Internship at GTTC, Mysore

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

CHAPTER 1 1.1

INTRODUCTION:

In-Plant Training will provide an industrial exposure to the students as well as to develop their career in the high tech industrial requirements. Reputed companies are providing in-plant training to Students. Here students are initially to get counseled in order to emerge out their interest in various streams and what are all the basic concepts they know about that domain. In-plant Training refers to a program which aims to provide supervised practical training with spiced timeframe. This training can be carried out either in government organizations or in private sector. In-plant training is a programme for post graduates that gives them an opportunity to expose themselves in the real career world so as to they will learn how to relate theoretical learning before and real practical in work environment. Besides tha t, in f uture, the y will be ha ving good prepara tion and understanding for their field of profession. After the successful completion of studies students has to face this competitive world with this knowledge to face many problems and to find the right solutions which is to be solved in the minimum duration of time. The implant training is getting totally different from the class environments.

Department of Mechanical Engineering, SJCE, Mysore

Page 1

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

1.2 Objectives of In-Plant Training:  To get an Industrial exposure.  To be aware of the happening in a particular industry.  To achieve knowledge about different sectors in the market for making a Choice as to which go for.  To learn functioning and operations of different departments in an organization.  To get knowledge about the working culture of the organization.  To have knowledge about the huge management practices and get the practical knowledge of what we have studied

1.3 METHODOLOGY OF COLLECTING DATA: There are many methods to collect required information during in-plant training like:  Observation of the entire process..  Discussion about the observed process with the staff involved.  Interview with the experienced employees involved.  Referring relevant documents related to the process.

Department of Mechanical Engineering, SJCE, Mysore

Page 2

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

Chapter 2 PROFILE OF THE COMPANY

“It`s precision that makes the world go round” A premier Tool Room and Training Centre established in 1992 at Mysore, Karnataka, India with assistance of the Government of Denmark, has extensive facilities in Tool making and training. Government tool and Training Centre (GTTC) is a modern tool room and training centre with state-of-art CAD/CAM equipment, machinery and inspection facilities to meet the complex needs of discerning customers. GTTC is committed to achieve customer satisfaction in quality and delivery of tool engineering education, services and precision machining. GTTC has acquired mastery in Tool Engineering and vast experience in conducting well structured, practical oriented training programmes leading to post graduation, diplomas and certificates. Realizing the need to update and upgrade the skills of existing technical personnel in industry, GTTC conducts a number of short term programmes in tool design, advanced manufacturing techniques, design analysis and CNC programming for manufacture and other aspect of manufacturing. The state-of-art sophisticated manufacturing facility consists of 3 to 5 axis highspeed CNC machining centres, CNC jig grinding, CNC wire EDM, CNC co-ordinate measuring machine and other supporting machineries and facilities. The computer integrated manufacturing facility in DNC network and supported by high end software`s such as I-DEAS, for design and manufacture, Uni-Graphics, Pro-E, Master-cam, Mechanical Desktop and Analysis package like C-Mold, Mold Flow and Pro-Cast. Department of Mechanical Engineering, SJCE, Mysore

Page 3

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

2.1 LAYOUT OF GOVERNMENT TOOL ROOM and TRAINING CENTER

E- ENTRANCE S- SECURITY ROOM 1. HSM M/C 2. MAINTENANCE 3. ASSEMBLY 4. BENCH WORKS 5. DNC 6. QUALITY ANALYSIS 7. CMM Department of Mechanical Engineering, SJCE, Mysore

Page 4

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

8. CNC MILLING 9. CNC MILLING 10. MARKETING DEPARTMENT 11. PLANNING DEPARTMENT 12. SURFACE GRINDING 13. CNC TURNING 14. JIG GRINDING 15. WIRE EDM 16. EDM 17. TRAINING AND ACCOUNTS SECTION 18. CANTEEN 19. CAD CCENTRE 20. LASER M/C

2.2 MANAGEMENT DEPARTMENT: The management of affairs of the Tool Room, which has been set up as Government of India Society, rests with the Governing Council constituted by Government of India. DC(SSI) is the President of this Society and Chairman of their Governing Council. Adequate representation to State Government, donor country and Industry Associations has been provided in the constitution of Governing Council. 2.3 MARKETING DEPARTMENT: Marking reaches right customers and explains him about special machines and quality of work carrying out in the industry through advertisement and by other means. Department of Mechanical Engineering, SJCE, Mysore

Page 5

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

Thus it brings work orders for company and takes care for dispatching the same in scheduled time. It consists of marketing departments HOD and marketing officials work under him.

Responsibilities and authorities  Receiving the customers and soliciting their enquiries.  Interacting with customers and preset the introduction broachers, hear doubts

and machines test etc, whenever required, arranging the shop visit if necessary.

 Preparation of estimations/worksheets, consulting tool planning and tool

production for schedule and cost details if required.

