Machine Shop Practices

8/11/2019 Machine Shop Practices

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MACHINE SHOP

PRACTICES


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IN CASE OF DOUBT

GET CLARIFICATIONS

NEVER ASSUME


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PRE-PLANNING 1. STUDY SCOPE

ORDER FOR SCOPE OF OPERATIONS TECHNOLOGICAL PROCESS

DRAWINGS QUALITY PLAN REQUIREMENTS

GET CLARIFICATIONS IN CASE OF DOUBTS NEVERASSUME


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PRE-PLANNING 2. STUDY DOCUMENTS

WHAT IS THE MATERIAL ? IS CORRECT MATERIAL SUPPLIED ?

IDENTIFICATIONS ATTESTATIONS (IF REQUIRED)EVIDENCE OF COMPLETION OF ALL

PREVIOUS OPERATIONS(FABRICATIONS , HEAT TREATMENTETC) GET CLARIFICATIONS IN CASE OF DOUBTS NEVER

ASSUME


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PRE-PLANNING 3. PLAN PRODUCTION PROCESS

WHAT ARE YOUR F ACI L I TI ES ? ARE THEY IN LINE WITH TECH

PROCESS ? MODIFY YOUR PROCESS TO SUIT YOURFA C I L I T I E S IF POSSIBLE

IDENTIFY THE ATTESTATIONSTRANSFER POINTS(IF REQUIRED)

GET CLARIFICATIONS IN CASE OF DOUBTS NEVER ASSUME


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PRE-PLANNING 4. PLAN SPECIAL REQUIREMENTS

IDENTIFY AND LIST THE REQUIREMENTSOF

JIGS FIXTURES SPECIAL TOOLS

GAUGES SPECIAL INSTRUMENTS etc

GET CLARIFICATIONS IN CASE OF DOUBTS NEVER ASSUME


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PRE-PLANNING 5. PLAN INSPECTION RE-STUDY THE DRAWING AND PROCESS

IN DETAIL

FORMAT THE I N-PROCESS I NSPECTI ON DOCUMENT (DIR) BASED ON THEDIMENSIONS AT EACH STAGE OF THEMANUFACURING SEQUENCE .

GET CLARIFICATIONS IN CASE OF DOUBTS NEVER

ASSUME


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INPROCESS INSPECTION REPORTPage 1 of 3

VENDOR CODE : Record No. Date :

Product and Project Pulvrisers / Record No

Work Order No Part no & Name JOURNAL HEAD

Drawing No 061000001690208 Identification

SRV/FGDC No

SNO DESCRIPTION DETAILS SIGN OF INSP

1 NDT Results

2 Hydrostatic Test Results

3 Other Tests (if any)

Actual ValuesSNO Characteristics as per Drg/Specificn

1 2 3 4

IDENTIFICATIONSRemarks

1 353-0.1/-0.3 (SEC AA

(2)

2 DEPTH 133 TOT HT 724

4 495.25 -0.05 (SEC AA)

(2)

5 CONC TAPER BORE 0.13


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PRE-PLANNING 5. PLAN INSPECTION

IDENTIFY THE MEASURING INSTRUMENTSTO BE USED FOR EACH DIMENSION



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PRE-PLANNING 6. CRITICAL DIMENSIONS

CLEARLY IDENTIFY CRITICALDIMENSIONS ON THE INSP DOCUMENT.

IDENTIFY AND MARK INSPECTIONCHECK POINTS AND AGENCY ON THEDOCUMENT ( INTERNAL/ BHEL/ 3rd

PARTY) BASED ON QUALITY PLAN / TECHPROCESS


INPROCESS INSPECTION REPORT


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INPROCESS INSPECTION REPORTPage 1 of 3

VENDOR CODE : Record No. Date :

Product and Project Pulvrisers / Record No

Work Order No Part no & Name JOURNAL HEAD

Drawing No 061000001690208 Identification

SRV/FGDC No

SNO DESCRIPTION DETAILS SIGN OF INSP

1 NDT Results

2 Hydrostatic Test Results

3 Other Tests (if any)

Actual ValuesSNO Characteristics as per Drg/Specificn

1 2 3 4

IDENTIFICATIONSRemarks

1 353-0.1/-0.3 (SEC AA MICR

(2)

