IN-PLANT TRAINING AT GOVERNMENT TOOL ROOM & TRAINING CENTERMYSORE

8/13/2019 IN-PLANT TRAINING AT GOVERNMENT TOOL ROOM & TRAINING CENTERMYSORE

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IN-PLANT TRAINING AT GOVERNMENT TOOL ROOM & TRAINING CENTERMYSORE

Chapter 1

1 introduction:

In-Plant Training will provide an industrial exposure to the students as well as to

deve lop the i r ca reer i n the h igh tech indus t r ia l requ i rements .

Reputed companies are prov iding in-plant t ra ining to Students.

Here studen ts are ini t ial ly to get counseled in order to e merge out

their in teres t in various streams and what are all t he basic

concepts they now about tha t do main.

In-plant Training re!ers to a program which aims to provide supervised

practical training with spiced time! rame. This training can be carried

out either in governme nt organi"ations or in priva te sector.

In-plant training is a programme !or post graduates that gives them an

opportunit y to expose the mselves in the real career world so as

to t hey wil l learn

how to relate theoret ical learning be!ore and real pract ical in woring#s

environment.

$esides that% in !uture% they wil l b e having good preparation and

understanding !or their !ield o! pro!ession. &!ter the success!ul completion o!

stud ies students has to !ace this compet i t ive wor ld wi th this

nowledge to !ace man y proble ms and to !ind the righ t

solut ions wh ich is to be solved in the minimum durat ion o!

time. The implant t ra in ing is gett ing tota lly di!!erent !rom the

class environments.'enerally the students will go !or their in-plant training during their

semester vacat ions. Such in-p lant t ra in ing wil l prov ide an

indus tr ia l exposu re to the s tuden ts as we ll as to develop

thei r caree r in the high tec h indus tr ia l requirements.

Reputed companies are prov iding in-plant t rain ing to our

studen#(s.Objectives of In-Plant Training:

Dep t of Mech anical Engine eing! S"CE! M#$oe

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CH&PTE' (

P'O$I!E O$ THE COMP&%# )"T * TC+

,Its precision that .a/es the 0orld go round

& premier Tool Room and Training entre established in 3445 at *ysore% 6arnataa%

India with assistance o! the 'overnment o! /enmar% has extensive !acilities in Tool

maing and training. "T*TC is a modern tool room and training centre with state-o!-art

C&2C&Mequipment% machinery and inspection !acilities to meet the complex needs o!

customers

.

"T*TCis committed to achieve customer satis!action in quality and delivery o! tool

engineering education% services and precision machining.

"T*TC has acquired mastery in Tool 1ngineering and vast experience in

conducting well structured% practical oriented training programmes leading to post

graduation% diplomas and certi!icates.

Reali"ing the need to update and upgrade the sills o! existing technical personnel

in industry% "T*TCconducts a number o! short term programmes in tool design% advanced

manu!acturing techniques% design analysis and 7 programming !or manu!acture and

other aspect o! manu!acturing.

The state-o!-art sophisticated manu!acturing !acility consists o! 8 to 9 axis high-

speed C%C .achining centres3 C%C jig grinding3 C%C spar/ erosion3 C%C 0ire EM3

C%C co-ordinate .easuring machine and other supporting machineries and !acilities.

The computer integrated manu!acturing !acility is supported by high end so!tware:s

such as 4ni-"raphics3 Pro-E3 Master-ca.3 Mechanical es/top and &nal5sis

pac/age li/e C-Mold3 Mold $lo0 and Pro-Cast for design and .anufacture6

;ith the bacing o! quali!ied and experienced designer:s production and quality assurance

engineer


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161 !O4T O$ "O7E'%ME%T TOO! 'OOM * T'&I%I%" CE%TE'3 M#8O'E:

1- 17TR&71

S- S1>RIT? R22*

3. HS* *@

5. *&I7T17&71

8. &SS1*$(?

A. $17H ;2R6S

9. /7

B. C>&(IT? &&(?SIS

D. **

E. 7 *I((I7'

4. 7 *I((I7'

3F.*&R61TI7' /1P&RT*17T

33. P(&77I7' /1P&RT*17T


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35.S>R)&1 'RI7/I7'

38.7 T>R7I7'

3A.GI' 'RI7/I7'

39.;IR1 1/*

3B.1/*

3D.TR&I7I7' &7/ &2>7TS S1TI27

3E.&7T117

34.&/ 17TR1

5F.(&S1R *@

M&%&"EME%T:

16( M&'9ETI%" EP&'TME%T:

*aring reaches right customers and explains him about special machines and

quality o! wor carrying out in the industry through advertisement and by other means.

Thus it brings wor orders !or company and taes care !or dispatching the same in

scheduled time. It consists o! mareting departments H2/ and mareting o!!icials wor

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 i! necessary.

Preparation o! estimations@worsheets% consulting tool planning and tool production

!or schedule and cost details i! required.

