1

INDUSTRIAL FAMILIARISATION

A project report on Summer Training
BACHELOR OF TECHNOLOGY
In
MECHANICAL ENGINEERING
By
RAHUL THAKUR 1021130122


DEPARTMENT OF MECHANICAL ENGINEERING
SRM UNIVERSITY, NCR CAMPUS, MODINAGAR-201204,
GHAZIABAD, U.P

ACKNOWLEDGEMENT
2


Firstly, I wish to express my deep gratitude to all the concerned persons
without whose generous cooperation and coordination, it would have been very
difficult for me to have a successful training experience in the organization.
It would like to thank Mr. V. K. Grover for giving me a golden opportunity
of industrial training, which would help me to enhance my technical skill and helps
me a lot besides some technical skills.
I am extremely grateful to the management of HMT, Pinjore for giving me
an opportunity to pursue four months training in their reputed organization. This
provides me a wonderful and learning experience for me to go through this
training.
Finally, I would like to thanks all those colleagues who help me out of
intensifying my technical knowledge and provide satisfactory solutions to my all
queries.


3

INDEX
12. PPT
13. Sheet Metal and Welding


Sr. no. Particulars Page no.

1. Introduction 4
2. Company profile 5-8
3. Foundry and Pattern Shop 9
4. Heat Treatment 10-14
5. Planning 15-16
6. MTK Small Parts 17-20
7. MTK Heavy Parts 21
8. NH/NL Lathe Assembly 22-23
9.
10.
CNC Assembly
Plant Service
24-26
11. Tool Room
27-28
30
31
32
4

INTRODUCTION


HMT Limited, formerly Hindustan Machine Tools Limited, is a state-owned
manufacturing company under the Ministry of Heavy Industries and Public
Enterprises in India
Hindustan Machine Tools was incorporated in 1953 by the Government of India as
a machine tool manufacturing company. Over the years diversified into watches,
tractors, printing machinery, metal forming presses, die casting & plastic
processing machinery, CNC systems & bearings. HMT is headquartered at
Bengaluru ( Bangalore ). Successful technology absorption in all product groups
through collaborations with world renowned manufacturers and further
strengthened by continuous in-house R&D. Today, HMT comprises six subsidiaries
under the ambit of a holding company, which also manages the tractors business
directly.



5

COMPANY PROFILE

Birth of HMT
In 1949 the idea of public sector tools was commissioned to be a corner stone for the
governments industrial development plans. This led to the birth of HINDUSTAN MACHINE
TOOLS at Bangalore in 1953 which started a single machine tools factory to produce lathes at
Bangalore, in collaboration with M/s Oerlikon of Switzerland.
Next, the company widened its product range beyond lathes by entering into technical
collaboration with other international leaders in machine tools such as Fritz Werner, Herman
Kolb, Errantly Somua, Gildermeister, Liebherr etc.
The second machine tool unit was set up in Bangalore in 1961 making use of the
Companys own resources. The company diversified itself when, in collaboration with Citizen
Watch Company of Japan, the first watch factory was setup in Bangalore in 1962 to produce
hand watches.
The third machine tool unit was set up in 1963 at Pinjore, Haryana to produce milling
machines. In next few years, Machine Tool Units were set up at Kalamessary in Kerala and in
Hyderabad. The Printing Machinery division was attached to machine tools factory at
Kalamessary to qualities Printing Machine.
HMTs tractor business commenced its operations in 1971 in technical collaboration with
M/s MOTOKOV, Czechoslovakia because of the priority given to the agriculture in the national
development plan and to take advantage of the green revolution. HMT started the operations
with the manufacturing of 25 Hp tractors. Over the years, it has developed tractors ranging from
25 75 Hp.
The unit in Hyderabad began to make lamps and lamp making machines in 1973 to cater
to the growing needs of rural. This was followed by producing automatic watches.
6

A third watches factory was established in Srinagar to manufacture hand wound watches
for men. In 1975, the company took over the machine tool corporation of Indias unit in Ajmer,
Rajasthan and its name was changed to HMT Limited.
In 1975, a separate international scales network called HMT was set up comprising of
companys own agencies as well as other sales agents in Australia, Europe and America. This
network was to handle the marketing strategy and operations of the company overseas and it also
extended its services to the other leading Indians and overseas engineering companies. Since
then this international arm of the company has set up the turkey project in Algeria, Indonesia,
Iraq, Kenya, Nigeria and Srilanka.

