th semester B.E in the

Department of Mechanical Engineering, PESIT-BSC, Bengaluru, would hereby
declare that the Internship entitled “Study on manufacturing of furnaces and
commercial heat treatment” was carried out by me and submitted in partial fulfilment
for the award of Bachelor of Engineering in Mechanical Engineering, Visvesvaraya
Technological University, Belagavi during the academic year 2019-2020.
I further declare that the work embodied in this report has not been submitted to any other
university or Institution for the award of any degree.
Place: Bengaluru Signature of the student

Date: RUDHRAVEENA C
1PE16ME115
BE, Dept of ME.
ACKNOWLEDGEMENTS
The satisfaction that accompanies the successful completion of the internship would be
complete only with the mention of people who made it possible, whose support rewarded
my effort with success.
I am very thankful to Hightemp Furnaces Limited, for giving me the opportunity to do

my internship at their company, it was a very good learning experience for me to have
worked at the site.
I would like to convey my heartiest thanks to Mr. R. Varadharajan, who gave an

opportunity to do internship at Hightemp Furnaces.
I would like to thank Mr. Ravi M, Mr. Uday, Mr. Rajesh and Mr. Naveen H E who
guided and encouraged me all through the internship training and imparted in-depth
knowledge of the programme.
Esteemed gratitude is towards Dr. Subrahmanya S Katte, Head of the Department of

Mechanical Engineering, PESIT-BSC for his support and encouragement.
Last but not the least I would like to thank all the staff of Hightemp Furnaces limited for
being so helpful during the internship.
EXECUTIVE SUMMARY
The purpose of my internship at Hightemp Furnaces was to understand the work

environment and to gain knowledge of the various steps and methods involved in
manufacturing of Sealed Quench Furnace and the commercial heat treatment. The
internship program helped me to gain practical knowledge and various aspects involved
in the production. The internship program helped to develop interpersonal relationships in
professional settings, to interact with the experienced people in the organization and to
develop and improve the required soft skills, learn about the various departments in the
organization, their objectives and also learn about the work flow interaction between
them.
The Internship was carried out at Hightemp Furnaces Ltd, Peenya and Gorguntepalya. At
the beginning of the internship, classes were conducted on the Heat treatment process and
the process flow of the heat treatment and the manufacturing of furnaces, to make me
understand how the Hightemp Furnaces functions.
They made me understand the entire process flow both at the manufacturing division and
the heat treatment division and had given me a task to make the process flow chart of
entire division.
After the completion of the above tasks they had assigned me to the quality department
for the inspection of the components.
TABLE OF CONTENT
CHAPTER
NUMBER CONTENT PAGE NO:
1 ABOUT THE COMPANY 1
1.1 INTRODUCTION 1
1.2 TIMELINE OF HIGHTEMP FURNACES LTD 3
1.3 VISION AND MISSION 3
1.4 GOALS AND OBJECTIVES 4
1.5 CERTIFICATIONS 4
1.6 GLOBAL PARTNETS 5
1.7 COMPETITORS 6
1.8 CUSTOMERS 6
1.9 INFRASTRUCTURAL FACILITY 8
1.10 PRODUCT PROFILE 8
2 ABOUT THE DEPARTMENT 13
2.1 MANUFACTURING DIVISION 13
2.1.2 FUNCTIONAL DIVISION 14
2.1.3 WORK INSTRUCTIONS 15
2.1.4 COMPONENTS OF THE FURNACE 16
2.2 COMMERCIAL HEAT TREATMENT DIVISION 19
2.2.1 FUNCTIONAL DIVISION 20
2.2.2 PROCESS FLOW CHART FOR SEALED QUENCH FURNACE 21

TABLE OF CONTENT
CHAPTER CONTENT PAGE

NUMBER NUMBER
2.2.3 EQUIPMENTS 22
3 TASKS PERFORMED 24
3.1 UNDERSTANDING WORKING PRINCIPLE OF FURNACE 24
3.1.1 FURNACE 24
3.1.2 VESTIBULE AND QUENCH TANK 26
3.1.3 PUSHER 27
3.1.4 CONTROL PANEL 28
3.2 UNDERSTANDING THE MATERIAL SELECTION 28
3.3 UNDERSTANDING THE MACHINING PROCESS OF THE FURNACE 30
3.4 UNDERSTANDING THE HEAT TREATMENT PROCESS 31
3.4.1 UNDERSTANDING OF STEELS 32
3.4.2 UNDERSTANDING OF TEMPERATURE AND PHASES 33
3.5 PROJECT OFMONITORING THEHEAT TREATMENT 34
3.5.1 CASE HARDENING 34
3,5.2 CARBONITRIDING 40
3.5.3 THROUGH HARDENING 44
4 REFLECTION NOTES 47
4.1 LIST OF TECHNICAL OUTCOMES 47
4.2 LIST OF NON-TECHNICAL OUTCOMES 48

TABLE OF FIGURES
FIGURE PAGE
NUMBER CONTENT NUMBER
1.1.1 HIGHTEMP FURNACES LIMITED LOGO 1

1.1.2 HIGHTEMP FURNACES LIMITED PLANT 2
1.10.1 BATCH TYPE INTEGRAL SEALED QUENCH 9
1.10.2 BATCH TYPE THN FURNACE 9
1.10.3 CONTINUOUS GAS CARBURIZERS 9
1.10.4 CONTROLLED ATMOSPHERE BRAZING 10
1.10.5 MESH BELT FURNACE 10
1.10.6 DECARB ANNEALING &BLUING 10
1.10.7 VACUUM HARDENING FURNACE 11
1.10.8 ALKALI WASHERS 11
1.10.9 ROTARY RETORT 11
1.10.10 TEMPERING 12
2.1.1 SEALED QUENCH FURNACE 13
2.1.2 PROCESS FLOW CHART 15
2.1.3 SEALED QUENCH FURNACE DESIGN 16
2.1.4.1 FURNACE SHELL 16
2.1.4.2 QUENCH TANK 17
2.1.4.3 PUSHER 17
2.1.4.4 CONTROL PANEL 18

