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Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”
Department of Mechanical Engineering, SJCE, Mysore Page 1
CHAPTER 1
1.1 INTRODUCTION:
In-Plant Training will provide an industrial exposure to the students as well as to
develop their career in the high tech industrial requirements. Reputed
companies are providing in-plant training to Students. Here students are initially to
get counseled in order to emerge out their interest in various streams and what are all
the basic concepts they know about that domain.
In-plant Training refers to a program which aims to provide supervised
practical training with spiced timeframe. This training can be carried out either in
government organizations or in private sector.
In-plant training is a programme for post graduates that gives them an
opportunity to expose themselves in the real career world so as to they will learn
how to relate theoretical learning before and real practical in work
environment.
Besides that, in future, they wi l l be having good preparation and
understanding for their field of profession. After the successful completion of
studies students has to face this competitive world with this knowledge to face
many problems and to find the right solutions which is to be solved in the
minimum duration of time. The implant training is getting totally different from the
class environments.
Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”
Department of Mechanical Engineering, SJCE, Mysore Page 2
1.2 Objectives of In-Plant Training:
To get an Industrial exposure.
To be aware of the happening in a particular industry.
To achieve knowledge about different sectors in the market for making a Choice
as to which go for.
To learn functioning and operations of different departments in an organization.
To get knowledge about the working culture of the organization.
To have knowledge about the huge management practices and get the practical
knowledge of what we have studied
1.3 METHODOLOGY OF COLLECTING DATA:
There are many methods to collect required information during in-plant training
like:
Observation of the entire process..
Discussion about the observed process with the staff involved.
Interview with the experienced employees involved.
Referring relevant documents related to the process.
Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”
Department of Mechanical Engineering, SJCE, Mysore Page 3
Chapter 2
PROFILE OF THE COMPANY
“It`s precision that makes the world go round”
A premier Tool Room and Training Centre established in 1992 at Mysore, Karnataka,
India with assistance of the Government of Denmark, has extensive facilities in Tool
making and training. Government tool and Training Centre (GTTC) is a modern tool
room and training centre with state-of-art CAD/CAM equipment, machinery and
inspection facilities to meet the complex needs of discerning customers.
GTTC is committed to achieve customer satisfaction in quality and delivery of
tool engineering education, services and precision machining.
GTTC has acquired mastery in Tool Engineering and vast experience in
conducting well structured, practical oriented training programmes leading to post
graduation, diplomas and certificates.
Realizing the need to update and upgrade the skills of existing technical
personnel in industry, GTTC conducts a number of short term programmes in tool
design, advanced manufacturing techniques, design analysis and CNC programming
for manufacture and other aspect of manufacturing.
The state-of-art sophisticated manufacturing facility consists of 3 to 5 axis high-
speed CNC machining centres, CNC jig grinding, CNC wire EDM, CNC co-ordinate
measuring machine and other supporting machineries and facilities.
The computer integrated manufacturing facility in DNC network and supported by
high end software`s such as I-DEAS, for design and manufacture, Uni-Graphics,
Pro-E, Master-cam, Mechanical Desktop and Analysis package like C-Mold, Mold
Flow and Pro-Cast.
Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”
Department of Mechanical Engineering, SJCE, Mysore Page 4
2.1 LAYOUT OF GOVERNMENT TOOL ROOM and TRAINING CENTER
E- ENTRANCE
S- SECURITY ROOM
1. HSM M/C
2. MAINTENANCE
3. ASSEMBLY
4. BENCH WORKS
5. DNC
6. QUALITY ANALYSIS
7. CMM
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Department of Mechanical Engineering, SJCE, Mysore Page 5
8. CNC MILLING
9. CNC MILLING
10. MARKETING DEPARTMENT
11. PLANNING DEPARTMENT
12. SURFACE GRINDING
13. CNC TURNING
14. JIG GRINDING
15. WIRE EDM
16. EDM
17. TRAINING AND ACCOUNTS SECTION
18. CANTEEN
19. CAD CCENTRE
20. LASER M/C
2.2 MANAGEMENT DEPARTMENT:
The management of affairs of the Tool Room, which has been set up as
Government of India Society, rests with the Governing Council constituted by
Government of India. DC(SSI) is the President of this Society and Chairman of their
Governing Council. Adequate representation to State Government, donor country and
Industry Associations has been provided in the constitution of Governing Council.
2.3 MARKETING DEPARTMENT:
Marking reaches right customers and explains him about special machines and
quality of work carrying out in the industry through advertisement and by other means.
Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”
Department of Mechanical Engineering, SJCE, Mysore Page 6
Thus it brings work orders for company and takes care for dispatching the same
in scheduled time. It consists of marketing departments HOD and marketing officials
work under him.
Responsibilities and authorities
Receiving the customers and soliciting their enquiries.
Interacting with customers and preset the introduction broachers, hear doubts
and machines test etc, whenever required, arranging the shop visit if necessary.
Preparation of estimations/worksheets, consulting tool planning and tool
production for schedule and cost details if required.
Responsible for preparation of quotation and sending same to the customer.
Coordinating with administration department for advertisement.
Responsible for releasing work order instructions to planning and follow-up for
the status of order.
In the event of any delay in meeting the delivery schedule the informing customer
accordingly.
Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”
Department of Mechanical Engineering, SJCE, Mysore Page 7
To dispatch the completed work order to customer with proper documents.
Authorizing to sign delivery note.
Table 2.1 Work Order Instruction
From: Marketing To: Planning
Order conformation number ******
Customer ISRO
Description Stud
Scope of work Mikron
Quality 102 Nos
Drawing and specification Provided by the customer.
Raw material/ specification Stainless Steel
Date of delivery 10/09/13
Priority Normal
Acceptance criteria Visual acceptance
Any other information ------
2.4 PLANNING DEPARTMENT:
Before starting the actual production process planning is done. It gives the idea of
sequence of operations, selection of machine, cost and time required, at the same time
process will be performed with high percentage of material utilization. Planning is a
primary function of human and material resources in an enterprise to realize maximum
profits.
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Department of Mechanical Engineering, SJCE, Mysore Page 8
Process planning represents the link between Engineering design and shop floor
manufacturing. Since process planning determines how a part will be manufactured, it is
the major determinant of manufacturing costs and profitability.
PLANNING CONSISTS OF FOLLOWING WORKS:
1. Tool and high tech components: It involves job planning with effective utilization
of machines available and using right tool for right operation
2. Preparing process sheet: process sheet in forms the operations and machining
conditions such as diameter of components, feed, speed, material setting etc.
3. Job follows up: to follow up the progress of the job in the shop floor.
4. Pre tooling: Pre machining of the job in conventional machines to save the time
of high tech machines.
5. Route card: Route card is prepared to mention in sequence.
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Department of Mechanical Engineering, SJCE, Mysore Page 9
Table 2.2 Job Card Format
GTTC MYSORE JOB CARD UNIT CODE:
OC number Description: Dept:
Part No: Qty:
Planned date of loading Completion date:
Recommended Estimated time: Actual time:
Machine Section
Operation
Special instruction
Foreman/ shift in charge
Remark
Date: Signature:
Job card prepared by: Section:
Name: Date:
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Department of Mechanical Engineering, SJCE, Mysore Page 10
Table 2.3 Process Sheet Layout
GTTC Process sheet Sheet no:
Customer Date:
Part drawing no: Material specification:
Part description code: Raw material size:
Qty: OC no: Drawing SN/no:
Operation
No
Process details/
Drawings
Machine Tool and gauges
*** **** **** ****
Process
Prepared
By:
Process
Approved
By:
Co-
ordinate
By:
Process sheet prepared by:
Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”
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Table 2.4 Operation Drawing Sheet
GTTC
MYSORE
Operation Drawing
OC No: Part No: Reference Drawing No:
Machine: Section: Date: Qty:
DRAWING..........................................................................................
Drawing No: Checked by:
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2.5 DESIGN and PROGARMMING DEPARTMENT:
It is the maim organ of the industry. Quality of work done, hence the name and fame
of the company depends largely on this section. Its function can be enlisted as below.
Collection of required technical data, study of component drawing etc.
Design calculations are done and suitable assumptions are made.
Design layout considering cost effectiveness, machine available. It also includes
comparing new design with similar.
Design review, design verification and changes if any will be implemented.
Assessment of material selection.
Preparation of drawing and bill of materials.
Generation of CNC part programs considering optimum cutting tools and
parameter.
GTTC Design is well equipped with the computers. The designers were engaged
in designing the ISRO projects.
The design department is well equipped with the software like.
1. AUTOCAD
2. MASTER CAM
3. SOLID WORKS
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Department of Mechanical Engineering, SJCE, Mysore Page 13
Chapter 3
Machines and its Specifications
3.1 CNC MACHINE:
The term “CNC” is a generic term which can be used to describe many types of
device, this would include plotters, vinyl cutters, 3D printers, milling machines and
others. CNC stands for Computer Numerically Controlled and basically means that the
physical movements of the machine are controlled by instructions, such as co-ordinate
positions that are generated using a computer.
