Internship Report_Jyoti CNC Automation Pvt Ltd

JYOTI CNC AUTOMATION PVT LTD

INTERNSHIP REPORT

ON

CNC MANUFACTURING

AT

BY

NASIT MALAY RAMESH

12BME0529

School of Mechanical & Building Sciences

15th October, 2014

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ABSTRACT

The internship at Jyoti CNC Automation Pvt. Ltd., Rajkot emphasizes on a production of all the components of CNC by casting process, their surface finishing by machining process and finally the assembly of all the CNC components and their testing through various quality process. Detailed explanation of the manufacturing, assembly and testing of CNC Machines of various capacities have been mentioned in the report. It is in reference to the 28 days in-plant training done in the foundry shop, machining shop, paint shop and assembly line area of the company. The whole focus of the training involves basic manufacturing processes like casting, machining (turning, drilling, milling, grinding), sheet metal bending, cutting, various quality control techniques that are used in research and development of Computer Numerical Control machines.

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ACKNOWLEDGEMENTS

It is one of the most difficult tasks in life to choose the appropriate words to express one’s gratitude towards the beneficiaries. I take this opportunity to express my gratitude and appreciation to all those who directly or indirectly motivated and encouraged me during the course of the internship.

This internship has had the help and support of several people whose time and expertise has facilitated us in the successful completion of our internship. We wish to thank all of them for their contributions.

I am very thankful to Mr. Vincent Dabhi for granting my industrial training in Jyoti CNC Automation PVT Ltd. and supporting me throughout my training.

Last but not the least I am very thankful to the company and the entire department Heads for their constant guidance. I feel very proud of being trainee of such a company.

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TABLE OF CONTENTS

S. No. DESCRIPTION Pg. No.

1. INTRODUCTION 1 1.1 COMPANY PROFILE 1 1.2 MISSION AND VISION OF THE COMPANY 2 1.3 AWARDS 2

2. CNC WORK THEORY 3

3. COMPANY PRODUCTS 4 3.1 TURNING/TURN MILL CENTERS (TMC) 4 3.2 VERTICAL MACHINING CENTERS (VMC) 4 3.3 HORIZONTAL MACHINING CENTERS (HMC) 6

4. COMPONENTS OF CNC 7 4.1 SPINDLE 7 4.2 SADDLE 7 4.3 BASE 7 4.4 LINEAR MOTION GUIDE WAYS (LM) 7 4.5 PALLET 8 4.6 AUTOMATIC TOOL CHANGER 8 4.7 HEAD STOCK 9 4.8 TAIL STOCK 9 4.9 TURRET ASSEMBLY 10 4.10 CONTROLLER 10 4.11 PUMPS 10 4.12 MOTORS 10 4.13 OUTER SHEET METAL BODY 10

5. ASSEMBLY OF CNC MACHINE 11

6. DIFFERENT TESTS AND QUALITY CONTROL 14 6.1 AUTO COLLIMATOR 14 6.2 LASER INTERFEROMETRY TEST 14 6.3 RENISHAW BALL BAR SYSTEM 14 6.4 CNC COORDINATE MEASURING MACHINE (CMM) 15

7. CASTING 16 7.1 CASTING PROCESS 16 7.2 CASTING DEFECTS 18

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8. VARIOUS DEPARTMENTS 19 8.1 R & D CENTER 19 8.2 GRINDING SHOP 19 8.2.1 HARDINGE KELLENBERGER 19 8.2.2 STUDER – KORBER SCHLEIFRING 19 8.2.3 ELB - SCHLIFF 20 8.2.4 VG 400 20 8.2.5 HINDUSTAN MACHINE TOOL 20 8.2.6 VRG 60 20 8.3 SHEET METAL SHOP 20 8.4 PAINT SHOP 21 8.4.1 DIVISIONS 21 8.5 QUALITY ASSURANCE 22

9. CONCLUSION 23

REFERENCES 24

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LIST OF FIGURES

Figure No.