TABLE OF FIGURES
FIGURE PAGE
2.2.1 RANGE OF PRODUCTS HEAT TREATED AT HIGHTEMP 19
2.2.3.1 VICKERS HARDNESS TESTER 22
2.2.3.2 MICRO VICKERS HARDNESS TESTER 23
2.2.3.3 ROCKWELL HARDNESS TESTER 23
2.2.3.4 OPTICAL MICROSCOPE 23
3.2.1 PIPES 29
3.2.2 MILD STEELS SHEETS 29
3.2.3 CHANNELS AND ANGLES 29
3.2.4 INSULATION BRICKS 29
3.3.1 HAND DRILL 30
3.3.2 LATHE MACHINE 30
3.3.3 BEND SAW CUTTING MACHINE 30
3.3.4 NUTS AND BOLTS 30
3.4.1 EAT TREATMENTS CYCLE 31
3.4.2.1 IRON CARBON DIAGRAM 33
3.5.1.1 GEAR RIM 35
3.5.1.2 CHARGE SHEET 35
3.5.1.3 JIGGING 36
3.5.1.4 ALKALI WASHERS 36

TABLE OF FIGURES
CHAPTER PAGE
3.5.1.5 HEAT TREATMENT OF GEAR RIM 37
3.5.1.6 CUT SECTION OF GEAR RIM 38
3.5.1.7 MOLDING MACHINE 38
3.5.1.8 INSPECTION REPORT OF CASE HARDEING OF GEAR RIM 39
3.5.1.9 DEJIGGING 39
3.5.1.10 PACKING OF GEAR RIM 40
3.5.2.1 BEARING INNER RING 40
3.5.2.2 CUT SECTIONOF INNER RING 42
3.5.2.3 MOLD OF INNER RING 42
3.5.2.4 INSPECTION REPORT OF BEARING INNER RING 43
3.5.3.1 CONTROL SCREW 44
3.5.3.3 PACKINGOF CONTROL SCREW 46

Study on manufacturing of Furnaces and commercial heat treatment.
CHAPTER 1
ABOUT THE COMPANY
1.1 INTRODUCTION
Fig 1.1.1 Hightemp Furnaces Limited Logo
Hightemp Furnaces Limited was founded in 1970, by Mr. Balakrishna and Gopal
Mahadevan. Hightemp Furnaces Limited is one of the largest manufacturers of industrial
heat treatment furnaces and also the largest heat treatment facilitators in the country
providing heat treatment services to manufacturers of automotive components, bearings
and fasteners in particular and other engineering industries in general. They have over
2500 industrial furnace installations operating worldwide. It is a part of the Dowa group,
Japan.
Initially Hightemp Furnaces Limited was registered as a private limited company with
very less Authorized capital .Initial capital was raised as 100rs per share. But after a
decade of activity Hightemp Furnaces Limited had managed to achieve massive turnover
which crossed the limits easily and became a Limited company.
Department of Mechanical Engineering PESIT-BSC 2019-20 1

Fig 1.1.2 Hightemp furnace limited plant
Initially Hightemp Furnaces dealt with manufacturing of ovens, electric heaters etc. They
first started serving bakeries with large oven according to the design and particular
specifications given by bakeries, which were widely accepted and the demand started
increasing. Due to the raise in the demand the company started manufacturing furnaces.
Later the automobile industries approached the company for heat treatment, and then the
company started commercial heat treatment.
Hightemp Furnaces Limited has a comprehensive furnace manufacturing facility-spread

over a 75,000 sq ft area –designed to conceptualize and build advanced atmospheric heat
treatment furnaces. The commercial Heat Treatment divisions, located at the industrial
clusters of Delhi, Pune, Chennai and Bangalore, command a total area of 598,950 sq ft.
Regular quality audits of products and services, sustained emphasis to guarantee

consistent quality, compliance to meet customer requirements have enabled the company
to exceed expectations and ensure customer delight. . Hightemp has earned a strong
reputation for providing reliable and high quality heat treatment services at competitive
prices with an unflinching commitment to quality assurance and on time delivery.

1.2 TIMELINE OF HIGHTEMP FURNACES LTD.

 1970- Established manufacturing laboratory ovens and furnaces.
 1979- Commenced commercial production (Furnace Building in Bangalore).
 1986- Technical collaboration with Tokyo Heat Treatment (DOWA).
 1992-Started Commercial Heat Treatment in Bangalore.
 1996-Started Commercial Heat Treatment in Pune.
 2000- Started Commercial Heat Treatment in Gurgaon.
 2004- Started Commercial Heat Treatment in Chennai.
 2006-Technical collaboration with TTI Services.
 2007-New manufacturing facility at Nelamangala.
 2008-Technical collaboration with Applied Process Inc.
 2010-Technical collaboration with AFC-Holcroft, USA for Controlled
Atmosphere Aluminum Brazing furnace.
 2011- Dowa invested in Hightemp with 80% shareholding and Hightemp became
a subsidiary of Dowa Japan.
 2015-Second New manufacturing facility at Yeshwanthpur Industrial Suburb.
 2016-Technical collaboration with Sanken Sangyo Company Ltd. Japan for
Aluminum Tower Melting furnaces.
 2016-Dowa increased its shareholding to 93%.
 2017- Commenced work on commercial heat treatment facility in Sanand,
Gujarat.
 2017-New land acquired in Bidadi, near Bangalore.
1.3 VISION AND MISION
VISION: “Become a global comprehensive heat treatment company”.
MISSION: “To create new benchmark in the heat treatment business, with specific
focus on innovative technology, combined with quality, cost and delivery”.

