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Plant & Facility
TAYO is situated at Gamharia, 16 km. West of Jamshedpur and is spread over an area of 50 acres. It comprises of suitable melting furnaces, a modern roll Foundry and a sophisticated machine shop. TAYO has an installed capacity of 10,000 tonnes of Cast Iron and Steel Rolls.
Melting
The melting furnaces of TAYO consist of the 25-tonne Electric Arc furnace, which is used to manufacture high strength alloy iron, high quality SG and steel rolls. The 8-tonne and 16-tonne mains frequency Induction Furnaces are used for small and medium size cast iron, steel and SG rolls. Shell metal for High Chrome Iron and Steel rolls are also processed in these furnaces. A modern analytical laboratory using a computerized vacuum emission spectrometer backs the melting unit.
Static Casting
The Foundry is equipped with modern facilities for preparing moulds to exacting standards. All rolls are bottom poured with tangential ingate to ensure maximum cleanliness of the body surface. All nodular iron rolls are poured with special ladle inoculation follovved by mould inoculation to ensure high strength requirements. Hot topping equipment is used for all Steel and Steel base rolls to ensure internal soundness, grain size and structure, making the rolls absolutely free from cavities and porosities.
Spin Casting
Horizontal spin casting machine is used to produce Work rolls for flat rolling. Spun cast rolls ranging from 450 mm to 1050 mm. are produced through this machine with strict control of rotation speed, cooling and casting time. The shell sleeve is tilted to vertical position and core metal is poured from top with precise thermal synchronization to achieve a perfect bond between shell and core. High core strength is achieved through mould inoculation.
Heat Treatment
The final properties of a roll depend on the heat treatment. The rolls are subjected to heat treatment in special heat treatment furnaces. Uniformity of temperature in all the heating zones of the furnace is ensured by special temperature controllers and the rate of heating can be controlled to as low as 2.8'C per hour. The heat treatment programme comprises low temperature Cycles for tempering and stress relieving as well as high temperature cycles for soft annealing and air quenching.
Machining
The Machine Shop is equipped with a versatile set of machine tools from Japan, Russia, Czechoslovakia, Germany, Italy and India. The heavy duty roll turning lathes can accommodate rolls upto a maximum of 1420 mm. in diameter and 30 tonnes in finished weight. Milling operations are carried out by special purpose machines. Specially designed Duplex Milling Machines are used for cutting clove leaf wobblers, flats and keyways.
Fluting and special grooving are done through suitably designed fixtures. Specified tolerances and desired surface finish are obtained through sophisticated grinding machines. Stringent demands on accuracies and designs are met by CNC lathes. CAD/CAM technology is available for translating the Customers' Drawings to internal standard as well as direct programming of the CNC lathes.
