training report on Jyoti cnc automation ltd.

AASHIT DHARIYAPARMAR (11BME010)

KETAN GOJIYA (11BME013)

MAYUR KACHA (11BME020)

BHAUTIK VADHER (12BME163)

JYOTI CNC AUTOMATION LTD.

Industrial Training at

Company overview

Foundry shop

Sheet metal shop

Paint shop

Machining shop

Assembly shop

Location

G - 506, Lodhika GIDC, Village Metoda, Rajkot – 360 021, Gujarat, India.

Company overview

• India + 37 other countries• 12.7 % share in domestic metal cutting segment in FY 2012• 24 products in 81 variants• 5 units : 3 in Rajkot, India and 2 in Strasbourg, France.• Their Indian operations are ISO 9001:2008 certified• manufacture 2,500 machines p.a. in India and 150 machines p.a. in France.

• In November 2007, Company acquired Huron Graffenstaden S.A.S.

Products

Entry Level Machines

5 types of Turning Machines

1 Milling Machine

3 types of 3- Axis Vertical Machining Centers

High End Machines

•4 types of Turning Machines

•3 types of 3-AxisVertical Machining centers

•1 Horizontal Machining Center

•6 types of 5-Axis Vertical Machining centres

SHEET METAL SHOP

1. LASER cutting machine

Trumpf machine of Germany having Laser cutting technology. It is semiautomatic type and only loading and unloading of sheetis done, all other operations are done by machine itself accordingto program given to it.

2. Bending machine

True band 5050Trumpf CNC press brake machine

3. Robotic welding machines

4. Grinding equipments

First sheet is cut by Laser cutting CNC machine which cutsthe sheet to the required size.

Then sheet is bent to the required shape in bendingmachine.

After bending spot welding is done to attach number ofsheets together.

Before dispatching the sheet to the assembly unit grindingof sheet is done.

PAINT SHOP

Surface Coating

7 tank pre-treatment process followed by Cathodic Electro Deposited(CED) primer coating and conveyor zed baking with powder coatingbooths.

4 powder coating booths for different colours.

satisfy the aesthetic & protective requirements of customers.

Pre-treatment Plant:

It has capacity of 2 baskets per hour. Each basket with 50 sq mtr of the substrate to be treated. Basket size is 3000 × 2500 × 2300 mm. Maximum weight per basket is 2500 kg.

Powder coating plant

It consists of 4 powder coating booths, one baking oven and overhead conveyor.

Process Duration(min) Temperature( °C)

Degrease 5-15 65-70

Rinse 1 Ambient

Rinse 1 Ambient

Derust-1 5-15 Ambient

Derust-2 30-45 Ambient

Rinse 1 Ambient

Rinse 1 Ambient

Activation 1 Ambient

Phosphate 5-15 50-55

Rinse 1 Ambient

D.I. Rinse 1 Ambient

Bake 15 160

Different surface coating processes are as follows:

FOUNDRY SHOP

FOUNDRYCasting process is used to make the main body parts of CNCmachine like CNC bed, tail stroke, turn-table, saddle, etc.

Basic process for casting is described below :

Sand Mixing• First of all, It all starts with thepreparation of sand. They use85% of recycled sand and 15%of fresh sand.

• it is prepared by mixing ofspecial kind of additives viz. Resinand Catalyst at particulartemperature.

• Special OMEGA companyautomatic sand mixer is used inJyoti for sand preparation.

• 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.

• Any internal features of the casting that cannot be formed by the pattern are formed by separate cores which are made of sand prior to the formation of the mold.

• It takes 45 minutes to get completely mixed and set over the pattern. In a mould box a pattern is kept over which the prepared sand is filled up.

• Now that box is carried to the roll over machine manufactured by OMEGA manufacturers.

• This machine turns the mould box upside down and separates the mould with the pattern.

Mould Making

• After separation, mould is further carried away to thepainting or coating machine and the separated patternreturns to be used again for the preparation of similarkinds of moulds.

• A roller is provided which takes mould from roll over tothe coating machine.

• Coating is carried out either by machine or manually. Ifthe portion to be coated is less, it is okay to go withthe manual coating and if the portion to be coated ismore, one has to go for machine coating.

• This water based graphite coating helps in easyseparation after the molten metal is being poured.

• The next thing comes to the path is drying of themould for which it is kept in the oven.

• After drying upper and lower part is being assembledwhich is known as cope and drag assesmbly.

Fast loop moulding technique

Once the mold has been made, it must be prepared for the molten metal to be poured. • The surface of the mold cavity is first lubricated to facilitate the removal of the casting.

• Then, 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.