1.4 GOALS AND OBJECTIVES:
 The Company believes to be the No1. Heat Treatment “solution provider” in

India. With the help of in house facilities they aim at achieving the focused goal.
 Develop the furnace manufacturing sector and to strengthen core business of
furnace manufacturing. Thus increasing the scope of the industry.
 Establish heat treatment centres of excellence, for easy access of heat treatment
facilities for variety of manufacturing companies.
 Expand backward integration service offer, by undertaking the component
manufacturing along with heat treatment.
 Compress and simplify the supply chain for customers, by undertaking backward
integration. The supply chain for the customers narrows down thus giving an
advantage for the firm as well as customers.
 Create customer satisfaction and delight. Satisfied customers are loyal customers.
1.5 CERTIFICATIONS
Hightemp furnaces limited have been recognized through various quality
certifications which are as follows.
 ISO 9001-2000 certified by SGS Yarsely International Certifications Services
Ltd for Bangalore and Pune plant.
 TS 16949 certification by Det Norse Vertias (DNV)
 AS 9100 for CHT plant in Bangalore.
 ISO 9100:2008 and ISO 14001:2004 for furnace division.
 NADCAP certifications by SAE Aerospace Standard AS7003 in Peenya.
 NADCAP certification by Aerospace Private Limited in Nelamangala Taluk.

1.6 GLOBAL PARTNERS

Hightemp strives hard to provide quality with world class services to address the
needs of the industry. These strategic relationships of Hightemp Furnaces limited
have enabled it to expand its service offerings and acquire a strong industry focused
worldwide. The partners of Hightemp across the globe are as follows.
Dowa Thermotech Japan is a pioneer in the design and

manufacture of highly reliable heat treatment technology
and systems.
AFC-Holcroft is one of the most reputed furnace

manufactures for CAAB systems.
TECHNICAL LICENSE
TTI-Nitrotech is a surface treatment technology which

can result in 66% saving in material cost.
TECHNICAL LICENSE
Applied Process Inc has been the technology leader in

treating Austempering of ductile iron since 1978.
TECHNICAL LICENSE
IISc is involved in innovative research and development

activities in the field of Bio-resource.
TECHNICAL LICENSE

1.7 COMPETITORS
Each and every industry faces severe competition both in national and international
market. Hightemp furnaces limited face stiff competition from other furnace
manufacturing companies. The following companies are as follows
a) Body care
b) Unitherm
c) Hertek Furnace
1.8 CUSTOMERS
Four decades since inception, products and services from the Hightemp portfolio
have been ensuring the delight factor for a growing customer base across the country.
The customers of Hightemp are as follows.


1.9 INFRASTRUCTURAL FACILITY
Infrastructural facilities means the basic requirements that the company should
look after in order to ensure free flow of activities .The company is providing
following infrastructural facilities inorder to satisfy its workers ,distributors and
customers. The company is providing following infrastructural facilities in order to
satisfy its workers, distributors and customer’s .The Company provides the following
facilities to the employees in the factory:
1. Uniform.
2. Allowances for shoes.
3. Leave Benefits.
4. First Aid facilities for employees.
5. Provide mineral water supply.
6. Well-furnished meeting hall with A/C.
7. Lunch Rooms.
8. Safety/Security.
9. Health care center.
10. Parking Facilities.
11. Lighting & ventilation.
1.10 PRODUCT PROFILE
Furnace Manufacturing constitutes the core of the competencies-a key asset that has
ensures HIGHTEMP’S position as one of the leading heat treatment furnace
manufacturers in India. The portfolio of process, product and technology that is offered
by Hightemp Furnaces Ltd has root in the wealth of in-house design expertise built over
the last four decades. The Hightemp furnace range:

1. Batch Type Integral Sealed Quench
Fig 1.10.1 Batch Type Integral Sealed Quench
2. Batch Type THN Furnace
Fig 1.10.2 Batch Type THN Furnace
3. Continuous Gas Carburizers
Fig 1.10.3 Continuous Gas Carburizers

4. Controlled Atmospheric Brazing
Fig 1.10.4 Controlled Atmospheric Brazing
5. Mesh Belt Furnace
Fig 1.10.5 Mesh Belt Furnace
6. Decarb Annealing & Bluing
Fig 1.10.6 Decarb Annealing & Bluing

7. Vacuum Hardening Furnace
Fig 1.10.7 Vacuum Hardening Furnace
8. Alkali Washers
Fig 1.10.8. Alkali Washers
9. Rotary Retort
Fig 1.10.9 Rotary Retort

10. Tempering
Fig 1.10.10 Tempering
11. Rotary Hearth
12. High Speed Tempering
13. Endo Gas Generators.

CHAPTER 2
ABOUT THE DEPARTMENT
2.1 MANUFACTURING DIVISION
The manufacturing division is responsible for the entire fabrication of the product.
The two manufacturing plants for Hightemp Furnaces are located at Yeshwanthpur and
Nelamangala. This plant manufactures and sells different types of furnaces for different
purposes. In this the plant the furnace is produced from scratch to the final product The
plant is divided into various sections pertaining to the processes or components
manufacturing such as welding, gas cutting, painting, electrical, assembly etc. The
drawings provided by the design department are studied carefully and manufactured
accordingly.
Fig 2.1.1 Sealed Quench Furnace

2.1.2 FUNCTONAL DIVISIONS
1. Marketing: This division is responsible for building the customer base for the
company. Its duty is also to introduce the products and services provided by the
company.
2. Design and development: This division plans the project in accordance to customer
requirements and customer specifications. The design layout of the product is developed
which will be later used by the manufacturing to build the product
3. Purchase: This division is responsible for purchasing the raw materials required to
manufacture the product, and also to deliver the raw materials to the stores.
4. Stores: Stores receives, inspect and approve the raw materials, store and provide the
raw materials to the manufacturing division.
5. Manufacturing: They study the drawing provided by the design division which is made
in accordance to the customer specifications and build the product (furnaces etc.) using
the raw materials. After the product is built, it is tested to check the proper functioning of
the product.
6. E&C (Erection and Commissioning): This division installs the furnaces in the
customer’s site. They also provide technical information about the furnace. Cold trial
(test trial) is run in the customer’s site to confirm the functioning of the furnace. The
customer is trained to handle the furnace.
7. Accounts: This division is responsible for planning the expenses for running the
company. They also handle all the financial records of the company.
8. Human resources: This division makes policies for running the firm. HR is primarily
concerned with the management of people within organizations, focusing on policies and
on systems. HR departments are responsible for overseeing employee-benefits design,
employee recruitment, training and development, performance appraisal, and rewarding