Responsible !or preparation o! quotation and sending same to the customer.

oordinating with administration department !or advertisement.

Responsible !or releasing wor order instructions to planning and !ollow-up !or the

status o! order.

In the event o! any delay in meeting the delivery schedule the in!orming customer

accordingly.


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To dispatch the completed wor order to customer with proper documents.

&uthori"ing to sign delivery note.

Table 1 or/ Order Instruction

)rom+ *areting To+ Planning2rder con!ormation number

ustomer ISR2

/escription 7on Sliver plate

Scope o! wor (aser maring

Cuality 3BF 7os

/rawing =speci!ication Provided by the customer.

Raw material@ speci!ication Silver

/ate o! delivery 35-3F 38

Priority 7ormal

Penalty clause i! any ------

&cceptance criteria isual acceptance

Special instructions i! any ------

&ny other in!ormation ------

16; P!&%%I%" EP&'TME%T:

$e!ore starting the actual production process planning is done. It gives the idea o!

sequence o! operations% selection o! machine% cost and time required% at the same time

process will be per!ormed with high percentage o! material utili"ation. Planning is a primary

!unction o! human and material resources in an enterprise to reali"e maximum pro!its.

Process planning represents the lin between 1ngineering design and shop !loor

manu!acturing. Since process planning determines how a part will be manu!actured% it is

the maor determinant o! manu!acturing costs and pro!itability.

P!&%%I%" CO%8I8T8 O$ $O!!OI%" O'98:

Tool and high tech components+ It involves ob planning with e!!ective utili"ation o!

machines available and using right tool !or right operation3. Preparing process sheet+ process sheet in !orms the operations and machining

conditions such as diameter o! components% !eed% speed% material setting etc.

5. Gob !ollows up+ to !ollow up the progress o! the ob in the shop !loor.

8. Pre tooling+ Pre machining o! the ob in conventional machines to save the time o!

high tech machines.

A. Route card+ Route card is prepared to mention in sequence.


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Table (


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$!O CH&T O$ I$$E'E%T OPE'&TIO%8 I% "TTC

16= E8I"% * P'O"&'MMI%" EP&'TME%T:

It is the maim organ o! the industry. Cuality o! wor done% hence the name and !ame

o! the company depends largely on this section. Its !unction can be enlisted as below.

ollection o! required technical data% study o! component drawing etc.

/esign calculations are done and suitable assumptions are made.

/esign layout considering cost e!!ectiveness% machine available. It also includes

comparing new design with similar.

/esign review% design veri!ication and changes i! any will be implemented.

&ssessment o! material selection.

Preparation o! drawing and bill o! materials.

'eneration o! 7 part programs considering optimum cutting tools and parameter.


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Planning Department

Customer

MarketingDepartment

Process Sheet

MachineSelection

TimeEstimation

Operator

Job Card Processing

Dispatch

Quality check


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The design department is well equipped with the so!tware lie.

3. &>T2&/

5. *&ST1R &*

8. S2(I/ ;2R6S

Chapter ;

M&CHI%E8 &T "TTC

(61 C%C MI!!I%":

'T = T *ysore is well equipped with the 7 milling machines. *ost o! the

machines are HI/17H&I7 control. So I engaged mysel! by observing how the obs setting

are done. )or every ob% designer o! design department does the modeling and generates

the tool paths. He will give the program !ile name to the operator o! the 7 milling

machines% who loads the programming to the P and calls the program on the machine.

So!tware used to mae the models in S2(I/ ;2R6S% and *&ST1R-&*. Tool paths are

being generated in *&ST1R-&*.


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Plate 1 C%C Milling

7umerical control o! machine tools may be de!ined as a method o! automation in which

various !unctions o! machine tools are controlled by letters% numbers and symbols.

In 7 machine tools one or more o! the !ollowing !unctions may be automatic+

aJ Starting and stopping o! machine tool spindle

bJ ontrolling the spindle speed

cJ Positioning the tool tip at desired locations and guiding it along desired paths by

automatic control o! the motion o! slides

dJ ontrolling the rate o! movement o! the tool tip Ki.e. !eed rateJ

eJ hanging o! tools in the spindle.

Table > 8pecification Of C%C Milling Machines

*&61 *I6R27 *I6R27 *I6R27 *I6R27 *I6R27*2/1( ;)83/1 ;)85 HD9F HS*95F >*BFF2RI'I7 S;ILL S;ILL S;ILL S;ILL S;ILL

72.2) *@ F5 F3 F3 F3 F3

ontrol T7AFD T7A59 T7A39 R*S8 T7A5BTable si"e

KmmJ

98Fx4FF BFFx3FFF MB8F BFFx9FF MB8F

Traverse 9BF BFF D9F 95F BFF


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KmmJ-N

Traverse

KmmJ-?

