ANAND INTENATIONAL COLLEGE OF ENGINEERING (Promoted by Anand Education & Research Trust, Jaipur)

A REPORTON

INDUSTRIAL TRAINING

Done byKAILASH CHAND KUMAWAT

College ID: 11ME041

ATHMT MACHINE TOOL LIMITED

Beawar Road, Ajmer (305003)

Submitted to:Department Of Mechanical Engineering

Anand International College Of EngineeringJaipur-303012

BONAFIDE CERTIFICATE

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It is certified that this industrial training report is a work of KAILASH CHAND KUMAWAT, College ID: 11ME041, who carried out the INDUSTRIAL TRAINING at HMT MACHINE TOOLS LIMITED, Beawar Road, Ajmer-305003.

Coordinator

PREFACE

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Industrial training is part and parcel of every technical course and gives a face or form to all the theoretical knowledge we gain in our classroom. We get to have a virtual experience of the processes, methods, objects and phenomenon which used to be just an imaginary picture in our minds. It also gives an exposure to the environment of the industries and workshops which are virtual components of our professional life. We too were provided with this opportunity this summer.

On the whole it was a wonderful experience and a great learning which would be cherished by me throughout my life. There was times when I was disheartened and disappointed however there were also times when thing went right and made me feel proud of what I am doing. Success doesn’t come at once, we have to start right from the scratch and struggle our way through all hardships with courage and determination.

We are thankful to our college administration that handed this invaluable chance to us and at the same time we pay our regards to the administration of HMT Ajmer (Grinding Machine Tools Division) that proved to be a great supporting force for the fulfillment of the purpose. The officials and the workers of the firm provided us with the best of their attention and share ample of knowledge of their concerned field with us.

ACKNOWLEDGEMENT

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It is always a pleasure to remind the people in the Engineering program for their sincere guidance received during the training for the practical as well as theoretical skills in engineering.

I express my immense pleasure and deep sense of gratitude to Mr, Satish Goyal (General Manager) and my guide Mr. U. K. Pandey (HDMS In-charge)for spending his valuable time with me and also helped me in completion of the task.

I would also like to thanks Mr. R. K. Verma (K130 In-charge), P.K. Singh (HRD Officer) for giving me this opportunity and guiding me during the course of the training.

I would like to thank the entire HMT limited who has provided me this six weeks training. I am thankful to the HRD officer of training centre who organized my training schedule and who have provided me the various knowledge about their respective shops.

I also thanks to the workers of their respective departments, who were always ready to clarify our doubts and helped us to increase our knowledge by illustrating us to the finer points.

I also thanks to head of department of Mechanical Engg. in my college Mr. K. C. Sharma for giving me proper way to do training in HMT Ajmer.

CONTENTS

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Chapter No. Topic Page No.

1. INTRODUCTION…………………………….………………..….............................6-71.1 Company Profile………………………………………….....………………………...6-7

2. DETAILS OF THE TRAINING…………………….……………………..……......8-122.1 About The Company…………………………………...….………...………………….8-92.2 Product & Services………………………………….………..………………………...102.3 Different Departments…………………………………..…..…….…....……………....112.4 About The Products & Processes Of HMT Ajmer………….…..………………….......112.5 Location of HMT Ajmer……………………………………….…………….........……122.6 Awards Won By HMT Ajmer…………………………..….………...………………...12

3. DETAILS OF STUDY………………………………….………………………......13-353.1 Details of Products Studied…………………………….…..….................................13-173.2 Details of Departments…………………………………...………………………....18-193.3 Details of Process Studied……………………………………...……..……….….....19-263.4 Details of Machines Studied…………………………..……………………....…….26-313.5 Details of Measuring Tools/ Gauges Studied………..….…………………………..31-333.6 Process Layout………………………………………..…….………..............................343.7 Safety………………………………………………..…………….……………………35

4. CONCLUSION…………………………………..………...…………..........................36

CHAPTER-1INTRODUCTION

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1.1 COMPANY PROFILE:

HMT Ltd is a public limited commercial organization involved in the manufacture and sales of engineering goods as well as project consultancy.

Their segments include machine tools, watches, tractors, bearings and exports. The company's products include printing machine, bearings, food processing machine,

machine tools, watches and tractors. The company was incorporated with the objective of producing a limited range of machine

tools, required for building an industrial edifice for the country. Over the years, the company diversified into Watches, Tractors, Printing Machinery, Metal

Forming Presses, Die Casting & Plastic Processing Machinery, CNC Systems & Bearings. Its mission is to be a key source of “Technology for Excellence" in the field of metal cutting /

metal forming. Its vision is to be a manufacturing solution provider of international repute, offering best of

products & services with contemporary technologies for customers’ ultimate delight.Fig.- Corporate Structure

HMT synonymous with excellence in precision engineering is a multi product company

established in 1953. Today HMT is well positioned at the fore front of the precision engineering field. Its

manufacturing plants employ highly skilled workforces strongly supported by R&D. Today over 780000 machine tools manufactured by HMT are in used in India and elsewhere.

When India achieved independence in 1947, there was hardly any industrial base in the country. Right form the prior H.M.T. has played an important role in providing the much needed industrial base as well as a launching pad for the growth & development of the country.

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HMT Ltd is a public limited commercial organization involved in the manufacture and sales of engineering goods as well as project consultancy.