 Responsible for preparation of quotation and sending same to the customer.

 Coordinating with administration department for advertisement.

 Responsible for releasing work order instructions to planning and follow-up for

the status of order.

 In the event of any delay in meeting the delivery schedule the informing customer

accordingly.

Department of Mechanical Engineering, SJCE, Mysore

Page 6

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

 To dispatch the completed work order to customer with proper documents.

 Authorizing to sign delivery note.

Table 2.1 Work Order Instruction From: Marketing

To: Planning

Order conformation number

******

Customer

ISRO

Description

Stud

Scope of work

Mikron

Quality

102 Nos

Drawing and specification

Provided by the customer.

Raw material/ specification

Stainless Steel

Date of delivery

10/09/13

Priority

Normal

Acceptance criteria

Visual acceptance

Any other information

------

2.4 PLANNING DEPARTMENT: Before starting the actual production process planning is done. It gives the idea of sequence of operations, selection of machine, cost and time required, at the same time process will be performed with high percentage of material utilization. Planning is a primary function of human and material resources in an enterprise to realize maximum profits.

Department of Mechanical Engineering, SJCE, Mysore

Page 7

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

Process planning represents the link between Engineering design and shop floor manufacturing. Since process planning determines how a part will be manufactured, it is the major determinant of manufacturing costs and profitability. PLANNING CONSISTS OF FOLLOWING WORKS: 1. Tool and high tech components: It involves job planning with effective utilization

of machines available and using right tool for right operation

2. Preparing process sheet: process sheet in forms the operations and machining

conditions such as diameter of components, feed, speed, material setting etc.

3. Job follows up: to follow up the progress of the job in the shop floor.

4. Pre tooling: Pre machining of the job in conventional machines to save the time

of high tech machines.

5. Route card: Route card is prepared to mention in sequence.

Department of Mechanical Engineering, SJCE, Mysore

Page 8

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

Table 2.2 Job Card Format GTTC MYSORE

JOB CARD

UNIT CODE:

OC number

Description:

Dept:

Part No:

Qty:

Planned date of loading

Completion date:

Recommended

Estimated time:

Machine

Actual time:

Section

Operation Special instruction Foreman/ shift in charge Remark Date:

Signature:

Job card prepared by: Name:

Section: Date:

Department of Mechanical Engineering, SJCE, Mysore

Page 9

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

Table 2.3 Process Sheet Layout GTTC

Process sheet

Sheet no:

Customer

Date:

Part drawing no:

Material specification:

Part description code:

Raw material size:

Qty: Operation No

OC no: Process details/

Machine

Tool and gauges

****

****

Drawings

***

****

Process

Process

Co-

Prepared

Approved

ordinate

By:

By:

By:

Drawing SN/no:

Process sheet prepared by:

Department of Mechanical Engineering, SJCE, Mysore

Page 10

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

Table 2.4 Operation Drawing Sheet GTTC

Operation Drawing

MYSORE

OC No:

Part No:

Reference Drawing No:

Machine:

Section:

Date:

Qty:

DRAWING..........................................................................................

Drawing No:

Checked by:

Department of Mechanical Engineering, SJCE, Mysore

Page 11

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

2.5 DESIGN and PROGARMMING DEPARTMENT: It is the maim organ of the industry. Quality of work done, hence the name and fame of the company depends largely on this section. Its function can be enlisted as below.  Collection of required technical data, study of component drawing etc.  Design calculations are done and suitable assumptions are made.  Design layout considering cost effectiveness, machine available. It also includes

comparing new design with similar. 

Design review, design verification and changes if any will be implemented.

 Assessment of material selection.  Preparation of drawing and bill of materials.  Generation of CNC part programs considering optimum cutting tools and

parameter.

GTTC Design is well equipped with the computers. The designers were engaged in designing the ISRO projects. The design department is well equipped with the software like. 1. AUTOCAD 2. MASTER CAM 3. SOLID WORKS

Department of Mechanical Engineering, SJCE, Mysore

Page 12

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

Chapter 3 Machines and its Specifications 3.1 CNC MACHINE: The term “CNC” is a generic term which can be used to describe many types of device, this would include plotters, vinyl cutters, 3D printers, milling machines and others. CNC stands for Computer Numerically Controlled and basically means that the physical movements of the machine are controlled by instructions, such as co-ordinate positions that are generated using a computer. A machine tool that uses programs to automatically execute a series of machining operations. CNC machines offer increased productivity and flexibility. All CNC machine types share this commonality: They all have two or more programmable directions of motion called axes. An axis of motion can be linear (along a straight line) or rotary (along a circular path). One of the first specifications that implies a CNC machine's complexity is how many axes it has. Generally speaking, the more axes, the more complex the machine. The axes of any CNC machine are required for the purpose of causing the motions needed for the manufacturing process. In the drilling example, these (3) axis would position the tool over the hole to be machined (in two axes) and machine the hole (with the third axis). Axes are named with letters. Common linear axis names are X, Y, and Z. Common rotary axis names are A, B, and C. GTTC Mysore is well equipped with the CNC milling machines. Most of the machines are HIDENHAIN and FANUC control. For jobs the job setting as well as programming is done by the operator itself. For every job, designer of design department does the modeling and generates the tool paths.