9FF BFF BFF A8F BFF

Traverse

KmmJ-L

AFF A9F 99F 55F 9FF

Cuill si"e

KmmJ

4F EF -- -- --

Spindle

speedKRP*

J

AF-AFFF 3F-B8FF 5F-B8FF 9FFFF 5F-B8FF

7 rotary

table M@P;

9FFOB BFFOB BFFOB -- BFFOB

&utomatic

tool changer

-- 55 8A FB AA

*ax. ;t o!

ob KgsJ

89F AFF 9FF 5FF 9FF

Tilting table

range !rom

m@c

)ive axis *achining centre >S* BFF 5FF

Tilting table

range to m@v

A9o

(6( E!ECT'IC I8CH&'"E M&CHI%I%" EP&'TME%T:

or/ing principle of EM process:

Electric discharge .achining KEMJ% sometimes also re!erred to as spar/

.achining% spar/ eroding% burning% die sin/ing or 0ire erosion% is a manu!acturing

process whereby a desired shape is obtained using electrical discharges KsparsJ. *aterial

is removed !rom the wor piece by a series o! rapidly recurring current discharges between

two electrodes% separated by a dielectricliquid and subect to an electric voltage.

1lectrical discharge machining is a machining method primarily used !or hard metalsor those that would be very di!!icult to machine with traditional techniques. 1/* typically

wors with materials that are electrically conductive% although methods !or machining

insulating ceramics with 1/* have also been proposed. 1/* can cut intricate contours or

cavities in pre-hardened steelwithout the need !or heat treatment to so!ten and re-harden

them. This method can be used with any other metal or metal alloy

In 1/*% a potential di!!erence is applied between the tool and wor piece. $oth the

tool and the wor material are to be conductors o! electricity. The tool and the wor

material are immersed in a dielectric medium. 'enerally erosene or deionised water is


Pa ge %%
http://en.wikipedia.org/wiki/Electrodehttp://en.wikipedia.org/wiki/Dielectrichttp://en.wikipedia.org/wiki/Liquidhttp://en.wikipedia.org/wiki/Voltagehttp://en.wikipedia.org/wiki/Ceramicshttp://en.wikipedia.org/wiki/Steelhttp://en.wikipedia.org/wiki/Electrodehttp://en.wikipedia.org/wiki/Dielectrichttp://en.wikipedia.org/wiki/Liquidhttp://en.wikipedia.org/wiki/Voltagehttp://en.wikipedia.org/wiki/Ceramicshttp://en.wikipedia.org/wiki/Steel


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used as the dielectric medium. & gap is maintained between the tool and the wor piece.

'enerally the tool is connected to the negative terminal o! the generator and the wor

piece is connected to positive terminal.

ielectric $luid:

/ielectric !luids used in 1/* process are hydrocarbon oils% erosene and deionisedwater. The !unctions o! the dielectric !luid are to+

&ct as coolant.

&ct as a !lushing medium !or the removal o! the chips.

It carries away the eroded metal particles along with it.

Electrode Material:

1lectrode material should be such that it would not undergo much tool wear when it is

impinged by positive ions.Q High electrical conductivity

Q High thermal conductivity

Q Higher density

Q High melting point

Q 1asy manu!acturability

Q ost

Table ? Electro ischarge Machines

*&61 1(1TR27I& *&6I72 1/7 *&6I72 1/7

2RI'I7 I7/I& G&P&7 G&P&7

27TR2( ------------------ 7 *'1 BF 7 *'1 5F


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T&$(1 SIL1KmmJ 99F89F 99FD9F 89F99F

T&76 SIL1KmmJ 859A4FE5F AFFDFF3FFF 8FFA8FBEF

TR&1RS1KmmJ-

N mm

8FF BFF 8FF

TR&1RS1KmmJ-

? mm

5FF AFF 59F

TR&1RS1KmmJ-

L mm

59F 59F 59F

*&N. G2$

;1I'HTKgJ

8FF 39FF 9FF

*&HI71 2St

KRSJ

EF (&6HS 3.9 R2R1 3.9 R2R1

*&HI71 H2>R

R&T1

RS 3FFF@Hr RS 3FFF@Hr RS 3FFF@Hr

ifferent t5pes of electrodes used in "T * TC:

Plate ( t5pes of electrodes

(6(61 I'E E!ECT'IC&! I8CH&'"E M&CHI%I%" )EM+ EP&'TME%T:

Principle of ire Electrical ischarge Machining

;ire electrical discharge machining K;1/*J% also nown as wire-cut 1/* and wire

cutting% a thin single-strand metal wire% usually brass% is !ed through the wor piece%

submerged in a tan o! dielectric !luid% typically deioni"ed water. ;ire-cut 1/* is typically

used to cut plates and to mae punches% tools% and dies !rom hard metals that are di!!icult

to machine with other methods.


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Plate ; Principle of ire Electrical ischarge

In wire 1/*% conductive materials are eroded and vapori"ed with a series o! high

!requency electrical discharges KsparsJ that are produced between an accurately

positioned moving wire Kthe electrodeJ and the worpiece in the presence o! a dielectric.