2.1.3 WORK INSTRUCTIONS
Work Instructions are laid out for each process before the start of manufacturing.
This improves the efficiency of the production cycles and allows for the proper use of the
machinery. The process flow chart is as follows
Fig.2.1.2 PROCESS FLOW CHART

Fig 2.1.3 SEALED QUENCH FURNACE DESIGN
2.1.4 COMPONENTS OF THE FURNACE
1. Furnace: Furnace is a structure which is used to heat a metal to high temperature for
the purpose of heat treatment. It is usually made out of a steel outer shell which is
annealed at 400- 500 °C. The inner lining is covered with heat refractory bricks like C1
insulation bricks, B4 insulation bricks and calcium silicate board. This is used for
insulation so as to prevent the heat from escaping. Pneumatic cylinders are used to
operate the doors of the furnace.
Fig 2.1.4.1 Furnace Shell

2. Vestibule & Quench Tank: Quenching process is done on steels to improve its
mechanical properties such as hardness. The goal of quenching is to produce the desired
hardness, strength and toughness in the part while minimizing distortion and residual
stress. This is done using a quenching tank which is made of the steel. The liquid used in
the quenching process is either water or oil.
Fig 2.1.4.2 Quench tank
3. Pusher Table: The pusher table is used to receive loaded charge from loader or traverser.
This is achieved by means of a chain drive at the rear end of the pusher table. The same
drive positions the charge in front of the door. The pusher table is grouted to the floor by
means of foundation bolt in front of the heating chamber.
Fig 2.1.4.3 Pusher

4. Power and Control Panel: It is a self-standing power and control panel housing all
electrical switchgear and instrumentation. The incoming power supply cable entry is
from the top. Inter connecting cable from panel to equipment terminal boxes are also
taken from the top of the panel. Console type front and rear operation panel are provided.
On the pusher table and rear door respectively these will house selector switches, push
buttons, indicating lamps. A selector switch is provided for choosing manual or automatic
operation modes. These panels are inter-connected through the terminal boxes to the
main power and control panel.
Fig 2.1.4.4 Control Panel

2.2 COMMERCIAL HEAT TREATMENT DIVISION
The Commercial Heat Treatment Division provides modern facilities, state of art
equipment, well equipped metallurgical laboratory and trained &component personnel
backed by controlled atmosphere furnaces, auxiliary equipment’s and advanced process
control systems.
Fig 2.2.1 Range of products heat treated at Hightemp
The Hightemp Commercial Heat Treatment services portfolio includes:
 Carburizing & Hardening

 Carburizing & Annealing
 Bright Hardening
 Carbon Nitriding
 Annealing
 Normalizing
 Tempering
 Nitro Carburizing
 Nitriding
 Steam Bluing

2.2.1 FUNCTIONAL DIVISIONS
1. Planning Division: This division carries out two types of planning namely prior
planning and active planning. Prior planning includes all the planning efforts which are
taking place prior to the active planning. Active planning includes various activities
directly related to the production at micro level immediately following prior planning.
2. Production Division: This division involves inspection of the incoming goods to ensure
its quality, jig the goods according to the schedule given by the planning division and
carry out the heat treatment process.
3. Quality Division: This division is responsible for the quality inspection /verification. It
involves receiving inspection, In-process inspection and final inspection.
4. Maintenance Division: This division involves the management that is concerned with
the day to day problems of keeping the physical plant in good operating condition.
5. Stores Division: This function of this division is to receive raw materials, account for
them, and provide adequate and proper storage.
6. Purchase Division: This division involves in a managerial activity which goes beyond
the simple act of buying, planning and policy planning activities covering a wide range of
related and complementary activities such as research and development strategies.
7. Finance and account division: This division provides accounting services and financial
support to the company .This division records the accounts payable, receivable,
inventory, payroll, fixed assets and other financial elements .The division’s accountants
review the records of each department to determine the company’s financial position and
any changes required to run the organization cost effectively.

2.2.2 PROCESS FLOW CHART FOR SEALED QUENCH FURNACE
INSPECTION OF INCOMING MATERIAL
STORAGE
SCHEDULE FOR HEAT TREATMENT
JIGGING
PRE-WASH
HEAT TREAT IN QUENCH FURNACE
POST WASH
SUB ZERO
TEMPERING
INSPECTION
DEJIGGING
OILING, PACKING &STORING
AUDIT
SHIPPING

2.2.3 EQUIPMENTS
1. Different type of process equipment’s used during heat treatment are
 Sealed Quench Furnace: It is a ‘straight through’ type of heat treatment

furnace with integral oil and gas quenching features.
 Alkali Washers: Alkali Washers are designed for pre-wash and post wash of
components before heat treatment and after quenching operations,
respectively.
 Preheating Furnace: This furnace is used to heat the components before
sending it into the heat treatment process.
 Tempering Furnace: It is a industrial oven designed to heat treat a ferrous
metal product and increase its toughness.
2. Different types of laboratory equipment’s used during Final Inspection are
 Vickers Hardness Tester: This machine is used to measure surface

hardness.
Fig 2.2.3.1 Vickers Hardness Tester

 Micro Vickers Hardness Tester: This machine is used to measure

effective case depth.
Fig 2.2.3.2 Micro Vickers Hardness Tester

 Rockwell Hardness Tester: This machine is used to measure surface
hardness.
Fig 2.2.3.3 Rockwell Hardness Tester

 Optical microscope: This machine is used to measure total case depth
and check the microstructure.
Fig 2.2.3.4 Optical microscope

CHAPTER 3
TASKS PERFORMED
3.1 UNDERSTANDING THE WORKING PRINCIPLE OF FURNACE
Sealed quench furnace are a type of heat treatment furnace. Hightemp’s sealed quench
furnaces are of 'straight through' type with integral oil and gas quenching features.
Suitable for carburising and carbo-nitriding under protective atmospheres, sealed quench
furnaces are fully automatic and PLC controlled. The components of a furnace are
3.1.1 Furnace
The parts of the furnace are as follows:

Description of the furnace construction:
1. Furnace shell: It is a welded gas type reinforced fabricated structure made out of
thick mild steel plate which is fixed on a steel base frame.
2. Front Door: It is a steel plate welded construction with lightweight insulation.
Lifting operation is by means of two pneumatic cylinders at 5-7 kgs/cm.sq
pressures. Doors are sealed by means of 19 mm sq. graphite rope fixed on front
plate of furnace shell.
3. Furnace Rail: It is a Silicon carbide skid rail.
4. Rear Door Flame Curtain: Automatic ignition of curtain burner by solenoid valves
whenever the rear door is open. Pilot burner is fixed above curtain burner near
rear door to ignite curtain.
5. Flame Detection: Flame is detected by means of a burner watch.
6. Fan Motor: Power- 3.7 kW; No of Ploes4: Speed- 1440 rpm; Freq-50 Hz: Phase -
3 indirect mounted induction motor.
7. Fan bearing cooling: Fan bearing is cooled by re-circulating water through a
bearing housing.
8. Intermediate door: Heat resistant steel plate is welded in construction with
lightweight insulation. Lifting operation is by means of one side mounted
pneumatic cylinder with door sealing by means of cam locking arrangement.
9. Furnace Temperature Control and Safety: Furnace temperature is controlled by
PID Controllers provided through the K type thermocouple mounted on top of the
furnace. Over heat protection is through the safety temperature controller.
Separate controller is provided for controlling quench oil temperature.
10. Temperature and Carbon Percentage Recording: A 6-point strip chart dot pen
alarm recorder is provided in the control panel to record furnace temperature,
percentage of Carbon and oil temperature.

3.1.2 Vestibule and Quench Tank
The parts of the vestibule and quench tank are as follows:
Description of the vestibule and quench tank construction:
1. Quenching Mechanism: The mechanism is done by means of pneumatically

operated elevator platform for quenching charge in quench oil tank. Lifting and
lowering of elevator platform is by means of pneumatically operated cylinder at
5-7 kgs / cm.sq.
2. Oil Agitation: It is done by means of two-cast aluminum impellers individually
drove by 1.5 kW, 3 phases, 50 Hz Motors. Agitator speed is controlled by
variable speed AC inverter drive.
3. Oil level indication: It is done by means of a float type oil level indicator. This
indicator is marked for high normal and lower levels. In additional magnetic a oil
level float switch for high and low level alarms for safety is provided. These
alarms are interlinked with PLC for stopping quench in case of alarm indication
automatically.
4. Oil Cooling Method: A Plate type water cooled heat exchanger is used to cool the
oil.
5. Oil Pump: A Centrifugal pump of 3.7 kW, 2800 rpm with mechanical seal is used
to pump the oil.
6. Oil Temperature control and Safety: It is done by means of PID automatic type
Digital Temperature Controller. Duplex thermocouples are installed for
temperature measurement. The overheating is controlled through the safety
temperature controller.

7. Vestibule Cooling Chamber: A Closed double walled jacket is fabricated out of

mild steel. This chamber is mounted above the Quench Tank. Oil is circulated
through the jacket for cooling the vestibule chamber. The circulated oil is cooled
by means of a heat exchanger and a pump. A mild steel reservoir stores the oil
and is mounted near the heat exchanger. (Capacity – 0.75 kW motor with 2900
rpm motor and pump).
8. Exhaust burn off : Pilot burner is continuously lit to ensure that the exhaust gases
are burnt off. These pilot burners are mounted at the top of the exhaust burner.
9. `Exhaust pilot burner flame detection: It is done by means of a burner watch
control.
10. Over Pressure safety in vestibule chamber: It is done by means of a spring loaded
thick circular steel plate arrangement mounted on top of the vestibule chamber.
This safety flange will open in case of excess pressure in the vestibule chamber.
11. Flow meter Panel: The flow meter panel is provided with flow meters, pressure
gauges, pressure reducers, solenoid valves and piping.
3.1.3 Pusher
The parts of the pusher are as follows:
Description of the pusher construction:
1. Charge Forks: Transfer of the charge from the charging position on to the SIC
skid rails inside the furnace chamber is achieved by means of two charging forks
mounted on the pusher table.
2. Pusher Fork: The pusher fork is driven by a 2.2 kW, 1440-rpm motor and
reduction gear with chain and sprocket arrangement.

3.1.4 Control Panel
The parts of the Control Panel are as follows:
Description of the control panel construction:
1. Power and control panel: This will be a self-standing power and control panel
housing all electrical switchgear and instrumentation. The incoming power
supply cable entry is from the top. Inter connecting cable from panel to
equipment terminal boxes are also taken from the top of the panel.
2. Operation Panels: Console type front and rear operation panel are provided. On
the pusher table and rear door respectively these will house selector switches,
push buttons, indicating lamps. A selector switch is provided for choosing
manual or automatic operation modes. These panels are inter-connected through
the terminal boxes to the main power and control panel.
3.2 UNDERSTANDING THE MATERIAL SELECTION
A number of different components are required to manufacture a furnace. These raw

materials are purchased from different vendors. The components are usually made of
mild steel. These include plates, sheets, rods angles, channels etc. These are procured in
various dimensions depending on where it is used. EN-8 steel rods are used to make
shafts and some components are also made of SS304 steel as and when required.
The furnace and quench tank body are made out of mild steel plates. Angles and channels
are used for supports. Rods are used in making shafts, sprockets etc. Pipes are used for air
and gas pipelines.

