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PREFACE
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.
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 Pinjore
(Machine Tools Division) that proved to be a great
supporting force for the fulfillment of the purpose. The
INTRODUCTION
Fulcrum of Indian Industrial Development:
HMT synonymous with excellence in precision
engineering is a multi product company established in
1953. Built on a strong foundation of technical know how
acquired from world leaders in machine tools such as
Oerlikon, Manurhin, Glidemeister, Liebherr, Rino Berardi,
Fritz Werner, Pegard, Waldrich Coburg etc. HMTs
machine tools expertise has been developed to such an
extent that HMT can design and develop any kind machine.
Having established as a machine tool manufacturer, HMT
diversified into other product lines.
From simple lathes to multi-station transfer lines from
stand alone CNC machine to flexible manufacturing
systems, leading to factory automation, HMTs broad range
of machine tools cover General Purpose Machine, Special
Purpose Machines and CNC machines, meetings the
application needs to every engineering industry.
Pioneering the concept of CNC technology in India
HMT has the destination of being the first company to
successfully manufacture its own CNC system in
association with Siemens.
HMTs commitment to the development of the
machine tools technology is clearly reflected in the fact that
HMT has as many as seven exclusive machine tool units,
spread across the country. Each superbly equipped to meet
the most challenging demand for machine tools. These
units are in Banglore, Pinjore, Kalamassery, Hyderabad,
and Ajmer are all ISO 9000 certified.
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
introduced.
In 1969 manufacture of Broaching Machines was
taken up as import substitution. Available in horizontal and
vertical versions, these ruggedly constructed machines have
infinitely variable cutting speeds with dead constant speeds
ensuring optimum tool life and fine surface finish.
In tune with HMTs commitment to usher in the latest
technologies to the countrys fast developing industrial
base, in 1976 the unit introduced the state of art
computerized numerically controlled machine offering
unlimited option in unmanned manufacturing concept.
The unit has designed a wide range of both Horizontal
and Vertical CNC Machining Centre to meet the stringent
accuracy standards, providing high flexibility and
productivity with enough muscle to remove large quantities
of material at low RPM for steel and high RPM for light
metal alloys. High processing speed is ensured through
CNC Systems that have powerful graphics and userfriendly features. The machine can be integrated with other
machine tools into flexible manufacturing line. The unit
also manufactures moving column type Special Purpose
Machines which can perform milling, drilling, tapping,
boring and reaming operation with re-circulating linear
motion bearing for high position accuracy with the encoder
x, y, and z axis.
PATTERN SHOP
FOUNDARY SHOP
Melting Department:
The process of melting in HMT is carried out in
induction furnaces at a temperature of about 1400-1450 C
Process:
At first the induction furnaces are coated with fine
cement clay. Now metal scrap is inserted in the furnace and
slag coagulant is added to it. The requisite amount of coke
is added to it. The current is supplied to copper coils
provided in the furnace which induce current in the metal
scrap and the scrap gets heated up, when the melting
temperature is reached the molten metal is collected in
ladles and taken to the pouring zone. When this process is
being carried out the copper coils are regularly cooled with
coolant (water) so that the coils donot melt due to the high
temperature generated in the coils.
The foundary of HMT has three furnaces, two, each
having capacity of 3MT and one of 1.5MT. The two types
of induction furnaces are: Main frequency Induction Furnace(50Hz)
Medium frequency Induction Furnace(250Hz)
Melting of metal ion medium frequency furnaces are faster
than the main frequency furnaces.
Line Voltage
:
11000 Volts
Primary Voltage :
440 Volts
Power Voltage
:
440 KW
Power Rating
:
5 KA
Melting Power
:
1 tonne per hour
Frequency
:
50 Hz
Lining Thickness :
95 mm
Power Factor
:
0.9
After the melting process is complete, the molten
metal is carried quickly to the moulds to prevent
solidification. The inversion of Induction Furnaces is
carried out by hydraulic lifts fitted just below the whole
apparatus.
Now the core is put in cope, drag and the molten metal
is poured after which pattern can be easily obtained.
Fettling:
Fettling is the process by which the pattern obtained is
given the desired finish by various processes. Before
fettling, the casting obtained is subjected to removal of
projections, chips, core, runner, riser etc. by the
following processes:
Decoring
Chipping
Shot blasting (for heavy pattern)
Wheel abrasion (for small pattern)
Decoring:
Decoring is the process of removing the fused sand.