HMTs Products


The main products produced by HMT ltd are
Machine tools,
Watches,
Tractors,
Bearings,
Printing Machinery,
Die Casting Machinery.
The divisions of HMT are described below
7

Bangalore
It produces lathes (both CNC and Non CNC), milling/ machining centers, grinding
machines, gear cutting machineries, simple drilling machines, special purpose machines, die
casting and plastic injection moulding.
It also produces refurbishing and retrofitting like heavy duty, turret lathe, multi spindle
drilling machines and fine boring machines.
The other application components include the jigs, fixtures, some radar and transonic
components. It also develops hinomerik control system, Hyderabad.




Hyderabad
It produces the machining centers, CNC, Boring machines, milling machines, die and
mould machining centers, presses and brakes. It also produces special purpose machines like
CNC tube chamfering machines, cam shaft milling machines, filament winding machines,
horizontal and vertical coil winding machines, multi spindle machining centers.


8

Kalamessary
It produces CNC lathes and printing machineries.

Ajmer
It produces grinders and lathes. It also manufactures some application components like
hydraulic lift mechanism for tractors, valve devices and oil priming pump.


The retrofitting includes center less grinders and double disc grinders.
After establishing two machine factories and a watch factory in Bangalore, the Pinjore
unit was established as the third machine tool factory. Breaking the ground on 2
nd
may, 1962,
this factory

9

FOUNDARY AND PATTERN SHOP

PATTERN SHOP
Pattern is a replica of final product to be manufactured by casting process. There are different
patterns, which can be classified as :-
1. Solid
2. Loose piece
3. Split pattern
4. Skeleton pattern
Pattern can be made of wood, wax, thermocol, etc. according to users need, the designer
will be providing a drawing from which a 3-d model is made. To make hollow sections in
the casting, cores are used, which is also made in pattern shop. After pattern is made its
dispatched to the foundry for further treatments.

FOUNDARY
1. Sand Making
Sand making is the primary step in foundry for casting process. Sand which is used for
casting process. Sand which is used for moulding are omega sand, black sand, CO
2
sand
etc. these above sands are required in the proportion for 1000 kg mix
Ingredients Amount (kg)
US Green US Dry
New sand 300 100
Return sand 700 900
Bentonite 27.5 300
Dextrine 2.5 10
Liquid coal dust 5 -
Saw dust - 10
Furnace oil - 2.5
Water 25 50
10


The sand thus prepared is used to make the mould. In order to make complicated
structure, moulding is divided into shape and drag. Pattern made is placed in drag filled
with sand to get a negative impression of similar procedure is applied to the cope.
After that the cores are inserted with the help of core prints and are placed with the help
of chaplets in the drag. Then the cope and drag are assembled together and its sealed. Air
holes and vent holes are provided in the moulding box.
Then the molten metal produced is poured to the mould through the runner and is kept for
solidification for 2-3 days.

Knock out
Its the process of removing core from the casting. As a finishing process the
casting made is machined to required dimensions.

Furnace
Furnace is another important part of foundry. Here metal is melted to do casting
process. There are mainly 2 types of furnace

Main furnace Medium furnace
Power 850 kW 1250 kW
Capacity 3 ton 2.5 ton
Melting rate 1 ton/hr 2.5 ton/hr

The maximum temperature that can be attained is 1500C and the ingredients which are
added to melt metal is pig iron, coke, silicon, chromium, steel scrapes, etc.
While pouring the molten metal to ladle inoculation is done adding calcium silicide in
following proportion:-
1) Wt. of liquid metal * 0.35% for G4 grade.
2) Wt. of liquid metal * 0.30% for G3 grade.
3) Wt. of liquid metal * 0.25% for G2 grade.
4) Wt. of liquid metal * 0.20% for G1 grade.
The slag produced while melting the metal is removed before its used for casting.
Working Instruction for Sintering Heat
1) When plug melts, charge only small scrap (wt. 15 kgs) a piece to build up the level.
Check for the charge hitting for the lining.
2) Do not charge wet or oily scrap. Check water (temperature and pressure) every half hour.
3) When the furnace is full raise the temperature to 1550C in about 2 hrs by ON & OFF.
4) Hold the temperature for 4 hrs for stabilising the fritting.
11


Shotdown Pour out plug and molten metal, cover with lid and let the water flow at 50
psi for 18 hrs.

