Acknowlegement

I want to express my gratitude towards all the seniors and the members of
JINDAL STEEL AND POWER LIMITED, it was very easy for us to earn
a lot of knowledge regarding Plate Mill & Mechanical Testing

We are greatly thankful to Mr. B Lakshminarasimham (HOD, TSD & R&D )

for his kind support and guidance to successfully complete our training.
We have been highly benefitted by this training and have gained a lot of
knowledge about the various processes and techniques employed in Plate
Mill & TSD

We gratefully acknowledge our training guides Mr. V.V. PERRAJU,

Mr.Pramod Gupta, Mr. Vipin Aggarwal & Mr. Kaushik Bose for
their inspiration, valuable guidance & support throughout this summer
training.

Finally we would like to thank all the employees of TSD , Plate Mill
JSPL, who have helped us and co-operated with us during our
training and project work.

Mr. B Lakshminarasimham Mr. Vipin Aggarwal Mr. Kaushik Bose

H.O.D

Plate Mill
 CERTIFICATE

This is to certify that Kumar Prakhar, 4th semester student

pursuing B.Tech (Mechanical & Automation Engineering) at Northern

India Engineering College, has submitted his report entitled
MECHANICAL TESTING & ANALYSIS to the Department of
PLATE MILL, TSD at Jindal Steel & Power Ltd., Raigarh (C.G.)
which is his original work, and is not a reproduction of any
previous such work to the best of my knowledge.
 INTRODUCTION

About Jindal Steel and Power Limited (JSPL)

Jindal Steel and Power Limited (JSPL) is a US$ 3.3 billion business
conglomerate, and one of India’s fastest growing and largest
integrated steel manufacturers, significantly present in Steel, Power
Generation and
Infrastructure segments, catering to a large part of India’s domestic
energy and infrastructure requirement. Part of the over US$ 18
billion diversified.

O. P. Jindal Group, JSPL’s business operations span across Asia, Africa

and Australia. The company has committed investments exceeding US$
30 billion in the future and has several business initiatives running
simultaneously across continents.

Led by Shri. Naveen Jindal, the youngest son of the legendary Shri
O.P. Jindal, the company produces economical and efficient steel and
power through backward and forward integration. From the widest flat
products to a whole range of long products, JSPL today has a product
portfolio that caters to markets across the steel value chain.

This plant is spread over 2000 acres area, which has Production Units
viz., Coal Washer, Sponge Iron Plant, Steel Melting Shop, Submerged
Arc Furnace, Blast Furnace, Coke Oven Plant, Sinter Plant, Rolling Mill,
Oxygen Plant, Lime-Dolime Plant, Captive Power Plant, PGP & Limekiln
Unit Etc. Part of the US$10 Billion Jindal Organization, unit believes in
the concept of self sufficiency. Through backward integration of its
captive coal & iron-ore mines, business at JSPL is done on most
economical and efficient means to produce quality steel and cheap
power. To fuel the industrial development in the state of Chhattisgarh,
JSPL has set up first of its kind Industrial Park over 750 acre lands in
Distt. Raigarh, where more than 30 units have already started
operations. More than Rs. 1200 Crores investment is expected in this
Industrial Park.

JSPL provides employment opportunities to over 20,000 Indians and

anchors a socio- economic eco system for over 50,000 families.
 Properties of Steel

 Chemical Composition: C=0.45%, Mn=0.75%, P=0.04% max,

S=0.05% max
 Density : 7.872* 10³ kg/m³
 Modulus of elasticity : 201 GPa
 Thermal expansion (20 ºC) : 11.7*10-6 ºCˉ¹
 Specific heat capacity : 486 J/(kg*K)
 Thermal conductivity : 50.9 W/(m*K)
 Electric resistivity: 1.62*10-7 Ohm*m
 Tensile strength (hot rolled) : 565 MPa
 Yield strength (hot rolled) : 310 MPa
 Elongation (hot rolled) : 16%
 Hardness (hot rolled) : 84 RB
Major Operational Units of JSPL Raigarh

•Captive Coal Mines and Washer of 6 MTPA capacity.

