Training Report: Mechanical Engineering Enroll: 207/12 Roll No: 53
Training Report: Mechanical Engineering Enroll: 207/12 Roll No: 53
Training Report: Mechanical Engineering Enroll: 207/12 Roll No: 53
Mechanical Engineering
Enroll: 207/12
Roll no: 53
Acknowledgment
Summer training in INDIAN ORDNANCE-SMALL ARMS
FACTORY was a learning experience for me. Working in such an
encouraging atmosphere with the people dealing with latest technology,
working in tight schedule, dedicated to work and ready to help is
privilege.
Working in different shops provide a real time experience of
engineering and technology being used, currently, in manufacturing
industry..
I would like to thank Mr. Ramakant Dubey who allowed &
made complete arrangement for this training. I am heartily grateful to
Mr. B.N.MUKHEJI(TOOL ROOM), Mr.D.S.RATHORE (CNC
SECTION) , Mr. S.K. MISHRA (BARREL SECTION), Mr.RAKESH
VERMA (RCS SECTION) and Mr. D.N. TRIPATHI (HT SECTION)
who gave me such affection,guidance and support for completing this
training and making this report.
UMANG BHATIA
PREFACE
The report on the following pages is the outcome of four
weeks training at the industry.
The report is the outcome of the practical knowledge that
we acquire during our training. This report presents the
brief summary of our industrial training.
I had the privilege of receiving such training at
INDIAN ORDNANCE- SMALL ARMS FACTORY,
KANPUR.
There could not be a better place to learn
TABLE OF CONTENTS
S.N
o
TOPIC
PAGE NUMBER
Introduction
SAF Kanpur
10
12
CNC Section
16
Tool Room
20
H.T Section
27
Cold Swaging
30
Geographical Spread
There are 39 Ordnance Factories geographically distributed all over the country at
24 different locations.
Name of State/ Union Territory
Number of factories
Maharashtra
10
Uttar Pradesh
Madhya Pradesh
Tamil Nadu
West Bengal
Uttaranchal
Andhra Pradesh
Chandigarh
Orissa
Factories
1. Ammunition Factory Khadki (AFK)
2. Cordite Factory Aruvankadu (CFA)
3. Engine Factory Avadi (EFA)
4. Field Gun Factory Kanpur (FGK)
5. Gun Carriage Factory (GCF)
6. Grey Iron Foundry (GIF)
7. Gun and Shell Factory (GSF)
8. Heavy Alloy Penetrator Project (HAPP)
9. High Explosive Factory (HEF)
SAF was built in 1942 as part of the strategic plan to have a shadow factory of RFI
at Kanpur to undertake manufacture of small arms as a sequel to threat on the
eastern border during world war-II.
The factory was known as Transplantation Project -1.
After independence, the factory was renamed as Small Arms Factory in the year
1949.
SAF is engaged in consistently supplying small arms to MOD & Paramilitary
forces.
Manufacturing facilities built over an area of 103 acres.
The organization possess highly skilled, qualified and dedicated team of 2200
personnel.
Small arms are a term of art used by armed forces to denote infantry weapons an
individual soldier may carry.
The description is usually limited to revolvers, pistols, submachine guns, carbines,
assault rifles, battle rifles, multiple barrel firearms, sniper rifles, squad automatic
weapons, light machine guns, and sometimes hand grenades. Shotguns, general
purpose machine guns, medium machine guns, and grenade launchers may be
considered small arms or as support weapons, depending on the particular armed
forces.
PRODUCTS OF SAF,KANPUR
LMG 5.56mm
Rifle 5.56mm
Amogh 5.56mm
Carbine
MAC gun
Assault rifle 7.62mm
Revolver
Tooling
Process planning
Material handling
Engineering system may also classified as productive departments and non
productive.
Production departments included IA , SC , CNC, TR, HT , RCS , MCS. Store and
maintenance sections come under non- production departments.
Barrel
The barrel is a tube which the bullet is projected. The pressure of gases driving a
rifle bullet can reach about fifty thousand pounds per square inch (3333 bar) and
temperature 3500 degrees Fahrenheit (2200 C) in the barrel. These rise and fall
during the few milliseconds (thousandths of seconds) when the projectile is in the
barrel. So both thermal and mechanical stresses affect the barrel. Formulas which
describe gas pressure and projectile position and velocity have been determined
experimentally, for example Leducs method. Pistol and shotgun rounds operate at
considerably lower pressures than rifle rounds at approximately one third.