Figure Name Page No

1. Jyoti CNC Automation Pvt. Ltd. 1 2. TMC 160 4 3. VMC 1260 4 4. General sketch of CNC 6 5. General block diagram of 3 axis CNC machine 6 6. Saddle 7 7. Linear Motion Guide Ways (L.M) 8 8. Pallet 8 9. Automatic Tool Changer (ATC) 9 10. Head stock 9 11. Tail stock 9 12. Turret assembly 10 13. 3-Point leveling 11 14. Chuck 12 15. Dx-200 13 16. Dx-250 13 17. Autocollimator test 14 18. Renishaw ball bar test 15 19. CMM test 15 20. Casting area 16 21. Clamping the molds 17 22. Heavy Cast and Shot Peening Machine 17 23. Holding Furnace and Shot peening balls 18 24. Sheet Metal shop 20 25. Spray coating and sheet metal drying shop 21 26. Water rinse tank 22

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1. INTRODUCTION

1.1 COMPANY PROFILE

Jyoti CNC Automation Pvt. Ltd. is a CNC manufacturing company which was established by Mr. P.G. Jadeja and Mr. S.L. Jadeja, 1989. Driven by a vision to build the company “A Temple of Technology” through teamwork, the company has grown manifold from manufacturing gear boxes for machines to developing precision all-geared head lathe machines. Later on Jyoti started manufacturing highly sophisticated CNC machines in the presence of manufacturers.

Jyoti was the first company to manufacture CNC machines in Gujarat. It was not an end, there are many firsts attached with Jyoti since then. Jyoti, driven by technology and innovation, keeps including new firepower in its arsenal by introducing machines like CNC Turning Centers, Vertical Machining Centers, Oval Turning Center, Horizontal Milling Machines and first Indian machines like VMC 40/70 Linear with innovative Linear technology.

Jyoti has good trajectory of growth rate. Export penetration and inclination has helped them to establish goodwill among the foreign buyers and distributors. Company's expanding footprint ensures its global presence with export operations in countries like Italy, Russia, Poland, Argentina, Brazil and rest of South America, Tanzania and some African countries, Middle East and Other Asian Countries like Malaysia.

The company provides solution in Aerospace, Automobile, Agriculture, Die and Mold Manufacturing Ind., Diamond and Jewelry Ind., Defense, Medical Equipment, Plastics Processing M/C and Textile Machinery.

Figure 1. Jyoti CNC Automation Pvt. Ltd.

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1.2 MISSION AND VISION OF THE COMPANY

i. Have presence in all major engineering hubs globally.

ii. Contribute humbly in making of a developed Nation by Technological advancements, catering to 20% of the Domestic Market, establishing Technology Centers in 10 major cities.

iii. Patronize technical education by Instituting a Machine Tool Academy.

iv. Promote Eco-friendliness by developing energy efficient solutions.

v. Facilitate all the team members to enjoy the higher standards of living for a happier & healthier life.

vi. Create a work environment that fosters- passion, creativity and optimism with fun, respect and pride for all individuals.

vii. Being exceptionally customer centric, delight all our customers by all means and action.

viii. Deeply admire brand among the Machine Tool fraternity.

1.3 AWARDS

i. Meaningful Technological Innovation Award at Engimach’08 held at Ahmedabad. ii. Black Pearl Award for Display & Demonstration of Best Innovative Technology at

ENGIMACH 2006. iii. Best Entrepreneurship Award for year 2004-05. iv. CMTI-PMT Trust Award in IMTEX' 2004 for the Best Innovative Machine Design

"VMC 70 Linear". v. FIE for Engineering Excellence in the IMTEX 2004 "SECT".

vi. Mr. Parakramsinh Jadeja, CMD, Jyoti CNC Automation Pvt. Ltd., has recently achieved a National award for Best Entrepreneurship: Year 2003 from his Excellency President of India Dr. APJ Abdul Kalam On behalf of Ministry of Small Industries, Govt. Of India.

vii. Award for the Best Innovative Technology Display in Engimach’02. viii. CMTI-PMT Trust Award in IMTEX 2001 for the Best Innovative Machine Design. ix. The Machinist Award in IMTEX 2001.