Tin Bronze

Plug - Cyprus block (1 kg)
Charge - copper (100 kgs)
Temperature - 1150C

Shot Blast
Its a process in which the cast metals are blown with small metallic balls known as
Shots. This is done to remove sand or impurities on the surface of the cast metal. Shots are made
of iron.

Fettling
Small level finishing or something of the surface of the cast metal done in foundry
before sending for machinery.

Zircour Hour
Used (as a white paint) to bring a layer between the sand and the molten metal.

How can you make KAIZENS :-
1) Doing normal work by a different method to improve productivity.
2) Identifying waste and eliminating it.
3) Copying improvements and improving over it.
4) Conducting experiments for making small improvements even if they fail.
5) Communicating improvements to others, encouraging their participation.
6) Doing work which couldnt be done due to lack of time.
7) Helping others to do their improvements even if they fail.

12

HEAT TREATMENT

Heat treatment is the process to change the properties of a material (metal). By this process we
can increase and decrease the strength of a metal. Processes that are done in heat treatment are:-
Pre heating
Carburizing
Quenching
Annealing
Chromium platting
Blackening

PRE HEATING
Its the process of heating the metal work piece in its primary stage. In this stage we can heat the
metal up to 500
o
C.
CARBURISING
To increase the strength of a metal we will dip the metal piece to carbon silicate bath for a 9
hours at 900
o
C. Due to this carbon atom will penetrate at a depth of 1mm.






(No)



Prepare for carburizing
Pre heat at 450 20
o
C for 1 hour
Carburize at 920 20
o
C for 1 hour for 0.15 mm depth
Remove cast and check for depth
Is depth as per specifications?
Whether next operation
Hardening Annealing
(yes)
13

QUENCHING
Its a process of sudden cooling of hot metal piece by dipping into cool water. By doing so we
can increase the hardness of metal.
ANNEALING
Its another type of heating process. In this the metal is heated upto 1000
o
C and is cooled at room
temperature. By this we can make the metal soft.







(No)






BLACKENING
Its the process of giving a black texture to the given work piece in order to protect the work
piece from corrosion.
CHROMIUM PLATTING
Its the process of coating the given jogs with chromium in order to protect it from corrosion

Heat at a annealing bath 650 20
o
C for 1 hour
Quench in quenching bath 180 20
o
C
Pre heat at 450 20
o
C for 1 hour
Heat the assembly at 650 20
o
C for 6 hours
Is hardness as per requirement? (35 HRC)
Send dispatch after washing
(yes)
Cooling at room temperature by water
quenching
Quench in quenching bath 180 20
o
C
14

In HMT, machines have the following composition of materials
MATERIAL ANALYSIS
Cast iron 70%
Steel 20%
Nonferrous alloys 5%
Nonmetals (Plastics, rubber, etc.) 5%

CAST IRON - Its got the favourable properties Castability, Machinability, Wear
Resistant, Damping characteristics,
Dimensional stability, Pressure tight.

STEEL - It can be shaped by forging hot to acquire any shape. It can be machined to any
required finish by various machining process. Heat treatment can be done to
improve machinability. Steel can be alloyed suitably & heat treated by various
heat treatment processes like toughening, nitriding, etc. In this the shaped
component can withstand.
- High service stress
- Corrosion
- Fatigue loading
- Wear & fitting resistance
- Impact

NON FERROUS - Copper based alloys are used --- copper + tin ---- bronze (split nuts
& brushes)
Copper + zinc ---- brass






15

PLANNING
This department is the most vital link between the production design and production
department. The production planning department provides necessary facilitates and technical
know-how for the manufacture of the products. Production requires the organized utilization of
the material, resources, money, men and machines. But before starting work actual production,
production planning has to be done in order to anticipate possible difficulties decision in advance
as how to production should be carried in best and economic way. The principle of production
planning lies in the statement first plans your work, and then works your plan. The role of
production department is shown below.
The production planning departments at MTK comprises the following sections:-
1. Productions pre-planning planning estimation (PPE & PPP).
2. Production planning ordering FPS-PPO & FPS.

Objective of Planning
In any business organization, production activity must be related to market demand as
indicated by a continuous stream of consumer order. Aggregate planning is carried out in an
economic manner for maximization of product. From the annual operating plan, roll production
plan for 3 months is made of objective of this production planning department is made to ensure
that annual production target is achieved in an economic manner.