The company is engaged in the business of manufacturing and selling tractors and food processing machines.

Their segments include machine tools, watches, tractors, bearings and exports. The company's products include printing machine, bearings, food processing machine, machine tools, watches and tractors.

In tune with changing business environment, HMT limited restructured into holding company tractors as its core business and the following subsidiaries: HMT Machine Tools Limited, HMT Watch Limited, HMT Bearings Limited, HMT Chinar Watches Limited, HMT (International) Limited, Praga Machine Tools Limited.

CHAPTER-2DETAILS OF THE TRAINING

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2.1 ABOUT THE COMPANY:

HMT was conceived by the Government of India in 1949, and was incorporated in 1953, with the objective of producing a limited range of machine tools, required for building an industrial edifice for the country.

This Unit was established as Machine Tool Corporation of India limited in January 1964 keeping in view the Government Policy of differing new industries in under developed areas of the country and achieving self reliance in production of Grinding Machine Tools which were imported.

This Unit was started 1970-71 with a production of Rs. 8.64 Lack faces with difficulty in procurement of quality Machine Tool Casings a captive Foundry Plant was installed in 1993 with a capital of about Rs.2 Crore.

Fig.- Organization Chart

The organizational hierarchy of HMT MTL Ajmer is based on functions. General Manager leading the unit, assisted by the General Manager, Directly controls in different department.

The organization hierarchy consists of seven management levels in all. They are listed below

in descending order: General Manager Joint General Manager Deputy General Manager Assistant General Manager Manager Deputy Managers Foremen

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Fig.- Hierarchy In The Organization

2.2 PRODUCT & SERVICES:

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GM

Joint GeneralManager

Deputy General Manager

Assistant GeneralManager

Manager

Deputy Manager

Foremen

YEAR UNITS/DIVISION LOCATION STATE

1953196119621963196519671971197119721972197319751975197519781981198119821983198519861991

Machine Tools IMachine Tools IIWatch Factory I

Machine Tools IIIMachine Tools IVMachine Tools VTractor Division

Die Casting DivisionPrinting Machine Division

Watch Factory IIPrecision Machine Division

Machine Tools VIHMT (International) Ltd.

Watch Factory IIIWatch Factory IVHMT Bearing Ltd.

Quartz Analog WatchesWatch Factory V

Stepper Motor DivisionBall Screw Division

CNC System DivisionCentral Re-Conditioning

BangloreBangloreBanglorePinjore

KalamesseryHyderabad

PinjoreBanglore

KalamesseryBangloreBanglore

AjmerBangloreSri NagarTumkur

HyderabadBangloreRanibaghTumkurBangloreBangloreBanglore

KarnatakaKarnatakaKarnatakaHaryanaKerala

Andhra PradeshHaryana

KarnatakaKerala

KarnatakaKarnatakaRajasthanKarnataka

Jammu & KashmirKarnataka

Andhra PradeshKarnataka

Uttar PradeshKarnatakaKarnatakaKarnatakaKarnataka

Fig. - HMT Centers with their date of establishment

Following products and services are provided by HMT:1. Machine Tools2. Project Consultancy3. Tractor & Agricultural Implements4. Watches5. Bearing6. Printing Machinery7. Software & IT Services8. Imports

2.3 DIFFERENT DEPARTMENTS:

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There are various departments at HMT Ajmer, which are as follows:1. Human Resource Department2. Manufacturing and Assembly Department3. Service & Inspection Department4. Materials Department5. Planning Department6. Design Department7. Foundry Department8. Finance Department9. Sales Department10. Security Department11. Quality Assurance Department

2.4 ABOUT THE PRODUCTS & PROCESSES OF HMT AJMER:Generally HMT Ajmer is a Grinding Machine Tools Division Which makes the following grinding machines:1. Center less Grinding Machine.2. Internal Grinder.3. Tool & Cutter Grinder.4. Crank Shaft Grinder.5. Roll Chamber Grinder.6. Vertical Surface Grinder.7. Duplex Surface Grinder.8. Centre less Grinding Machine.9. Knife edge Grinding Machine.10. Hydraulic Cylindrical Grinder K-130.

The processes for making these products are as follows:1. Casting2. Fettling3. Painting4. Marking5. Milling6. Planning7. Boring8. Turning9. Drilling10. Grooving11. Grinding12. Threading13. Heat Treatment14. Scraping15. Assembling2.5 LOCATION OF HMT AJMER:

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1. The HMT Ajmer is situated near Ajmer Dairy 6 Km. from Ajmer City of Ajmer-Beawar Road.

2. It's foundation stone was laid on December 16, 1966 and production was started in 1970. 3. It produced various types of Grinding Machine, Lathe Machines of various sizes. 4. The product of H.M.T., however could not orient the local market towards them due to tough

competition but they have nicely attached the foreign market. 5. The H.M.T. were highly appreciated by Foreign Experts in many industries trade fair

organized in India and Abroad.

2.6 AWARDS WON BY HMT AJMER:

1. National Productivity Award, in Machine Tools Category for the year 1986-87.2. National Award for R&D efforts in Mechanical Engineering Sector in 1990.3. ISO-9001 Certification on 24th February 1994 HMT Ajmer was the First Unit to receive this

certification in Rajasthan & Second in HMT Units.4. National Award for excellence in indigenization of Defense Stores in the category of

Mechanical Engineering for the year 1993-94. This Award was for development & supply of Hydraulic Unit for T-72 Tank.