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2. CNC WORK THEORY

Computer Numerical control (CNC) is used to automate the machine tools that are operated by precisely programmed commands encoded on a storage medium, as opposed to controlled manually via hand wheels or levers, or mechanically automated via cams alone. Computers play an integral part of the control.

In modern CNC system computer-aided design (CAD) and computer-aided manufacturing (CAM) programs are used for development and machining of the final finished product. The series of steps needed to produce any part is highly automated and produces a part that closely matches the original CAD design.

Modern CNC mills differ little in concept from the original model built at MIT in 1952. Mills typically consist of a table that moves in the X and Y axes, and a tool spindle that moves in the Z (depth). The position of the tool is driven by motors through a series of step-down gears in order to provide highly accurate movements, or in modern designs, direct-drive stepper motor or servo motors. Open-loop control works as long as the forces are kept small enough and speeds are not too great. On commercial metalworking machines closed loop controls are standard and required in order to provide the accuracy, speed, and repeatability demanded.

As the controller hardware evolved, the mills themselves also evolved. One change has been to enclose the entire mechanism in a large box as a safety measure, often with additional safety interlocks to ensure the operator is far enough from the working piece for safe operation. Most new CNC systems built today are completely electronically controlled.

CNC-like systems are now used for any process that can be described as a series of movements and operations. These include laser cutting, welding, friction stir welding, ultrasonic welding, flame and plasma cutting, bending, spinning, hole-punching, pinning, gluing, fabric cutting, sewing, tape and fiber placement, routing, picking and placing (PnP), and sawing.

Most CNC machines use Siemens or Fanuc made control systems. For Fanuc generally the coding is done using G codes and M codes. G codes are used for machining operations and movement of the tools whereas M codes are used for controlling the spindle movement like on/off, rotation in clockwise or anti-clockwise direction and also for tool change operation.

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3. COMPANY PRODUCTS

Company mainly makes following categories of CNC machines :

3.1 TURNING/TURN MILL CENTERS (TMC)

i. Horizontal turning a. Simple turning b. Twin Spindle turning c. Turn-Mill Centre

ii. Vertical turning center a. Inverted turning line machine

iii. Oval turning center

This CNC machines are mainly used for facing, turning and center drilling operations. Oval turning center is used for oval turning mainly for pistons of an engine.

Figure 2. TMC 160 Figure 3. VMC 1260.

3.2 VERTICAL MACHINING CENTERS (VMC) i. 3 Axis machines

a. C- frame machines(PX series, VMC series) b. Fixed table travelling column c. Double column machines d. High speed bridge type machines e. High speed gantry machines

ii. 5-Axis machines a. High speed bridge type machines b. Double column high speed machines c. High speed machines

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VMC machines were developed for higher precision and high speed over TMC machines. It has moving table for easy access. The main difference between TMC and VMC is tool holder (headstock) is rotating and job which clamped on pallet (table) moves in X-Y directions refer Figure 4. Many operations like facing, turning, milling, profile cutting, boring, drilling can be done easily with the help of VMC.

Mainly machine has three axis to move job and vertical column X-Y-Z. Usually pallet can only move in X-Y direction and vertical column can move in Z- direction. In addition to this 3 axis two more axis are available mainly for rotation and tilting action for easy machining of even complex profiles.

VMC has ATC (Automatic Tool Changer) controlled by three servo motors to automatically change the tool during machining process according to the requirement. Vertical spindle can rotate up to 15000 rpm. Maximum torque that is available in any axis is 700 Nm

For fast work both two and six pallet VMC is also available which has APC (automatic pallet changer) in which after completion of one operation in one job, pallet is automatically rotated and another pallet is positioned for machining operation.

VMC can hold up to 120 tools in the tool post.

All movements of pallet and vertical column are through bolt screw. For less friction movement of saddle and pallet over Linear Motion Guide ways (LM) either pneumatic or hydraulic system is used. The whole VMC machine is operated by mainly Siemens and Fanuc controllers.