Clamping

• Induction furnace is used to melt themetal.

• Pig Iron, steel scrap, runners andrisers are used as a row material formelting.

• Generally the temperature of moltenmetal goes upto 1430 ̊C.

• Jyoti has two 3 tons capacityinduction melting furnace and one 10tons capacity induction furnace forholding the molten metal.

• According to % ratios of carbon,silicon and magnesium pig iron, steelscrap is used in melting.

• Special additives are also used toachieve particular property.

• Dust collector is placed above the

Melting of Metal

• 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.

• The pouring can be performed manually or by an automated machine.

• Enough molten metal must be poured to fill the entire cavity and all channels in the mold.

• The filling time is very short in order to prevent early solidification of any one part of the metal.

• Inoculate is added at the time of pouring.

Pouring

• The molten metal that is poured into the mold will begin tocool and solidify once it enters the cavity.

• When the entire cavity is filled and the molten metalsolidifies, the final shape of the casting is formed.

• It is allowed 24-48 hours of cooling.• The mold can not be opened until the cooling time haselapsed. The desired cooling time can be estimated basedupon the wall thickness of the casting and the temperatureof the metal.

• Most of the possible defects that can occur are a result ofthe solidification process. If some of the molten metal coolstoo quickly, the part may exhibit shrinkage, cracks, orincomplete sections.

Cooling

• After the predetermined solidificationtime has passed, the sand mold cansimply be broken, and the castingremoved.

• This step, sometimes called shakeout,is typically performed by a vibratingmachine that shakes the sand andcasting out of the flask.

• Then runner and risers are removedby hammering.

• In Jyoti, there is a dust collectorabove knock off machine.

Removal of casting

• After removal of casting it goes into shoot blasting chamber, in which steel balls of very small diameter is imparted on the casting.

• Shot blasting removes the any remaining sand, especially from internal surfaces, and reduce the surface roughness.

• In Jyoti, there are 2 shoot blasting furnace, one is automatic and one is manual.

Fettling

• During cooling, the material from the channels inthe mold solidifies attached to the part.

• This excess material must be trimmed from thecasting either manually via cutting or sawing, orusing a grinding and trimming process.

• The time required to trim the excess material canbe estimated from the size of the casting'senvelope. A larger casting will require a longergrinding and trimming time.

• The scrap material that results from this trimming iseither discarded or reused in the sand castingprocess. However, the scrap material may need tobe reconditioned to the proper chemical compositionbefore it can be combined with non-recycled metaland reused.

Grinding and Trimming

• Heat treatment process is used toincrease hardness of casting orfor stress relieving.

• In this process, casting is heatedat particular temperature forparticular time and then it iscooled down.

• Temperature, time and coolingrate decide the properties ofcasting.

Heat treatment process

• Patterns are made up of many different materials as perthe requirements.

• In general wooden pattern is being used over here whichis cheap in coast as well as long lasting.

• For the complicated parts aluminium metal is being used.• Thermocole is preferred if the pattern is going to be usedfor only once.

Pattern making

Inspection tests• Strength of sand mold• Tensile strength of casting• Metallurgy of casting• Chemical compositions of scrap.

Different tools for inspection• Ultimate tensile strength machine• Polishing machine• Impact testing machine• spectrometer

Inspection Lab

ASSEMBLY SHOP

ASSEMBLY LINES & TYPE OF LAYOUT

Assembly unit is mainly divided into three lines:1)HMC line2)TMC line3)VMC line including ATMs

Fixed position layout is used to assemble different CNCs. In this, after fixation of leveling points, all the other mountings are done at same position.

The sub-assembly required in the machinery is carried out in different department.

Assembly of DX-150 AND DX-250

Head-stock :

It supports chuck and itsmechanism. It hassystem which clampsand de-clamps of work-piece.

Tail-stock: It contains the supporting supporting elements i.e. i.e. quill

Turret assembly: It is the part of machine which has tools to work on job. Generally it has ten to twelve tools.

Ball-screw: Ball-screw has bolt-nut which converts its rotating motion to linear motion.

Electrical panel : It contains lots of electrical and electronic devices which leads it to automatic.automatic.

Motors : There are four different motors.

1) One for revolving of chuck (induction motor)2) another two for ball-screw (servo motor) (motion in X

(motion in X and Z axis)3)One motor for revolving of turret. (servo motor)

motor)

Pumps : There are two pumps in DX-250 and DX-150. One is forhydraulic oil transmission and the other is for coolant circulation.coolant circulation.

Outer sheet metal body : It provide safety to user and gives goodlooks.

