1. Govt. Engineering College Bikaner (An Autonomous Institution
of Govt. of Rajasthan) A PRESENTATIONON VOCATIONAL TRAINING AT INDO
DANISH TOOL ROOM , JAMSHEDPUR By : By Dept. of Mechanical
Engineering Gaurav Gunjan B. Tech. (Final Year) Dept. of Mechanical
Engineering1
2. ABOUT IDTR:- Indo Danish Tool Room, Jamshedpur was
established in 1991 by Government of India under the assistance of
Govt. of Denmark. Their main objective is to provide consistent,
reliable, quality service for industrial growth based on its
trained, skilled and innovative manpower capabilities backed by the
state of the art tool room facilities and provide trained manpower
(through long & short term training). They undertake Design and
Manufacturing of Jigs, Fixtures, Gauges, Die Casting Dies, Press
Tooling and Plastic Moulds for the Automobile and Engineering
Sectors and machining of precision components. MSME Tool Room and
Training Centre, Jamshedpur (IDTR) is a Government of India
Society, Under Ministry of MSME
3. To impart long-term and short-term training to youngsters in
the fieldof Tool & Die making course with the latest
technologies (and otherallied Engineering trades) both for freshers
and personnel alreadyengaged in this field.To provide Consultancy
Services primarily to Small scale Units in thefield of Tool
Engineering aimed at improving the productivity of theSmall Scale
UnitsTo design and manufacture Moulds, Tools, Dies, Jigs Fixtures
etc ofhigh precision quality.To provides common facility services
in precision machining / heattreatment and other technical
engineering know-how in tooling toSmall Scale Industries in the
Country.
4. DEPARTMENTS:-Design & Manufacturing:Design and
manufacture of precision dies and tools, moulds, jigs &
fixtures,gauges etc. and their appropriate use and maintenance.Tool
manufacturing using latest technology.Tool related innovations for
improved product design using Rapid PrototypingTechnology.Precision
machining and Heat Treatment.Consultancy & Others:Product &
Process Development.Productivity/ Quality improvement.Training
Program/Course curriculum development for training
institutes.Execution of Turn-key projects.Vacuum Heat
Treatment.Productivity/ Quality improvement.Inspection and
calibration facilities.
5. Partners:-SIEMENSIDTR offers following training program in
collaboration withSIEMENS:--CNC COMMISSIONING & MAINTENANCE.AC
SERVO DRIVE COMMISSIONING & MAINTENANCE.CNC PROGRAMMING &
OPERATION (SinuTrain).IGNOU, New DelhiIDTR offers Certificate
Course on Motorcycle Service andRepairing in collaboration with
IGNOU and Hero-Honda.
8. Computer Numerical Control (CNC) The idea of computer
numerical control is to position a computer right at the machine
tool.The introduction of CNC machines radically changed the
manufacturing industry. Curves are as easy to cut as straight lines
complex 3-D structures are relatively easy toproduce, and the
number of machining steps that required human action have been
dramatically reduced.
9. Advantages:-Reduces tooling costsReduces layout
timeIncreases machine and tool lifeReduces storage problemsLess
setup timeReduces actual machining time Allows rapid designchanges
in part Less jigs and fixtures are neededAvoids human errorsComplex
geometry is produced as cheaply as simpleones
10. 10Hardware Configuration of CNC Mechanical Engineering Ken
YoussefiMachine Department Machine Control Unit (MCU) the brain of
the NC machine. The Data Processing Unit (DPU) reads the part
program. The Control Loop Unit (CLU) controls the machine tool
operation.
11. NUMERICAL DATA (NC CODE) NUMERICALMANUFACTURING CONTROLLER
OPERATOR Drive Control PROCESSED PART MACHINE UNIT 11
12. HOW CNC WORKS:- Controlled by G and M codes. These are
number values and co-ordinates. Each number or code is assigned to
a particular operation. Typed in manually to CAD by machine
operators. G&M codes are automatically generated by the
computer software.