2 DEPTH 13 DEP GG

3 TOT HT 724 VERN.

4 495.25 -0.05 (SEC AA) MICR

(2)

5 CONC TAPER BORE 0.13

6 PERP FACE : A 0.08

BHEL ON M/C


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PRE-PLANNING 7. GEOMETRICAL TOLERANCES

IDENTIFY ALL THE GEOMETRICALTOLERANCES ON THE DRAWING. (eg

etc IDENTIFY THE REFERENCE DIMENSION

FOR THESE TOLERANCES

GET CLARIFICATIONS IN CASE OF DOUBTS NEVER

ASSUME


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PRE-PLANNING 8. PLANNING FOR GEOM. TOLS

FORMALISE THE GEOMETRICALTOLERANCES

HOW TO IN-BUILT IN THE PROCESS

HOW TO INSPECT

INSPECTION ON MACHINE / OFF MACHINE



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EXECUTION 9. DISCUSSION

DISCUSS WITH THE OPERATOR(S) INDETAIL ABOUT ALL THE EARLIER

STAGESMANUFACTURING PROCESS

INSPECT HOLD POINTS

RECORDING FORMAT

ATTESTATION REQUIREMENTS etc

MODIFY THE EARLIER STEPS IF NECESSARY.


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EXECUTION 10. JOB MARKINGMARK THE JOB FOR MACHINING ALLOWANCES

START WITH REFERENCE DIMENSION ASBASE.

CHECK FOR ALLOWANCES ON ALL OTHERDIMENSIONS WITH RESP TO REF DIMENSION.

RE-DISTRIBUTE FOR EQUAL ALLOWANCE ONALL MACHINED SURFACES.


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EXECUTION 10. JOB MARKINGENSURE THAT

WALL THICK-NESSES.

FLANGE THICK-NESSES. CRITICAL BUT UN-MACHINED SURFACES

ARE MAINTAINED.


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EXAMPLEA SEGMENTAL COMPONENT HAS 90DEGREE SPAN.


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FOUR SUCH SEGMENTS ARE ASSEMBLEDTOGETHER TO MAKE A RING.

- THE PARTING PLANES ARE MILLED, - PARTING PLANE HOLES ARE DRILLED ,- FOUR HALVES ARE JOINED FOR FINAL

BORING.


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AT THE TIME OF BORING, IT WAS FOUNDTHAT ONE SEGMENT IS NOT MATCHING

WITH OTHER THREE : THERE IS NOMACHINING ALLOWANCE ON OUTSIDEDIAMETER


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IF THE PROBLEM IS ANALYSED IT CANBE EASILY SEEN THAT THE COMPONENTCOULD HAVE BEEN SALVAGED HAD ITBEEN MARKED EARLIER BY TAKING THECENTER OF THE DIAMETERS ASREFERENCE


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THE COMPONENT SHOULD HAVE BEEN MARKEDWITH REFERENCE TO THE DIAMETERS AND THEMACHINING ALLOWANCES ON THE FLANGESSHOULD HAVE BEEN FIXED BASED ON THIS


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JOB SETTINGPROVIDE SUPPORTS/SHIMS BELOW EACH

CLAMP.NECESSARY CARE SHOULD BE TAKEN

WHILE CLAMPING SUCH THAT THE JOB

STRESS DUE TO CLAMPING IS MINIMUM .IN CASE COOLANT IS USED DURING

MACHINING CHECK THE COOLANT TO

BE USED FOR THE MATERIAL.ENSURE THE COOLANT CONDITION


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EXECUTION 12. MACHININGFIRST ROUGH MACHINE THE MAIN

REFERENCE SURFACE.ALL OTHER PARAMETERS RELATED TO

THIS PLANE MUST WITH REFERENCE TOTHIS PLANE.

ROUGH MACHINE ALL OTHER SURFACESWITH RESPECT TO THIS PLANE

PREFERABLE ALLOWANCE AT THISSTAGE IS APPROXIMATELY 3mm.