These high !requency pulses o! alternating or direct current is discharged !rom the wire to

the wor piece through an insulated dielectric !luid KwaterJ creating a very small discharge

spar gap.

Plate = ire EM Process

ire Electrode

;ire used in this machine as the cutting tool. The wire is usually made o! brass%copper% or tungsten% "inc- or brass- coated and multi-coated wires are also used. Pure

copper or electrolyte grade copper is extensively used as an electrode material. It is used

when !ine !inishes are required in the wor piece.

P'OCE88 P&'&METE'8 O$ I'E EM P'OCE88:

Machine Para.eters :

3. Table !eed

5. Pulse on time


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8. Pulse o!! time

A. )lushing

ire Para.eters :

3 *aterial o! wire

5 ;ire speed8 /iameter o! wire

A ;ire tension

Table @ ire Electrical ischarge Machining )EM+

*ae 1(1TR27I& *&6I722rigin I7/I& G&P&77o. 2!

*achines

F3 F3

Table

Si"eKmmJ

39FAFF9FF DDF9DF53F

Traverse-

N KmmJ

8FF BFF

Traverse-

? KmmJ

AFF AAF

Traverse-

L KmmJ

39F 55F

Traverse-

> &xis

KmmJ

O39 5E


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Traverse-

&xis

KmmJ

O39 5E

(6; C%C T4'%I%" EP&'TME%T:

Introduction &bout Turning Process:

Turning is the process whereby a single point cutting tool is parallel to the sur!ace. It

can be done manually% in a traditional !orm o! lathe% which !requently requires continuous

supervision by the operator% or by using a computer controlled and automated lathe which

does not. This type o! machine tool is re!erred to as having computer numerical control. In

the 7 turning process% a piece o! material is rotated on the lathe and a cutting tool is

traversed along two axis o! motion% transverse or longitudinal. The cutting tool is used until

the required depth and dimension is achieved. Turning can be on both sides% inside or

outside as per the needs and speci!ications.

C4TTI%" 8PEE8 &% $EE8 $O' I$$E'E%T T#PE O$ M&TE'I&!8 :

Table A

*aterial being turned )eed mm@rev uttingspeed

m@min.

&luminium F.5-3.FF DF@3FF

$rass KalphaJ-ductile F.5-3.FF 9F-EF

$rass K!ree cuttingJ F.5-3.9 DF-3FF

$ron"e KphosphorJ F.5-3.FF 89-DF

ast iron KgreyJ F.39-F.D 59-AF

opper F.5-3.FF 89-DF

Steel KmildJ F.5-3.FF 89-9F

Steel Kmedium carbonJ F.39-F.D 8F-89


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http://en.wikipedia.org/wiki/Computer_numerical_controlhttp://en.wikipedia.org/wiki/Computer_numerical_control


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Steel Kalloy-high tensileJ F.FE-F.8 9-3F

Table B C%C Turning Machines

*ae M&&9 T&9I8&&2rigin


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(6= "'I%I%" EP&'TME%T:

I%T'O4CTIO% &DO4T "'I%I%" P'OCE88:

& grinding machine% o!ten shortened to grinder% is a machine tool used !or grinding%

which is a type o! machining using an abrasive wheel as the cutting tool. 1ach grain o!abrasive on the wheel#s sur!ace cuts a small chip !rom the worpiece via shear

de!ormation.

'rinding is the most common !orm o! abrasive machining. It is a material cutting

process which engages an abrasive tool whose cutting elements are grains o! abrasive

material nown as grit. These grits are characteri"ed by sharp cutting points% high hot

hardness% chemical stability and wear resistance.

Plate > the grinding process

"'I%I%" HEE!8:

'rinding wheel consists o! hard abrasive grains called grits% which per!orm the

cutting or material removal. & grinding wheel commonly identi!ied by the type o! the

abrasive material used. The conventional wheels include aluminum oxide and silicon

carbide wheels while diamond and $7 Kcubic boron nitrideJ wheels !all in the category o!

super abrasive wheel.

8PECI$IC&TIO% O$ "'I%I%" HEE!:

& grinding wheel requires two types o! speci!ication

KaJ 'eometrical speci!ication

KbJ ompositional speci!ication

8E!ECTIO% O$ "'I%I%" HEE!8:

Selection o! grinding wheel depends upon the !ollowing !actors+

Physical and chemical characteristics o! the wor material

'rinding conditions


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Type o! grinding

)inish required

&rea o! contact

;heel speed

*ethod o! cooling

&mount o! stoc to be removed

&D'&8I7E8 O$ $O!!OI%" T#PE8:

16 %atural

Sandstone

1mery

/iamond

'arnet

(6 85nthetic

&luminum oxide

Silicon carbide

ubic boron nitride

$oron carbide


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Plate 1 84'$&CE "'I%I%" M&CHI%E I% "T * TC