5. MTA product, computer controlled double disk grinder CNC GDS-22 displayed in IMTEX-98 at New Delhi, was confirmed upon CMTI – Trust Award for the best innovative design of the year.

CHAPTER-3

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DETAILS OF STUDY

3.1 DETAIL OF PRODUCTS STUDIED:

3.1.1 Center less Grinding Machine 106:Center less grinding is a machining process that uses abrasive cutting to remove material from a work piece. Center less grinding differs from centered grinding operations in that no spindle or fixture is used to locate and secure the work piece, the work piece is secured between two rotary grinding wheels, and the speed of their rotation relative to each other determines the rate at which material is removed from the work piece.

Center less grinding is typically used in preference to other grinding processes for operations where many parts must be processed in a short time.

Fig. - A schematic diagram of the center less grinding process

In center less grinding, the work piece is held between two grinding wheels, rotating in the same direction at different speeds, and a work holding platform. One wheel, known as the grinding wheel (stationary wheel in the diagram), is on a fixed axis and rotates such that the force applied to the work piece is directed downward, against the work holding platform. This wheel usually performs the grinding action by having a higher tangential speed than the work piece at the point of contact. The other wheel, known as the regulating wheel (moving wheel in the diagram), is

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movable. This wheel is positioned to apply lateral pressure to the work piece, and usually has either a very rough or rubber-bonded abrasive to trap the work piece.

The speed of the two wheels relative to each other provides the grinding action and determines the rate at which material is removed from the work piece. During operation the work piece turns with the Regulating wheel, with the same linear velocity at the point of contact and (ideally) no slipping. The grinding wheel turns faster, slipping past the surface of the work piece at the point of contact and removing chips of material as it passes.

There are three forms of center less grinding, differentiated primarily by the method used to feed the work piece through the machine-

Through-feed:In through-feed center less grinding, the work piece is fed through the grinding wheels completely, entering on one side and exiting on the opposite. The regulating wheel in through-feed grinding is canted away from the plane of the grinding wheel in such a way as to provide a lateral force component, feeding the work piece through between the two wheels. Through-feed grinding can be very efficient because it does not require a separate feed mechanism; however, it can only be used for parts with a simple cylindrical shape.

End-feed:In end-feed center less grinding, the work piece is fed axially into the machine on one side and comes to rest against an end stop; the grinding operation is performed, and then the work piece is fed in the opposite direction to exit the machine. End-feed grinding is best for tapered work pieces.

In-feed:In-feed center less grinding is used to grind work pieces with relatively complex shapes, such as an hourglass shape. Before the process begins, the work piece is loaded manually into the grinding machine and the regulating wheel moved into place. The complexity of the part shapes and grinding wheel shapes required to grind them accurately prevent the work piece from being fed axially through the machine.

3.1.2 Vertical Surface Grinder GVS 30:Ideally suited for heavy stock removal with high degree of accuracy combined with economic method of grinding for engine block, cylinder head, refractory bricks and many other general engineering components.

Salient Features: Bed is a single piece high tensile strength casting, heavily ribbed for better vibration damping

and shock absorption ensuring rigidity to the machine. Rectangular, box type turcite lined guide ways for wheel head. Precision scraped V & Flat guide ways for table with forced feed continuous lubrication.

Turcite lining for GVS 30.

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Rapid movement of wheel head by electric motor for faster setting. Fig.- Vertical Surface Grinder

Hydraulically operated auto in feed at each table reversal along with inching feed. Built in motor drive to the grinding wheel head. Hollow spindle for better coolant supply to ensure full power utilisation. Speed regulation of table in GVS 30 with remote operated proportional valve. Table stroke

sensed by limit switches. Built in safety interlocks.

3.1.3 CNC Double Disc Grinding Machine CNC GDS 22:

Salient Features: Ideal grinder for mass production of components having two flat and opposite parallel

surfaces with higher geometrical accuracies. Machines up to 4-axes CNC control. User-friendly grinding cycles by customized screen (picto programming). Preloaded antifriction guide ways for precise positioning and rigidity. Direct driven ball screws with AC digital servomotors for linear axes. Super precision antifriction bearings for grinding spindles. Hydraulic swing arm dresser. Automatic centralized lubrication system. Free-standing electrical panel and hydraulic power pack.

Fig.- CNC Double Disc Grinding Machine

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Pendant type operator panel. Built-in safety interlocks. Input resolution 0.0001 mm.

3.1.4 CNC Crankshaft Disc Grinding Machine CSG 500:Fig.- CNC Crankshaft Disc Grinding Machine CSG 500

Salient Features:

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High precision 5-axes Crankshaft Grinding Machine that offers economic solution for grinding of crank pins and journals of crankshafts in automatic cycle.

In process two jaw steady rest and gauge controls the finished size Directly driven ball screws with AC servomotor for in feed axes. Only loading/unloading and indexing for next pin set-up to be done manually. Both ends fixed and pre-stretched precision ball screws driven by AC servomotors for

reliability of positions. Profile dressing along with end radius. Infinitely variable speed for work head. Rigid structure. Wheel spindle runs in special high precision tilting pad type hydrodynamic bearing with

independent continuous lubrication system. Dual table with aerostatic lifting arrangement enable precise and easy taper setting (CSG 500

CNC). Counter balancing device and chucking device mounted on work spindle. Work drive motor

is de-energized for balancing of crankshaft easily.

