Lab Specifications Machining - · PDF fileMinimum Machine Speciﬁcation CNC lathe, ... Manual lifter Bosch or 29 Power ... Minimum Machine Speciﬁcartion CNC Lathe, LAB SPECIFICATIONS

Machining

Lab Specifications

An initiative of Ministry of Skill Development & Entrepreneurship, Govt. of India

and National Skill Development Corporation

02LAB SPECIFICATIONS MACHINING

03

Shri Narendra ModiHonourable Prime Minister

LAB SPECIFICATIONS MACHINING

If we have to promote the

development of our country

then our mission has to be

‘skill development’ and

‘skilled India’.

04

OVERVIEW

The lab standardization guidelines envisions to standardize the lab infrastructure for machining across sectors.

The document intends to ensure industry linked training with state-of-art infrastructure.


05

1. Description of Lab

2. List of Tools & Equipment - Machining

3. 3D Representation of Machining Lab

4. Illustrative Architectural Layout of Lab

5. Illustrative Pricing of Tools & Equipment

6. Safety Instructions

SECTORMACHINING


06

DESCRIPTION OF LAB

Lab Specifications for the Listed Sectors / Job Roles

1

Proposed Batch Size


1. Capital Goods

a Conventional Turning

b CNC turning operator

c Conventional Milling

d CNC Milling

e CNC Setter Cum Operator Turning

f CNC Programmer

2. Indian Iron & Steel Sector Skill Council – Machinist

3. Mining Machinist

4. Automotive

a Machining Assistant

b Machining / CNC Operator Level – 3

c Machining / CNC Operator Level – 4

d Lathe Operator

25

Machining/CNC Operator Level 3 – 1:12Lathe Operator – 1:6Universal Milling Machine – 1:10

Machine - ManRatio

2

07

S. No.

Name Description QtyUnitType

Conven-tional MillingCGSC

ASDC Machining (including

Lathe Operate

and Machining

techinician)

IISSSC Machinist

CNC Turning -

CGSC

CNC - Milling - CGSC

Conven-tional

Turning - CGSC

Minimum Specification as: Centre Height

SS and SC Centre 1 4 Nos 4 2 1 2 150 mm and Centre Distance 1000 mm 4

Lathe (all Geared) Along with Jaw and 3 Jaw Chucks, Auto Feed System, Safety Guard, Motorized Coolant System and Lighting Arrangement

Steel Rule 30 cm 2 Steel Rule 30 cm 10 Nos 10 10 10 10 10 10Graduated Both in English & Metric Units

3 Divider Spring 150 mm 10 Nos 10 10 10 10 10 10

4 Centre Punch 100 mm 10 Nos 10 10 10 10 10 10

5 Hammer Hammer with Handle 5 Nos 5 5 5 5 5 5

6 Combination Plier 150 mm 2 Nos 2 2 2 2 2 2

7 Safety Glasses Safety Goggles 10 Nos 10 10 10 10 10 10

8 File Flat Assorted 10 Nos 10 10 10 10 10 10

9 Surface Plate Surface Plate 400 mm x 400 mm Grade 1 Nos 1 1 1 1 1 1

10 Marking off Table Marking off Table 1200 x 1200 x 900 mm 1 Nos 1 1 1 1 1 1

11 Scribing Block Scribing Block Universal 300 mm 3 Nos 3 3 3 3 3 3

12 V Block V Block 100 mm 2 Nos 2 2 2 2 2 2

Vernier Gear Tooth 13 Mitutuyo or Equivalent 2 Nos 2 2 2 2 2 2 Caliper

14 Try Square Try Square 300 mm 5 Nos 5 5 5 5 5 5

Outside, Inside Spring 15 10 Nos 10 10 10 10 10 10 Caliper

16 Oil Stone Oil Stone 150 x 50 x 25 mm 10 Nos 10 10 10 10 10 10

Hacksaw Frame 17 Hacksaw Frame Adjustable 250 x 300 mm 5 Nos 5 5 5 5 5 5 with Blades