A machine tool that uses programs to automatically execute a series of
machining operations. CNC machines offer increased productivity and flexibility.
All CNC machine types share this commonality: They all have two or more
programmable directions of motion called axes. An axis of motion can be linear (along a
straight line) or rotary (along a circular path). One of the first specifications that implies a
CNC machine's complexity is how many axes it has. Generally speaking, the more
axes, the more complex the machine.
The axes of any CNC machine are required for the purpose of causing the
motions needed for the manufacturing process. In the drilling example, these (3) axis
would position the tool over the hole to be machined (in two axes) and machine the hole
(with the third axis). Axes are named with letters. Common linear axis names are X, Y,
and Z. Common rotary axis names are A, B, and C.
GTTC Mysore is well equipped with the CNC milling machines. Most of the
machines are HIDENHAIN and FANUC control. For jobs the job setting as well as
programming is done by the operator itself. For every job, designer of design
department does the modeling and generates the tool paths.
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Table 3.1 Specification of CNC Milling Machine
MAKE MIKRON MIKRON MIKRON MIKRON MIKRON
MODEL WF31DE WF32C VHC750 HSM520 UMC600
ORIGIN SWIZZ SWIZZ SWIZZ SWIZZ SWIZZ
NO.OF M/C 02 01 01 01 01
Control TNC407 TNC425 TNC415 RMS3 TNC426
Table size
(mm)
530x900 600x1000 Ф630 600x500 Ф630
Traverse
(mm)-X
560 600 750 520 600
Traverse
(mm)-Y
500 600 600 430 600
Traverse
(mm)-Z
400 450 550 220 500
Spindle
speed(RPM)
40-4000 10-6300 20-6300 50000 20-6300
NC rotary
table Ф/PW
500±6” 600±6” 600±6” -- 600±6”
Automatic
tool changer
-- 22 34 06 44
Max. Wt of
job (kgs)
350 400 500 200 500
Tilting table
range from
m/c
Five axis Machining centre USM 600 200
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3.2 Electric discharge machining (EDM):
Introduction about EDM process:
Electrical Discharge Machining (EDM) is a controlled metal-removal process that
is used to remove metal by means of electric spark erosion. In this process an electric
spark is used as the cutting tool to cut (erode) the workpiece to produce the finished
part to the desired shape. The metal-removal process is performed by applying a
pulsating (ON/OFF) electrical charge of high-frequency current through the electrode to
the workpiece. This removes (erodes) very tiny pieces of metal from the workpiece at a
controlled rate.
h = height of crater, mm, D = diameter of crater
Figure 3.1 Principle of EDM
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Table 3.2 Specifications of Electro discharge machines
MAKE ELECTRONICA MAKINO EDNC MAKINO EDNC
ORIGIN INDIA JAPAN JAPAN
CONTROL ------------------ CNC MGE 60 CNC MGE 20
TABLE
SIZE(mm)
550×350 550×750 350×550
TANK
SIZE(mm)
325×490×820 400×700×1000 300×430×680
TRAVERSE(m
m)- X mm
300 600 300
TRAVERSE(m
m)- Y mm
200 400 250
TRAVERSE(m
m)- Z mm
250 250 250
MAX. JOB
WEIGHT(kg)
300 1500 500
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3.3 Wire electrical discharge machining (WEDM)
Principles of EDM Electrical Discharge Machining (EDM) is a controlled
metal-removal process that is used to remove metal by means of electric spark erosion.
In this process an electric spark is used as the cutting tool to cut (erode) the workpiece
to produce the finished part to the desired shape. The metalremoval process is
performed by applying a pulsating (ON/OFF) electrical charge of high-frequency current
through the electrode to the workpiece. This removes (erodes) very tiny pieces of metal
from the workpiece at a controlled rate.
Major Components
A Wire EDM system is comprised of four major components.
(1) Computerized Numerical Control (CNC)
Think of this as “The Brains.”
(2) Power Supply
Provides energy to the spark.
Think of this as “The Muscle.”
(3) Mechanical Section
Worktable, work stand, taper unit, and wire drive mechanism.
Think of this as “The Body.”
(4) Dielectric System
The water reservoir where filtration, condition of the water and temperature of the
water is provided and maintained.
Think of this as “The Nourishment.”