Department of Mechanical Engineering, SJCE, Mysore

Page 13

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

Table 3.1 Specification of CNC Milling Machine

MAKE

MIKRON

MIKRON

MIKRON

MIKRON

MIKRON

MODEL

WF31DE

WF32C

VHC750

HSM520

UMC600

ORIGIN

SWIZZ

SWIZZ

SWIZZ

SWIZZ

SWIZZ

NO.OF M/C

02

01

01

01

01

Control

TNC407

TNC425

TNC415

RMS3

TNC426

Table size

530x900

600x1000

Ф630

600x500

Ф630

560

600

750

520

600

500

600

600

430

600

400

450

550

220

500

40-4000

10-6300

20-6300

50000

20-6300

600±6”

600±6”

--

600±6”

22

34

06

44

400

500

200

500

(mm) Traverse (mm)-X Traverse (mm)-Y Traverse (mm)-Z Spindle speed(RPM) NC

rotary 500±6”

table Ф/PW Automatic

--

tool changer Max. Wt of 350 job (kgs) Tilting table Five axis Machining centre USM 600 range

200

from

m/c

Department of Mechanical Engineering, SJCE, Mysore

Page 14

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

3.2 Electric discharge machining (EDM): Introduction about EDM process: Electrical Discharge Machining (EDM) is a controlled metal-removal process that is used to remove metal by means of electric spark erosion. In this process an electric spark is used as the cutting tool to cut (erode) the workpiece to produce the finished part to the desired shape. The metal-removal process is performed by applying a pulsating (ON/OFF) electrical charge of high-frequency current through the electrode to the workpiece. This removes (erodes) very tiny pieces of metal from the workpiece at a controlled rate.

h = height of crater, mm, D = diameter of crater

Figure 3.1 Principle of EDM

Department of Mechanical Engineering, SJCE, Mysore

Page 15

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

Table 3.2 Specifications of Electro discharge machines

MAKE

ELECTRONICA

MAKINO EDNC

MAKINO EDNC

ORIGIN

INDIA

JAPAN

JAPAN

CONTROL

------------------

CNC MGE 60

CNC MGE 20

TABLE

550×350

550×750

350×550

325×490×820

400×700×1000

300×430×680

300

600

300

200

400

250

250

250

250

1500

500

SIZE(mm) TANK SIZE(mm) TRAVERSE(m m)- X mm TRAVERSE(m m)- Y mm TRAVERSE(m m)- Z mm MAX.

JOB 300

WEIGHT(kg)

Department of Mechanical Engineering, SJCE, Mysore

Page 16

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

3.3 Wire electrical discharge machining (WEDM) Principles of EDM Electrical Discharge Machining (EDM) is a controlled metal-removal process that is used to remove metal by means of electric spark erosion. In this process an electric spark is used as the cutting tool to cut (erode) the workpiece to produce the finished part to the desired shape. The metalremoval process is performed by applying a pulsating (ON/OFF) electrical charge of high-frequency current through the electrode to the workpiece. This removes (erodes) very tiny pieces of metal from the workpiece at a controlled rate.

Major Components

A Wire EDM system is comprised of four major components. (1) Computerized Numerical Control (CNC) Think of this as “The Brains.”

(2) Power Supply Provides energy to the spark. Think of this as “The Muscle.”

(3) Mechanical Section Worktable, work stand, taper unit, and wire drive mechanism. Think of this as “The Body.”

(4) Dielectric System The water reservoir where filtration, condition of the water and temperature of the water is provided and maintained. Think of this as “The Nourishment.”

Department of Mechanical Engineering, SJCE, Mysore

Page 17

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

Table 3.3 Specifications of Wire electrical discharge machining (WEDM)

Make

ELECTRONICA

MAKINO

Origin

INDIA

JAPAN

Table

150×400×500

770×570×210

300

600

400

440

150

220

±15

28

±15

28

Size(mm) TraverseX (mm) TraverseY (mm) TraverseZ (mm) TraverseUAxis (mm) TraverseV

Axis

(mm)

Department of Mechanical Engineering, SJCE, Mysore

Page 18

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

3.4 Grinding: 3.4.1 Introduction about grinding process: Grinding is a metal cutting operation performed by means of abrasive particles rigidly mounted on a rotating wheel. Each of the abrasive particles act as a single point cutting tool and grinding wheel acts as a multipoint cutting tool. The grinding operation is used to finish the work pieces with extremely high quality of surface finish and accuracy of shape and dimension. Grinding is one of the widely accepted finishing operations because it removes material in very small size of chips 0.25 to 0.50 mm. It provides accuracy of the order of 0.000025 mm. Grinding of very hard material is also possible.