LIST OF TOOLS & EQUIPMENT - MACHINING

08

S. No.

Name Description



Lathe Operate

and Machining

techinician)

IISSSC Machinist

CNC Turning -

CGSC


Conven-tional

Turning - CGSC

18 Hand Vice Hand Vice 50 mm Jaw 10 Nos 10 10 10 10 10 10

19 Angle Plate 2 Nos 2 2 2 2 2 2

Solid Parallels in Pairs

To Suit Drill Machines 20 4 Nos 4 4 4 4 4 4 (Different Sizes)

Taper Shank Sleeves

Set of Double Ended

21 Spanner, Set of Box

Spanner with Ratchet Handle; Adjustable

2 Nos 2 2 2 2 2 2

Spanner 300 mm

Parallel Shank HSS Drill 3 mm to 12 mm in a Step of 1 mm 22 3 Nos 3 3 3 3 Twist Drill

Taper Shanks HSS Drill 15 mm, 19 mm, 22 mm & 25 mm 23 1 Nos 1 1 1 1 Twist Drill

Drilling Tools & 24 2 Nos 2 2 2 2 Boring Tools

Compound Dial Gauge with Stand Compound Dial Gauge25 2 Nos 2 2 2 2 2 2 (Metric) Dial Test Indicator withWith Stand (Metric) D Magnetic Gauge Type 1 Grade a with Magnetic Base – 0.002 mm

26 Vice Mounted Tables Vice Mounted Tables Octagonal 2 Nos 2 2 2 2 2 2

DE Grinder 30 cm Wheel Motorized Pedestal 27 Grinders 2 Nos 2 2 2 2 2 2 Type; AG-4 & AG-7 Grinders


2 LIST OF TOOLS & EQUIPMENT - MACHINING

QtyUnitType

09

S. No.

Name Description



Lathe Operate

and Machining

techinician)

IISSSC Machinist

CNC Turning -

CGSC


Conven-tional

Turning - CGSC

Leather Apron; Goggles; Leg Guard; Hand 28 PPE 10 Nos 10 10 10 10 10 10

Guard; Manual Lifter; 29 Power Saw 1 Nos 1 1 1 1 1 1

30 Scrap Box 3 * 3, 3*4 1 Nos 1 1 1 1 1 1

Inverters and Generators of Adequate 31 Power Backup 1 Nos 1 1 1 1 1 1 Capacity to Run all Machines at a Time

32 First Aid Kit 2 Nos 2 2 2 2 2 2

Minimum Machine Specification CNC lathe,

33 CNC Turning Center 1 Nos 1 1 1

with Chuck Size:135 mm Between Centre

Distance: 250 mm Travel in X: 100 mm Travel in Z: 200 mm Rapid: 20 m/min No. of Tool Stations: Minimum 6 Spindle Power: 3.7kW

(Continuous Rating) Control System: Fanuc etc.

Tool Holders to Suit the CNC Machine for

34 Cutting Tools 2 Nos 2 2 2 Turning, Threading (External & Internal),

Grooving (External & Internal), Parting off Operations, Drilling, Boring, Under Cutting (with 20 Inserts for Each Operation)

Vernier Calipers 300 mm. Micrometer –

Nos 35 Measuring Instruments 5 5 5 5 5 5 5

External, 0-25 mm, 25-50 mm, 50-75 mm.