*&61 G&62$S17 G&62$S17 G&62$S17

*2/1( B3E 3F5B 3E85

2RI'I7 /17*&R6 /17*&R6 /17*&R6

72.2)

*&HI71

FB FA F3

T&$(1 SIL1 A9F59F B9F59F EFFA9F

TR&1RS1

N &NISK mmJ

A9F B9F 4FF

TR&1RS1

? &NISK mmJ

5FF 8FF 9FF

TR&1RS1

L &NISK mmJ

AFF AFF B9F

*&'71TI

$1/

59FA9F 59FBFF A9FEFF

Table 11 C5lindrical "rinding Machine


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*&61 ST>/1R

2RI'I7 S;ITL1R(&7/

72.2) *&HI71S F3

S;I7' 21R $1/% mm 89F

H>6I7' /I&

I7T1R7&( mm

359

17TR1 /IST&71%

mm

B9F

T&$(1 S;I1(% /egree 3F

;H1(( H1&/ S(I/1%

mm

8FF

(6=61


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speed wheels% which reciprocate up and down the component. Gig 'rinding is used where

it is necessary to produce holes or slots to very tight tolerances.

Plate ? jig grinding process


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? axis 5EFmm> axis 3.9mm Kdepth o! cutJ axis rotary 8BF'rinding Headapacity o!

inside diameter

F.A to 4Fmm

>sing extension

plate

8A8mm

apacity o!

outside diameter

34Bmm

Spindle RP**inimum AFFF*iddle BF%FFF*aximum 3% 5F%FFF*aximum weight

o! ob

39F g

(east count o!

machine

F.FFF3mm

&ccuracy o!

machine

5 to 8microns

(6> !&8E' EP&'TME%T:

(6>61 !&8E' E!I%"

The creation o! a laser weld is based on the phenomenon o! locali"ed !usion o! the

material at the beam impact.


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Plate A 8ho0s Principle of !aser elding

;elding requires high energy density that can be achieved by woring at the !ocal point o!

the optical system. The absorption coe!!icient o! the laser beam by the material depends o!

material nature and ;avelength o! the laser source

&t su!!iciently high speci!ic powers% a ey hole !illed with metal vapours is !ormed in

the material. The wall o! the eyhole consists o! 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 resolidi!ies behind the laser beam.

This phenomenon% which occurs in the case o! a continuous beam KlaserJ is

signi!icantly di!!erent in the case o! a pulsed beam Kpulsed ?&' laserJ. Indeed% the bead is

then created by a series o! partially overlapping spots. The welding process is then similarto that already described+as a result o! the reached pea energy levels% the material is

melted.

&PP!IC&TIO%8:

&nchorage welding

Tight welding

M&I% M&TE'I&!8 O'9E ITH !&8E' #&" M&CHI%E:

3. )errous metals

5. 7on-!errous metals

8. Plastics

A. eramics

9. (eather

The .aFi.u. per.issible clearance for each of the .ost co..onl5 used joints:


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1dge to edge UF.F9smallest thicness

$y transparency UF.5top thicness

(ap oint UF.F9smallest thicness

%d #&" CO%TI%4E8 &7E !&8E':

Plate B % #ag Continues ave !aser

Table 1; %d #&" Continues ave !aser 8pecification

apacity AFF; ;-7d

Si"e 9FF8FFPrecision F.F5mm on 9Fmm

2peration utting and welding

ontrol so!tware )(227

&ssisting gas 25%75%&5

*achinability >TTI7'+ Steel up to 5mm%

Stainless steel up to 3 mm% suitable

!or thin !oil cutting

;1(/I7'+ Stainless steel and Steelup to 3mm

%d #&" !&8E' C4TTI%" &% E!I%" 'ODOT


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Plate 1 %d #ag !aser Cutting and elding 'obot

Table 1= %d #&" !aser Cutting &nd elding 'obot 8pecification

Power 39FF; P;-7/Robot arm coverage 5B9FEFF3D9FmmPrecision F.F3mm on 9Fmm&ttachments B-axis robot&pplication ut and weld any pro!ile on metals lie

stainless steel-Amm thic% *S-Emm thic%

&l-8mm thic

(6>6( !&8E' C4TTI%"

(aser cutting is one o! the most common industrial applications o! the laser. In many

cases% the laser happens to be able to cut !aster and with a higher quality than the

competing processes K punching@nibbling% plasma% abrasive !luid et% wire 1/*VJ

&88I8TI%" "&8:

In addition to the !ocusing procedure% a gas is inected on the beam axis through a

small-diameter no""le. This gas has the !ollowing e!!ect+

Mechanical action+ owing to its speed% it expels the molten material.

Che.ical action+ in cases o! the steels% oxygen can be used. This maes use o! the

exothermic character o! the combination o! iron in oxygen to improve cutting per!ormances.