C1 insulation bricks, B4 insulation bricks and calcium silicate boards are used for
insulation purposes. The insulation blocks are made into different shapes and sizes for the
necessary fit. Different welding items are also purchased based on the quality of weld
required. Standard sizes for materials are:
MS Angle: ISA-50x50x6
MS Channel: ISMC-200x75
MS Plates: 2100x6000x10; 1500x1500x25; 2000x2500x12
EN 8 Rod: Diameter = 20, 25, 30, 40, 45, 50 mm
Fig 3.2.1 Pipes Fig 3.2.2 Mild Steels Sheets
Fig 3.2.3 Channels and Angles Fig 3.2.4 Insulation Bricks

3.3 UNDERSTANDING THE MACHING PROCESS OF FURNACE
The raw materials are made into component parts by using different machining processes.
These include:
Welding: Arc welding, CO2 welding, TIG welding
Cutting: Gas cutting, Sheering, PUG cutting, Laser cutting, CNC robo plasma cutting
Angle, Flat and Channel cutting: Band saw Machine
Drilling: Hand drill, Radial drill, Magnetic drill
Tapping: Pneumatic tapping machine, Tap and Tap wrench
Fig 3.3.1 Hand Drill Fig 3.3.2 Lathe Machine
Fig 3.3.3 Bend Saw Cutting M/c Fig 3.3.4 Nuts and Bolts

3.4 UNDERSTANDING THE HEAT TREATMENT PROCESS

Heat Treatment is a metallurgical process of controlled heating and cooling to extreme
temperatures to achieve desired results such Hardening or Softening .This Phenomena of
controlled heating and cooling results into transformation of microstructure which
enhances the physical and mechanical properties like hardness, toughness, ductility and
wear resistance with high tensile, impact and yield strength .These properties remarkably
Improve the performance and life of the product in use.
Fig 3.4.1 Heat Treatment Cycle
Different types of atmosphere controlled furnaces are available for conducting heat
treatment Process. These furnaces are electrically heated and custom-made depending on
the desired gross capacity. Below is a list of few types of furnaces -
1. Sealed Quench Furnaces

2. Pit Type Furnaces
3. Rotary Furnaces
4. Mesh belt Furnaces
5. Continuous Furnaces
6. Salt Baths

3.4.1 UNDERSTANDING OF STEELS
Pure iron is too soft and without any beneficial properties for the purpose of engineering
use, and hence it is made stronger by adding Carbon. This alloy of iron and carbon is
called steel. Steels are generally categorized based on carbon content, as below-
- Carbon steels
-Alloy steels
-Stainless steels
-Tool steels
There are many grades of steels in each category depending on the %age of carbon (0.22
to 2.14%) and other alloying elements added to it. Numbering system is used for
identifying different grades of steel. This system is based on four digit code numbers for
identifying the base carbon and alloy content in steels. If the first digit is a one (1) it
indicates a carbon steel. All carbon steels are in this group (1xxx). The second digit
indicates the concentration of the major element in percentiles (1 equals 1%).The last two
digits indicate the carbon concentration to 0.10%.
Classification of carbon steels based on percentage of carbon present in it: Carbon steels
are classified into 3 categories
-Low Carbon Steels (C ≤ 0.20%)

-Medium Carbon Steels (C 0.30-0.50%)
-High Carbon Steels (C 0.51-1.50%)
Carbon steels owe their properties chiefly to the carbon. They are called straight or plain
C steels and alloy steels are those to which one or more alloying elements like Silicon,
Manganese, Chromium, Nickel, Molybdenum, Vanadium, Tungsten, and Boron are
added to modify certain mechanical properties.

3.4.2 UNDERSTANDING OF TEMPERATURE AND PHASES
TEMPERATURE:
1. Critical or Transformation Temperatures: The temperature at which a change in

phase occurs is called critical or transformation temperature. Critical temperatures
w.r.t heat treatment of steels is.
A1-727°C the temperature at which austenite begins to form during heating.
A3-912°C the temperature at which transformation to austenite is completed
during heating.
Fig 3.4.2 .1 Iron Carbon Diagram
PHASES AND TRANSFORMATION STRUCTURES:
1. Austenite Phase (gamma iron): Austenite is a solid solution of Carbon dissolved in

gamma iron. Maximum solubility is 2.14 % C at 1147°C.High formability, most of
heat treatments begin with this single phase.
2. Ferrite Phase (alpha iron): Ferrite is a common constituent in steels and has a Body
Centered Cubic (BCC) structure [which is less densely packed than FCC].
3. Cementite structure: Cementite or iron carbide is very hard, brittle intermetallic
compound of iron & carbon, as Fe3C, contains 6.67 % C.It is the hardest structure
that appears on the diagram.

4. Pearlite structure: Pearlite is the eutectoid mixture containing 0.80 % C and is

formed at 727°C on very slow cooling. It is a very fine plate like or lamellar mixture
of ferrite and cementite. The white ferritic background or matrix contains thin plates
of cementite (dark).
5. Martensite structure: Martensite is a super-saturated solid solution of carbon in

ferrite. It is formed when steel is cooled so rapidly that the change from austenite to
pearlite is suppressed. It is responsible for the hardness of quenched steel.
3.5 PROJECT OF MONITORING THE HEAT TREATMENT
Heat treatment is an operation or combination of operations involving heating at a

specific rate, soaking at a temperature for a period of time and cooling at some specified
rate. The aim is to obtain a desired microstructure to achieve certain predetermined
properties (physical, mechanical,) resulting in Hardening or Softening of steel. Heat
Treatment is required to intentionally achieve various desired Microstructures by varying
the cooling rates of hypo, hyper & eutectoid steels. Mechanical properties depend on the
resultant microstructure.
3.5.1 CASE HARDENING
Case hardening is a process to increase the surface hardness and wear resistance of parts
without affecting the soft and tough core which is required to possess resistance to
breakage upon impact and resistance to wear in the life of the component. Carburizing or
Case hardening increases the surface carbon content of a low & alloyed carbon steel
(0.15- 0.20%C) to around 0.80 to 1.00%,by addition and diffusion of carbon through the
surface of the steel at temperatures between 880 and 950 deg C. The %age of carbon
potential, process temperature and holding time is maintained such that the desired case
depth with eutectoid carbon is achieved. The Carbon rich atmosphere is achieved by
means of LPG.