Each

Bore Gauge 18-35 mm Inside Caliper for Measuring ID Grooves Thread Ring Gauge M20 x 2.5, Thread Plug Gauge M10 x 1.5, M12 x 1.75, Soft Jaws Feeler Gauge Radius Gauge Thread Pitch Gauge

4 gb RAM, Core i3 Processor, HDD 350 Gb, 36 PCs in Lan Network 10 Nos 10 10 10Windows 7 or Higher. 23' Display, Touchscreen Display Preferred



QtyUnitType

10

S. No.

Name Description



Lathe Operate

and Machining

techinician)

IISSSC Machinist

CNC Turning -

CGSC


Conven-tional

Turning - CGSC

37 Printer Plotter 1 Nos 1 1 1

Integrated CNC Skill Development Software 38 Software 10 Nos 10 10 10for Operators

Table Length x Width 1200 x 300 mm Having

39 Universal Milling 2 Nos 2 1 2

Motorized Up & Down Movement Along with Auto Feed Arrangement and with Attachments Such as Vertical Head, Slotting Head, Rack Cutting Attachment, Rotary Machine Table, Dividing Head, Adaptors and Collects for Holding Shank Drills and Cutters from 3 mm to 25 mm

CNC Machining Centre with Minimum

40 CNC Machining Center

Specification as: Table Size: 500 x 250mm,

Travel X-axis x Y-axis x Z-axis: 300 x 250 x 250mm Auto Tool Changer: 8 Nos. Spindle Power: 3.7kW (Continuous Rating) Preferably with Popular Control System Like Fanuc/

1 Nos 1 1 1

Sinumeric Along with Motorized Coolant System.

To Suit Above Machine: to Accommodate Face

41 CNC Milling Tools 2 Nos 2 2 2 Cutter, Shell End Mill Cutter, Taper Shank and

Parallel Shank Drills/Cutters, Reamers. Taps with Suitable Tool Holders.



QtyUnitType

3D REPRESENTATION OF MACHINING LAB3

11

List of Equipment

Work Benches Drilling Machine

Grinding Machine Lathe Machines

Universal Milling Machine CNC Milling Machine

CNC Turning Machine Display Space for Tools and Jobs


12

ILLUSTRATIVE ARCHITECTURAL LAYOUT OF LAB4

Machining


5

13

S. No.

Name

Minimum Specification as: Centre Height

SS and SC Centre Lathe 1 4 Nos Multi Branded 1,50,000 6,00,000150 mm and Centre Distance 1000 mm Along

(all Geared) with 4 Jaw / 3 Jaw Chucks, Auto Feed System,

Safety Guard, Motorized Coolant System and Lighting Arrangement.

Steel Rule 30 cm 2 Steel Rule 30 cm 10 Nos Non Branded 50 500 Graduated Both in English & Metric Units

3 Divider Spring 150 mm 10 Nos Non Branded 130 1,300

4 Centre Punch 100 mm 10 Nos Non Branded 200 2,000

5 Hammer Hammer with Handle 5 Nos Non Branded 230 1,150

6 Combination Plier 150 mm 2 Nos Non Branded 650 1,300

7 Safety Glasses Safety Goggles 10 Nos Non Branded 200 2,000

8 File Flat Assorted 10 Nos Non Branded 500 5,000

9 Surface Plate Surface Plate 400 mm x 400 mm Grade 1 Nos Non Branded 3,500 3,500

10 Marking off Table Marking off Table 1200 x 1200 x 900 mm 1 Nos Non Branded 6,000 6,000

11 Scribing Block Scribing Block Universal 300 mm 3 Nos Non Branded 2,000 6,000

12 V Block V Block 100 mm 2 Nos Non Branded 3,000 6,000

Vernier Gear Tooth Mitutoyo or 13 Mitutuyo 2 Nos 3,000 6,000 Caliper Equivalent

14 Try Square Try Square 300 mm 5 Nos Non Branded 150 750

Outside, Inside Spring 15 10 Nos Non Branded 1,300 13,000 Caliper

16 Oil Stone Oil Stone 150 x 50 x 25 mm 10 Nos Non Branded 400 4,000

Hacksaw Frame Adjustable 250 x 300 mm 17 Hacksaw Frame 5 Nos Non Branded 600 3,000 with Blades

18 Hand Vice Hand Vice 50 mm Jaw 10 Nos Non Branded 2,500 25,000

Description Qty UnitType

Brands*


Unit Price**(INR)