Job has to be cooled down while operation is being done on it due to friction between tool and job. Cooling system of job is also installed along with vertical column. Generally 1000 litre coolant tank is used.

Usually cooling fluid is mixture of water and cutting oil of job. Scrap cleaning system is also installed in VMC so that accumulated scrap or chips can easily be drained by flow of fluid.

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3.3 HORIZONTAL MACHINING CENTERS (HMC)

i. 4-Axis machines

HMC 560 is high speed, high precision 4 axis Horizontal Machining Center with worlds best available features to match the demanding requirement of the industry. The machine has special features like Three Point Leveling, axis rotary table and Electro Spindle. Maximum of 10,000 rpm is available for spindle. It is available either for single, double or six pallets out of which all of them are rotary tables.

All the features are almost same as that of VMC but major difference is VMC has vertical spindle axis whereas HMC has horizontal spindle axis. Also HMC is used for machining bigger size components and is more precise.

Figure 4. General sketch of CNC

Figure 5. General block diagram of 3 axis CNC machine

Base

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4. COMPONENTS OF CNC

4.1 SPINDLE

The spindle is directly coupled with the spindle motor refer Figure 4 and avoids any errors in indirect drive mechanism. This high speed spindle is specially designed to meet the requirement of small component machining with high precision and dynamism. Spindle is having BT-40 and 50Tool, HSK 100 interface taper for VMC machines.

4.2 SADDLE

Saddle is the part of CNC which is mounted on the Linea Motion guide ways (LM).

They provide for the linear motion in either X or Y axis.

4.3 BASE

Base is the base structure of CNC on which the entire operation of CNC is performed. It is made of rigid structure of Cast Iron because of good compressive strength and vibrational damping capacity. Refer Figure 4.

Figure 6. Saddle

4.4 LINEAR MOTION GUIDE WAYS (LM)

Linear motion guide ways or LMs are V or U shaped solid structure mounted on base for saddle and on saddle for pallet to allow the saddle and pallet to slide over them linearly along X and Y axis respectively.

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Figure 7. Linear Motion Guide Ways (L.M)

4.5 PALLET

Figure 8. Pallet

Pallet is used to clamp or unclamp job piece. It is mounted on LM which are mounted on saddle. They are perpendicular to the LM mounted on base. That is, if one is in X- direction then other one is in Y- direction.

4.6 AUTOMATIC TOOL CHANGER

The tool changer is a umbrella type Servo ATC having a 12 Tool magazine. The tool change time is 3.5 seconds. Its main function is to change the tool during the machining according to the requirement. It works with 3 servo motors. One for vertical motion up-down, one for rotary action about Z-axis and one for clamping and releasing the tool.

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Figure 9. Automatic Tool Changer (ATC)

4.7 HEAD STOCK

It supports chuck and its mechanism. It possesses system which clamps and de-clamps of work-piece.

Figure 10. Head stock

4.8 TAIL STOCK

It possesses the supporting elements. It is also used for supporting the long job pieces and also used for centering and drilling purpose.

Figure 11. Tail stock

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4.9 TURRET ASSEMBLY

It is that part of machine which has tools to work on job. Generally it has ten to twelve tools. It is used for holding the tools to carry out machining operations.

Figure 12. Turret assembly

4.10 CONTROLLER

It contains Siemens or Fanuc or Heidenhaim controller which controls the whole machine.

4.11 PUMPS

There are generally two pumps in CNC. One is for hydraulic oil transmission and another for coolant circulation. Thus pump keeps the cooling and the lubrication system of the CNC alive.

4.12 MOTORS

There are many different motors used mainly for revolving of chuck, another two for bolt-screw, revolving of turret, and motion of work table i.e pallet in X and Y-axes..

4.13 OUTER SHEET METAL BODY

It provides safety to user and adds aesthetic value to the machine.

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5. ASSEMBLY OF CNC MACHINE

First step of assembly is to do three point leveling system by spirit level and then tight the other 3 points. Thus the Base of CNC is fixed on the floor.