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Table 3.3 Specifications of Wire electrical discharge machining (WEDM)
Make ELECTRONICA MAKINO
Origin INDIA JAPAN
Table
Size(mm)
150×400×500 770×570×210
Traverse-
X (mm)
300 600
Traverse-
Y (mm)
400 440
Traverse-
Z (mm)
150 220
Traverse-
UAxis
(mm)
±15 28
Traverse-
V Axis
(mm)
±15 28
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3.4 Grinding:
3.4.1 Introduction about grinding process:
Grinding is a metal cutting operation performed by means of abrasive particles
rigidly mounted on a rotating wheel. Each of the abrasive particles act as a single point
cutting tool and grinding wheel acts as a multipoint cutting tool. The grinding operation
is used to finish the work pieces with extremely high quality of surface finish and
accuracy of shape and dimension. Grinding is one of the widely accepted finishing
operations because it removes material in very small size of chips 0.25 to 0.50 mm. It
provides accuracy of the order of 0.000025 mm. Grinding of very hard material is also
possible.
Figure 3.2 cutting action of abrasive grains in Grinding Machine
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3.4.2 Grinding wheels
Grinding wheel consists of hard abrasive grains called grits, which perform the
cutting or material removal. A grinding wheel commonly identified by the type of the
abrasive material used. The conventional wheels include aluminum oxide and silicon
carbide wheels while diamond and CBN (cubic boron nitride) wheels fall in the category
of super abrasive wheel.
3.4.3 Grinding wheel abrasives:
An abrasive is a hard and tough substance. It has many sharp edges.
Abrasives of following types
1. Natural
Sandstone
Emery
Diamond
Garnet
2. Synthetic
Aluminum oxide
Silicon carbide
Cubic boron nitride
Boron carbide
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Table 3.4 Surface grinding machine
MAKE JAKOBSEN JAKOBSEN JAKOBSEN
MODEL 618 1026 1832
ORIGIN DENMARK DENMARK DENMARK
NO.OF
MACHINE
06 04 01
TABLE SIZE 450×250 650×250 800×450
TRAVERSE
X AXIS( mm)
450 650 900
TRAVERSE
Y AXIS( mm)
200 300 500
TRAVERSE
Z AXIS( mm)
400 400 650
MAGNETIC
BED
250×450 250×600 450×800
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3.5 Cylindrical grinding
The cylindrical grinder is a type of grinding machine used to shape the outside of
an object. The cylindrical grinder can work on a variety of shapes; however the object
must have a central axis of rotation. This includes but is not limited to such shapes as a
cylinder, an ellipse, a cam, or a crankshaft.
Plate 3.1 Cylindrical Grinding Machine
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Table 3.5 Specification of Cylindrical Grinding Machine
MAKE STUDER
MODEL FAVOURIT-S 30
ORIGIN SWITZERLAND
NO.OF MACHINES 01
SWING OVER BED, mm 350
CHUCKING DIA
INTERNAL mm
125
CENTRE DISTANCE, mm 650
TABLE SWIVEL, Degree 10 ◦
WHELL HEAD SLIDE,
mm
300
3.6 Jig Grinding
Introduction about jig grinding process:
A jig grinder is a machine tool used for grinding complex shapes and holes
where the highest degrees of accuracy and finish are required.
It may be used to grind items such as jigs, dies, and gauges. A jig grinder
typically uses a removable, air-driven spindle. This is used to rotate the grinding wheels.
The air spindles are interchangeable to achieve varying surface speeds.
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Grinding machines generally work on a similar principle to jig grinding. But one of
the limitations of the various grinding machines is their lack of precision. Hence for
precision grinding Jig grinding machines are used. Many Jig machines are now
computerized and operate with special software.
This often eliminates much of the geometric calculating once required of the
operator. Much of the labor has also been reduced by the automation of these
machines. The improvements made can result in much faster grinding, operation by
less-skilled workers, and a higher degree of accuracy.
Plate 3.2 Jig Grinding Machine
Jig grinding machine in GTTC:
MOORE Jig grinding machine
Model CPS 450
ORIGIN USA
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Table3.6 MOORE Jig grinding machine Specification
Maximum bed
travels
X axis 460mm
Y axis 280mm
U axis 1.5mm (depth of cut)
C axis rotary 360˚
Capacity of
outside diameter
196mm
Spindle RPM
Minimum 4000
Middle 60,000
Maximum 1, 20,000
Maximum weight
of job
150 kg
Least count of
machine
0.0001mm
Accuracy of M/c 2 to 3microns
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3.7 LASER WELDING
Laserwelding is a non-contact process that requires access to the weld zone
from one side of the parts being welded. The weld is formed as the intense laser light
rapidly heats the material-typically calculated in milli-seconds. The flexibility of the laser
offers three types of welds; conduction mode, conduction/penetration mode and
penetration or keyhole mode.