Numbering System
A component should be numbered for identification while manufacturing, under the new
system a component is identified by a 9 digits. As the grouping of the assemblies are different for
machine tools & printing machines. Two types of systems are made for component numbering in
MTK & FMT.

FUNCTION AND RESPONSIBILITIES OF PLANNING PERSONNEL
Function and Responsibilities of pre-planning personnel
1) Processing of design documents received for corresponding products.
2) Identification of in house & outside manufacturing items.
3) Preparation of layout for all in house manufacturing items.
4) Implementation of design alteration.
16

5) Attending shop problems.
6) Preparation of documents related to the assembly of the product viz. List of assembly
operations, assembly flow chart & segregation of parts list into assembly operation wise.
7) All data entries in computer related to PPP area of concerned products.
8) Verification and approval of material warrant being released by the PPO.
9) Coordinating all activities related to the concerned product viz. Value engineering, cost
reduction, waste elimination & productivity improvement.
10) Co-ordinate with foundry for the manufacture / alteration of patterns.
Functions and responsibilities of PPE personnel
1) Estimation of standard time for all manufacturing / assembly operations identified in
operation layouts & the assembly list if operations.
2) Data & co-ordination of all activities related to computerization of PPE functions.
3) Authorization of special time in job cards.

Function and responsibilities of monitoring wing:-
Provide all required info to support operations, management and decision making functions into
organizations as detailed below:-
1) Analyse the organizational requirements for information.
2) Design the structures of statement / report & prepare it periodically.
3) Create an appropriate database for the information.
4) Prepare mailing list& ensure the dispatch of statement / report according to the list at the
appropriate time.
5) The information regarding manpower, plant performance, capacity load, production &
sales, stock in trade etc. shall be processed and circulated through weekly, monthly and
yearly statements/ reports.
Function of costing section:-
1) Arranging & finishing data to count department through computer centre about the
standard labour, material & assembly cost of components & assembly groups.
2) Arranging standard labour & material cost for spares, reconditioning machines etc.
3) Assessment of rectification & rework expenses etc.

STANDARD TIME
Its the required for a qualified worksman under supervision to do a defined amount of
work in the specified quantity following the prescribed method.

17


MTK SMALL PARTS

STC 25
The machine has some good features and plenty of power. For example we have a job that
requires the use of a bar puller and need to find the M code or other means to override the
interlock. As it stands now, the turret will not move when the jaws are opened in auto mode. It is
designed for high productivity and accuracy with high transverse rates and reduced non cutting
time.
12 stallion tool turret
Large precision coupling ensure accuracy of indexing and rigidity.
It has slant bed for easy chip flow and heat dissipation
Specifications
Maximum turning dia 250 mm
Maximum turning length 600/1000/1500/2000
Spindle power (100%) 15 kw
Speed range 35 3500 rpm
Rapid traverse 12m/min

STALLION 200
Latest breed of CNC turning centre offering economical solution for production of high precision
turned parts
30
o
slant saddle
Programmable tailstock
Direct coupled servomotors

Specifications
Swing over bed 460 mm
18

Maximum turning length 600 mm
Maximum turning dia 250mm
Main drive power (100%) 7.5 kW
Speed range 100 4000 rpm

CNC LATHE ECOCNOCNC 26
Designed to machine complex job profiles with high accuracy and maximum operator fatigue. Its
ideal for small scale industry. Also suitable for medium and not techno-economically justified.
It has got a hydraulic chuck and its run by a program (computer program) in
which X defines the diameter of job Y defines the length of job
Specifications
Height of centers 260 mm
Swing over bed 575 mm
Spindle power (100%) 11 kW
No. of turned stations 8
Control system Siemens/ France

GRINDING MACHINE
These are devices which are used to remove burrs and unevenness on the metal surfaces. The
grinding wheels are made of Aluminium oxide (in HMT). There are different types of grinding
machine which is used to grind different parts of work piece and they are as follows
Cylindrical grinder internal grinder
Centerless grinder Surface grinder
Rotary surface grinder
Rotary surface grinding It has got a magnetic base. The gears or the jobs are used to grind
surface by grinding wheel and they are fastened to the agnatic
19

base.
Table (i) It rotates (which is electrically controlled)
(ii) It also has a to and fro motion (which is hydraulically
controlled).
Internal grinding machine Like other grinding machine, it exceptionally smoothens
the internal surface of a hollow job and has got a
dresser with diamond point so as to redress the grinding
wheel.