Figure 13. 3-Point leveling

Second step is to scrapping the paint from guide-ways for fitting L.M.. Then worker clean the surface by diesel and air cleaner. Then fit the L.M. and it is supported by eccentric head bolts.

Then worker uses spray-cleaner to remove dust and mounts saddle on it. After that, he does “Auto-collimator Test” for measuring allowances for top and side of L.M. Same process is carried out for L.M. of saddle and then bolt-screw is mounted on saddle with two bearing and its run-out testing is carried out and then again top and side of bolt-screw is maintained in tolerance limit with help of dial-gauge indicator.

Dial gauge indicator is most important testing device for which range is between 2 µm to 10 µm for different purposes.

After that saddle is mounted on CNC bed. Then bolt-screw is mounted on CNC bed for z-axis. Than the same process is carried out as it is carried out for bolt-screw of saddle. Then lock-nut is mounted on it.

If surface plate is not accurately machined, scrapping is carried out till it slides thoroughly on L.M.

During this process another worker mounts head-stock and tail stock on its base.

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After that chuck, pulley, motor and spindle is mounted on head-stock. Then mandrel is mounted on chuck.

Figure 14. Chuck

Center line of head-stock and tail-stock must be co-lined, if not then it must carried out with the help of height-gauge. Then the ATC is mounted and at the same time all the wirings are connected with the motors and the pumps and then the entire electrical system is mounted.

After that telescopic cover is mounted on saddle to cover sliding mechanism from coolant.

After that hydraulic oil system is fitted with its all mountings like oil sump with nitrogen gas accumulator, solenoid valves, pipe.

Finally the cold roll coil sheets are used for final guard (from metal chips and from water-oil coolant). For preventing leakage of coolant, copper stripes is rigidly fitted with silicon gel.

Then Siemens or Fanuc controller is attached to the machine. Finally the doors are fitted so that entire machine remains closed during operation for the safety of the operators. Chip removal system and cooling fluid system was installed according to the demand

Now the machine is started and data is loaded on it.

Some of the CNC machine models are:

VMC -640, DX-250, ATM-160, VMC-430, TM-020, AM-430, TMC-350

Given is an example of DX-200 and DX-250.

i. Complete CNC machine Dx-200 is completely assembled within 6-7 days, while Dx-250 takes 8 to 10 days.

ii. Minimum rpm is 1 and maximum rpm can be up to 6000. iii. Hydraulic power pack is installed (hydraulic pressure up to 70 bar is generally used). iv. Hydraulic system used is oil based. v. It uses 440V AC source.

vi. Has pneumatic pressured air cleaning gun.

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vii. For all movement bolt screw is used. viii. Tool post (turret) can hold up to 24 tools at a time. ix. Using the Siemens controller operation begins and can prepare most complicated

operation with high accuracy.

Model Dx-250 is also available which is bigger in size than Dx-200, main difference in assembling method between them is, In Dx-200 saddle is assembled at inclination keeping base horizontal while in Dx-250 the saddle is assembled keeping the base inclined at 45degree for assembly ease.

Figure 15. Dx-200

Figure 16. Dx-250

SADDLE

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6. DIFFERENT TESTS AND QUALITY CONTROL

6.1 AUTO COLLIMATOR

First and very important test is “Auto-collimator” is performed for perfect alignment of L.M. with base. In this process, “Auto-collimator” which is light sensing device is used. For final fixing of L.M., they provide 5 µm for side and 10 µm for top allowances.

Figure 17. Autocollimator test

6.2 LASER INTERFEROMETRY TEST

Laser interferometry is a well-established method for measuring distances with great accuracy. Laser Interferometer contains a monitor, laser, retro reflector, measurement retro reflector. Beam is passed from laser which goes through retro reflector. This retro reflector allows few of the beams to pass through and it directly goes to measurement retro reflector. This is connected to monitor which some the variation. If surface is fully flat then the intensity of rays is higher. If any misalignment is present then the rays will be deflected. It will be monitored in the computer.