3.1.5 Roll Camber Grinder GRC 55:Versatile grinder for micro precision grinding of rolls with concave or convex cambering and heavy duty cylindrical grinding applications in general engineering industries.

Salient Features: Single piece robust construction with long guided sleeve for better rigidity of tailstock. Bed

made of high tensile strength cast iron, heavily ribbed for better vibration damping and shock absorption.

Dual table arrangement for taper setting and taper grinding facility. Antifriction roller guide ways for in feed slide, ensuring micronic response and repeatability. Automatic in feed at table for traverse grinding operations. Plunge grinding cycle. Bearing pads of hydrodynamic super precision bearings are supported on cylindrn ical

surfaces that adjust themselves automatically according to load changes during operations and ensure minimum clearance.

Special Executions: Machine with 2-Axes CNC control. Dynamic wheel balancing. In process gauging system. Hydraulic actuation of tailstock. Angular head grinding machines with single axis CNC control. Grinding head with wheel size f 750x150 mm & 22 kW power. Swing dia. Up to 630 mm. Grinding machine for drilling rig cone (oil rigs and water borings). Table for up to 60 taper setting.3.2 DETAIL OF DEPARTMENTS:

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3.2.1 Human Resource Department:Headed by Joint General Manager (HRM) this department is setup with an aim of conservation and proper utilization of human resources and is also responsible for maintaining the cordial relations between employees and management. The other important functions of this department are performance appraisal and different welfare activities for the employee.

3.2.2 Manufacturing and Assembly Department:Headed by JGM (manufacturing). HMT Ajmer’s manufacturing environment is highly advanced; this department also looks after utilizing only the latest production techniques in all phases of manufacturing maintenance. This assembly of machine is done stages, much as sub assembly. Group assembly and final assembly of individual components. There subassemblies after inspection pass on group assembly, which consists of head stock assembly, saddle, gearbox, tail stock assemblies etc. this group then reaches to the final assembly to be fitted on the bed. Electrical are also inter faced and the machine is ready for final testing and printing of plant and equipment.

3.2.3 Service & Inspection Department:Headed by DGM. This department is responsible for inspection & Servicing of the M/C’s. This department is concerned with the inspection of various components and machines being manufactured. The inspection is carried out in various stages, beginning from the inspection of individual components at different stages of manufacturing followed by the inspection of the whole machine while included final runs etc. Inspection of incoming material is also handled.

3.2.4 Materials Department:Headed by JGM. It is responsible for all kinds of purchases made by unit. This department also maintains a Central store and looks after appropriate levels.

3.2.5 Planning Department:Headed by JGM(EQ). The main functions of the planning department are as under:1. Time calculations for each operation. Job card booking of workers in shifts.2. To prepare monthly progress reports for the production activities carried out in shop.3. To calculate manpower and machines available, accordingly new machines are ordered and

component.4. Counting of products and components.5. Prepare machines and sectional layouts

3.2.6 Design Department:Headed by JGM. Its functions are: -1. Design & development of products.2. Vendor development for new items.3. Drawing of component, group assembly, special assembly etc. along with master part list

(BOM) for machines.4. Deciding the type of material required for each component grade such as casting alloy etc.5. Testing & trials of machines.6. Marketing of special purpose machine.

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3.2.7 Foundry Department:Headed by JGM Foundry. This department is administratively under HMT Ajmer, but functionally under executive director.

3.2.8 Finance Department:Headed by AGM Finance. The functions of this department include maintenance of all accounts of the Company. The balance sheet is finally prepared which is sent to the head office for the preparation of combined balance sheet. The costing section of this dept. is responsible for the computing of each product of that the selling price may be determined accordingly.

3.2.9 Sales Department:It is headed by JGM(Sales). This dept. is divided into 3 sections viz. Sales, Spares and Reconditioning. These functions of sales sections are the execution of sales order and to bid for contracts through tenders. The function of service section is to provide after sales & also looks after customer’s complaints and supply of spares.

3.2.10Security Department:This is headed by Junior Security officer. Main function of this dept. is preventions of theft, sabotage and maintenance of industrial security within the HMT compound including Township.

3.2.11Quality Assurance Department:Dy. General Manager heads this department. This department also looks after the feedback received from marketing division so as to make improvement accordingly.

3.3 DETAIL OF PROCESS STUDIED:

3.3.1 Casting:Casting is a manufacturing process by which a liquid material is usually poured into a mold, which contains a hollow cavity of the desired shape, and then allowed to solidify. The solidified part is also known as a casting, which is ejected or broken out of the mold to complete the process. Casting materials are usually metals or various cold setting materials that cure after mixing two or more components together; examples are epoxy, concrete, plaster and clay. Casting is most often used for making complex shapes that would be otherwise difficult or uneconomical to make by other methods.

Casting is of two types:i. Metal

ii. Plaster, concrete, or plastic resin

Fig.-Metal Casting

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Metal casting is one of the most common casting processes. Metal patterns are more expensive but are more dimensionally stable and durable. Metallic patterns are used where repetitive production of castings is required in large quantities.