One of the largest advantages that pulsed laser welding offers is the minimal
amount of heat that is added during processing. The repeated "pulsing" of the beam
allows for cooling between each "spot" weld, resulting in a very small "heat affected
zone". This makes laser welding ideal for thin sections or products that require welding
near electronics or glass-to-metal seals. Low heat input, combined with an optical (not
electrical) process, also means greater flexibility in tooling design and materials.
Figure 3.3 Laser Welding Process
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Welding requires high energy density that can be achieved by working at the
focal point of the optical system. The absorption coefficient of the laser beam by the
material depends of material nature and Wavelength of the laser source
At sufficiently high specific powers, a key hole filled with metal vapour is formed
in the material. The wall of the keyhole consists of molten liquid metal. The molten pool,
which is created and maintained in this way, is moved between the parts to be
assembled and the metal resolidifies behind the laser beam.
This phenomenon, which occurs in the case of a continuous beam (laser) is
significantly different in the case of a pulsed beam (pulsed YAG laser). Indeed, the bead
is then created by a series of partially overlapping spots. The welding process is then
similar to that already described as a result of the reached peak energy levels, the
material is melted or, even, vaporized instantaneously. This is followed condensation
and immediate solidification.
3.7.1 Preparations of Joints
The preparation of joints is very important having many implications regarding
the design of the weld.
The workpieces are correctly positioned together
The workpieces are not beveled.
3.7.2 Main Materials Worked With Laser Yag Machine
Ferrous metals,
Non-Ferrous Metals
Plastics
Ceramics
Leather
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Plate 3.3 Nd YAG Continues Wave Laser:
Table 3.7 Specification of Nd YAG Continues Wave Laser
Capacity 400W CW-Nd
Size 500×300
Precision 0.02mm on 50mm
Operation Cutting and welding
Control software FLOCON
Assisting gas O2,N2,A2
Machinability CUTTING: Steel up to 2mm, Stainless
steel up to 1 mm, suitable for thin foil
cutting
WELDING: Stainless steel and Steel up to
1mm
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3.8 LASER CUTTING
Laser cutting is one of the most common industrial applications of the laser. In
many cases, the laser happens to be able to cut faster and with a higher quality than the
competing processes ( punching/nibbling, plasma, abrasive fluid jet, wire EDM…)
Plate 3.4 Laser Cutting Process
The principle of laser cutting
Laser cutting is a thermal separation process. Our pulsed Nd: YAG and fiber
lasers permit a controlled heat entry which is optimum for fine cutting. The high peak
performance of our laser permits a maximum cut depth of up to 10mm.
As the laser beam can be focused on a very small diameter for high precision,
fine cuts are possible with a minimum cut width of up to 15 µm (0.0006 in). In addition,
the heat-affected zone along the cut is very small (up to 2µm). This means that
deformations of the parts to be processed can be avoided.
The high energy depth in the focus point of the laser beam causes the material to
melt and evaporate. By using an active or neutral process gas, for example, oxygen,
nitrogen, or argon, the melted material is blown out. If the work piece or laser beam is
now moved, a cut is created.
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The smallest possible cut width is dependent on both the beam characteristics
and the material and material strength. When cutting fine contours, the precision and
dynamics of the cutting machine are of extreme importance.
Table 3.8 Specification of Laser Cutting Machine
Power 2000W CO2
X/Y/Z table 1250×1250×400mm
Precision 0.05mm on 50mm
Application Cut any profile on metals:MS:14mm thick,
stainless steel-5mm thick,Al-4mm thick,
Cu-1.5 mm thick, wood upto-25mm thick
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Chapter 4
QUALITY CONTROL
4.1 INSPECTION
Inspection is the most common method of attaining standardization, uniformity
and quality of workmanship. It is the cost art of controlling the product quality after
comparison with the established standards and specifications. It is the function of quality
control. If the said item does not fall within the zone of acceptability it will be rejected
and corrective measure will be applied to see that the items in future conform to
specified standards.
Inspection is an indispensable tool of modern manufacturing process. It helps to
control quality, reduces manufacturing costs, eliminate scrap losses and assignable
causes of defective work
4.2 PURPOSE OF INSPECTION
1. By thorough inspection, we can detect faults at every manufacturing process and
rectify them.
2. It helps in building up the reputation of a firm or concern.
3. It improves the quality of the product.
4. It reduces cost spent on scrap pieces and further process can be stopped if
mistake is going on.