MILLING MACHINE
Milling is the machining process of using rotary cutters to remove material from a workpiece
advancing (or feeding) in a direction at an angle with the axis of the tool. Workpiece and cutter
movement are precisely controlled to less than 0.001 in (0.025 mm). Usually by means of
precision ground slides and lead screws an analogous technology. Milling machines may be
manually operated, mechanically automated or digitally automated via computer numerical
control.
Milling machine can perform a vast no. of operations from simple (e.g. slot & key
making, planning, drilling) to complex (e.g. contouring, die sinking). There are usually 3 types of
milling machines at the basic level
1. Horizontal miller has long arbor
2. Vertical miller has stub arbor
3. Double head miller
In the miller here in HMT, they have removable tip cutter and usually are in
shapes
All the 3 sides can be used
For step cutting
Arbors are quick release type.


20


DRILLING MACHINE
Its a cutiing process that uses a drill bit to cut or enlarge a hole of circular cross- section in solid
material. The drill bit is a rotary cutting tool often multipoint. The bit is pressed against the
workpiece and rotated at 100 to 1000 rpm. This forces the cutting edge against the workpiece,
cutting the chips from what will become the hole being drilled. There are different types of
drilling machines as per requirements, they are as follows
1. Radial drilling machine
2. Sensible drilling machine
3. CNC drilling machine

GEAR MANUFACTURING
There are multiple ways in which a gear blank can be shaped through the cutting and finishing
process.
Hobbing
Its a machining process for making gears, splines and sprockets on a
hobbing machine, which is special type of milling machine. The teeth or
splines are progressively cut into the workpiece by a series of cuts made by
a cutting tool called hob. Oil is used as lubricant.

Shaping
The process of gear shaping uses a toothed disk cutter which reciprocates
in axial rotations. The workpiece (or blank gear) rotates on a second shaft
(spindle). The workpiece is aligned with the cutter and it gradually feeds
into the cutter while rotating. If a two-step process is used, all tooth spaces
are partially cut before finishing.

21

HEAVY PARTS

PROFILE MILLING MACHINE
This is a type of milling machine in which heavy parts are cut in special profile and are used
to mill usually the beds, a tail and head stocks and the gear box of normal lathes like NH/N
lathes and slant beds of the CNC lathes. In this the
1) Arbor - In this arbor is perpendicularly with respect to the jobs bed travel.
2) Tool - In this milling machine, it has a profile cutter according to the job and so every
time we have to take the cutter along with the arbor to change the profile of the cutter or
tool. The spacing and the angles between the cutters are changed accordingly. In the
profile cutter there are different types of cutter and of different sizes. This cutter can only
shapes and dos ide milling.
3) In this milling is employed, which is milling in going like, doing side milling, surface
milling and all together.The tooth profile and the spacing are custom made according to
the job. The cutters are designed for the parts to the cut.

PLANING MACHINE
It uses linear motion between work piece and single point cutting tool. Analogous to a
shaper but larger & with entre workpiece moving on a table beneath the cutter, instead of a
cutting rod, a ram that moves above a stationary workpiece.
Planning machine uses a quick return mechanism so as to reduce the non-cutting time. The
cutting tool only cuts in one stroke and as the tool undergoes to and fro motion, the return is not
very useful as there is no cutting in return stroke. It also uses a clapper box which raises the
cutting tool in the return stroke. The job moves linearly to & fro and at the same time slightly
sideways after each stroke.
Application
1. Linear planning
2. Generate accurate flat surfaces.
3. Its not as precise as grinding as the surface finish and grind size arent that perfect of
grinding.
4. Its usually and widely used for cutting shots.

22

NH/NL LATHES ASSEMBLY

SCRAPPING
Its a man power work done by a tool known as scraper. When a machined job or metal
has dents or minutely uplifted portions, then scrapping is used to flatten or reduce the number of
dents or upliftments on the surface of the job. We use scrapping to increase the extent of
accuracy. We do scrapping for doing the following to the metals job:
1. flatten.
2. for making holes; we use triangular scrapper.
3. to make concave or convex surfaces.
The scraper is made of high speed steel (HSS).

How is scrapping done?
We apply a colored die over a standard surface (which is already flattened or finished or
well surfaced) and then slide it over the surface to be scrapped. The places where the metal to be
scrapped has die is then scrapped off using the scraper. Usually the die is in the form of dots on
unfinished surface. The quality of the scrapped surface is given by counting the number of
colored dots in 1 inch square. The dots are known as bearings (dots per square inch).