13. ELECTRICAL DISCHARGE MACHINE - EDMDie-sinking EDM systems,
the electrode (cutting tool) and workpiece are held bythe machine
tool. The power supply controls the electrical discharges
andmovement of the electrode in relation to the workpiece. During
operation theworkpiece is submerged in a bath of dielectric fluid
(electrically nonconducting).(Die-Sinking EDM is also called
Sinker, Ram-Type, Conventional, Plunge orVertical EDM)MECHANICAL
ENGINEERING DEPARTMENT Ken Youssefi 13
14. EDM DIE-SINKING (PLUNGE) During normal operation the
electrode never touches the workpiece but is separated by a small
spark gap. The electrode (plunger) can be a complex shape, and can
be moved in X, Y, and Z axes, as well as rotated, enabling more
complex shapes with accuracy better than one mil. The spark
discharges are pulsed on and off at a high frequency cycle and can
repeat 250,000 times per second. Each discharge melts or vaporizes
a small area of the workpiece surface. The amount of material
removed from the workpiece with each pulse is directly proportional
to the energy it contains. Plunge EDM is best used in tool and die
manufacturing, or creating extremely accurate molds for injection-
molding plastic parts.
15. EDMThe EDM process can be used on any material that isan
electrical conductorThe EDM process does not involve
mechanicalenergy, therefore, materials with high hardness
andstrength can easily be machined. Applications include producing
die cavity for large components, deep small holes, complicated
internal cavities
16. EDM DIE-SINKING (PLUNGE) During normal operation the
electrode never touches the workpiece but is separated by a small
spark gap. The electrode (plunger) can be a complex shape, and can
be moved in X, Y, and Z axes, as well as rotated, enabling more
complex shapes with accuracy better than one mil. The spark
discharges are pulsed on and off at a high frequency cycle and can
repeat 250,000 times per second. Each discharge melts or vaporizes
a small area of the workpiece surface. The amount of material
removed from the workpiece with each pulse is directly proportional
to the energy it contains. Plunge EDM is best used in tool and die
manufacturing, or creating extremely accurate molds for injection-
molding plastic parts.
17. FLOW OF COMPUTER-AIDEDCNC PROCESSING Develop or obtain the
3D geometric model of the part, using CAD. Decide which machining
operations and cutter-path directions are required (computer
assisted). Choose the tooling required (computer assisted). Run CAM
software to generate the CNC part program. Verify and edit program.
Download the part program to the appropriate machine. Verify the
program on the actual machine and edit if necessary. Run the
program and produce the part.
18. CNC MACHINESMachining Centers, equipped with automatic tool
changers, arecapable of changing 90 or more tools. Can perform
milling, drilling,tapping, boring on many faces. MECHANICAL
ENGINEERING DEPARTMENT Ken Youssefi 18
19. TOOLS:-- Most are made from high speed steel (HSS),
tungsten carbide or ceramics. Tools are designed to direct waste
away from the material. Some tools need coolant such as oil to
protect the tool and work.
20. TOOL PATHS, CUTTINGAND PLOTTING MOTIONS Tool paths
describes the route the cutting tool takes. Motion can be described
as point to point, straight cutting or contouring. Speeds are the
rate at which the tool operates e.g. rpm. Feeds are the rate at
which the cutting tool and work piece move in relation to each
other. Feeds and speeds are determined by cutting depth, material
and quality of finish needed. e.g. harder materials need slower
feeds and speeds. Rouging cuts remove larger amounts of material
than finishing cuts. Rapid traversing allows the tool or work piece
to move rapidly when no machining is taking place.
21. CNC Programming Basics Each letter address relates to a
specific machine function. G and M letter addresses are two of the
most common. A G letter specifies certain machine preparations such
as inch or metric modes, or absolutes versus incremental modes. A M
letter specifies miscellaneous machine functions and work like
on/off switches for coolant flow, tool changing, or spindle
rotation. Other letter addresses are used to direct a wide variety
of other machine commands.
23. BASIC CNC PRINCIPLES Using a vertical mill machining center
as an example, there are typically three linear axes of motion.
Each is given an alphabetic designation or address. The machine
table motion side to side is called the X axis. Table movement in
and out is the Y axis, while head movement up and down the column
is the Z axis.