COMPANY: MOTHERSON SUMI SYSTEMS LIMITED
PART NAME: GEAR RIM
Fig 3.5.1.1 GEAR RIM
STEPS FOR HEAT TREATMENT
Step 1: The inspection of the goods to ensure it quality and account its quantity
Step 2: The goods are stored till the heat treatment process is scheduled.
Step 3: The schedule is prepared for heat treatment using Axpert software.
Fig 3.5.1.2 Charge sheet

Step 4: Jigging of the parts is done.
Fig 3.5.1.3 Jigging
Step 5: The parts are pre washer in the alkali washers to remove the oils, dust and other
unwanted impurities accumulated on the part. Pre wash happens at 3 stages I,e Dipping
for approx. 10 mins; Spraying for approx. 15mins; Drying for approx. mins at 100-120˚C.
Fig 3.5.1.4 Alkali Washers
Step 6: The parts are moved into the furnace for the heat treatment. Before loading the
furnace with parts the furnace is preheated. The process parameters of the process are
shown below.
TEMPERATURE ˚C 800 925 925 840

TIME( mins) 15 240 90 60
ENDO GAS(m3/h) 9.0 9.0 9.0 9.0
LPG(lpm Auto) 3.0 3.0 3.0 3.0
CP (%) 0.30 0.30 0.30 0.30

Fig 3.5.1.5 Heat Treatment of gear rim
Step 7: After the process in the furnace is completed, the tray of parts is moved to the
quench tank. The quench parameters are shown below.
OIL TEMPERATURE 140˚C

QUENCH TIME 30 mins
AGITATOR SPEED 300rpm
Step 8: The parts are sent to the alkali washer for post wash to remove the unwanted
accumulation on the parts.
Step 9: The parts tempered. Tempering is performed to convert the un-uniform martensite
into Fine tempered martensite. The tempering parameters are shown below.
TEMPERATURE 155˚C
TIME 120 mins

Step 10: The part is cut at a section where the hardness and microstructure is to be tested.
The location of the cut of the part is mentioned by the company.
Fig 3.5.1.6 Cut Section of Gear Rim
Step 11: The mold of the cut section is made in the mold making machine by placing the
cut section in the machine and pouring the Bakelite powder at high temperature.
Fig 3.5.1.7 Molding Machine
Step 12: The surface of the mold is polished using different grades of sand paper and
etched to obtain a mirror finish surface on which the microstructure is checked and
hardness is measured.
Step 13: The part is tested for case depth and case hardness using Vickers hardness tester
applying a 10kg load and microstructure using the optical microscope.

Fig 3.5.1.8 Inspection report of case hardening of Gear rim
Step 14: After inspection, the parts are de-jigged
Fig 3.5.1.9 De-jigging

Step 15: The parts are oiled packed and shipped.
Fig 3.1.5.10 Packing of Gear Rim
3.5.2 CARBONITRIDING
Carbonitriding is also a casehardening process to achieve a very hard wear resistance

case on parts with a ductile core which are required to possess resistance to breakage
upon impact and resistance to wear in the life of the component. Carbonitriding increases
the surface carbon content of very low & un-alloyed carbon steel(< 0.15%C) to around
0.80 to 1.00%,by addition and diffusion of carbon & nitrogen through the surface of the
steel at temperatures between850 and 900 deg C. The percentage of carbon , process
temperature and holding time is maintained such that the desired case depth with
eutectoid carbon is achieved. The Carbonitriding atmosphere is achieved by means of
LPG & Ammonia.
COMPANY: S.K.F INDIA LIMITED
PART NAME: BEARING INNER RING
Fig 3.5.2.1 BEARING INNER RING

Step 1: The inspection of the goods to ensure it quality and account its quantity.
shown below.
TEMPERATURE˚ 860 _ 860

TIME(mins) 240 - 60
ENDO GAS (m3/h) 9.0 9.0 9.0
LPG(lpm auto) 3.0 3.0 3.0
NH3(cfh) 17 14 14
CARBON PERCENT % 1.20 1.10 1.10

QUENCH TIME 30 mins

Step 9: The parts tempered. Tempering is performed to convert the un-uniform martensite
into tempered martensite. The tempering parameters are shown below.
TEMPERATURE 160˚C
TIME 120 mins
Step 10: The part is cut at a section where the hardness and microstructure is to be tested.
The location of the cut of the part is mentioned by the company.
Fig 3.5.2.2 Cut section of Inner ring
Fig 3.5.2.3 Mold of Inner Ring

Step 13: The part is tested for case hardness using Vickers hardness tester applying a
10kg load, core hardness is checked using Rockwell hardness tester and microstructure
using the optical microscope.
Fig 3.5.2.4 Inspection Report of Bearing Inner Ring

Step 14: After inspection, the parts are de-jigged.
3.5.3 THROUGH HARDENING
Through hardening is a process to achieve a uniformly hard surface and core on medium
to high carbon steels (0.45 – 1.00%C) which are required to possess very high impact and
tensile strengths in addition to wear resistance. The process or austenizing temperature
varies from830degC to 880degC .As carbon is already in the saturated state; no further
carbon need be added. But a positive atmosphere with C potential equal to the parent
carbon of the steel must be maintained to avoid depletion of existing surface carbon.
COMPANY: ACWA AUTOMATICS LLP
PART NAME: CONTROL SCREW
Fig 3.5.3.1 CONTROL SCREW
Step 1: The inspection of the goods to ensure it quality and account its quantity.

shown below.
TEMPERATURE ˚C 860
TIME (mins) 60
N2(m3/h) 3.0
CH3OH (lph) 3.3
LPG(lpm auto) 1.0
CP% 0.4

QUENCH TIME 30 mins

Step 9: The parts tempered. Tempering is performed to obtain tempered martensite. The
tempering parameters are shown below.
TEMPERATURE 250˚C
TIME 90 mins
Step 10: The part is cut at a section where the hardness is to be tested. The location of the
cut of the part is mentioned by the company.
Step 13: The part is tested for surface hardness using Micro Vickers hardness tester
applying a 0.05kg load.
Step 14: After inspection, the parts are de-jigged.
Fig 3.5.3.3 Packing of Control Screw