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EXECUTION 12.1. ROUGH MACHININGNECESSARY CARE MUST BE TAKEN

WHILE ROUGH MACHINING TO :

A) AVOID OVER-LOADING THE MACHINE B) AVOID OVER STRESSING THE JOB: THIS

MAY GIVE RESULT IN BURNING/

DISTORTION. C) LEAVE SUFFICIENT ALLOWANCE FOR

FINISH MACHINING


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MACHINING STRESSESANY MACHINING CREATES

MACHINING STRESSES IN THE JOB

MORE DEPTH OF CUT / FEED / SPEED

MEANS MORE STRESS THESE MACHINING STRESS DISTORT

THE JOB OVER TIME : WHICH MAY

TAKE FROM A FEW HOURS TOMONTHS OR MAY BE YEARS


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MACHINING STRESSESTHE BEST WAY TO REMOVE THESE

STRESSES IS TO STRESS RELIEVEAFTER ROUGH MACHINING

THIS IS MANDATORY FOR CRITICALCOMPONENTS

HOWEVER A FEW PRE-CAUTIONS

MAY KEEP THESE STRESSES WITHINMANAGEABLE LIMITS FOR MOST OFTHE JOBS


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MACHINING STRESSESA) ENSURE THAT THE JOB IS NOT

DISTORTED DURING CLAMPINGB) DO NOT TAKE HEAVY CUT DURING

ROUGH MACHINING

C) COMPLETE THE ROUGH M/Cng ANDALLOW THE JOB TO REST BY REMOVINGTHE CLAMPS, AND ALLOWING THE JOBTO STAND FOR A FEW HOURS.

D) A PRACTICAL WAY TO DO THIS WILLBE TO ROUGH MACHINE ALL THE JOBSAND THEN ONE BY ONE FINISH MACHINE


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12.2 FINISH MACHINING1. ASSESS

THE CONDITION OF THE MACHINE. THE ACCURACY IT CAN ACHIEVE

THIS HELPS IN SCHEDULING (PLANNING

THE JOB FOR A MACHINE)

2. SELECT THE RIGHT TOOL FOR THE

MATERIAL OF THE COMPONENT


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FINISH MACHINING3. ASSESS THE FEED/ SPEED/ DEPTH OF

CUT PARAMETERS FOR THE MATERIALTO GET THE REQUIRED FINISH. THISCAN BE FOUND DURING ROUGHINSTAGE BY TAKING A TRIAL FINISHINGCUT WITH FINISHING TOOL IF NO DATAIS AVAILABLE.

KEEP A RECORD OF M/C ACCURACIESALL PARAMETERS etc. THIS WILL

HELP YOU IN FUTURE JOBS.


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FINISH MACHINING1. START BY MACHINING THE REFERENCE

PLANE FIRST2. ALL THE REFERENCE M/C SURFACES

REQUIRED TO ACHIEVE GEOMETRICAL

TOLERANCES MUST BE MACHINED WITHREFERENCE TO THIS SURFACE3. ADHERE TO THE DECIDED SEQUENCE

OF OPERATIONS.


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FINISH MACHINING4. DO NOT CARRY OUT MEASUREMENTS

WHEN JOB IS HOT OR STRESSED. ALLOWTHE JOB TO COOL DOWN. ENSURE THATTHE JOBS, CLAMPS, ETC ARE NOT OVERSTRESSING THE COMPONENT(EXTREMELY CRITICAL FOR THINWALLED COMPONENTS )


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UNDERSTANDING GEOMETRICAL TOLERANCES


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O.O2 A


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O.O2 A

TOLERANCE VALUE

TOLERANCE CHARACTERISTIC DATUM


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TOLERANCE OF FORM


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TOLERANCE OF FORM

FEATURE CHARACTERISTIC

SYMBOL ASME Y14.5M

Ref.

STRAIGHTNESS 4.4.1

FLATNESS 6.4.2

CIRCULARITY (ROUNDNESS )

6.4.3

CYLINDRICTY 6.4.4

TOLERANCE OF PROFILE


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TOLERANCE OF PROFILE

FEATURE CHARACTERISTIC SYMBOLASMEY14.5M Ref.

PROFILE OF LINE

6.5.2(b)

PROFILE OF SURFACE 6.5.2(a)

TOLERANCE OF ORIENTATION


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TOLERANCE OF ORIENTATION

FEATURE CHARACTERISTIC SYMBOLASMEY14.5M Ref.