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$igure 11 8ho0s !aser Cutting

P'I%CIP!E O$ !&8E' C4TTI%"

CO(!&8E' C4TTI%" M&CHI%E:

Plate 1( CO(!aser Cutting Machine

Table 1> CO(!aser Cutting Machine8pecification


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Focused beam

Rapid heating up on the surface

Injection of a gas

Drilling

Relative displacement/beam

Cutting


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Power 5FFF; 25N@?@L table 359F359FAFFmmPrecision F.F9mm on 9Fmm&pplication ut any pro!ile on metals+*S+3Amm thic%

stainless steel-9mm thic%&l-Amm thic%

u-3.9 mm thic% wood upto-59mm thic

(6>6; &7&%T&"E8 O$ !&8E' TECH%O!O"#:

'ood control o! the process% excellent reproducibility% increased quality

7o !iller required

;eld oint precision and beam !ineness allowing% !or example% welding o! groove or

in areas that are inaccessible when using conventional techniques.

(ow energy input and low temperature increases o! the worpiece put to use in

welding o! compact electronic units.

2nly slight de!ormations allowing the use o! light clamping tools.

(ittle or no reworing or resur!acing a!ter welding so that !inished parts are

obtained.

;elding on one pass% eliminating tedious preparatory worKbevelingJ and worpiecetooling operations.

Short cycle times thans to high welding speeds-high productivity

7o or little spatter.

CH&PTE' =

=61 G4&!IT# CO%T'O!


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I%8PECTIO%:

The acquire quality and per!ecting in the part it is necessary to inspect the tool parts

in all stages. This can be achieved by through inspection at every stage o! manu!acturing.

Inspection may be de!ined as Wthe !unction o! comparing or determining the con!ormance o!

product to speci!ication or requirements.

P4'PO8E O$ I%8PECTIO%:

3. $y through inspection% we can detect !aults at every manu!acturing process and

recti!y them.

5. It helps in building up the reputation o! a !irm or concern.

8. It improves the quality o! the product.

A. It reduces cost spent on scrap pieces and !urther process can be stopped i! mistae

is going on.

&ll parts are inspected in their respective stages while processing. This is nown as

stage inspection. It helps in recti!ying the mistae occurred during each operation. )inal

inspection is one in which the product manu!actured is inspected completely a!ter

completion o! all !inal assembly.

I%8PECTIO% CHEC9 !I8T:3. hec !or the dimensional accuracy o! the !inished product.

5. hec !or the sur!ace !inish o! the !inished product.

T#PE8 O$ I%8PECTIO%:

/ue to the varieties o! product being manu!actured% there are various inds o!

inspections. $ut mainly they are as !ollows.

3. Tool inspection

5. )irst piece inspection

8. ;oring inspection

A. Sampling inspection

9. 2peration inspection

B. )inal inspection


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D. Pilot inspection

E. Pilot piece inspection

4. 6ey operation inspection

3F.)unctional inspection

33. )loor inspection

35.1ndurance inspection

38.entrali"ed inspection

I%8PECTIO% EP&'TME%T H&8 THE $O!!OI%" I%8T'4ME%T8:

3. (inear height gauge

5. Height master

8. Pro!ile proector

A. Tool maers microscope

9. o-ordinate measuring machine

B. Three point micrometer

(6?61 P'O$I!E P'O


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Plate 1; Profile Projector

Table 1? Profile Projector 8pecification

I7STR>*17T PR2)I(1 PR2G1T2R

*&61 *IT>T2?2 PG-593

2RI'I7 G&P&7

1!!ective diameter% mm 59F

&ngular resolution% range% degree 3.O8BFX

ross travel range%mm 9F9F

;or stage dimension%mm 395395

*icrometer head% mm F.FF359

*ax. wor piece height%mm D9

Special accessories 5FN%9FN%3FN

&ccuracy F.FF3

(6?6( TOO! M&9E'8 MIC'O8COPE:

& tool maer microscope is a type o! a multi !unctional device that is primarily used

!or measuring tools and apparatus. These microscopes are widely used and commonly

seen inside machine and tools manu!acturing industries and !actories. These microscopes

are also inside electronics production houses and in aeronautic parts !actories. & tool

maer microscope is an indispensable tool in the di!!erent measurement tass per!ormed

throughout the engineering industry.