For rough surface 2-4 bearings
For finished surface 12-14 bearings
For fine finished surface 24&above bearings



We have a surface plate which has many divided sections of scrapped parts with
different bearings. For the sliding lengths of the lathes for the tools carriage to move is finished
by using it as the standard surface since it is grinded and already finely finished. To alter the
sliding length or the topmost part of the lathe bed we use scraper.
Now, to find whether the sliding surface is flat, convex or concave, we use an instrument
known as spirit meter:
If the motion the spirit meter and the bubble are in the same direction then the surface
is concave.
If the motion of the spirit meter and the bubble are in opposite direction then the
surface is convex.




23

HEADSTOCK GEARBOX ASSEMBLY
The gears are used in the headstocks gearbox are firstly dipped in boiled water so as to
heat, which will make it easier for slitting it over the shafts, and make its adjust (due to the
expansion) . In lathes we use double role bearing which is specially meant for taking the load on
axial and rotational cutting a high cutting speed of the shaft. The double role bearing is brought
from Germany.
There are many shafts in the headstocks gearbox
1-6 shafts are used for speed selection.
1-9 shafts are used for feed selection.


3





Shaft 1- is main shaft which is the headstock shaft.
Shaft 4 - is the main, powerful and the braking are applied to this shaft.
Shaft 5 - is used for reverse threading and deciding forward and backward.
Shaft 6 - is the shaft with clutch and pulley system.
It has a pump for providing coolant to the shafts which pumps12-13L/min. The shaft 1 needs
upto 3-4L/min of coolant oil for cooling and lubricating of the bearings (the bearings can heat
upto +40C to atmospheric temperature). The shaft 6 has 3 holes for the flow of lubrication and
coolant.
- lubrication of clutch.
- lubrication of shaft.
Brakes are applied by hydraulic pressure and retrieved by compressed springs.


4
2
1
24

CNC ASSEMBLY

Ever increasing demands, the need for high accuracy, scrap reduction, etc. have led to the
invention and improvement of CNC machines and undoubtedly termed as one of the milestones
of the century. The accuracy of a micrometer can be acquired in CNC machines.
HMT Kalamassery is famous for its world class CNC turning centers. The earlier models
of machine used Sinumerik and hinumerik control systems and MCUs whereas the new
generation CNC machines of the unit uses Fannuc/ Seimens control system. State of the art
technologies are such as Hydraulic jaws, Ball screws, feedback servomotors, encoders, etc.
The assembly of CNC turning centers can be divided into
Group assembly
Pre final assembly
Final assembly


GROUP ASSEMBLY
This is the place where the assembly of headstock, tailstock, turret- indexing unit, power pack,
turret fixing, etc. is done. HMTK produces following CNCs
STC-20, STC-25, SBCNC-30, SBCNC-40, SBCNC- 60, FMC- gantry loader, STALLION 100
& STALLION 200
The CNC group assembly unit is equipped with various testing apparatus. For ex.
Turret In its assembly, hydraulic motor & power pack assosciated with it are tested.
Headstock The bearings and gears are heated above 90oC for easy assembling.
Hydraulic motor This reaches the spindle through a worm and worm gear arrangement.

The fluids are controlled by solenoid valves. The grease used is special variant called
isoflex. The headstock is run at different speeds and several parameters are noted and then the
next speed I shifted only when the temperature is controlled and then this is done till maximum
speed is achieved.

25


PRE- FINAL ASSEMBLY
Its the section where the assemblies of various components of the CNC lathe like
headstock take place to the lathe bed. Its here that the ball screw alignment is done. The
assemblies of saddle, cross slide, etc. to the bed. Once the various parts are assembled together,
the lathe is taken for final assembly.