Figure 3.2 cutting action of abrasive grains in Grinding Machine

Department of Mechanical Engineering, SJCE, Mysore

Page 19

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

3.4.2 Grinding wheels Grinding wheel consists of hard abrasive grains called grits, which perform the cutting or material removal. A grinding wheel commonly identified by the type of the abrasive material used. The conventional wheels include aluminum oxide and silicon carbide wheels while diamond and CBN (cubic boron nitride) wheels fall in the category of super abrasive wheel. 3.4.3 Grinding wheel abrasives: An abrasive is a hard and tough substance. It has many sharp edges. Abrasives of following types 1. Natural 

Sandstone



Emery



Diamond



Garnet

2. Synthetic 

Aluminum oxide



Silicon carbide



Cubic boron nitride



Boron carbide

Department of Mechanical Engineering, SJCE, Mysore

Page 20

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

Table 3.4 Surface grinding machine

MAKE

JAKOBSEN

JAKOBSEN

JAKOBSEN

MODEL

618

1026

1832

ORIGIN

DENMARK

DENMARK

DENMARK

NO.OF

06

04

01

TABLE SIZE

450×250

650×250

800×450

TRAVERSE

450

650

900

200

300

500

400

400

650

250×450

250×600

450×800

MACHINE

X AXIS( mm) TRAVERSE Y AXIS( mm) TRAVERSE Z AXIS( mm) MAGNETIC BED

Department of Mechanical Engineering, SJCE, Mysore

Page 21

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

3.5 Cylindrical grinding The cylindrical grinder is a type of grinding machine used to shape the outside of an object. The cylindrical grinder can work on a variety of shapes; however the object must have a central axis of rotation. This includes but is not limited to such shapes as a cylinder, an ellipse, a cam, or a crankshaft.

Plate 3.1 Cylindrical Grinding Machine

Department of Mechanical Engineering, SJCE, Mysore

Page 22

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

Table 3.5 Specification of Cylindrical Grinding Machine MAKE

STUDER

MODEL

FAVOURIT-S 30

ORIGIN

SWITZERLAND

NO.OF MACHINES

01

SWING OVER BED, mm

350

DIA 125

CHUCKING INTERNAL mm

CENTRE DISTANCE, mm

650

TABLE SWIVEL, Degree

10 ◦

WHELL

HEAD

SLIDE, 300

mm

3.6 Jig Grinding Introduction about jig grinding process: A jig grinder is a machine tool used for grinding complex shapes and holes where the highest degrees of accuracy and finish are required. It may be used to grind items such as jigs, dies, and gauges. A jig grinder typically uses a removable, air-driven spindle. This is used to rotate the grinding wheels. The air spindles are interchangeable to achieve varying surface speeds.

Department of Mechanical Engineering, SJCE, Mysore

Page 23

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

Grinding machines generally work on a similar principle to jig grinding. But one of the limitations of the various grinding machines is their lack of precision. Hence for precision grinding Jig grinding machines are used. Many Jig machines are now computerized and operate with special software. This often eliminates much of the geometric calculating once required of the operator. Much of the labor has also been reduced by the automation of these machines. The improvements made can result in much faster grinding, operation by less-skilled workers, and a higher degree of accuracy.

Plate 3.2 Jig Grinding Machine Jig grinding machine in GTTC: MOORE Jig grinding machine 

Model

CPS 450



ORIGIN

USA

Department of Mechanical Engineering, SJCE, Mysore

Page 24

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

Table3.6 MOORE Jig grinding machine Specification Maximum

bed

travels X axis

460mm

Y axis

280mm

U axis

1.5mm (depth of cut)

C axis

rotary 360˚

Capacity

of 196mm

outside diameter

Spindle RPM Minimum

4000

Middle

60,000

Maximum

1, 20,000

Maximum weight 150 kg of job Least count of 0.0001mm machine Accuracy of M/c

2 to 3microns

Department of Mechanical Engineering, SJCE, Mysore

Page 25

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

3.7 LASER WELDING Laserwelding is a non-contact process that requires access to the weld zone from one side of the parts being welded. The weld is formed as the intense laser light rapidly heats the material-typically calculated in milli-seconds. The flexibility of the laser offers three types of welds; conduction mode, conduction/penetration mode and penetration or keyhole mode. One of the largest advantages that pulsed laser welding offers is the minimal amount of heat that is added during processing. The repeated "pulsing" of the beam allows for cooling between each "spot" weld, resulting in a very small "heat affected zone". This makes laser welding ideal for thin sections or products that require welding near electronics or glass-to-metal seals. Low heat input, combined with an optical (not electrical) process, also means greater flexibility in tooling design and materials.