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Plate 1= Tool Ma/ers Microscope

Table 1@ Tool Ma/ers Microscope 8pecification

I7STR>*17T T22( *&61RT2?2 PG-593

2RI'I7 G&P&7

*agni!ication 3FN%39N%5FN

Stage si"e 395395

Travelling distance% mm 9F9F

*ax.wor piece height% mm 339

&ccuracy F.FF9

(6?6; HEI"HT M&8TE':

It is a high precision instrument to measure and trans!er o! height on the ob. It can

be used as a master !or calibration in Standards Room and in Tool Room

Plate 1> Height Master

Table 1A Height Master 8pecification:


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I7STR>*17T H1I'HT *&ST1R*&61 *IT>T2?2 S1)RI1S 9392RI'I7 G&P&7*ax.height%mm 8FF&ccuracy% mm F.FF3Read out /I'IT&(

Stroe%mm 5F

(6?6= CO-O'I%&TE ME&84'I%" M&CHI%E:

& coordinate .easuring .achineK**J is a device !or measuring the physical

geometrical characteristics o! an obect. This machine may be manually controlled by an

operator or it may be computer controlled. *easurements are de!ined by a probe attached

to the third moving axis o! this machine. Probes may be mechanical% optical% laser% or white

light% amongst others.

The typical 0bridge0 ** is composed o! three axes% an N% ? and L. These axes are

orthogonal to each other in a typical three dimensional coordinate system. 1ach axis has a

scale system that indicates the location o! that axis.

Plate 1? Co-ordinate Measuring Machine

& coordinate measuring machine K**J is also a device used in manu!acturing and

assembly processes to test a part or assembly against the design intent. $y precisely

recording the N% ?% and L coordinates o! the target% points are generated which can then be

analy"ed via regression algorithms !or the construction o! !eatures. These points are

collected by using a probe that is positioned manually by an operator or automatically via

/irect omputer ontrol K/J.

Table 1B Co-Ordinate Measuring Machine 8pecification:

*&61 &R( LI1SS


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2RI'I7 '1R*&7?*2/1( *-99F*easuring range-YN

C&8E 8T4#:

This case study has details about cost types o! machines used% machining hour:s

calculations% di!!erent complications involved and inspection done throughout the

completion o! the process is discussed by conducting a case study on !ollowing

components. I R channel detector and stud.

;61 I ' CH&%%E! ETECTO':


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Plate 1@ I ' channel detector

$lo0 Chart of Manufacturing I ' channel detector fro. I8'O is as follo0s:

C%C T4'%I%":

In the 7 turning process% a piece o! material is rotated on the lathe and a cutting

tool is traversed along two axis o! motion% transverse or longitudinal. The cutting tool is

used until the required depth and dimension is achieved. Turning can be on both sides%

inside or outside as per the needs and speci!ications. 7 turningprocess cuts the metal

into various di!!erent shapes ranging !rom plain sur!ace% taper ends% contour% and !ilter to

radius pro!iles and threaded sur!aces.


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CC Turning

Stage !nspection

CC Milling

Stage !nspection

"ench#ork

$inal!nspection
http://www.emachineshop.com/machines/turning-lathe.htmhttp://www.emachineshop.com/machines/turning-lathe.htm


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Plate 1A C%C Turning

8T&"E I%8PECTIO%:


stage inspection. It helps in recti!ying the mistae occurred during each operation.The wor

o! inspection is done while the production process is simultaneously going on. Inspection isdone at various wor centres o! men and machines and at the critical production points.

This had the advantage o! preventing wastage o! time and money on de!ective units and

preventing delays in assembly.

C%C MI!!I%":

*ost 7milling machines are computer controlled vertical mills with the ability to

move the spindle vertically along the L-axis. This extra degree o! !reedom permits their use

in diesining% engraving applications etc. 7machines can exist in virtually any o! the

!orms o! manual machinery% lie hori"ontal mills. The most advanced 7 milling-

machines% the multiaxis machine% add two more axes in addition to the three normal axes

KN?LJ.

Plate 1B C%C Milling

8T&"E I%8PECTIO%:


stage inspection. It helps in recti!ying the mistae occurred during each operation.The wor

o! inspection is done while the production process is simultaneously going on. Inspection is

done at various wor centres o! men and machines and at the critical production points.

This had the advantage o! preventing wastage o! time and money on de!ective units and

preventing delays in assembly.

DE%CH O'9:

It re!ers to production o! article by hand on the bench. It plays important role to !inish

a ob to the desired accuracy.

eburring:

& burr is a raised edge or small pieces o! material remaining attached to a wor

piece a!ter a modi!ication process.


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http://en.wikipedia.org/wiki/CNChttp://en.wikipedia.org/wiki/CNChttp://en.wikipedia.org/wiki/CNChttp://en.wikipedia.org/wiki/Multiaxis_machininghttp://en.wikipedia.org/wiki/CNChttp://en.wikipedia.org/wiki/CNChttp://en.wikipedia.org/wiki/CNChttp://en.wikipedia.org/wiki/Multiaxis_machining


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It is usually an unwanted piece o! material and when removed with a deburring tool

in a process called #deburring#. $urrs are most commonly created a!ter machining

operations% such as grinding% drilling% milling% engraving or turning. It may be present in the

!orm o! a !ine wire on the edge o! a !reshly sharpened tool or as a raised portion o! a

sur!ace, this type o! burr is commonly !ormed when a hammer stries a sur!ace.Tapping:

Tapping is the process o! producing threads in a metal using certain tools.