ANGULARITY 6.6.2

PERPENDICULARITY

6.6.4

PARALLEISM // 6.6.3

TOLERANCE OF LOCATION


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TOLERANCE OF LOCATION

FEATURE CHARACTERISTIC SYMBOL

ASME

Y14.5M Ref.

POSITION 5.2

CONCENTRICTY 5.11.3

SYMMETRY 5.13

TOLERANCE OF RUN OUT


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TOLERANCE OF RUN-OUT

FEATURE CHARACTERISTIC SYMBOLASME Y14.5M Ref.

CIRCULAR RUNOUT 6.7.1.2.1

TOTAL RUNOUT 6.7.1.2.2


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SPECIAL MACHINING

ACTIVITIES

1. REFERENCE CUT


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REFERENCE MACHINING

IF THE JOB IS TO BE MACHINED FROMMORE THAN ONE SIDE , (ie JOB TO BEUNCLAMPED AND RE-CLAMPED AT ADIFFERENT POSITION), eg MACHININGON VERTICAL BORING ON 2 FACES


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REFERENCE : VERTICAL BORING

IT IS NECESSARY TO HAVE A FACE ASWELL AS MINIMUM ONE SETTINGDIAMETER (IDEAL 2 DIAS) REFERENCE

FOR RE-ALIGNMENT PURPOSE.FOR VERTICAL BORING OPERATIONS,

REFERENCE DIMENSIONS MAY BE

A) SEATING FACE ON BEDB) REFERENCE DIAMETER FOR DIALLINGC) REFERENCE FACE FOR DIALLING


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REFERENCE : VERTICAL BORING

REFERENCE VERTICAL BORING


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REFERENCE : VERTICAL BORING(PREFERABLE)


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REFERENCE : CENTER LATHES

FOR CENTER LATHES ALMOST ALWAYSTHE SETTING IS BY TWO SETTINGDIAMETER REFERENCE FOR RE-ALIGNMENT PURPOSE.


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REFERENCE MACHINING

FOR HORIZONTAL BORING OPERATIONS,THE NUMBER OF FACTORS AND HENCENUMBER OF REFERENCE AXIS BECOMESMUCH HIGHER

A JOB LOOSENED AND RE-TIGHETENEDCAN BE DISTURBED IN 3 AXIS (X,Y & Z)


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REF MACHINING : HORIZ BORING

CONSIDER A PIPE UNDER MACHINING.THIS CAN BE RE-CLAMPED DISTURBED IN 3

AXIS AS SHOWN.


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IN ADDITION IT CAN BE DISTURBED IN ATLEAST TWO ANGLES .



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TO COMPLICATE THE MATTER FURTHER,THE MACHINE POSITION ITSELF CAN BEDISTURBED WITH REFERENCE TO JOB.



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ANOTHER PROBLEM USUALLY FACEDWITH HORIZONTAL BORING IS THESPINDLE SAG AS IT IS MOVED OUT.



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ONE MAY END UP WITH THE SHAPE OF ASTRAIGHT BORE AS SHOWN.



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ONE OF THE WAY TO OVERCOME THIS SAGIS BY BED MOVEMENT.

THE SPINDLE IS KEPT STATIONARY THEMACHINE BED IS MOVED FORWARD/BACKWARD.( PROVIDED TABLE FEEDFACILITY IS AVAILABLE IN THE M/C)



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HOWEVER IT IS NECESSARY THAT FORTHIS PURPOSE, THE MOVEMENT AXIS OFTHE BED MUST BE EXACTLY PARALLELTO THE MACHINE AXIS



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OTHER WISE THE SHAPE OF THE BORESMAY BE AS SHOWN



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TO OVERCOME THIS THE REFERENCE

MACHINING IS CARRIED OUT.ALL THE ERRORS WHETHER BECAUSE OF

POSITIONING OR ANGLE CAN BE

DIVIDED INTO 5 GROUPS


REF MACHINING HORIZ BORING


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A) X AXIS POSITION

B) Y AXIS POSITIONC) Z AXIS POSITION

D) ANGLE IN Y-Z PLANE

E) ANGLE IN X-Z PLANE



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IF THE JOB IS SET IN 2 PERPENDICULAR DIRECTION AND THE X, Y AND ZPOSITIONS ARE FIXED WITH RESPECT TOANY FIXED PLANES, THE JOB AFTERDISTURBANCE (DUE TO JOB ROTATION,JOB RESETTING) ETC CAN BE SET BACKTO ORIGINAL POSITION.