Figure 3.3 Laser Welding Process Department of Mechanical Engineering, SJCE, Mysore

Page 26

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

Welding requires high energy density that can be achieved by working at the focal point of the optical system. The absorption coefficient of the laser beam by the material depends of material nature and Wavelength of the laser source At sufficiently high specific powers, a key hole filled with metal vapour is formed in the material. The wall of the keyhole consists of molten liquid metal. The molten pool, which is created and maintained in this way, is moved between the parts to be assembled and the metal resolidifies behind the laser beam. This phenomenon, which occurs in the case of a continuous beam (laser) is significantly different in the case of a pulsed beam (pulsed YAG laser). Indeed, the bead is then created by a series of partially overlapping spots. The welding process is then similar to that already described as a result of the reached peak energy levels, the material is melted or, even, vaporized instantaneously. This is followed condensation and immediate solidification. 3.7.1 Preparations of Joints  The preparation of joints is very important having many implications regarding

the design of the weld.  The workpieces are correctly positioned together  The workpieces are not beveled.

3.7.2 Main Materials Worked With Laser Yag Machine 

Ferrous metals,



Non-Ferrous Metals



Plastics



Ceramics



Leather

Department of Mechanical Engineering, SJCE, Mysore

Page 27

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

Plate 3.3 Nd YAG Continues Wave Laser: Table 3.7 Specification of Nd YAG Continues Wave Laser Capacity

400W CW-Nd

Size

500×300

Precision

0.02mm on 50mm

Operation

Cutting and welding

Control software

FLOCON

Assisting gas

O2,N2,A2

Machinability

CUTTING: Steel up to 2mm, Stainless steel up to 1 mm, suitable for thin foil cutting WELDING: Stainless steel and Steel up to 1mm

Department of Mechanical Engineering, SJCE, Mysore

Page 28

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

3.8 LASER CUTTING Laser cutting is one of the most common industrial applications of the laser. In many cases, the laser happens to be able to cut faster and with a higher quality than the competing processes ( punching/nibbling, plasma, abrasive fluid jet, wire EDM…)

Plate 3.4 Laser Cutting Process

The principle of laser cutting Laser cutting is a thermal separation process. Our pulsed Nd: YAG and fiber lasers permit a controlled heat entry which is optimum for fine cutting. The high peak performance of our laser permits a maximum cut depth of up to 10mm. As the laser beam can be focused on a very small diameter for high precision, fine cuts are possible with a minimum cut width of up to 15 µm (0.0006 in). In addition, the heat-affected zone along the cut is very small (up to 2µm). This means that deformations of the parts to be processed can be avoided. The high energy depth in the focus point of the laser beam causes the material to melt and evaporate. By using an active or neutral process gas, for example, oxygen, nitrogen, or argon, the melted material is blown out. If the work piece or laser beam is now moved, a cut is created. Department of Mechanical Engineering, SJCE, Mysore

Page 29

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

The smallest possible cut width is dependent on both the beam characteristics and the material and material strength. When cutting fine contours, the precision and dynamics of the cutting machine are of extreme importance.

Table 3.8 Specification of Laser Cutting Machine Power

2000W CO2

X/Y/Z table

1250×1250×400mm

Precision

0.05mm on 50mm

Application

Cut any profile on metals:MS:14mm thick, stainless steel-5mm thick,Al-4mm thick, Cu-1.5 mm thick, wood upto-25mm thick

Department of Mechanical Engineering, SJCE, Mysore

Page 30

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

Chapter 4 QUALITY CONTROL 4.1 INSPECTION Inspection is the most common method of attaining standardization, uniformity and quality of workmanship. It is the cost art of controlling the product quality after comparison with the established standards and specifications. It is the function of quality control. If the said item does not fall within the zone of acceptability it will be rejected and corrective measure will be applied to see that the items in future conform to specified standards. Inspection is an indispensable tool of modern manufacturing process. It helps to control quality, reduces manufacturing costs, eliminate scrap losses and assignable causes of defective work

4.2 PURPOSE OF INSPECTION 1. By thorough inspection, we can detect faults at every manufacturing process and

rectify them. 2. It helps in building up the reputation of a firm or concern. 3. It improves the quality of the product. 4. It reduces cost spent on scrap pieces and further process can be stopped if

mistake is going on.

Department of Mechanical Engineering, SJCE, Mysore

Page 31

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

4.3 Types of Inspection Floor Inspection: It suggests the checking of materials in process at the machine or in the production time by patrolling inspectors. These inspectors move from machine to machine and from one to the other work centres. Inspectors have to be highly skilled. This method of inspection minimize the material handling, does not disrupt the line layout of machinery and quickly locate the defect and readily offers field and correction. Centralized Inspection:

Materials in process may be inspected and checked at centralized inspection centre which are located at one or more places in the manufacturing industry.