3.3.2 Milling: Milling is the machining process of using rotary cutters to remove material from a work piece advancing (or feeding) in a direction at an angle with the axis of the tool. It covers a wide variety of different operations and machines, on scales from small individual parts to large, heavy-duty gang milling operations. It is one of the most commonly used processes in industry and machine shops today for machining parts to precise sizes and shapes.

Fig.- Milling Process

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Milling can be done with a wide range of machine tools. The original class of machine tools for milling was the milling machine (often called a mill). After the advent of computer numerical control (CNC), milling machines evolved into machining centers (milling machines with

automatic tool changers, tool magazines or carousels, CNC control, coolant systems, and enclosures), generally classified as vertical machining centers (VMCs) and horizontal machining centers (HMCs). The integration of milling into turning environments and of turning into milling environments, begun with live tooling for lathes and the occasional use of mills for turning operations, led to a new class of machine tools, multitasking machines (MTMs), which are purpose-built to provide for a default machining strategy of using any combination of milling and turning within the same work envelope.

Milling is a cutting process that uses a milling cutter to remove material from the surface of a work piece. The milling cutter is a rotary cutting tool, often with multiple cutting points. As opposed to drilling, where the tool is advanced along its rotation axis, the cutter in milling is usually moved perpendicular to its axis so that cutting occurs on the circumference of the cutter. As the milling cutter enters the work piece, the cutting edges (flutes or teeth) of the tool repeatedly cut into and exit from the material, shaving off chips (swarf) from the work piece with each pass.

The cutting action is shear deformation; the metal is pushed off the work piece in tiny clumps that hang together to more or less extent (depending on the metal type) to form chips. This makes metal cutting a bit different (in its mechanics) from slicing softer materials with a blade.The milling process removes material by performing many separate, small cuts. This is accomplished by using a cutter with many teeth, spinning the cutter at high speed, or advancing the material through the cutter slowly; most often it is some combination of these three approaches. The speeds and feeds used are varied to suit a combination of variables. The speed at which the piece advances through the cutter is called feed rate, or just feed; it is most often measured in length of material per full revolution of the cutter.

3.3.3 Grooving:In manufacturing or mechanical engineering a groove is a long and narrow indentation built into a material, generally for the purpose of allowing another material or part to move within the groove and be guided by it.

Examples include:A canal cut in a hard material, usually metal. This canal can be round, oval or an arc in order to receive another component such as a boss, a tongue or a gasket. It can also be on the circumference of a dowel, a bolt, an axle or on the outside or inside of a tube or pipe etc. This canal may receive a circlip an o-ring or a gasket.

A depression on the entire circumference of a cast or machined wheel, a pulley or sheave. This depression may receive a cable, a rope or a belt.

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A longitudinal channel formed in a hot rolled rail profile such as a grooved rail. This groove is for the flange on a train wheel.

Fig.- Grooving Process

3.3.4 Boring:In machining, boring is the process of enlarging a hole that has already been drilled (or cast), by means of a single-point cutting tool (or of a boring head containing several such tools), for

Fig.-Boring Process

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example as in boring a gun barrel or an engine cylinder. Boring is used to achieve greater accuracy of the diameter of a hole, and can be used to cut a tapered hole.Boring can be viewed as the internal-diameter counterpart to turning, which cuts external diameters.

There are various types of boring. The boring bar may be supported on both ends (which only works if the existing hole is a through hole), or it may be supported at one end (which works for both through holes and blind holes). Line boring (line boring, line-boring) implies the former. Back boring (back boring, back-boring) is the process of reaching through an existing hole and then boring on the "back" side of the work piece (relative to the machine headstock).Because of the limitations on tooling design imposed by the fact that the work piece mostly surrounds the tool, boring is inherently somewhat more challenging than turning, in terms of decreased tool holding rigidity, increased clearance angle requirements (limiting the amount of support that can be given to the cutting edge), and difficulty of inspection of the resulting surface (size, form, surface roughness). These are the reasons why boring is viewed as an area of machining practice in its own right, separate from turning, with its own tips, tricks, challenges, and body of expertise, despite the fact that they are in some ways identical.Boring and turning have abrasive counterparts in internal and external cylindrical grinding. Each process is chosen based on the requirements and parameter values of a particular application.

3.3.5 Grinding:A grinding machine, often shortened to grinder, is any of various power tools or machine tools used for grinding, which is a type of machining using an abrasive wheel as the cutting tool. Each grain of abrasive on the wheel's surface cuts a small chip from the work piece via shear deformation.

Fig.-Grinding Process

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Grinding is used to finish work pieces that must show high surface quality (e.g., low surface roughness) and high accuracy of shape and dimension. As the accuracy in dimensions in grinding is on the order of 0.000025 mm, in most applications it tends to be a finishing operation and removes comparatively little metal, about 0.25 to 0.50 mm depth. However, there are some roughing applications in which grinding removes high volumes of metal quite rapidly. Thus, gr grinding is a diverse field

The grinding machine consists of a bed with a fixture to guide and hold the work piece, and a power-driven grinding wheel spinning at the required speed. The speed is determined by the wheel’s diameter and manufacturer’s rating. The user can control the grinding head to travel across a fixed work piece, or the work piece can be moved while the grind head stays in a fixed position. Fine control of the grinding head or tables position is possible using a vernier calibrated hand wheel, or using the features of controls. Grinding machines remove material from the work piece by abrasion, which can generate substantial amounts of heat. To cool the work piece so that it does not overheat and go outside its tolerance, grinding machines incorporate a coolant. The coolant also benefits the machinist as the heat generated may cause burns. In high precision grinding machines (most cylindrical and surface grinders), the final grinding stages are usually set up so that they remove about 200 nm (less than 1/10000 in) per pass - this generates so little heat that even with no coolant, the temperature rise is negligible.