•World’s largest coal based Sponge Iron facility to produce 1.32 MTPA of
DRI.

•353.6 MW of Power generation from washery rejects and through

waste heat recovery process.

•Non-recovery type Coke Oven of 0.8 MTPA capacity to fulfill the coking
coal requirement of Blast furnace.

•Sinter Plant to produce 2.3 MTPA of quality sinter for use

in Blast furnace.

•Lime dolomite and Oxygen plant to feed the need of iron and steel
making process.

•Modern Blast Furnaces to produce 1.6 MTPA of hot metal.

•0.36 MTPA Submerged Arc Furnace to produce quality ferro-alloys.

•Steel melting shop of 3.2 MTPA capacity with 3 EAF’s and 5 LRF’s.

•Rolling mills of 0.75 MTPA capacity to roll flat and long products.

• Plate mill of 1.0 MTPA capacity to roll plates and steel roll.
Fundamental
Mechanical
Properties

(i)Tensile strength- Universal Testing Machine

(ii) Hardness- Rockwell Hardness Test, Brinell Hardness,

(iii) Impact strength- Izod & Charpy Test

Principle of Operations

Operation of the machine is by hydraulic transmission of load from the test

specimen to a separately housed load indicator. The system is ideal since it
replaces transmission of load : through levers and knife edges, which are
prone to wear and damage due to shock on rupture of test pieces. Load is
applied by a hydrostatically lubricated ram. Main cylinder pressure is
transmitted to the cylinder of the pendulum dynamometer system housed in
the control panel. The cylinder of the dynamometer is also of self - lubricating
design. The load transmitted to the cylinder of the dynamometer is transferred
through a leverage to the pendulum. Displacement of the pendulum actuates
the rack and pinion mechanism which operates the load indicator pointer and
the autographic recorder. The deflection of the pendulum represent the
absolute load applied on the test specimen. Return movement of the pendulum
is effectively damped to absorb energy in the event of sudden breakage of the
specimen.
• This is the maximum conventional stress that can be
sustained by the material.

• It is the ultimate strength in tension and corresponds to the

maximum load in a tension test.

• It is measured by the highest point on the conventional

stress-strain curve. In engineering tension tests this
strength provides the basic design information on the
materials.

• The tensile strength of a material is the maximum amount

of tensile stress that it can be subjected to before failure.

• There are three typical definitions of tensile strength.

Yield strength
 • The stress at which material strain changes from elastic
deformation to plastic deformation, causing it to deform
permanently is known as yield strength.

Ultimate strength
• The maximum stress a material can withstand is known as
ultimate strength.

Breaking strength
• The strength co-ordinate on the stress-strain curve at the
point of rupture is known as breaking strength.

Tension Test Stress-strain Curve

Figure 2.1 A typical stress-strain curve obtained from a

tension test, showing various features
 2
Material Tensile Strength kg/mm

Alloy steel 60 -70

Mild Steel 42

Grey CI 19

White CI 47

Aluminum alloy 47

Figure 2.2 (a) A standard tensile-test specimen before

and after pulling, showing original and final gage
lengths. (b) A tensile-test sequence showing different
stages in the elongation of the specimen.

Tensile strength = Maximum Load

Cross section area

Maximum load is the highest point on the graph.

Often called Ultimate Tensile Strength (UTS)

 If the specimen is loaded beyond its UTS it begins to “neck.”

 This linear relationship is known as Hooke’s Law

SOME SPECIMENS & TEST RESULTS

Impact tests are designed to measure the resistance to failure of a material
to a suddenly applied force. The test measures the impact energy, or the
energy absorbed prior to fracture. The most common methods of measuring
impact energy are the:

 Charpy Test
 Izod Test

The Pendulum is mounted on antifriction bearings. It has two starting

positions, the upper one for Charpy and the lower one for Izod testing. On
release, the Pendulum swing down to break the specimen and the energy
absorbed in doing so is measured as the difference between the height of
drop before rupture & height of raise after repture of the test specimenn and
is read from the maximum pointer on the daily scale.