FINAL ASSEMBLY
Here the electrical components required for the functioning of the lathe are installed. The
electrical drivers, system and special tools like steady rest, etc. are imported. The stabilizer unit
and conveyer belt are also assembled during this stage. Then the machine is carried for tests.
The various functional groups are explained briefly as follows
Bed most of the CNCs have slant bed to reduce thermal growth, ease chip removal &
to acquire more load capacity.
Headstock In CNCs, we have servomotors which are of variable speed type and so we
dont have gears and pulley systems with shafts. Two types of pulley systems are employed
tapered pulley and keyed pulley. The spindle is loaded on Angular contact bearings which could
take both axial & radial loads. These have hydraulic jaws. The main spindle also has an encoder
which acts as the feedback ot the servomotors, so that required speed is attained. The spindle are
manufactured vibration free for accuracy.
Drives The machine contains 3 servomotors 1 for main spindle, 1 for saddle traverse
over the bed and third one for cross slide/turret movement across the saddle. These servomotors
are specially designed for providing relatively constant torque at all speeds.
Saddle It is that part which carries the turret & slides over the bed. The ball screw
mounted on it is powered by servomotors. It also uses braked motor for cross feed. An encoder is
coupled to the ball screw to get feedback on the current position of the tool.
Turret It is the part that holds the various tools and would position the required tool to
perform the cutting. Its radial direction is decided by (X) in the computer and axial direction by
(Z).
The sequence of operation during indexing is as given below-
1. Unclamping The turret male part unclamps from the curvic coupling(a piston
cylinder arrangement within the turret housing).
26

2. Rotation The hydraulic motor is actuated by means of direction control
valves(solenoid valves). This rotation is fed back to the controller by
another encoder. This rotation takes place in the direction of shortest
possible angle.
3. Creep As the turret reaches the desired angle, an opposite flow is given to motor so
as to reduce the speed of rotation.
4. Clamping Once the desired position is attained, the turret clamps back into the
coupling and is ready for machining. For operation such as drilling/
milling a special C axis motor is required & is fitted only on customer
request.
Tailstock The tailstock of a CNC machine is highly advanced. Instead of stationary, a
rotating center is used to reduce heat generation. The tailstock quill is attached to a movable
cylinder and tailstock body acts as a piston. A check valve is provided to avoid the loosening
under pressure. A pressure switch continuously monitors the cylinder pressure and terminates the
operation if any sudden drop is detected.
Lubrication System Ensuring sufficient lubrication for the rotating as well as parts are
essential to maintain smooth running for the machine as well as to reduce vibrations, heat
generation and errors. Lubrication is consumed and is not returned to the system . the common
lubrication used in CNC machines is Servo 68. The lubrication pipes are made of copper pipes
and flow is controlled by metering cartridges.
Axis Alignment Axis alignment is done on every machine produced at HMT. But in
case of CNC machines, it is of slightly higher importance, because CNCs accuracy is
determined by this process. This is done by giving the tool a predefined feed and then comparing
with the actual position of the tool. The actual position is determined by the means of laser
interferometry.


27

PLANT SERVICE
OBJECTIVE
To maintain the plant, machine &equipment in good condition & performance ensuring
the availability for production.
To ensure that the machines & equipment are well maintained to meet customer
requirements.

SECTION & MAINTENANCE
a) Administration
b) Electrical maintenance of MTD
c) Mechanical maintenance
d) Internal transport

MECHANICAL SECTION
a) Erection, comprising and maintenance of all machines & equipments, crane, air
compressor & AC plant in the factory of MTK & PMD.
b) Preventing maintenance of all critical machines & equipments.
c) Reconditioning of all critical machines & equipments.
d) Testing of EOT cranes and compressors as per factory regulations.
e) Maintenance planning.
f) Housekeeping function in the factory.
g) Lubrication services.

SECTION ELECTRICAL
a) Maintenance of power supply system in 66 kw subsystem, MTK & PMD plants and
HMT colony.
b) Erection, commissioning & maintenance of electrical portion in machines & of
equipments & operation of all electrical machines.
c) Safety of all electrical equipments as per factory electrical rules.
d) Internal communication system.
e) Energy conservation.
f) Internal transport activities.
28

g) Ensuring compliance to ISO: 9001 standards of all activities in the section.