As described above, barrels are usually rifled since the spin imparted by the rifling
stabilizes the projectile in flight, decreasing wind deflection, and increasing
aerodynamic stability. Exceptions include shotguns which fire a collection of
projectiles with each shot, and anti-armour guns which fire light, high-velocity
sub-calibre rounds. The latter are usually fired from tanks with smooth bore barrels
(barrels with no rifling).
The latter are usually surrounded by a sabot while in the barrel. The increased bore
diameter occupied by the sabot means pressure is applied over a larger surface
area, resulting in a higher velocity. The sabot falls away after the projectile leaves
the barrel. The smaller projectile also has less frontal area to be affected by
aerodynamic drag and travels more efficiently to target. Sabot slugs and bullets are
sometimes used in rifles, shotguns, and black powder small arms.
Chamber
The chamber is the portion of the barrel or barrel extension which supports the
cartridge case while it is in firing position.
Trigger
The trigger is the user interface to the firing assembly. It can be activated by finger
pressure, or it can be an electro-mechanical device. In some systems the entire
firing chain is electrical, for example in most 20mm and larger cannon and a few .
22 rim fire competition rifles. In those systems the trigger is a switch or electrical
relay.
Sear
The sear is the portion of the trigger mechanism which directly holds and releases
the bolt or striker. It interfaces directly or indirectly with the trigger.
Receiver
The receiver is the body or frame of the gun to which the barrel, ammunition
feeding devices, stocks or handles attach, and in which bolt operates. The bolt
often rides on rails, rods, or recesses in the receiver. The receiver is sometimes
divided into separate assemblies to facilitate cleaning, stoppage clearing, or other
operational issues. The receiver and operating parts inside are also called the action.
The receiver can be made from stamped sheet metal, cast and/or machined metal,
high-technology plastics, or combinations thereof. One of the most successful
applications of a plastic receiver is the frame of the Glock pistol.
Bolt (Breech)
The bolt or breech constrains the cartridge in such a way that high pressure gases
generated upon firing are kept in the chambered case and barrel. This allows
pressure to fall to safe levels before the action is opened to load the next round or
stop firing. The Operating Systems section describes various ways this can happen.
Bolt Carrier
Especially in designs which use rotary locking, the bolt and bolt carrier can be
separate objects. The bolt engages locking lugs in the receiver or chamber and the
bolt carrier holds the bolt. Different methods of accomplishing this are described in
the next Functions section. The bolt carrier is usually larger and more massive than
the bolt.
CNC Section
Numerical Control (NC) refers to the method of controlling the manufacturing
operation by means of directly inserted coded numerical instructions into the
machine tool. It is important to realize that
NC is not a machining method; rather, it is a concept of machine control. Although
the most popular applications of NC are in machining, NC can be applied to many
other operations, including welding, sheet metalworking, riveting, etc.
The major advantages of NC over conventional methods of machine control are as
follows:
higher precision: NC machine tool are capable of machining at very close
tolerances, in some operations as small as 0.005 mm;
better quality: NC systems are capable of maintaining constant working
conditions for all parts in a batch thus ensuring less spread of quality
characteristics;
Higher productivity: NC machine tools reduce drastically the non
machining time.
Adjusting the machine tool for a different product is as easy as changing the
computer
program and tool turret with the new set of cutting tools required for the particular
part.
Multi-operational machining: some NC machine tools, for example
machine centers, are capable of accomplishing a very high number of
machining operations thus reducing significantly the number of machine
tools in the workshops.
Low operator qualification: the role of the operation of a NC machine is
simply to upload the work piece and to download the finished part.
Types of NC systems
Machine controls are divided into three groups,
traditional numerical control (NC);
computer numerical control (CNC);
Distributed numerical control (DNC).
The original numerical control machines were referred to as NC machine tool.
They have hardwired control, whereby control is accomplished through the use
of punched paper (or plastic) tapes or cards. Tapes tend to wear, and become dirty,
thus causing misreading. Many other problems arise from the use of NC tapes, for
example the need to manual reload the NC tapes for each new part and the lack of
program editing abilities, which increases the lead time. The end of NC tapes was
the result of two competing developments, CNC and DNC.