3.3.6 Drilling:Drilling is a cutting process that uses a drill bit to cut or enlarge a hole of circular cross-section in solid materials. The drill bit is a rotary cutting, often multipoint. The bit is pressed against the work piece and rotated at rates from hundreds to thousands of revolutions per minute. This forces the cutting edge against the work piece, cutting off chips (swarf) from the hole as it is drilled.

Fig.-Drilling Process

Exceptionally, specially-shaped bits can cut holes of non-circular cross-section; a square cross-section is possible.

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Drilled holes are characterized by their sharp edge on the entrance side and the presence of burrs on the exit side (unless they have been removed). Also, the inside of the hole usually has helical feed marks.

Drilling may affect the mechanical properties of the work piece by creating low residual stresses around the hole opening and a very thin layer of highly stressed and disturbed material on the newly formed surface. This causes the work piece to become more susceptible to corrosion at the stressed surface. A finish operation may be done to avoid the corrosion. Zinc plating or any other standard finish operation of 14 to 20 µm can be done which helps to avoid any sort of corrosion.

For fluted drill bits, any chips are removed via the flutes. Chips may be long spirals or small flakes, depending on the material, and process parameters. The type of chips formed can be an indicator of the mach inability of the material, with long gummy chips reducing machinability.

When possible drilled holes should be located perpendicular to the work piece surface. This minimizes the drill bit's tendency to "walk", that is, to be deflected, which causes the hole to be misplaced. The higher the length-to-diameter ratio of the drill bit, the higher the tendency to walk.

3.3.7 Threading:Threading is the process of creating a screw thread. More screw threads are produced each year than any other machine element. There are many methods of generating threads, including subtractive methods (many kinds of thread cutting and grinding, as detailed below); deformative or transformative methods (rolling and forming; molding and casting); additive methods (such as 3D printing); or combinations thereof.

Fig.-Threading Process

There are various methods for generating screw threads. The method chosen for any one application is chosen based on constraints—time, money, degree of precision needed (or not

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needed), what equipment is already available, what equipment purchases could be justified based on resulting unit price of the threaded part (which depends on how many parts are planned), etc.In general, certain thread-generating processes tend to fall along certain portions of the spectrum from tool room-made parts to mass-produced parts, although there can be considerable overlap. For example, thread lapping following thread grinding would fall only on the extreme tool room end of the spectrum, while thread rolling is a large and diverse area of practice that is used for everything from micro lathe lead screws (somewhat pricey and very precise) to the cheapest deck screws (very affordable and with precision to spare).

Threads of metal fasteners are usually created on a thread rolling machine. They may also be cut with a lathe, tap or die. Rolled threads are stronger than cut threads, with increases of 10% to 20% in tensile strength and possibly more in fatigue resistance and wear resistance.

3.4 DETAIL OF MACHINES STUDIED:

3.4.1 Capstan Lathe:A capstan lathe is a milling machine used to create the same parts over and over again. The cutting bits are mounted on a rotatable turret known as a capstan, which allows the user to quickly change the orientation of the bits for cutting without having to take off the first bit and then mount the second. A piece of raw material, sometimes known as a blank, is mounted into the capstan lathe and is then spun at high speed. The cutting tools, sometimes known as knives, are then used to cut into the blank to create a new shape or design.

Fig.-Capstan Lathe

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When a new shape or design needs to be cut on the same blank, the tool turret can be rotated and a different knife can make contact with the rotating blank. This makes the capstan lathe quick and easy to use, which is important when the user is creating the same part over and over again from various blanks. All of the tools are already mounted on the capstan lathe, and with a simple turn of the turret, the user can make the necessary cuts. Older machines do require that the user rotate the turret manually.

3.4.2 Drum Turret Lathe:This lathe was designed for mass producing small high-precision parts in the arms, sewing and typewriter industries.

The tool holder can handle sixteen tools for longitudinal and surface lathing, drilling, reaming, and countersinking and counter boring. With a hand-operated gear drive, the operator positions the tools one after the other. 

Fig.-Drum Turret Lathe

Thanks to special cutting tools, this lathe can also be used for surfacing, slotting and cutting off stock. A forming tool with thread chasers permits cutting of uniform threads in large numbers.Preparing and setting this type of machine required a great deal of time and experience. Work steps had to be carefully thought out so that work pieces did not have to be rechucked and to keep non-productive times to a minimum.

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3.4.3 Vertical Turret Lathe:The vertical turret lathe is used for the processing of heavy and large work pieces. These machines characteristically have a large faceplate, upon which the work piece is clamped. In order to keep the work piece balanced, it is clamped in the centre. The frame of this machine can either have one or two machine columns. There is a strong crossbeam formed between the two columns, which is used to support one or several tool slides. The two column design is very robust and allows for high output torques. This means that up to three independently operated tools can be used simultaneously for the processing of one work piece.