Chipping:
Chipping is the process of removing the runner, riser
etc.
Spindle Section:
This section is concerned with the manufacturing of
small cylindrical parts or spindles which may be hollow,
solid, shell type etc. according to machines requirement.
The jobs concerned are larger in size as compared to other
sections. This section manufactures all the head related obs.
This machine requires for the purpose include lathe
machines like LB26 lathe, centre lathe, turret lathe. Also
use of drilling machine is there .Thread cutting operation is
also carried out in this section. The job to be worked upon
is supplied by the foundry department.
Examples of the parts manufactured:- Bearing housing
Cylindrical Grinding Machine:This is used to grind cylindrical jobs with the motion
of grinder itself. This job is held in the jaw chuck.
Slotter:-
Gear Teeth Grinding Machines:It is used for grinding the teeth of the gears. In this
machine gear teeth are grinded by a worm type grinding
wheel. Here the tooth profile are checked with a machine
called gear tooth profile tester.
Components Manufacturing:
Blocks, rectangular strips, gibs, pump body, stop
block, adjustable plate, clump levers etc.
Operations Performed:
Marking
Vertical milling
Drilling
Fitting
Grinding
MATERIAL TESTING
UNIVERSAL TESTING MACHINE:
It has component load scale, oil pump, hydraulic
press, main piston, fixed cross head, & movable cross
head. It has range according to load applied:
0-1 tons
0-4 tons
0-10 tons
It is generally used to determine:
Proportional & elastic limit
Yield point
Ultimate tensile strength
Percentage elongation & reduction of area
Working:
It is generally used to perform tensile test which is
widely used in the design of material for structure & other
purposes. Here, test piece is pulled out at a constant rate
gradually increasing the axial pull, till the rupture take
place. The tensile test for ductile material is generally,
carried out with the help of a Universal Testing Machine on
the specimen made from material to be tested.
SPECTROSCOPE:
It is a method of qualitative analysis of material with
the help of electricity. Argon gas is being used as it
prevents oxidizing of piece. Here piece is not destroyed.
This is used for chromium, ammonium, nickel, tungsten,
manganese, zinc, tin, lead etc. the spectrum is directly
compared with a chart as it is moved by caliper & is then
compared. It is used to find what materials are present.
SPRING TESTING MACHINE:
In this machine, spring test is done. We will find out
compression or extension of spring & the load applied
which is noted from load indicator. Then we calculate
spring stiffness.
POLISHING MACHINE:
In this machine polishing of material is done. In this
belts are present on which abrasive powder is applied. In
this machine belt is passed over two pulleys & which is
driven by motor.
MAGNETIC CRACKING TEST:
In this method, magnetic crack test machine is used. It
SPECTOMETER:
It is basically computerized control program in which
material is kept under observation than software is there
which give composition of each element present in the
material.
PORTABLE MICROSCOPE:
It is a method used for analysis of the structure
without cutting. And also it is used for determining the
composition of element present in the material. It is used
for the analysis of the structure.
M CODES
M00 Program Stop
M01 Optional (Planned) Stop
M02 End of program
M03 Spindle CW
G CODES
G00 Rapid Positioning
G01 Linear Interpolation
G02 CW circular Interpolation
G03 CCW circular Interpolation
G04 Dwell
G05.1 Q1 Ai Nano contour control
G05 P10000 HPCC
G07 Imaginary axis designation
G09 Exact stop check
G10/G11 Programmable Data input/ Data write cancel
G12 CW Circle Cutting
G13 CCW Circle Cutting
G17 X-Y Plane selection
G18 X-Z Plane selection
G19 Y-Z Plane selection
G20 Programming in inches
G21 Programming in mm
G28 Return to home position
Plano Milling Machine:This is similar to a double housing planer but the tool
can be milling tool. One of the machines is TNC (three axis
turning centre) in which only one axis can be moved at a
time. Thus round jobs cannot b machined here.
Another machine is CNC in which two axis can be
moved simultaneously to machine round job. The length of
the bed is 2800mm.
TOOL ROOM
This department keeps various kinds of tools which
are useful during manufacturing of heavy pats. Most of the
tools are measuring devices such as vernier caliper,
micrometer etc.
Types of Micrometer:
Outside Micrometer (aka micrometer caliper),
typically used to measure wires, spheres, shafts and
blocks.
Inside Micrometer, used to measure the diameter of
holes.