Combined Inspection: Combination of two methods whatever may be the method of inspection, whether floor or central. The main objective is to locate and prevent defect which may not repeat itself in subsequent operation to see whether any corrective measure is required and finally to maintained quality economically.

4.4 INSTRUMENTS AT INSPECTION DEPARTMENT 1. Profile projector 2. Tool makers microscope 3. Height master 4. Co-ordinate measuring machine

Department of Mechanical Engineering, SJCE, Mysore

Page 32

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

1. PROFILE PROJECTOR The main principle of operation is a specimen is placed on the glass stage. The stage is then illuminated from below and the resulting image is picked up by the microscope objectives and projected to a large built-in projection screen. Since the specimen has underlighting, the fine microscopic details are eliminated and only the details of contour and profile are seen. A drawing can be affixed to the profile projector‟s large viewing screen and the contour can be easily traced or compared to other profiles and contours on the other drawings.

Plate 4.1 Profile Projector

Department of Mechanical Engineering, SJCE, Mysore

Page 33

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

Table 4.1 Specifications of Profile Projector INSTRUMENT

PROFILE PROJECTOR

ORIGIN

JAPAN

Effective diameter, mm

250

Angular resolution, range, degree

1.±360º

Cross travel range, mm

50×50

Work stage dimension, mm

152×152

Micrometer head, mm

0.001×25

Max. work piece height, mm

75

Special accessories

20X,50X,10X

Accuracy

0.001

2. TOOL MAKER’S MICROSCOPE

A tool maker microscope is a type of a multi functional device that is primarily used for measuring tools and apparatus. These microscopes are widely used and commonly seen inside machine and tools manufacturing industries and factories. These microscopes are also inside electronics production houses and in aeronautic parts factories. A tool maker microscope is an indispensable tool in the different measurement tasks performed throughout the engineering industry. The main use of a tool maker microscope is to measure the shape, size, angle, and the position of the small components that falls under the microscope‟s measuring range. A tool maker microscope is primarily used for measuring the shape of different components like the template, formed cutter, milling cutter, punching die, and cam. The pitch, external, and internal diameters are specifically measured as well. Department of Mechanical Engineering, SJCE, Mysore

Page 34

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

The thread gauge, guide worm, and guide screw are conveniently handled as well. As far angles are concerned, the thread and pitch angle are of chief concern.

Plate 4.2 Tool Maker‟s Microscope

Table 4.2 Specification of Tool Maker‟s Microscope INSTRUMENT

TOOL MAKER‟S MICROSCOPE

ORIGIN

JAPAN

Magnification

10X,15X,20X

Stage size

152×152

Travelling distance, mm

50×50

Max.work piece height, mm

115

Accuracy

0.005

Department of Mechanical Engineering, SJCE, Mysore

Page 35

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

3. HEIGHT MASTER It is a high precision instrument to measure and transfer of height on the job. It can be used as a master for calibration in Standards Room and in Tool Room

Plate 4.3 Height Master

Table 4.3 Specification of Height Master INSTRUMENT

HEIGHT MASTER

ORIGIN

JAPAN

Max.height,mm

300

Accuracy, mm

0.001

Read out

DIGITAL

Stroke,mm

20

Department of Mechanical Engineering, SJCE, Mysore

Page 36

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

4. CO-ORDINATE MEASURING MACHINE A coordinate measuring machine (CMM) is a device for measuring the physical geometrical characteristics of an object. This machine may be manually controlled by an operator or it may be computer controlled. Measurements are defined by a probe attached to the third moving axis of this machine. Probes may be mechanical, optical, laser, or white light, amongst others. The typical "bridge" CMM is composed of three axes, an X, Y and Z. These axes are orthogonal to each other in a typical three dimensional coordinate system. Each axis has a scale system that indicates the location of that axis. The machine will read the input from the touch probe, as directed by the operator or programmer. The machine then uses the X,Y,Z coordinates of each of these points to determine size and position with micrometre precision typically. A coordinate measuring machine (CMM) is also a device used in manufacturing and assembly processes to test a part or assembly against the design intent. By precisely recording the X, Y, and Z coordinates of the target, points are generated which can then be analyzed via regression algorithms for the construction of features. These points are collected by using a probe that is positioned manually by an operator or automatically via Direct Computer Control (DCC). DCC CMMs can be programmed to repeatedly measure identical parts, thus a CMM is a specialized form of industrial robot.

