Documentos de Académico
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CHAPTER 1
Realizing the need to update and upgrade the skills of existing technical
personal in industry, GT&TC conducts a number of short term programs in tool
design, advanced manufacturing techniques, design analysis and CNC programming
for manufacture and other aspect of manufacturing.
MRP Module backs the computer-aided process planning system for close
monitoring of the schedule. With the backing of qualified and experienced designers
production and quality assurance engineers GT&TC can commit to delivery of
quality tools on schedule, which meet international standards.
Vission:
Mission:
Core Objectives:
Quality policy:
Brief introduction about tool and how the tool is manufactured known as tool
planning. The assembly JIG consists of structure and locators depending upon which
the tool are manufactured or prepared.
The locators further consists of contour plates and tooling hole locators which
are used to locate the hole or reverting across the main assembly plate. Depending
upon the flight direction the dimension like X-length, Y-width, and Z-height are
calculated and riveted or joined by considering fuselage reference line.
Also visited tool room and glanced different machining of tool on milling,
drilling, turning etc machines.
1.2 SCOPE
To know the maintenance work and technique used in industry, i.e. preventive
maintenance and breakdown maintenance carried out on machineries.
To minimize the breakdown and make available machinery for production.
Introduction to the organization or company.
Exposure to work environment briefing on manufacturing or production
process flow ( subject to nature of business activities involved ).
Students are required to fill up the daily activities section in their training log
book. Therefore, students should be given task relevant aspects.
Example of tasks or assignments to be given to the student includes:
Daily task or assignments.
Short term project which may include data collection, lab analysis,
trouble shooting, equipments, performance evaluation, data analysis,
r&d and other activities deemed relevant by the supervisor in charge.
Students should be allowed for a site visit.
Presentation by the student for the project or task completed during or at the
end of the training period is highly encouraged.
Discipline is very important and full attendance is compulsory. Supervisor
should inform FKK industrial training co-ordinator should student fail to
show up at training site without notice or proper documents.
HUMAN RESOURCES
The total approved sanctioned strength of the department as on 1.3.2014 is
17625 out of which 12155 are in scientific and technical categories and 5470 are in
administrative categories. Welfare measures like housing, medical, canteen, schooling
for children, are extended to the existing personnel under different approved schemes.
Life insurance coverage from accidents in the work place namely VISWAS and a
special scheme for assistance to families in exigency, namely, SAFE are also
extended to employees at a relatively low premium through an internal trust.
The scheme of industrial training program for newly recruited
scientists/engineers which was introduced in 2002, has been continued during the
year. The scheme is useful for youngsters to understand various systems in the Indian
space program. Similar industrial training program have been continued for newly
recruited administrative staff wherein, they are introduced to various rules, regulation,
systems and processes that are in vogue in the organization.
Activities in GT&TC
Press tools
Plastic moulds
Patient lift
General manager controls the management for GT&TC. The simple system
which GT&TC fallows is as shown in the chart.
GENERAL MANAGER
DEPUTY GENERAL
MANAGER
DEPUTY MANAGER
ASSISTANT MANAGER
E- ENTRANCE
S- SECURITY ROOM
1. HSM M/C
2. MAINTENANCE
3. ASSEMBLY
4. BENCH WORKS
5. DNC
6. QUALITY ANALYSIS
7. CMM
8. CNC MILLING
9. CNC MILLING
16. EDM
18. CANTEEN
Marketing reaches right customers and explain him about special machines
and quality of work carrying out in the industry through advertisement and by other
means. 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.
Date:
MYSORE
WORK ORDER
INSTRUCTION
Customer
Description
Scope of work
Quality
Raw material/specification
Date of delivery
Priority
Acceptance criteria
Marketing
High tech
Design Sub contract
Quality
Marketing
assurance Design/programming
Quality
production
Marketing
assurance
components
CNC MILLING
Products
Bill of materials
Production
Quality assurance
Before starting the actual production process planning is done. It gives the
idea of operation, selection of machine, cost and time required, at the same tine
process will be performed with high percentage of material utilization. Planning is a
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.
Tool and high tech components: it involves job planning with effective
utilization of machines available and using right tool for right operation.
Preparing process sheet: process sheet in forms the operations and machining
conditions such as diameter of components, feed, speed, material setting etc.