Most CNC milling machines (also called machining centres) are computer
controlled vertical mills with the ability to move the spindle vertically along the Zaxis. This extra degree of freedom permits their use in diesinking, engraving
applications, and 2.5D surfaces such as relief sculptures. When combined with the
use of conical tools or a ball nose cutter, it also significantly improves milling
precision without impacting speed, providing a cost-efficient alternative to most
flat-surface hand-engraving work.
CNC machines can exist in virtually any of the forms of manual
machinery, like horizontal mills. The most advanced CNC milling-
MILLING MACHINE
A milling machine is a machine tool used to machine solid materials. Milling
machines exist in two basic forms: horizontal and vertical, which refers to the
orientation of the cutting tool spindle. Both types range in size from small, bench
mounted devices to room-sized machines. Unlike a drill press, which holds the
work piece stationary as the drill moves vertically to penetrate the material, milling
machines also move the work piece against the rotating cutter, which cuts on its
flanks as well as its tip? Work piece and cutter movement are precisely controlled
to less than 0.001 in (0.025 mm), usually by means of precision ground slides and
leadscrews or analogous technology. Milling machines may be manually operated,
mechanically automated, or digitally automated via computer numerical control
(CNC).
Milling machines can perform a vast number of operations, some
very complex, such as slot and keyway cutting, planning, drilling,
die sinking, rebating, routing, etc. Cutting fluid is often pumped to
the cutting site to cool and lubricate the cut and to wash away the
resulting swarf.
Tool Room
The tool room section mainly dealt with tool making and tool repairing of various
drilling and milling cutters.
MILLING CUTTERS
Milling cutters are cutting tools used in milling machines or machining centres.
They remove material by their movement within the machine (eg: a ball nose mill)
or directly from the cutters shape (a form tool such as a Hobbing cutter).
Features of a milling cutter
Milling cutters come in several shapes and many sizes. There is also a choice of
coatings, as well as rake angle and number of cutting surfaces.
END MILL
End mills (middle row in image) are those tools which have cutting teeth at one
end, as well as on the sides. They are usually made from high speed steel (HSS) or
carbide, and have one or more flutes. They are the most common tool used in a
vertical mill.
SLOT DRILL
Slot drills (top row in image) are generally two (occasionally three or four) fluted
cutters that are designed to drill straight down into the material. This is possible
because there is at least one tooth at the centre of the end face. They are so named
for their use in cutting keyway slots.
SLAB MILL
Slab mills are used either by themselves or in gang milling operations on manual
horizontal or universal milling machines to machine large broad surfaces quickly.
They have been superseded by the use of carbide-tipped face mills which are then
used in vertical mills or machining centres.
SIDE-AND-FACE CUTTER
The side-and-face cutter is designed with cutting teeth on its side as well as its
circumference. They are made in varying diameters and widths depending on the
application. The teeth on the side allow the cutter to make unbalanced cuts (cutting
on one side only) without deflecting the cutter as would happen with a slitting saw
or slot cutter (no side teeth).
FACE MILL
A face mill consists of a cutter body (with the appropriate machine taper) that is
designed to hold multiple disposable carbide or ceramic tips or inserts, often
golden in colour. The tips are not designed to be resharpened and are selected from
a range of types that may be determined by various criteria, some of which may be:
tip shape, cutting action required, and material being cut. When the tips are blunt,
they may be removed, rotated (indexed) and replaced to present a fresh, sharp face
to the workpiece, this increases the life of the tip and thus their economical cutting
life.
DRILL BIT
Drill bits are cutting tools used to create cylindrical holes. Bits are held in a tool
called a drill, which rotates them and provides torque and axial force to create the
hole. Specialized bits are also available for non-cylindrical-shaped holes.
This article describes the types of drill bits in terms of the design of the cutter. The
other end of the drill bit, the shank, is described in the drill bit shank article. Drill
bits come in standard sizes, described in the drill bit sizes article.
The term drill can refer to a drilling machine, or can refer to a drill bit for use in a
drilling machine. In this article, for clarity, drill bit or bit is used throughout to
refer to a bit for use in a drilling machine, and drill refers always to a drilling
machine.