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THE ONLY CARE TO BE TAKEN

HERE IS THAT THE ANGLESETTING (BY DIALLING) MUST BEDONE IN THE SAME WAY AS THE

ACTUAL MACHINING :



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A) IF ACTUAL MACHINING IS BY TABLE

MOVEMENT : SETTING DIALLING MUSTBE BY TABLE MOVEMENT .



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B) IF ACTUAL MACHINING IS BY SPINDLE

MOVEMENT : SETTING DIALLING MUSTBE BY SPINDLE MOVEMENT.



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C) IF ACTUAL MACHINING IS BY RAM

MOVEMENT : SETTING DIALLING MUSTBE BY RAM MOVEMENT.



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THE POSITIONAL REFERENCE SHOULDBE TAKEN FROM AN UN-DISTURBEDPOINT.

THUS IF A BED IS ROTATED, THEHEIGHT FROM BED WILL NOT GIVEPOSITIONAL ACCURACY UNLESS THEGEOMETRIC ACCURACY OF THE BEDIS KNOWN AND ADJUSTED.



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THE MOST PREFERRED WAY MAY BETO TAKE A CUT ON THE JOB ITSELFIF POSSIBLE



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DIAL THIS SURFACE AS DISCUSSEDEARLIER ( BED MOVEMENT / RAMMOVEMENT /SPINDLE MOVEMENT )



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IN SECOND SETTING AGAIN DIAL THE


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IN SECOND SETTING AGAIN DIAL THEREFERENCE FACE MACHINE THE

FEATURE SO THAT THE SAMEDIMENSION X IS ACHIEVED ( AFTERCORRECTING FOR THE

DIMENSIONAL DIFFERENCES Y1 &Y2)

X

IN SECOND SETTING AGAIN DIAL THE


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IN SECOND SETTING AGAIN DIAL THEREFERENCE FACE

MACHINE THE FEATURE SO THAT THE


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MACHINE THE FEATURE SO THAT THESAME DIMENSION X IS ACHIEVED (

AFTER CORRECTING FOR THEDIMENSIONAL DIFFERENCES Y1 &Y2)

X X

Y1

Y2

IF THIS REFERENCE CUT IS TAKEN IN


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IF THIS REFERENCE CUT IS TAKEN INTWO PERPENDICULAR AXES, THEN

BY DIALING THESE TWO AXIS ANDMAINTAINING THE DIMENSIONS X,POSITIONAL AND ANGULAR

POSITIONS ON 2 AXIS CAN BEENSURED INDEPENDENT OF THEMACHINE.


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SPECIAL MACHINING

ACTIVITIES

2. BLUE MATCHING

BLUE MATCHING


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BLUE MATCHINGIN CASE ANY PARTING PLANE BLUE

MATCHING IS REQUIRED, IT IS TOBE DONE BY FINISH MACHININGTHE CORERSPONDING SURFACESIMMEDIATELY AFTER ROUGHMACHINING.

FOR BLUE MATCHING TWO MATINGSURFACES, FIRST BLUE MATCHBOTH INDIVIDUALLY WITH A

MASTER LEVEL BED


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BLUE MATCHING


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BLUE MATCHINGENSURE THE CONDITION OF THE

LEVEL BED BEFORE STARTING THEOPERATION.

BLUE MUST BE APPLIED ON THE BEDBY A ROLLER, AND A VERY SMALLQUANTITY OF BLUE MUST BESPREAD EVENLY

ALTERNATELY A CLEAN CLOTH MAYBE USED TO SPREAD THE BLUE.

BLUE MATCHING


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BLUE MATCHINGAFTER BOTH THE SURFACES ARE

INDIVIDUALLY MATCHED, MATCHTHE SURFACES WITH EACH OTHER.

APPLY MINIMUM QUANTITY OF BLUEON ONE SURFACE

MOVEMENT OF ONE SURFACE

AGAINST SECOND MUST BELIMITED TO APPROXIMATELY 10-15mm ONLY.