This leads to a shorter processing time, of up to one day per work piece. Hydrostatic bearings carry the heavy faceplates and can carry a work piece weighing several tones. The operation of the working spindle comes from the machine table. Operation and control panels are usually located next to this big machine.

The slide of the tool carriage and the hydrostatic bearings are centrally lubricated. The very compact and stable composition of this machine means that it is very popular in heavy industry. The vertical turret lathe is often custom-made for special processes.

Fig.-Vertical Turret Lathe

The vertical turret lathe has a long tradition. The requirements of the construction of power station plants, power generators and engines made it necessary to develop a stable machine that can process big and heavy work pieces. Currently, there are a variety of supporting structures that are also available. Automatic measuring of data and CNC-operation are common, and optimize work processes. For example, data (for example, cutting force, surface quality and dimensional accuracy) are continually being monitored.

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3.4.4 Radial Drilling Machine:A radial drilling machine or radial arm press is a geared drill head that is mounted on an arm assembly that can be moved around to the extent of its arm reach. The most important components are the arm, column, and the drill head. The drill head of the radial drilling machine can be moved, adjusted in height, and rotated. Aside from its compact design, the radial drill press is capable of positioning its drill head to the work piece through this radial arm mechanism.

This is probably one of the reasons why more machinists prefer using this type of drilling machine. In fact, the radial drilling machine is considered the most versatile type of drill press. The tasks that a radial drilling machine can do include boring holes, countersinking, and grinding off small particles in masonry works.

Although some drill presses are floor mounted, the most common set-up of radial arm drill presses are those that are mounted on work benches or tables. With this kind of set-up, it is easier to mount the drill and the work pieces. There is no need to reposition work pieces because the arm can extend as far as its length could allow. Moreover, it is easier to maneuver large work pieces with the radial arm drilling machine. Large work pieces can be mounted on the table by cranes as the arm can be swiveled out of the way.

Fig.-Radial Drilling Machine

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Here are some of the major parts of the radial arm drilling machine:

Column - is the part of the radial arm drill press which holds the radial arm which can be moved around according to its length.

Arm Raise - adjusts the vertical height of the radial arm along the column

On/Off Button - is the switch that activates and deactivates the drill press

Arm Clamp - secures the column and the arm in place

Table - is the area where the work pieces are fed and worked on

Base - is the radial arm drill press part that supports the column and the table

Spindle - is the rotated part of the drill press which holds the drill chuck used in holding the cutting tool

Drill Head - is the part of the drill press that penetrates through the material or work piece and drill through the specific hole size.

Radial Arm - holds and supports the drill head assembly and can be moved around on the extent of its length

There are a number of advantages of using the radial arm drill press. One of these advantages is the amount of area that it can cover which is only dependent on the length of the arm. Another advantage is the considerable size of work that it can handle since the arm can actually swivel out of the working area allowing cranes and derricks to place work pieces on the table. Finally, less effort is required during the drilling process because the arm assembly seemingly is doing all that is needed for specific tasks to be completed.

3.4.5 Horizontal Boring Machine:A horizontal boring machine or horizontal boring mill is a m/c tool which bores holes in a horizontal direction. There are three main types- table, planer and floor. The table type is the most common and, as it is the most versatile, it is also known as the universal type.

A horizontal boring machine has its work spindle parallel to the ground and work table. Typically there are 3 linear axes in which the tool head and part move. Convention dictates that the main axis that drives the part towards the work spindle is the Z axis, with a cross-traversing X axis and a vertically traversing Y axis. The work spindle is referred to as the C axis and, if a rotary table is incorporated, its centre line is the B axis.

Horizontal boring machines are often heavy-duty industrial machines used for roughing out large components but there are high-precision models too. Modern machines use advanced CNC control systems and techniques. Charles DeVlieg entered the Machine Tool Hall of Fame for his

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work upon a highly precise model which he called a JIGMIL. The accuracy of this machine convinced the USAF to accept John Parson's idea for numerically controlled machine tools.

Fig.-Horizontal Boring Machine

3.5 DETAIL OF MEASURING TOOLS/ GAUGES STUDIED:

3.5.1 Vernier Caliper:A vernier scale is a device that lets the user measure more precisely than could be done by reading a uniformly-divided straight or circular measurement scale. It is scale that indicates where the measurement lies in between two of the marks on the main scale. Verniers are common on sextants used in navigation, scientific instruments used to conduct experiments, machinists' measuring tools (all sorts, but especially calipers and micrometers) used to work materials to fine tolerances, and on the odolites used in surveying.

3.5.2 Micrometer:A micrometer sometimes known as a micrometer screw gauge, is a device incorporating a calibrated screw widely used for precise measurement of components in mechanical engineering and machining as well as most mechanical trades, along with other metrological instruments such as dial, vernier, and digital calipers. Micrometers are usually, but not always, in the form of calipers (opposing ends joined by a frame), which is why micrometer caliper is another common name. The spindle is a very accurately machined screw and the object to be measured is placed between the spindle and the anvil. The spindle is moved by turning the ratchet knob or thimble until the object to be measured is lightly touched by both the spindle and the anvil.

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3.5.3 Plug Gauge:These gauges are referred to as plug gauges; they are used in the manner of a plug. They are generally assembled from standard parts where the gauge portion is interchangeable with other gauge pieces (obtained from a set of pin type gauge blocks and a body that uses the collect principle to hold the gauges firmly.