Coolant circulation system : This system circulates coolant whichaims to cool down the working area and also directs th removal of

Hydraulic pressurized oil system : There is oil sump whichcontain pressurized oil and one pump for circulation. Onecirculation. One most important component for hydraulichydraulic system is solenoid valve. There are two valvestwo valves require for it. Each solenoid valve is electricallyis electrically controlled for oil circulation.

Lubrication system :This system is require to reduce friction and increase efficiency.increase efficiency.Lubrication is provided in two X and Z axis ball-screw and L.M. screw and L.M. through metering cartridge.Lubrication is also provided in tailstock sleeve.

STEPS OF ASSEMBLY

Base assemblyset the bad on level pad3 point leveling system by spirit level

Attach the L.M. guide ways on base with nut and bolts

Set the guide ways linearly using AUTO-COLLIMETERcheck the parallelism of it by means of straight edge(linear dial)This is very important test as saddle is mounted on it. So, it must be perfect.

Z-axis ball screw assembly mountingX-axis saddle and ball screw mountingAfter that saddle is mounted on CNC bed with the help of hoists available in assembly unit.

Tail stock assemblyL.M. guide is fixed and same process is carried out as saddle ball screw assembly

Head stock assemblyfixed by hoist and alignment is done by dial gaugegaugesquareness test is carried out for x-axis bolt-screw.

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

THERE ARE SEVERAL TESTS USED IN ASSEMBLY, AS DESCRIBED BELOW.

GEOMETRICAL TEST SQUARENESS TEST LASER TEST BALL BAR TEST PRACTICAL TEST COOLANT TRIAL ELECTRICAL FINAL TEST FINAL INSPECTION PRE DISPATCHED INSPECTION

MACHINE SHOP

Shop and sub-section

Machining shop is located at Unit-1 of company premises.

Total 7 Sub Sections :Machining shop-1Machining shop-2Machining shop-3Grinding shop-1Grinding shop-2Raw material inlet & dispatch areaA quality control and measurement laboratory.

PROCESSES

The components made from casting process, are machinedto give them accurate size and shapes.Following operations are carried out on raw parts to givethem desired finish and accuracy:TurningFacingMillingGrindingDrillingBoring etc.

Parts being machined

Following parts are machined at the machining unit:• Bearing covers• Tool sockets• Jigs& fixture parts• Main spindle shaft• Work table• Bed of CNC machines Some of the parts are imported from the outside vendors

Machining shops features

Main attractions of machine shops at Jyoti:

5 phase CNC machining centre Head positioning changer and multi tool ATC. One of the best Horizontal Machining center havingAPC with 60 tools ATC. Programming Controller by ‘Siemens pt. Ltd.’ or ‘Fanuc’ Higher quality & productivity machines

Unique Features

Due to uneven mass its difficult to locate m/c on 3 points

4 point location is tedious and requires patience

Easy to locate on 3 point moreover leads to no stress or twisting

Unique Features

TRIM : Use of high torque integral servo motor

Replacements of complex mechanical components like worm and worm wheel

Torque transmission is direct to motor hence perfect

Machine companies and models

Although a significant amount of mother machinery at machining unit isfrom foreign companies, many of the machines are manufactured by Jyotiitself.

Some other manufacturing companies of mother machines are: Huron pvt. Ltd. Nicola correa DMC ltd. SNK machines

Here are some model no. of machines used at machining shop:• VMC -640• DX-250• ATM-160• VMC-430• AM-430

Machining shop overview

Horizontal turning CNC m/c centers

Grinding shops

All the critical parts are finished using various CNC grinding machines.

It gives finest accuracy finishes to the machine parts that is in perfect tune with

mission of the company.

Grinding Shops consists of:

Cylindrical grinding CNC m/c

Rotary horizontal-spindle surface grinding

Rotory vertical-spindle surface grinding CNC m/c.

Grinding CNC centers at Jyoti

References

1. http://www.jyoti.co.in/company_profile.aspx?pg=abt&sub=comp

2. http://www.jyoti.co.in/category.aspx

3. http://www.jyoti.co.in/foundry.aspx?pg=str&sub=fdry

4. http://www.jyoti.co.in/mfg_excellence.aspx?pg=str&sub=mfg

5. http://www.jyoti.co.in/sheet_metal_shop.aspx?pg=str&sub=sms

6. http://www.jyoti.co.in/paint_shop.aspx?pg=str&sub=paint

7. http://www.jyoti.co.in/research_dev.aspx?pg=str&sub=rd

8. http://www.jyoti.co.in/training.aspx?pg=str&sub=training

9. http://www.jyoti.co.in/qlty_assurance.aspx?pg=str&sub=qlty