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4.3 Types of Inspection
Floor Inspection:
It suggests the checking of materials in process at the machine or in the
production time by patrolling inspectors. These inspectors move from machine to
machine and from one to the other work centres. Inspectors have to be highly skilled.
This method of inspection minimize the material handling, does not disrupt the line
layout of machinery and quickly locate the defect and readily offers field and correction.
Centralized Inspection:
Materials in process may be inspected and checked at centralized inspection
centre which are located at one or more places in the manufacturing industry.
Combined Inspection:
Combination of two methods whatever may be the method of inspection, whether floor
or central. The main objective is to locate and prevent defect which may not repeat itself
in subsequent operation to see whether any corrective measure is required and finally
to maintained quality economically.
4.4 INSTRUMENTS AT INSPECTION DEPARTMENT
1. Profile projector
2. Tool makers microscope
3. Height master
4. Co-ordinate measuring machine
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1. PROFILE PROJECTOR
The main principle of operation is a specimen is placed on the glass stage. The
stage is then illuminated from below and the resulting image is picked up by the
microscope objectives and projected to a large built-in projection screen. Since the
specimen has underlighting, the fine microscopic details are eliminated and only the
details of contour and profile are seen. A drawing can be affixed to the profile projector‟s
large viewing screen and the contour can be easily traced or compared to other profiles
and contours on the other drawings.
Plate 4.1 Profile Projector
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Table 4.1 Specifications of Profile Projector
INSTRUMENT PROFILE PROJECTOR
ORIGIN JAPAN
Effective diameter, mm 250
Angular resolution, range, degree 1.±360º
Cross travel range, mm 50×50
Work stage dimension, mm 152×152
Micrometer head, mm 0.001×25
Max. work piece height, mm 75
Special accessories 20X,50X,10X
Accuracy 0.001
2. TOOL MAKER’S MICROSCOPE
A tool maker microscope is a type of a multi functional device that is primarily
used for measuring tools and apparatus. These microscopes are widely used and
commonly seen inside machine and tools manufacturing industries and factories. These
microscopes are also inside electronics production houses and in aeronautic parts
factories. A tool maker microscope is an indispensable tool in the different
measurement tasks performed throughout the engineering industry.
The main use of a tool maker microscope is to measure the shape, size, angle,
and the position of the small components that falls under the microscope‟s measuring
range.
A tool maker microscope is primarily used for measuring the shape of different
components like the template, formed cutter, milling cutter, punching die, and cam. The
pitch, external, and internal diameters are specifically measured as well.
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The thread gauge, guide worm, and guide screw are conveniently handled as
well. As far angles are concerned, the thread and pitch angle are of chief concern.
Plate 4.2 Tool Maker‟s Microscope
Table 4.2 Specification of Tool Maker‟s Microscope
INSTRUMENT TOOL MAKER‟S MICROSCOPE
ORIGIN JAPAN
Magnification 10X,15X,20X
Stage size 152×152
Travelling distance, mm 50×50
Max.work piece height, mm 115
Accuracy 0.005
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3. HEIGHT MASTER
It is a high precision instrument to measure and transfer of height on the job. It
can be used as a master for calibration in Standards
Room and in Tool Room
Plate 4.3 Height Master
Table 4.3 Specification of Height Master
INSTRUMENT HEIGHT MASTER
ORIGIN JAPAN
Max.height,mm 300
Accuracy, mm 0.001
Read out DIGITAL
Stroke,mm 20
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4. CO-ORDINATE MEASURING MACHINE
A coordinate measuring machine (CMM) is a device for measuring the physical
geometrical characteristics of an object. This machine may be manually controlled by an
operator or it may be computer controlled. Measurements are defined by a probe
attached to the third moving axis of this machine. Probes may be mechanical, optical,
laser, or white light, amongst others.
The typical "bridge" CMM is composed of three axes, an X, Y and Z. These axes
are orthogonal to each other in a typical three dimensional coordinate system. Each
axis has a scale system that indicates the location of that axis. The machine will read
the input from the touch probe, as directed by the operator or programmer. The
machine then uses the X,Y,Z coordinates of each of these points to determine size and
position with micrometre precision typically.
A coordinate measuring machine (CMM) is also a device used in manufacturing
and assembly processes to test a part or assembly against the design intent. By
precisely recording the X, Y, and Z coordinates of the target, points are generated which
can then be analyzed via regression algorithms for the construction of features. These
points are collected by using a probe that is positioned manually by an operator or
automatically via Direct Computer Control (DCC). DCC CMMs can be programmed to
repeatedly measure identical parts, thus a CMM is a specialized form of industrial robot.