6.3 RENISHAW BALL BAR SYSTEM

The Renishaw QC20-W ball bar system consists of the ball bar itself (essentially a very high accuracy, telescoping linear sensor with precision balls at each end) and precision magnetic mounts, one (adjustable) attached to the machine table and the other to the machine spindle or spindle housing. In use the balls of the sensor are kinematically located in the magnetic cups. This arrangement enables the ball bar to measure minute variations in radius as the machine follows a programmed circular path around the mount on the machine table.

The data collected is sent to a PC, where Renishaw's software calculates overall measures of

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positioning accuracy (circularity, circular deviation) in accordance with international standards such as ISO 230-4 and ASME B5.54 or in Renishaw’s own analysis reports.

Figure 18. Renishaw ball bar test

6.4 CNC COORDINATE MEASURING MACHINE (CMM)

3D Coordinate measuring machine which is compatible for providing increased accuracy and measuring speed that helps to increase the quality of processes and products.

Figure 19. CMM test

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7. CASTING

7.1 CASTING PROCESS

Casting process is used to make the main body parts of CNC machine. The process cycle for sand casting consists of six main stages, which are explained below.

Mold-making - The first step in the sand casting process is to create the mold for the casting. In an expendable mold process, this step must be performed for each casting. A sand mold is formed by packing sand into each half of the mold. The sand is packed around the pattern, which is a replica of the external shape of the casting. When the pattern is removed, the cavity that will form the casting remains.

Figure 20. Casting area

Clamping - Once the mold has been made, the cores are positioned and the mold halves are closed and securely clamped together. It is essential that the mold halves remain securely closed to prevent the loss of any material.

Pouring - The molten metal is maintained at a set temperature in a furnace. After the mold has been clamped, the molten metal can be ladled from its holding container in the furnace and poured into the mold.

Cooling - The molten metal that is poured into the mold will begin to cool and solidify once it enters the cavity. When the entire cavity is filled and the molten metal solidifies, the final shape of the casting is formed.

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Figure 21. Clamping the molds

Removal - After the predetermined solidification time has passed, the sand mold can simply be broken, and the casting removed. This step, sometimes called shakeout, is typically performed by a vibrating machine that shakes the sand and casting out of the flask. Once removed, the casting will likely have some sand and oxide layers adhered to the surface. Shot blasting is sometimes used to remove any remaining sand, especially from internal surfaces, and reduce the surface roughness.

Trimming - During cooling, the material from the channels in the mold solidifies and attached to the part. This excess material must be trimmed from the casting either manually via cutting or sawing, or using a trimming press.

Figure 22. Heavy Cast and Shot Peening Machine

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7.2 CASTING DEFECTS

There are various types of defects that occur in casting process which is categorized by American Foundarymen’s Society (AFS).

i. Broken or cracked castings ii. Carbon floatation and other gross segregation iii. Cuts iv. Drops v. Shrinkage defects

vi. Gas defects vii. Hard spots, hand areas and chilled spots viii. Inverse chills ix. Mass hardness x. Metal penetration

xi. Rough surface xii. Runouts – escape of molten metal from casting mold xiii. Warped Casting – bend out of shape due to pressure or heavy heat

Figure 23. Holding Furnace and Shot peening balls

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8. VARIOUS DEPARTMENTS

The company has following departments as well:

i. R & D center ii. Grinding Shop iii. Sheet metal shop iv. Paint shop

8.1 R & D CENTER

Jyoti has developed a well versed and a versatile R & D center to keep up the company with the international trends towards the automation and manufacturing excellence. This research and development center has been developed to carry on the research activity in a full fledged manner. The exclusive R & D center is been established to design and develop technologically advanced world class machines for the better quality, reliability & productivity to cater to sophisticated Aerospace, Automobile and Defense applications where high level of accuracies and reliabilities are inevitable.

The Active R & D team of Jyoti has achieved outstanding success by developing TPM (Total Productive Maintenance) friendly machines, CNC Machines with Linear Technology of higher dynamics and productivity, in house developed software like POTS etc.