Amount (INR)

ILLUSTRATIVE PRICING OF TOOLS & EQUIPMENT

*Brands are illustrative, other brands with same specifications may be used

**Price is indicative for the major brands, similar tools/equipment may be used

14

S. No.

Name Brands*

19 Angle Plate 2 Nos Non Branded 2,800 5,600

20 Solid Parallels in Pairs To Suit Drill Machines 4 Nos Non Branded 780 3,120 (Different Sizes) Taper Shank Sleeves

Set of Double Ended Set of Box Spanner with Ratchet Handle ; 21 2 Nos Non Branded 500 1,000 Spanner Adjustable Spanner 300 mm

Parallel Shank HSS 22 Drill 3 mm to 12 mm in a Step of 1 mm 3 Nos Non Branded Twist Drill

Taper Shanks HSS 23 Drill 15 mm, 19 mm, 22 mm & 25 mm 1 Nos Non Branded Twist Drill

Drilling Tools & Boring 24 2 Nos Non Branded Tools

25 Compound Dial Gauge Compound Dial Gauge with Stand (Metric) Dial 2 Nos Bosch or 1,012 2,024 With Stand (Metric) D Test Indicator with Magnetic Gauge Type 1 Grade Equivalent A with Magnetic Base – 0.002 mm,

26 Vice Mounted Tables Vice Mounted Tables Octagonal 2 Nos Fabricated 20,000 40,000

DE Grinder 30 cm Wheel Motorized Pedestal Bosch or 27 Grinders 2 Nos 5,000 10,000 Type; AG-4 & AG-7 Grinders Equivalent

Leather Apron; Goggles; Leg Guard; Hand 28 PPE 10 Nos Welspring 2,000 20,000Guard; Manual lifter

Bosch or

29 Power Saw 1 Nos 7,000 7,000 Equivalent

30 Scrap Box 3*3, 3*4 1 Nos Fabricated 7,000 7,000


Unit Price**(INR)

Amount (INR)

5 ILLUSTRATIVE PRICING OF TOOLS & EQUIPMENT



Description Qty UnitType

15

S. No.

Name Brands*

Inverters and Generators of Adequate Capacity Kirloskar or 31 Power Backup 1 Nos to Run all Machines at a Time Equivalent

32 First Aid Kit 2 Nos 2,000 4,000

Minimum Machine Specificartion CNC Lathe,

33 CNC Turning Center 1 Nos 1,217,000 1,217,000

with Chuck Size:135mm Between Centre

Distance: 250mm Travel in X: 100 mm Travel Mitutoyo or in Z: 200mm Rapid: 20 m/min No. of Tool Equivalent Stations: Minimum 6 Spindle Power: 3.7kW

(Continuous Rating) Control System: Fanuc etc.

Tool Holders to Suit the CNC Machine for Turning,

34 Cutting Tools 2 Nos Multi Brand 2,00,000 4,00,000 Threading (External & Internal), Grooving

(External & Internal), Parting off Operations, Drilling, Boring, Under Cutting (with 20 Inserts for Each Operation)

Vernier Calipers 300 mm. Micrometer – External,

Nos Mitutoyo or 35 Measuring Instruments 5 6,000 30,000

0-25 mm, 25 -50 mm, 50 – 75 mm. Bore Gauge

Each Equivalent

18 – 35 mm Inside Caliper for Measuring ID

Grooves Thread Ring Gauge M20 x 2.5, Thread Plug Gauge M10 x 1.5, M12 x 1.75, Soft Jaws Feeler Gauge Radius Gauge Thread Pitch Gauge

4 gb RAM, Core i3 Process or, HDD 350 gb, Branded or 36 PCs in Lan Network 10 Nos 35,000 3,50,000 Windows 7 or Higher. 23' Display, Touch Screen Assembled Display Preferred

HP or 37 Printer Plotter 1 Nos - Equivalent

Siemens, 38 Software Integrated CNC Software 10 - Nos Cutviewer or Equivalent


Unit Price**(INR)