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Plate 4.4 Shows Co-ordinate Measuring Machine
Table 4.4 Specification of Co-ordinate Measuring Machine
MAKE CARL ZIESS
ORIGIN GERMANY
Measuring range-„X‟, mm 550
Measuring range-„Y‟, mm 500
Measuring range-„Z‟, mm 450
Overall CMM size 1260×1340×2660
Max.wt of work piece 600
Applications Co-ordinate measuring, surface
scanning, Digitizing curve and
contour measurement
Note: Machine Hour Rate of co-ordinate measuring machine (CMM) - Rs1000/hr
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Chapter 5
CASE STUDY
The manufacturing process and time estimation of following components:
1. BRACKET
2. WASHER
Figure 5.1 Bracket Model
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5.1 Flow Chart of Manufacturing Bracket
Procedure
5.2 CNC Milling:
Most CNC milling machines are computer controlled vertical mills with the ability
to move the spindle vertically along the Z-axis. This extra degree of freedom permits
their use in diesinking, engraving applications etc. CNC machines can exist in virtually
any of the forms of manual machinery, like horizontal mills. The most advanced CNC
milling-machines, the multiaxis machine, add two more axes in addition to the three
normal axes (XYZ).
CNC MILLING
Stage Inspection
Wire EDM
Bench Work and
Fitting
Final Inspection
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These machines have developed from the basic NC (NUMERIC CONTROL)
machines. A computerized form of NC machines is known as CNC machines. A set of
instructions (called program) is used to guide the machine for desired operations.
SETTING UP A CNC MACHINE:
Clean all surfaces, for example table, vise jaws and part very good with a
lint free cloth.
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Load tools needed.
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Load part in vise.
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Set work fixture offsets. Make sure the machine is using the WFO that
the program will be using.
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Adjust coolant lines so coolant can properly cool tools and wash
chips away.
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Cycle Start.
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Plate 5.2 Milling Operation
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5.3 STAGE INSPECTION:
All parts are inspected in their respective stages while processing. This is known
as stage inspection. It helps in rectifying the mistake occurred during each operation.
Suppliers shall establish and maintain documented procedures for inspections
and tests of the equipment during manufacturing and assembly. The procedures shall
provide for the verification by inspections or tests, at appropriate points in the
manufacturing, that the characteristics of the item conform to the requirement specified
for that stage of the process. In general the verification should be made as close as
possible to the point of realisation of the characteristic.
The in-process verification may include:
Set-up and first piece inspection.
Inspection or test by machine operator.
Automatic inspection or test.
Fixed inspection stations.
Equipment shall be held until the required inspection and test has been completed.
Equipment shall not be released for further use until it has been verified and the
results of the verification are satisfactory.
5.4 Wire EDM:
Wire electrical discharge machining (WEDM), also known as wire-cut EDM and
wire cutting, a thin single-strand metal wire, usually brass, is fed through the work piece,
submerged in a tank of dielectric fluid, typically deionized water. Wire-cut EDM is
typically used to cut plates and to make punches, tools, and dies from hard metals that
are difficult to machine with other methods.
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Wire EDM uses electro-thermal mechanisms to cut electrically conductive
materials. The material is removed by a series of discrete discharges between the wire
electrode and the workpiece in the presence of dielectric fluid, which creates a path for
each discharge as the fluid becomes ionized in the gap. The area where discharge
takes place is heated to extremely high temperature, so that the surface is melted and
removed. The removed particles are flushed away by the flowing dielectric fluids. The
wire EDM process can cut intricate components for the electric and aerospace
industries.
Plate 5.4 Wire EDM
5.5 Bench Work:
The bench work and fitting plays an important role in every engineering workshop
to complete and finish the job to the desired accuracy. The work carried out by hand at
the bench is called bench work. Whereas fitting is the assembling of parts together by
fitting, chipping, sawing, fore capping, tapping etc. necessary after the machine
operation. This may or may not be carried out of the bench.
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The tools use in filling practice may be classified into the following group:
1) Holding tools
2) Striking tools
3) Measuring tools
4) Marking tools
5) Cutting tools
6) Scrapping tools
5.6 Holding tools (Vices): The holding tools are vice are required to hold the work
firmly. Following are the various types of vice for different purposes. Following are the
different types of holding tools:-
Bench Vice
Hand Vice
5.7 Striking tools (Hammers): The striking tools are hammers are used to strike the
job or tool. A hammer consists of a bead, striking face, peen and a shaft or handle.