R & D activities here are conducted through a young team of 55 technocrat professionals facilitated by latest softwares & assembly/testing and calibration equipments from world renowned manufacturers.

8.2 GRINDING SHOP

There are different types of grinding machines in which many are imported from Europe.

8.2.1 HARDINGE KELLENBERGER

This machine is used for the grinding of ID as well as OD of the workpieces. This machine uses the mixture of water and oil as coolant. The machine is imported from Switzerland.

8.2.2 STUDER – KORBER SCHLEIFRING

This is used for the grinding of OD of the workpiece. This machine is also imported from Switzerland. It works around 1600 rpm.

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8.2.3 ELB – SCHLIFF

Edmund Lang Babenhausen is used for precision grinding. Grinding through this machine gives very high accuracy. This machine works around 1500 rpm. These machines are mainly manufactured in Hessen, Germany.

8.2.4 VG 400

This is used for the ID as well as OD grinding of workpieces.

8.2.5 HINDUSTAN MACHINE TOOL

This machine functions same as VG 400.

8.2.6 VRG 60

This is the twin spindle grinding machine. It runs around 12000 rpm. Japan is the main manufacturer and Jyoti is one of the customers of VRG 60.

8.3 SHEET METAL SHOP

The machineries adopted by Jyoti are the world’s latest technologies. Sheet Metal is equipped with very precise and versatile machinery producing precision sheet metal components. The most modern first of its kind in India is the Sheet Metal plant of Jyoti having following facilities:

Figure 24. Sheet Metal shop

Trumpf Machine of Germany is having Laser Cutting Technology. Welding and bending are one of the main areas of sheet metal shop. The Sheet Metal is coated with CED primer and finished with automated powder coating line and painting line. Robotic Welding has also been carried out in the welding area.

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8.4 PAINT SHOP

Jyoti has established its own paint shop which is fully automated and it comprises of several tanks pre-treatment process followed by CED primer coating.

Figure 25. Spray coating and sheet metal drying shop

Versatile paint shop which will deliver sheet–metal components duly powder coated / painted with CED primer coating and castings will be delivered with CED primer coatings and followed by backing.

8.4.1 DIVISIONS

The paint shop constitutes of the following tank:

i. Degreasing tank ii. Water rinse 01tank iii. Water rinse 02 tank iv. Derusting tank tank v. Water rinse 03 tank

vi. Water rinse 04 tank vii. Surface activation tank viii. Phosphating tank ix. Water rinse 05 tank x. Cathodic Electro Deposition – CED tank

xi. Permeate tank

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Figure 26. Water rinse tank

8.5 QUALITY ASSURANCE

Jyoti believes in the quote “Quality is avoidance of financial loss to society after the product is shipped.”

Jyoti strives to achieve best-in-class quality and reliability of performance of all products through a systematic approach that emphasizes quality at every stage of product development through manufacturing. Before leaving the plant, the Jyoti CNC machine is passed through a series of quality assurance tests.

Jyoti has established a system of quality in line with the ISO 9001:2000. We are aspiring to be recognized as the quality manufacturers in the industry we serve by providing solutions to customer’s problems by engineering and manufacturing quality machines at competitive price.

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9. CONCLUSION

In the 21st century there will be an increasing demand of highly accurate machining and that too in very less machining time. For this the best possible option as of now is Computer Numerical Control Machines. This internship in Jyoti CNC Automation PVT Ltd has offered a great learning experience in the field of automated lathe machines that is CNC machines and exploiting its various aspects starting from their casting in their casting industry, machining of that casted components for surface finishing, assembly of all the components and their quality testing through various techniques.

This one month training has been very helpful in bringing out the thinking that real engineering requires mainly focused on manufacturing concepts and the creativity of an engineer’s mind.

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REFERENCES

[1] www.jyoti.co.in

[2] www.huron.fr

[3] CAD/CAM/CIM, Third edition by New Age International Publishers