Charpy Test
The Charpy test piece rests on alloy steel supports anvils fitted on the base
of the machine rigidly held in position by alien screws. End stopper is
provided for quickly & accurately locating the test piece centrally between
the supports.

Izod Test

The Izod test piece is clamped vertically in Izod support anvils, fitted on the
base of the machine. The support is provided with a machined vertical
groove to suit the test piece size. The front clamp piece & alien screw enable
clamping of the test piece in correct height with the help of Izod setting
gauge supplied.

CHARPY TEST SETUP

 IZOD TEST SETUP

Izod test

 Strikes at 167 Joules.

 Test specimen is held

vertically(Cantilever)

 Notch faces striker.

 Hammer strikes from

120Degrees
 Charpy impact test

 Strikes form higher position

 with 300 Joules.

 Test specimen is held horizontally.

 Notch faces away from striker.

 Hammer strikes from 120Degrees

Before the Impact Test After Impact Test

• Impact strength is the resistance of a material to fracture
under dynamic load.
• It is a complex characteristic which takes into account both
the toughness and strength of a material.
• In S.I. units the impact strength is expressed in Mega
2 2
Newton per m (MN/m ).
• It is defined as the specific work required to fracture a test
specimen with a stress concentrator in the mid when
broken by a single blow of striker in pendulum type impact
testing machine.

• Impact strength is the ability of the material to absorb

energy during plastic deformation.

• Brittleness of a material is an inverse function of its impact

strength.

• Course grain structures and precipitation of brittle layers at

the grain boundaries do not appreciably change the
mechanical properties in static tension, but substantially
reduce the impact strength

• Impact strength is affected by the rate of loading,

temperature and presence of stress raisers in the materials.

• It is also affected by variation in heat treatment, alloy

content, sulphur and phosphorus content of the material.

• Impact strength is determined by using the notch-bar

impact tests on a pendulum type impact testing machine.

• This further helps to study the effect of stress concentration

and high velocity load application
 Ansys Impact Test for Result for Charpy Method
IS 2062 : 2011
Table Mechanical Properties
(Clauses 5, 10.3, 10.3.1, 11.3.1, 12.2 and 12.4)
Grade Quality Tensile Yield Stress Percentage Internal Charpy
Designation Strength Elongation Bend Impact Test
ReH, Min A, Min Diameter
R , Min MPa1) at Gauge Min (See Note 3)
m Length,
 MPa1)
(See Note 2) Temp Min
Lo=5.65
(See Note 1) <20 20-40 >40 ≤ 25 >25 o
C J
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)

A — —
BR RT 27
E 250 410 250 240 230 23 2t 3t
B0 0 27
C (–) 20 27
A — —
BR RT 27
E 275 430 275 265 255 22 2t 3t
B0 0 27
C (–) 20 27
A — —
BR RT 27
E 300 440 300 290 280 22 2t —
B0 0 27
C (–) 20 27
A — —
BR RT 27
E 350 490 350 330 320 22 2t —
B0 0 27
C (–) 20 27
A — —
BR RT 25
E 410 540 410 390 380 20 2t —
B0 0 25
C (–) 20 25
A — —
E 450 570 450 430 420 20 2.5t —
BR RT 20
A — —
E 550 650 550 530 520 12 3t —
BR RT 15
A — —
E 600 730 600 580 570 12 3.5t —
BR RT 15
A — —
E 650 780 650 630 620 12 4t —
BR RT 15

NOTES
1 In case of product thickness/diameter more than 100 mm, lower minimum limit of tensile strength may be
mutually agreed to between the purchaser and the manufacturer/supplier.
2 Bend test not required for thickness > 25 mm for grades E 300 to E 650. ‘t’ is the thickness of
the test piece. 3 For sub-quality BR, impact test is optional; if required, at room temperature
(25 ± 2°C).
1)
1MPa = 1N/mm2 = 1MN/m2 = 0.102 kgf/mm2 = 144.4 psi.