Depth Micrometer, measures depths of slot and steps.
Bore Micrometer, typically a three-anvil head on a
micrometer base used to accurately measure inside
diameters.
Tube Micrometer, used to measure the thickness of
tubes.
Dial Indicator:
Dial indicators, also known as dial gauge and probe
indicators, are instruments used to accurately measure
small linear distances, and are frequently used in industrial
and mechanical processes. They are named as so because
the measurement results are displayed in a magnified way
by means of a dial.
Dial Indicator may be used to check the variation in
tolerance during the inspection process of a machined part,
measure the deflection of a beam or ring under laboratory
conditions, as well as many other situations where a small
measurement needs to be registered or indicated. Dial
indicators typically measure ranges from 0.25mm to
300mm (0.015in to 12.0in), with graduations of 0.001mm
to 0.01mm (metric) or 0.00005in to 0.001in (imperical).
Assembly of Milling Machines:1) First of all the parts are obtained from the foundary and
machined accordingly to give the desired shape to them.
2) The base is leveled properly with proper instruments .
3) Then the column is aligned w.r.t. the base. The column is
attached to the base with the help of guide pins which form a
right fit and later with the help of screws.
4) The knee is then aligned with the base keeping in mind that
the face of the saddle is parallel with the base.
5) Then the saddle is mounted on the knee and aligned properly.
6) The table is then mounted on the saddle with the help of
guides which form a proper fixture with each other.
7) The ball screw is then attached which is responsible for the
vertical movement.
8) The gears and the pulleys are then assembled inside the
column along with other basic components.
9) The electrical assembly is carried out with proper earthing
facility.
10) Then all the accessories are attached to it.
11) Final inspection is done and machine is dispatched.
CNC SECTION
Introduction
We know that GPMs are semi - automatic machines. They
require an operator for each work piece loaded on machine and in
a limited period. Mass production is not possible in these
machines. Moreover complex shaped jobs require high precision.
They need for flexible automation has always been felt. And this
is an era of machine tool automation. So, flexible automation is
implemented in machine tools in the form of NC and CNC
(Computerized Numerical Control) technology . Today HMT is
producing a lot of CNC variants of conventional machine tools
with the specialized functions and mostly CNC products.
CNC machines are part of the field named mechatronics. This
field is the combination of electronics and mechanical
engineering fields. When they work in combination they are
termed as above. A single CNC machine can perform variety of
machining operations in a sequential order (based upon the
programme). For example drilling , tapping , slotting, milling, etc.
operator is used only for clamping and declamping purpose ( after
feeding the programme ). These machines ensure repeatability of
the dimensions (precision). Accuracy of these machines is in
microns.
A CNC machine may be of three dimensional coordinate system
with XYZ axis. Rest two are available
on machines whose table
can rotate and tilt. These are 4th and 5th axis. The axis of the
spindle is termed as Z axis. The axis which crosses Z axis
perpendicularly is X axis and the other mutually perpendicular
axis is Y axis. CNC machines differ in orientation of the main
spindle. If spindle is horizontal it is termed as HMC (horizontal
machining centre) and if the spindle is vertical it is termed as
VMC (vertical machining centre). Model number of machine
depends upon capacity of machine. Capacity means traverse
length along various axis or maximum size of the pallet. Thus a
VTC 1000 designates a CNC machines whose spindle is vertical
with pallet size or traverse length of 1000mm.
Various CNCs produced here:- HMC 320M, HMC 400M,
HMC 500M, HMC 600M, HMC 800M, VMC 400M, VMC
500M, VMC 800M, VMC 1000M etc.
Assembly:Main parts of the CNC machine are:1. Bed
2. Column
3. Saddle
4. Table
5. Pallet chaner (optional)
6. Magazine
7. AC servo motors
8. Tool changer arm
9. Head
10. Main spindle
The different processes of assembly are:1. Procurement of various parts.
2. Bed is leveled.
Machine Description:Salient features of CNC machines are as follows: Bed type machine configuration:Bed type construction with longitudinal and cross movement
to work table and vertical movement to head , provides stable
cutting condition and maximum rigidity. Box type construction of
bed and column with properly ribbed reinforcement minimizes
torsion and flexural deflection.
Linear motion with guide ways:Preloaded anti - friction linear motion type. Guide ways in the
entire three provide clearance free guidance for slides during
cutting. Their use significantly reduces the coefficient of friction
and eliminates stick slip and thermal generation during high