Amount (INR)




Qty UnitType

Description

16

S. No.

Name Numbers Nos/Set

Brands* Unit Price**(INR)

Amount (INR)

Table Length x Width 1200 x 300 mm Having

CadEM, Universal Milling39 2 Nos 3,00,000 6,00,000

Motorized up & Down Movement Along with

Machine

auto Feed Arrangement and with Following

Attachments Such as Vertical Head, Slotting

Hytech,

Head, Rack Cutting Attachment, Rotary Table, LMW, Jyoti

Dividing Head, Adaptors and Collects for Holding or equivalent

Shank Drills and Cutters from 3 mm to 25 mm

CNC Machining Centre with minimum Cad EM,

40 CNC Machining Center 1 Nos 14,28,000 14,28,000

Specification as: Table Size:500x250mm, Hytech,

Travel X-axis x Y-axis x Z-axis: 300 x 250 x LMW, Jyoti

250mm Auto Tool Changer: 8 nos. Spindle or Equivalent Power: 3.7kW (Continuous Rating) Preferably

with Popular Control System Like Fanuc/ Sinumeric along with motorized coolant system

To Suit Above Machine: to Accommodate Face 41 CNC Milling Tools 2 Nos Multi Brand 88,000 1,76,000 Cutter, Shell end Mill Cutter, Taper Shank and Parallel Shank Drills/Cutters, Reamers. Taps with Suitable Tool Holders.

Total 53,65,765





Description

SAFETY INSTRUCTIONS6

17

Given below Safety Instruction posters should be placed at appropriate places in the lab. The posters should

be digitally printed and pasted on sun board.

Safety Checks

Safety glasses must be worn at all times

in work areas

Safety shoes must be worn at all times

in work areas

Close fitting/protective clothing must be worn.

Rings and jewellery must not be worn.

Gloves must not be worn when using this machine

Long and loose hair must be tied tightly

Types of Mechanical

HazardsCrushing Shearing

Cutting Entanglement

Drawing-in ortrapping

Stabbing orpuncture



18

Pre-operational Safety Checks Milling and Turning Machines

• Ensure no slip/trip hazards are present in workspaces and walkways

• Ensure that you are familiar with the operation of the ON/OFF starter and Emergency -Stop (if fitted)

• Do not leave any equipment on top of the machine

• Check that machine guards are in position

• Ensure cutter is in good working condition and securely mounted

• Check coolant delivery system to allow for sufficient flow of coolant

• Do not use faulty equipment. Immediately report suspect machinery

Operational Safety Checks for Milling and Turning Machines

• Keep clear of moving machine parts

• Never leave the running machine unattended

• Follow correct clamping procedures - keep overhangs as small as possible and check work

piece is secure

• Set the correct speed to suit the cutter diameter, depth of cut and material

• Bring the machine to a complete standstill and switch it off before making adjustments/

measurements or before cleaning swarf accumulations



19

Housekeeping

• Switch off the machine when not working on it

• Remove milling cutters and store them safely

• Store the machine and work area in a safe, clean and tidy state

Potential Hazards

• Sharp cutters

• Moving components - hair/clothing entanglement

• Metal Splinters and burrs

• Flying Debris

Potential hazards may cause eye injury, skin irritation, metal splinters and blurs

DO NOT use the machine unless instructed by the trainer


20

Shri Rajiv Pratap RudyMinister of State (I/C) for

Skill Development & Entrepreneurship

Govt. of India

We are a youthful nation.

Our youth is our

strength. The world and

India need a skilled

workforce and we are

committed to achieve this

mission.


21LAB SPECIFICATIONS MACHINING

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Lab Specifications Machining - · PDF fileMinimum Machine Speciﬁcation CNC lathe, ... Manual lifter Bosch or 29 Power ... Minimum Machine Speciﬁcartion CNC Lathe, LAB SPECIFICATIONS

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