CHAPTER 4
REFLECTION NOTES
My internship experience at Hightemp Furnaces Limited has allowed me to apply my

knowledge gained in the classroom and apply it to real world work experience. Thus
allowing me to grow in new ways that is difficult to teach in the classroom. Interning at
Hightemp has helped to highlight my fortes and flaws as not only an engineering student,
but also as a young adult entering the professional world. I discovered that
communication is the key to being successful as an individual and as a team.
Encouraging social cognizance provides necessary balance within an organization. It is
also immaculate to ignore the fact that time management plays a vital role in performance
of any employee. On time reaching of the workplace, dedicated working during the work
hours depicts the efficiency of an individual. I understood the dependency of various
disciplines of engineering in order to solve a real time problem. I noticed that various
courses learned in the classroom are being utilized here. Every employee including our
guide Mr. Ravi M in spite of their individual works took out time to help me to
understand the functioning of their department and answer queries.
4.1 LIST OF TECHNICAL OUTCOMES:
 Understanding the working principle of the sealed quench furnace.

 Understanding the raw material selection for the manufacturing of the
furnace based on the design calculations and the various physical and
mechanical properties.
 Understanding the machining process involved in the manufacturing of
the furnace.
 Studying a CAD drawing.

 Development of sheet metal layout of various components.

 Understanding the heat treatment process.
 Monitoring the heat treatment process and the inspection process.
4.2 LIST OF NON TECHNICAL OUTCOMES:
I was exposed to real world of working in which I came across various

variety of people with different background and culture, this internship helped me in
improving my communication skills and also helped in understanding the various
problems faced by them. I learned to work in groups and also engage myself in various
technical and non-technical activities. I also gained a good amount of confidence on
facing various problems about to overcome in coming future and learnt how the company
uses its resources in an appropriate way by fulfilling both the needs of lower level and
higher level management and demands of the customer and learned various ethics and
policies followed by the company for the up liftment of people working there. Overall I
would like to conclude it by saying that it was good experience of doing internship in
such a prestigious company which helped us in knowing various aspects of the company
and also gave an opportunity to explore various fields in mechanical engineering.
Hightemp at every stage of its working strictly follows standards. Following standards
increases production rate and quality of product produced too. The major learning
through this at a personal level was how important it is to inculcate discipline, for growth.
During the period of the internship communication was carried out with Top officials of
the factory and workmen too. Most employees were supportive during the internship and
were equally involved in their work too. Overall the internship was a great learning
experience and helped us about get an overview about industry.

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VISVESVARAYA TECHNOLOGICAL UNIVERSITY

JNANA SANGAMA, BELAGAVI – 590018, KARNATAKA, INDIA

“Study on manufacturing of furnaces and commercial heat treatment”

Department of Mechanical Engineering

PESIT BANGALORE SOUTH CAMPUS

Signature of the guide Signature of the guide Signature of the HOD

Name of the Examiner Signature with Date

I, RUDHRAVEENA C bearing USN 1PE16ME115 student of 8th semester B.E in the

Place: Bengaluru Signature of the student

I am very thankful to Hightemp Furnaces Limited, for giving me the opportunity to do

I would like to convey my heartiest thanks to Mr. R. Varadharajan, who gave an

Esteemed gratitude is towards Dr. Subrahmanya S Katte, Head of the Department of

The purpose of my internship at Hightemp Furnaces was to understand the work

1 ABOUT THE COMPANY 1

1.2 TIMELINE OF HIGHTEMP FURNACES LTD 3

1.3 VISION AND MISSION 3

1.4 GOALS AND OBJECTIVES 4

1.6 GLOBAL PARTNETS 5

1.9 INFRASTRUCTURAL FACILITY 8

1.10 PRODUCT PROFILE 8

2 ABOUT THE DEPARTMENT 13

2.1 MANUFACTURING DIVISION 13

2.1.2 FUNCTIONAL DIVISION 14

2.1.3 WORK INSTRUCTIONS 15

2.1.4 COMPONENTS OF THE FURNACE 16

2.2 COMMERCIAL HEAT TREATMENT DIVISION 19

2.2.1 FUNCTIONAL DIVISION 20

2.2.2 PROCESS FLOW CHART FOR SEALED QUENCH FURNACE 21

CHAPTER CONTENT PAGE

3.1 UNDERSTANDING WORKING PRINCIPLE OF FURNACE 24

3.1.2 VESTIBULE AND QUENCH TANK 26

3.1.4 CONTROL PANEL 28

3.2 UNDERSTANDING THE MATERIAL SELECTION 28

3.3 UNDERSTANDING THE MACHINING PROCESS OF THE FURNACE 30

3.4 UNDERSTANDING THE HEAT TREATMENT PROCESS 31

3.4.1 UNDERSTANDING OF STEELS 32

3.4.2 UNDERSTANDING OF TEMPERATURE AND PHASES 33

3.5 PROJECT OFMONITORING THEHEAT TREATMENT 34

3.5.1 CASE HARDENING 34

3.5.3 THROUGH HARDENING 44

4.1 LIST OF TECHNICAL OUTCOMES 47

4.2 LIST OF NON-TECHNICAL OUTCOMES 48

1.1.1 HIGHTEMP FURNACES LIMITED LOGO 1

1.10.1 BATCH TYPE INTEGRAL SEALED QUENCH 9

1.10.2 BATCH TYPE THN FURNACE 9

1.10.3 CONTINUOUS GAS CARBURIZERS 9

1.10.4 CONTROLLED ATMOSPHERE BRAZING 10

1.10.5 MESH BELT FURNACE 10

1.10.6 DECARB ANNEALING &BLUING 10

1.10.7 VACUUM HARDENING FURNACE 11

1.10.8 ALKALI WASHERS 11

1.10.9 ROTARY RETORT 11

2.1.1 SEALED QUENCH FURNACE 13

2.1.2 PROCESS FLOW CHART 15

2.1.3 SEALED QUENCH FURNACE DESIGN 16

2.1.4.1 FURNACE SHELL 16

2.1.4.2 QUENCH TANK 17

2.1.4.4 CONTROL PANEL 18