PROCEDURE FOR PREVENTIVE MAINTENANCE




















Prepare preventive maintenance
schedule
Intimate schedule to chief of
manufacturing
Ensure ability of machine
Perform PM as per check list
After completion of PM handover
machine to production
Update PM schedule
Review in the fortnightly maintenance meeting
for process improvement & effectiveness
Record
deviation if any
Review and
reschedule plan
(No)
29

TOOL DESIGN

Tool room is the place where special purpose tools and jigs and fixtures are produced.
Most of the tools are produced as per outside requirements. The different divisions in this
department are in housing tooling and customer tooling. Jigs are used in machining operations
for grinding the tool they assist in mass production. The operation need not know much about the
final shape of the work piece. He just needs to fix the workpiece on the table and guide the tool
at desire spots using jigs. Fixtures are used for fixing the workpiece on the table.
Different tools in tool room.
JIG BORING
It is used to machine tools which must be related with higher degree of accuracy with
reference to datum surface of workpiece within 0.001mm in addition to all kinds of holes
their precise centre be employed for milling flat surface and also as a measuring machine
for inspection and layout operation.
POLYGON DRILLING
In this machine we can make square and hexagonal holes from 3-27 acres flat for each
size holes. There are different cutters. For making square holes, 3 tipped for hexagonal
holes 5 lifted cutters are used. The working mechanism is cam-gear mechanism.
ENGRAVING MACHINE
This is used for engraving / etching letters and numbers in finished parts. After
completing the special notes, working, drawing, etc. are engraved.
THREAD WINDING MACHINE
This finds an extensive application in toll production. To manufacture threads of higher
grades of accuracy. They are employed to grind thread of any form of screws, taps, thread
gauges, worm shafts, different types of cutters, crushers, etc.
TOOL GRINDING MACHINE
Tool an cutter grinding machine are used for shaping and reconditioning of cutting tools
like twists, drills, holes, mills, reamers, taps, gears, etc. this machine also can be used for
parting or slitting of hardened jobs like collets, taps, etc. for parts rubber, bonded
grinding wheels are used.
CARBIDE PLANNING
Carbide tips are braised with tool shanks for manufacturing of special carbide tool. The
carbide tips are tapped to the required shapes in this machine. The re-shaping of carbide
tipped tool can also be performed in this machine. 1 carbide and 1 diamond wheel is used
for tapping carbide tolls in this machine.


30

PRODUCTION PLANNING TOOLS(PPT)

PPT is divided into 2 sections
(i) Tool issuing
(ii) Tool reshaping
Tool used may be cutting or making tool based on requirements. Spirit level gauge,
dies, micrometers, cutting, milling cutter, reamer, bores, drills, bush, etc. are available from PPT.
Flange micrometer to measure stops on the jobs. The level protracted to measure
angle dial indication to check inside of basis.
The bore diameter is checked using inside micrometer. Die are used to cut treads on
flange manually. Plugs, gauges are used to check holes whereas key ways in bores. These are
based on tolerance.
Spline plug gauges to measure splines in shafts and gears. Taper gauge to check
taper inside above. Its male and female type. Snap gauge to check shaft diameter chaises
substituted for dies that is to cut threads on shaft. Splitting saw are used in milling machine to cut
grooves and for parting.
The radial cutters are used to enlarge the bore and angle cutters are used to cut dove
tails with the help of milling machine.
Grinding mandrels are used to hold grinders, Reamers are used to give a smooth
finish to the holes.
Gear hobs are used to cut gears. Center bore is used to deepen the screw. Flat drill is
the drill with flat base and is used to obtain flat base for hole instead of angles. Slip bash used in
jigs and fixtures. The drill may be taper shank (T/s) or straight shank(S/s).
Hole mill is used just before using reamers. It gives depth of 2mm only. Taper
reamers are used to tapper a given hole and expansion reamer to expand a hole (used in
assembly). Extension sleeves are used to increase the length of tool holders. Fixtures and jigs are
used to hold & guide the jobs of the tool. Grinding involves the reshaping & correcting the
angles of tools.

31

SHEET METAL AND WELDING

1. Nibbling Machine
Its a rugged, sturdy and reliable multipurpose machine capable of sheet cutting and
forming operations. Its versatility is best expressed by turning it as the sheet metal work
lathe. The working principle is that the sheet is cut or formed between the fast
reciprocating motion of an upper tool and stationary lower tool by progressive punching
as sheet is fed.
2. Shearing Machine
Its extremely versatile. Its designed to give high degree of stability & cutting
process is CAM activated ensuring precise but free and accurate cutting. Machine uses CI
bearing to ensure cutting accuracy.

3. Bearing Machine
Its used in sheet furniture making industries panel board work, bus body, etc. They
are manufactured using quality raw potential produced from most reliable vendor

4. Arc Welding
Its a type of welding process that use welding power supply i.e. to create an
electric arc between an electrode and the base material to melt the metalat welding point
using DC or AC. The welding region is protected by some sought of shielding gas,
vapour or slag.















32