Department of Mechanical Engineering, SJCE, Mysore

Page 37

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

Plate 4.4 Shows Co-ordinate Measuring Machine Table 4.4 Specification of Co-ordinate Measuring Machine MAKE

CARL ZIESS

ORIGIN

GERMANY

Measuring range-„X‟, mm

550

Measuring range-„Y‟, mm

500

Measuring range-„Z‟, mm

450

Overall CMM size

1260×1340×2660

Max.wt of work piece

600

Applications

Co-ordinate scanning,

measuring, Digitizing

surface

curve

and

contour measurement

Note: Machine Hour Rate of co-ordinate measuring machine (CMM) - Rs1000/hr

Department of Mechanical Engineering, SJCE, Mysore

Page 38

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

Chapter 5 CASE STUDY The manufacturing process and time estimation of following components: 1. BRACKET 2. WASHER

Figure 5.1 Bracket Model

Department of Mechanical Engineering, SJCE, Mysore

Page 39

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

5.1 Flow Chart of Manufacturing Bracket CNC MILLING

Stage Inspection

Wire EDM

Bench Work and Fitting

Final Inspection

Procedure 5.2 CNC Milling: Most CNC milling machines are computer controlled vertical mills with the ability to move the spindle vertically along the Z-axis. This extra degree of freedom permits their use in diesinking, engraving applications etc. CNC machines can exist in virtually any of the forms of manual machinery, like horizontal mills. The most advanced CNC milling-machines, the multiaxis machine, add two more axes in addition to the three normal axes (XYZ).

Department of Mechanical Engineering, SJCE, Mysore

Page 40

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

These machines have developed from the basic NC (NUMERIC CONTROL) machines. A computerized form of NC machines is known as CNC machines. A set of instructions (called program) is used to guide the machine for desired operations . SETTING UP A CNC MACHINE:



Clean all surfaces, for example table, vise jaws and part very good with a lint free cloth.

Department of Mechanical Engineering, SJCE, Mysore

Page 41

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”



Load tools needed.

Department of Mechanical Engineering, SJCE, Mysore

Page 42

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”



Load part in vise.

Department of Mechanical Engineering, SJCE, Mysore

Page 43

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”



Set work fixture offsets. Make sure the machine is using the WFO that the program will be using.

Department of Mechanical Engineering, SJCE, Mysore

Page 44

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”



Adjust coolant lines so coolant can properly cool tools and wash chips away.

Department of Mechanical Engineering, SJCE, Mysore

Page 45

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”



Cycle Start.

Department of Mechanical Engineering, SJCE, Mysore

Page 46

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

Plate 5.2 Milling Operation

Department of Mechanical Engineering, SJCE, Mysore

Page 47

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

5.3 STAGE INSPECTION: All parts are inspected in their respective stages while processing. This is known as stage inspection. It helps in rectifying the mistake occurred during each operation. Suppliers shall establish and maintain documented procedures for inspections and tests of the equipment during manufacturing and assembly. The procedures shall provide for the verification by inspections or tests, at appropriate points in the manufacturing, that the characteristics of the item conform to the requirement specified for that stage of the process. In general the verification should be made as close as possible to the point of realisation of the characteristic. The in-process verification may include: 

Set-up and first piece inspection.



Inspection or test by machine operator.



Automatic inspection or test.



Fixed inspection stations.

Equipment shall be held until the required inspection and test has been completed. Equipment shall not be released for further use until it has been verified and the results of the verification are satisfactory.

5.4 Wire EDM:

Wire electrical discharge machining (WEDM), also known as wire-cut EDM and wire cutting, a thin single-strand metal wire, usually brass, is fed through the work piece, submerged in a tank of dielectric fluid, typically deionized water. Wire-cut EDM is typically used to cut plates and to make punches, tools, and dies from hard metals that are difficult to machine with other methods.

Department of Mechanical Engineering, SJCE, Mysore

Page 48

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

Wire EDM uses electro-thermal mechanisms to cut electrically conductive materials. The material is removed by a series of discrete discharges between the wire electrode and the workpiece in the presence of dielectric fluid, which creates a path for each discharge as the fluid becomes ionized in the gap. The area where discharge takes place is heated to extremely high temperature, so that the surface is melted and removed. The removed particles are flushed away by the flowing dielectric fluids. The wire EDM process can cut intricate components for the electric and aerospace industries.

Plate 5.4 Wire EDM 5.5 Bench Work: The bench work and fitting plays an important role in every engineering workshop to complete and finish the job to the desired accuracy. The work carried out by hand at the bench is called bench work. Whereas fitting is the assembling of parts together by fitting, chipping, sawing, fore capping, tapping etc. necessary after the machine operation. This may or may not be carried out of the bench.

Department of Mechanical Engineering, SJCE, Mysore

Page 49

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

The tools use in filling practice may be classified into the following group: 1) Holding tools 2) Striking tools 3) Measuring tools 4) Marking tools 5) Cutting tools 6) Scrapping tools 5.6 Holding tools (Vices): The holding tools are vice are required to hold the work firmly. Following are the various types of vice for different purposes. Following are the different types of holding tools:

Bench Vice



Hand Vice

5.7 Striking tools (Hammers): The striking tools are hammers are used to strike the job or tool. A hammer consists of a bead, striking face, peen and a shaft or handle. 5.8 Cutting Tools: The chief cutting tools used in fitting are cold, chisels, and files. 5.9 Method Filling: The following three methods are commonly used for filling. 