VARIOUS DRILL BITS (TOP TO BOTTOM): SPADE, LIP AND SPUR (BRAD
POINT), MASONRY BIT, TWIST DRILL
Centre drill bits are used in metalworking to provide a starting hole for a largersized drill bit or to make a conical indentation in the end of a work piece in which
to mount a lathe centre. In either use, the name seems appropriate, as the drill is
either establishing the centre of a hole or making a conical hole for a lathe centre.
Use in making holes for lathe centres
Centre drills are meant to create a conical hole for "between centres"
manufacturing processes (typically lathe or cylindrical-grinder work). That is, they
provide a location for a (live, dead, or driven) centre to locate the part about an
axis. A work piece machined between centres can be safely removed from one
process (perhaps turning in a lathe) and set up in a later process (perhaps a grinding
operation) with what is often a negligible loss in the co-axiality of features.
Use in spotting hole centres
Traditional twist drill bits may tend to wander when started on an unprepared
surface. Once a bit wanders off-course it is difficult to bring it back on center. A
center drill bit frequently provides a reasonable starting point as it is short and
therefore has a reduced tendency to wander when drilling is started.
CORE DRILL
A core drill bit is used to enlarge an existing hole. The existing hole may be the
result of a core from a casting or a stamped (punched) hole..
Core drill bits are similar in appearance to reamers as they have no cutting point or
means of starting a hole. They have 3 or 4 flutes which enhance the finish of the
hole and ensure the bit cuts evenly. Core drill bits differ from reamers in the
H.T Section
The amount of carbon present in plain carbon steel has a pronounced effect on the
properties of steel and on the selection of suitable heat treatments to attain certain
desired properties. Various heat treatment processes like carburising, tempering,
induction hardening, stress reduction, shot blasting etc. are done in the various
parts of gun in heat treatment section.
or less proportional to the temperature rise. Upon cooling a metal, the reverse
reaction takes place. That is, a contraction is observed. When a steel bar or plate is
heated at one point more than at another, as in welding or during forging, internal
stresses are set up. During heating, expansion of the heated area cannot take place
unhindered, and it tends to deform. On cooling, contraction is prevented from
taking place by the unyielding cold metal surrounding the heated area. The forces
attempting to contract the metal are not relieved, and when the metal is cold again,
the forces remain as internal stresses. Stresses also result from volume changes
which accompany metal transformations and precipitation. The term stress has
wide usage in the metallurgical field. It is def1ed simply as bad or force divided
by the cross-sectional area of the part to which the bad or force is applied. Internal,
or residual stresses, are bad because they may cause warping of steel parts when
they are machined. To relieve these stresses, steel is heated to around 1100 0F (595
0C) assuring that the entire part is heated uniformly, then cooled slowly back to
room temperature. This procedure is called stress relief annealing, or merely stress
relieving.
Swaging machine processes are typically divided into two categories, tube
swaging and rotary swaging.
Tube swaging machines use a process similar to drawing wire. These swaging
machines can be expanded by placing a mandrel in the tube and applying radial,
compressive forces on the outer diameter, which allows the inside shape to differ
from the outer, circular diameter. Cold tube swaging machines are commonly used
with aluminium, copper, and thin steel.
Rotary swaging, also known as radial swaging, is often a cold working process
used to reduce tube diameter, produce a tapered end, or to add a point to a round
workpiece. This type of swaging machine uses two or four dies that hammer up to
2,000 a minute. Dies are mounted on the machines spindle, located inside a cage
containing rollers, which is rotated by a motor. As the spindle spins inside the
rotary swaging machine, the dies push out to ride the cage by centrifugal force.
When the dies cross the rollers, they push the dies together due to their large size.
Like tube swaging, rotary swaging can also create internal shapes inside the tube
through use of a mandrel, as long as the shape has a constant cross-section. Rotary
swaging machines are common in two basic types, standard and butt swaging. Butt
swaging machines contain sets of wedges that close the dies onto the workpiece by
placing them between the annular rollers and the dies, often by use of a foot pedal.
These swaging machines allow the piece to be inserted without the dies closing on
it. Common applications for swaging machines include attaching fittings to cables
or pipes, pipe flaring, sawmilling, fire arms and ammunition, rubber components,
automotive components, aerospace applications, agricultural machinery,
measurement and adjustment systems, medical devices, optics, tool construction,
welding and brazing devices, jewellery manufacture, metal joining and fixtures,
and more.
BIBLIOGRAPHY
www.ofbindia.nic.in
www.wikipedia.com