There are various t5pes of Taps6

& starter tap is used to start threading.

The large taper easily guides the tap into the hole.

& Plug Tap has less taper and has more threads !or going deeper into holes.

Plate ( Tapping

$I%&! I%8PECTIO%:

)inal inspection is one in which the product manu!actured is inspected completely.

Inspection o! !inished goods. This is the last stage when !inished goods are inspected and

carried out be!ore mareting to see that poor quality product may be either reected or

sold at reduced price.

Table (

Time Taen )or *anu!acturing I R channel detector2peration Time in *inutes7 Turning 59Stage Inspection 3F7 *illing 8F

Stage Inspection 3F$ench ;or KTapping% Deburring ) 8F


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)inal Inspection 5FT2T&( Time Taen 359

;6( 8T4

Plate (1 stud

$!O CH&'T O$ M&%4$&CT4'I%" 8T4 $'OM I8'O I8 &8 $O!!O8:

T4'%I%":


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Turning

Stage !nspection

Cylindrical grinding

"ench#ork

$inal!nspection


39/42


Turning is a machining process to produce parts round in shape by a single point

tool on lathes. The tool is !ed either linearly in the direction parallel or perpendicular to the

axis o! rotation o! the worpiece% or along a speci!ied path to produce complex rotational

shapes. The primary motion o! cutting in turning is the rotation o! the worpiece% and the

secondary motion o! cutting is the !eed motion. & set o! instructions Kcalled programJ isused to guide the machine !or desired operations.

Plate (( 8ho0s Turning

8T&"E I%8PECTIO%:

The wor o! inspection is done while the production process is simultaneously going

on. Inspection is done at various wor centres o! men and machines and at the critical

production points

C#!I%'IC&! "'I%I%":

C5lindrical grinding

In this operation% the external or internal cylindrical sur!ace o! a worpiece are

ground. In external cylindrical grinding Kalso center-type grindingJ the worpiece rotates

and reciprocates along its axis% although !or large and long worparts the grinding wheel

reciprocates.

In internal cylindrical grinding% a small wheel grinds the inside diameter o! the part.

The worpiece is held in a rotating chuc in the headstoc and the wheel rotates at veryhigh rotational speed. In this operation% the worpiece rotates and the grinding wheel

reciprocates.


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Plate (; C5lindrical "rinding

ylindrical grinding is de!ined as having !our essential actions+

3. The wor KobectJ must be constantly rotating

5. The grinding wheel must be constantly rotating

8. The grinding wheel is !ed towards and away !rom the wor

A. 1ither the wor or the grinding wheel is traversed with respect to the other.

;hile the maority o! cylindrical grinders employ all !our movements% there are grinders that

only employ three o! the !our actions.

DE%CH O'9:

The main operations commonly per!ormed in bench wor may be classi!ied as.

3. hipping

5. )iling

8. Tapping

eburring:

It is usually an unwanted piece o! material and when removed with a deburring tool

in a process called #deburring#. $urrs are most commonly created a!ter machining

operations% such as grinding% drilling% milling% engraving or turning. It may be present in the

!orm o! a !ine wire on the edge o! a !reshly sharpened tool or as a raised portion o! a

sur!ace, this type o! burr is commonly !ormed when a hammer stries a sur!ace.

Tapping:

Tapping is the process o! producing threads in a metal using certain tools.

$I%&! I%8PECTIO%:

)inal inspection is one in which the product manu!actured is inspected completely.Inspection o! !inished goods. This is the last stage when !inished goods are inspected and


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carried out be!ore mareting to see that poor quality product may be either reected or

sold at reduced price.

Table (1 Ti.e Ta/en $or Manufacturing 8T4 fro. I8'O

2peration Time in *inutesTurning 5F

Stage Inspection 3Fylindrical grinding 3F$ench ;or KTapping% /eburring J 39)inal Inspection 3FT2T&( Time Taen B9


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CO%C!48IO%:

*y eight wees o! industrial training in W'21R7*17T T22( R22* &7/

TR&I7I7' 17TR1 has been one o! the most interesting% productive and instructiveexperience. Through this training% I have gained new insight and more comprehensive

understanding about the real industrial woring condition and practice% it has also improved

my !unctional sills. &ll these valuable experiences and nowledge that I have gained

were not only acquired through the direct involvement in tas but also through other

aspects o! the training such as + wor observation% interaction with collegues% superior and

other people related to the !ield. &nd !rom what I have undergone% I am sure that industrial

training program has achieved its primary obective. &s a result o! the program I am now

more con!ident to build my !uture career.

So in this way there is unlimited nowledge and many things to learn here in this

center. I sincerely than to all the instructor and other who guided me and gave me the

in!ormation about the machine and other things.

IN-PLANT TRAINING AT GOVERNMENT TOOL ROOM & TRAINING CENTERMYSORE

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