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BLUE MATCHING


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BLUE MATCHINGCHECK THE GAP BETWEEN

SURFACES WITH A FEELER 0.02 TO0.03 mm THICK.

REMOVE THE COMPONENTS ANDINSPECT BOTH THE SURFACES.

IN THE CLEAN SURFACE OBSERVE

BLUE MARK,IN THE BLUE SURFACE OBSERVE

FOR ANY SHINE/ SCRATCH

BLUE MATCHING


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BLUE MATCHINGCONTINUE BLUE MATCHING BY SCRAPING

TILL A) % CONTACT IS AS PER REQUIREMENT B) FEELER DOES NOT ENTER THE SURFACE

IN FREE CONDITION (WITHOUT BOLT)C) NO ABNORMAL SCRATCH MARKS ON

SURFACES

D) THE AREAS WITHOUT BLUE ARESCATTERED AND DO NOT CREATE ALEAKAGE PATH ACROSS


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SPECIAL MACHININGACTIVITIES

3. MACHINING HALF DIAMETERS

HALF DIA MACHINING


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HALF DIA MACHININGVERY OFTEN COMPONENTS ARE

MACHINED IN 2 HALVES.EACH OF THE HALF SEGMENT OF

HAS TO HAVE HALF OF THE BORE

ie THE BORE AXIS SHOULD PASSTHROUGH THE PARTING PLANE


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HALF DIA MACHINING


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HALF DIA MACHININGTHERE MAY BE SEVERAL METHODS

AVAILABLE TO MEET THIS TYPE OFREQUIREMENTS.

HALF DIA MACHINING VERT BORING


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MOST CRUDE METHOD IS TO DIAL

THE PARTING PLANE.

THE ALIGNMENT CHECK IS VISUALAND ACCURACY IS LOW



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SECOND METHOD IS TO MACHINE

HALF BORE IN ONE OF THE HALVES.

MEASURE DIMENSIONS X & YCALCULATE HALF BORE OFFSET AS

= Y - X/2 ON VERTICAL BORING WHILEDIALING GET THIS VALUE.

X

Y



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FOR EXAMPLE, IF

X= 300.00 Y = 150.20Y - X/2 = 150.20 - 300/2 = 0.20

X

Y



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FOR EXAMPLE, IF

X= 300.00 Y = 150.20Y - X/2 = 150.20 - 300/2 = 0.20

0 0+0.20

HALF DIA MACHINING


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HALF DIA MACHININGADJUST THE JOB ON TABLE TILL

THIS DIAL READING PATTERN ISACHIEVED.


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HALF DIA MACHINING


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HALF DIA MACHININGSET THE JOB APPROXIMATELY (BY

TRACING THE PARTING PLANE ASPER METHOD-1)

MEASURE THE DIAMETER ANDDIMENSION Y

D

Y

HALF DIA MACHINING


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IF THE DIMENSION

Y = X - D/2THE SETTING IS OK

ELSE ADJUST THE JOB TILL THEVALUE IS ACHIEVED

D

YX

HALF DIA MACHINING


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IF THE CENTERING IS TO BE DONE

ON 2 DIRECTIONS, 2 REFERENCECUTS AS SHOWN MAY BE TAKEN

X

Y

R

P

HALF DIA MACHINING


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X-R

P/2+Y-R

HALF DIA MACHINING


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FOR SETTING OF THE JOB, ALONG

WITH THIS REFERENCE CUT,ANOTHER SETTING IS REQUIRED TOENSURE VERTICALLITY OF THEPARTING PLANE.

THE USUAL PRACTICE IS TO HAVETHE REFERENCE CUTTHROUGHOUT THE LENGTH FORDIALLING.


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OR


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HALF DIA MACHINING


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THIS IS THE MOST PREFERABLE

METHOD OF JOB SETTING SINCEA) THE HALF DIA SETTING CAN BE

MOST ACCURATELY DONE

B) THE SETTING AND THE RESULTCAN BE CROSS CHECKED EVEN

AFTER UN-LOADING FROMMACHINE.

HALF DIA MACHINING


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THIS IS METHOD CAN BE APPLIED

EVEN ON HORIZONTAL BORINGOPERATION


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Machine Shop Practices

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