5.8 Cutting Tools: The chief cutting tools used in fitting are cold, chisels, and files.
5.9 Method Filling: The following three methods are commonly used for filling.
Cross Filling
Straight Filling
Draw Filling
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5.10 Final Inspection:
Final inspection is one in which the product manufactured is inspected completely after
completion. The contractor shall carry out all final inspection and testing in accordance
with the quality plan and/or documented procedures to complete the evidence of the
conformance of the finished equipment to the specified requirements. The quality plan
and/or documented procedures for all final inspection and testing shall require that all
specified inspections and tests, including those specified on receipt of equipment or in-
process, have been carried out and that the results meet specified requirements.
Inspections and tests procedures shall define:
The location where the inspection or test is to be performed (supplier premises)
The parameters to be measured.
The characteristics or functions that have to be verified.
The acceptance criteria, including any applicable standards or codes.
The requirements for special tools, fixtures, gauges, test set-ups and measuring
equipment.
Table5.1 Time Taken For Manufacturing Bracket
Operation Time in Minutes
CNC Milling 30
Stage Inspection 10
Wire EDM 30
Bench Work 15
Final Inspection 20
TOTAL Time Taken 105
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2. Washer Model
Figure 5.2 Model of a WASHER
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5.11 Flow Chart of Manufacturing Washer
PROCEDURE
5.12 TURNING:
Turning is a machining process to produce parts round in shape by a single point
tool on lathes. The tool is fed either linearly in the direction parallel or perpendicular to
the axis of rotation of the workpiece, or along a specified path to produce complex
rotational shapes. The primary motion of cutting in turning is the rotation of the
workpiece, and the secondary motion of cutting is the feed motion. A set of instructions
(called program) is used to guide the machine for desired operations.
Turning
Stage Inspection
Wire EDM
Bench Work
Final Inspection
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5.13 Cutting fluids
Application of the cutting fluid is very important in a turning operation. The cutting
fluid should be applied in adequate quantity and at moderate pressure. The cutting
fluid should be directed on the work just above the point where it makes contact with
the tool.
5.14 Design Consideration for Turning Operation
• Parts should be designed so that can be fixtured and clamped in the work
holding devices
• Dimensional accuracy and surface finish specified should be as wide as possible
• Avoid sharp corners, tapers, and major dimensional variations in the part
• Cutting tools should be able to travel across work piece without obstruction
• Standard cutting tools, inserts, and tool holders should be used
Materials should be selected for their machineability.
Plate 5.14 Turning Process
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5.15 STAGE INSPECTION:
All parts are inspected in their respective stages while processing. This is
known as stage inspection. It helps in rectifying the mistake occurred during each
operation.
5.16 Wire EDM:
Wire electrical discharge machining (WEDM), also known as wire-cut EDM and
wire cutting, a thin single-strand metal wire, usually brass, is fed through the work piece,
submerged in a tank of dielectric fluid, typically deionized water. Wire-cut EDM is
typically used to cut plates and to make punches, tools, and dies from hard metals that
are difficult to machine with other methods.
5.17 BENCH WORK:
The main operations commonly performed in bench work may be classified
1. Chipping
2. Filing
3. Grinding
4. Sawing
5. Marking
6. Tapping
5.18 FINAL INSPECTION:
Final inspection is one in which the product manufactured is inspected
completely after completion.
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Table 5.2 Time Taken For Manufacturing Washer
Operation Time in Minutes
Turning 10
Stage Inspection 5
Wire EDM 10
Bench Work 5
Final Inspection 10
TOTAL Time Taken 40
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CONCLUSION
It is necessary for an organization to compete in the fluctuating market and to be
profitable one. Profit always comes when goods are produced with maximum
productivity cost reduction proper training. This can be achieved through optimum use
of resources available in the organization and also by optimizing the time involved in
every element of the process. Non-productive time should be eliminated wherever
possible in order to increase productivity.
Through this training, is comprehensive understanding about the real industrial
working condition and practice. All these valuable experiences and knowledge is
acquired through the direct involvement in task but also through other aspects of the
training such as: work observation, interaction with collogues, superior and other people
related to the field. So in this way there is unlimited knowledge and many things to learn
here in this center.
The details about the EDNC Department, CNC Turning, Quality control, Laser
Department, Planning, CNC Milling and the machines used and respective
specifications operations are learnt.
Along with it detailed case study about the manufacturing process of Washer and
Bracket are learnt.