To use this style of gauge, one end is inserted into the part first and depending on the result of that test, the other end is tried.

Fig.-Plug Gauge

3.5.4 Slip Gauge:Slip Gauge are a system for producing precision lengths. The individual gauge block is a metal or ceramic block that has been precision ground and lapped to a specific thickness.

Gauge blocks come in sets of blocks with a range of standard lengths. In use, the blocks are stacked to make up a desired length.

An important feature of gauge blocks is that they can be joined together with very little dimensional uncertainty. The blocks are joined by a sliding process called wringing, which causes their ultra flat surfaces to cling together. A small number of gauge blocks can be used to create accurate lengths within a wide range. By using 3 blocks from a set of 30 blocks, one may create any of the 1000 lengths from 3.000 to 3.999 mm in 0.001 mm steps.

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3.5.5 Dial Bore Gauge:A dial or vernier bore gauge measures a bore directly. The gauge has three symmetrical anvils that protrude from the gauge body that are connected to the dial or micrometer mechanism. As the knob is rotated it moves the anvils in or out with respect to the measurements.

The knob usually has a slipping mechanism to take the feel out of the device and increase reliability between measurements. The measurement given is the mean diameter of the three anvils, and is usually good to 0.001 mm.

3.5.6 Depth Gauge:A depth gauge is a pressure gauge that displays the equivalent depth in water. It is a piece of diving equipment often used by SCUBA divers.

Most modern diving depth gauges have an electronic mechanism and digital display. Older types used a mechanical mechanism and analogue display.

A diver uses a depth gauge with decompression tables and a watch to avoid decompression sickness. A common alternative to the depth gauge, watch and decompression tables is a dive computer. A depth gauge and an oxygen analyzer/oxygen sensor can be used to measure the partial pressure of oxygen of the breathing gas, which is necessary to avoid oxygen toxicity.

Digital depth gauges commonly also include a timer showing the interval of time that the diver has been submerged. Some show the diver's rate of ascent and descent, which can be is useful for avoiding barotraumas.

As the gauge only measures water pressure, there is an inherent inaccuracy in the depth displayed by gauges that are used in both fresh water and seawater due to the difference in the densities of fresh water and seawater.

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3.6 PROCESS LAYOUT:

For BOP Items

For Work Instructions

For Documentation req.

For Loading & Issue For Loading to Shop

SHOP: HP, SP, MP, TR, SMS

Components

Deposit of components & Issue to Assy.

Assembly of Machine

Group Assy./Inspection of Machine

Dispatch/Packing

Fig.- Production Flow Chart

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ORDER

PPO

PPF

SHOP

INSPECTION

FPS

ASSEMBLY

INSPECTION

DESPATCH

PPM

PURCHASE

IG INSPECTION

STORES

CUSTOMER

DESIGN SPM

RECEIVING ORDER

MARKETING

SALES

1. Material Pre Planning

2. Office Pre Product

3. Feed Pre Product

4. Invert Goods

5. Finish Part Store

PLANNING

3.7 SAFETY:Safety Procedures are available across all industries and for all types of equipment and processes. Procedures that are easy to understand and easy to use can significantly help manage the safety of your workplace.

Some important rules for safety: HMT believes that NO JOB OR TASK IS MORE IMPORTANT THAN WORKER

HEALTH AND SAFETY. If a job represents a potential safety or health threat, every effort will be made to plan a safe

way to complete the task in a safe manner. Every procedure must be a safe procedure. Shortcuts in safe procedures by management and

all other associates will not be tolerated. If a worker observes any unsafe or unprotected exposure, which may pose a potential threat

to their safety & health, he or she must inform management immediately. Provide workers with a safe work environment. Conduct routine/regular workplace inspections. Provide Personal Protective Equipment. Develop and implement safe work procedures and rules. Provide on-going safety training Enforce safety rules and appropriate discipline. All injuries must be reported as soon as possible. No horseplay, alcohol, or drugs allowed on premises. No alcohol usage allowed during lunch break. Personal Protective Equipment must be worn as prescribed by management. All tools/equipment must be maintained in good condition. Only appropriate tools shall be used for specific jobs. All guards must be kept in place. Smoking not allowed in company.

Employee Responsibilities: Each employee is responsible to follow established policies and procedures. Regular attendance is required of all. Responsibility does not end with just taking care of you. Unsafe working conditions and acts must be reported to management. It is the responsibility of each employee to work in a professional and safe manner.

CHAPTER-4

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CONCLUSION

From the last month of June and July we were going in the one month summer training in the industry. This one month period of training is the most important time for the engineering students because in the time of industrial training the students getting the knowledge about the industries.

In the time period of training we are getting as the practical knowledge and also the theoretical knowledge. In the duration of the training we are getting the knowledge about the working of the industries.

In this last month I was also going in a industry named HMT Machine Tools Ltd. As I explained above that what is the work are done in this industry. In the one month time of training I was going regular in the industry. The first one thing in the industry is the discipline.

In the industries all the workers are the come regular and at the time.

So at the final we concluded that in the industries we getting the knowledge of the practical working and about the discipline.

In the industry we saw that the workers are very hard worker and they done there work separately and honestly and they are in the discipline.

This last month of training period is very good time for me and I getting the knowledge about the work procedure of the industry.

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