Cross Filling



Straight Filling



Draw Filling

Department of Mechanical Engineering, SJCE, Mysore

Page 50

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

5.10 Final Inspection: Final inspection is one in which the product manufactured is inspected completely after completion. The contractor shall carry out all final inspection and testing in accordance with the quality plan and/or documented procedures to complete the evidence of the conformance of the finished equipment to the specified requirements. The quality plan and/or documented procedures for all final inspection and testing shall require that all specified inspections and tests, including those specified on receipt of equipment or inprocess, have been carried out and that the results meet specified requirements. Inspections and tests procedures shall define: 

The location where the inspection or test is to be performed (supplier premises)



The parameters to be measured.



The characteristics or functions that have to be verified.



The acceptance criteria, including any applicable standards or codes.



The requirements for special tools, fixtures, gauges, test set-ups and measuring equipment.

Table5.1 Time Taken For Manufacturing Bracket Operation

Time in Minutes

CNC Milling

30

Stage Inspection

10

Wire EDM

30

Bench Work

15

Final Inspection

20

TOTAL Time Taken

105

Department of Mechanical Engineering, SJCE, Mysore

Page 51

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

2. Washer Model

Figure 5.2 Model of a WASHER

Department of Mechanical Engineering, SJCE, Mysore

Page 52

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

5.11 Flow Chart of Manufacturing Washer

Turning

Stage Inspection

Wire EDM

Bench Work

Final Inspection

PROCEDURE 5.12 TURNING: Turning is a machining process to produce parts round in shape by a single point tool on lathes. The tool is fed either linearly in the direction parallel or perpendicular to the axis of rotation of the workpiece, or along a specified path to produce complex rotational shapes. The primary motion of cutting in turning is the rotation of the workpiece, and the secondary motion of cutting is the feed motion. A set of instructions (called program) is used to guide the machine for desired operations. Department of Mechanical Engineering, SJCE, Mysore

Page 53

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

5.13 Cutting fluids Application of the cutting fluid is very important in a turning operation. The cutting fluid should be applied in adequate quantity and at moderate pressure. The cutting fluid should be directed on the work just above the point where it makes contact with the tool. 5.14 Design Consideration for Turning Operation •

Parts should be designed so that can be fixtured and clamped in the work holding devices

•

Dimensional accuracy and surface finish specified should be as wide as possible

•

Avoid sharp corners, tapers, and major dimensional variations in the part

•

Cutting tools should be able to travel across work piece without obstruction

•

Standard cutting tools, inserts, and tool holders should be used Materials should be selected for their machineability.

Plate 5.14 Turning Process

Department of Mechanical Engineering, SJCE, Mysore

Page 54

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

5.15 STAGE INSPECTION: All parts are inspected in their respective stages while processing. This is known as stage inspection. It helps in rectifying the mistake occurred during each operation. 5.16 Wire EDM:

Wire electrical discharge machining (WEDM), also known as wire-cut EDM and wire cutting, a thin single-strand metal wire, usually brass, is fed through the work piece, submerged in a tank of dielectric fluid, typically deionized water. Wire-cut EDM is typically used to cut plates and to make punches, tools, and dies from hard metals that are difficult to machine with other methods.

5.17 BENCH WORK: The main operations commonly performed in bench work may be classified 1. Chipping 2. Filing 3. Grinding 4. Sawing 5. Marking 6. Tapping 5.18 FINAL INSPECTION:

Final inspection is one in which the product manufactured is inspected completely after completion.

Department of Mechanical Engineering, SJCE, Mysore

Page 55

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

Table 5.2 Time Taken For Manufacturing Washer Operation

Time in Minutes

Turning

10

Stage Inspection

5

Wire EDM

10

Bench Work

5

Final Inspection

10

TOTAL Time Taken

40

Department of Mechanical Engineering, SJCE, Mysore

Page 56

Industrial Training at “GOVERNMENT TOOL ROOM AND TRAINING CENTRE”

CONCLUSION It is necessary for an organization to compete in the fluctuating market and to be profitable one. Profit always comes when goods are produced with maximum productivity cost reduction proper training. This can be achieved through optimum use of resources available in the organization and also by optimizing the time involved in every element of the process. Non-productive time should be eliminated wherever possible in order to increase productivity. Through this training, is comprehensive understanding about the real industrial working condition and practice. All these valuable experiences and knowledge is acquired through the direct involvement in task but also through other aspects of the training such as: work observation, interaction with collogues, superior and other people related to the field. So in this way there is unlimited knowledge and many things to learn here in this center. The details about the EDNC Department, CNC Turning, Quality control, Laser Department, Planning, CNC Milling and the machines used and respective specifications operations are learnt. Along with it detailed case study about the manufacturing process of Washer and Bracket are learnt.

Department of Mechanical Engineering, SJCE, Mysore

Page 57