Job follows up: to follow up the progress of the job in shop floor.
Pre tooling: pre machining of the job in conventional machines to save the
time of high tech machines.
Route card: route card is prepared to mention in sequence.
Description Department:
MYSORE
O.C. NO: Drawing/part No: Quantity:
Machine Section:
Operation:
Special instruction:
Date: Signature:
Production
planning
Sheet no:
MYSORE
Customer: Date:
Drawing
Unit code:
PURCHASE REQUISITION
MYSORE
TEMPLATE
Department:
Date : P.R. No
Received by:
It is the organ of the industry. Quality of work, hence the name and fame of
the company depends on this section. Its function can be enlisted as below.
GT&TC Design is well equipped with computers. The designers were engaged in
designing the ISRO projects.
AUTOCAD
IDEAS
MASTERCAM
SOLIDWORKS
CHAPTER 2
ABOUT THE DEPARTMENTS
2.1 CNC MILLING
DEPARTMENT OF MECHANICAL ENGINEERING, NIE, MYSURU Page
CNC MILLING
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 axis 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 modelling and generates the tool paths.
Automatic 22 - 12 20
tool
changer
Tilting
200 - - -
table range
from m/c
DEPARTMENT OF MECHANICAL ENGINEERING, NIE, MYSURU Page
CNC MILLING
TRAVERSE(mm)- X
mm 600 300 300
TRAVERSE(mm)- Y
mm 200 400 250
TRAVERSE(mm)- Z
250 250 250
mm
Major Components
Traverse-UAxis (mm) 15 28
Traverse-VAxis (mm) 15 28
2.4 GRINDING
INTRODUCTION ABOUT GRINDING PROCESS
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.
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.
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.
JIG GRINDING MACHINE IN GTTC:
X axis 460 mm
Y axis 280 mm
SPINDLE RPM
Minimum 4000
Middle 60,000
Maximum 1, 20,000
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.
2.5.1 PREPARATIONS OF JOINTS
The preparation of joints is very important having many implications
regarding the design of the weld.
The work pieces are correctly positioned together.
The work pieces are not beveled.
Size 500300
2.6.1 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
It reduces cost spent on scrap pieces and further process can be stopped
if
mistake is going on.
2.6.3 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:
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.
Height master
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 under lighting, the fine microscopic
details are eliminated and only the details of contour and profile are seen. A
drawing can be affixed to the profile projectors large viewing screen and the contour
can be easily traced or compared to other profiles and contours on the other drawings.
Accuracy 0.001
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 microscopes
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.
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.
ORIGIN JAPAN
Magnification 10X,15X,20X
0.005
Accuracy
HEIGHT MASTER
ORIGIN JAPAN
Max.height,mm 300
Accuracy, mm 0.001
Stroke,mm 20
ORIGIN GERMANY
CHAPTER 3
TASK PERFORMED
DESIGN OF CAD
MODEL
CNC MILLING
STAGE INSPECTION
WIRE EDM
FINAL INSPECTION
3.2 PROCEDURE
Clean all surfaces, for example table, vise jaws and part very good with a
lint free cloth.
Set work fixture offsets. Make sure the machine is using the WFO that the
program will be using.
Adjust coolant lines so coolant can properly cool tools and wash chips
away.
In cnc milling after generating the cad model of the design we must generate
the program by taking absolute and incremental dimensioning into consideration.
Next is to select the necessary tool for manufacturing. Now we should clamp the
work piece and adjust coolant into position. then we should insert card containing
program. Before loading the program first and foremost we must take the machine
offset so that dimension can be taken from the origin. Next is cycle start of the
machine.
3nd setting :Wire cutting of block into single component by wire EDM machine
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.
3.5 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.
Stage Inspection 10
Wire EDM 60
Bench Work 15
Final Inspection 30
Quality and
inspection
department
Glass enclosure
CNC
milling
CNC Machine 4
milling
Machine 7
CNC
milling
Machine 3
Cnc milling
Machine 6
CNC
milling
Machine 2
CNC
milling CNC
Machine 5 milling
Machine 1
Planning Marketing
department department Customer order
3.7 SUGGESTION
We can change the milling section to u shaped line may reduce employ
movement and space requirements while enhancing communication, reducing the no
of workers, and facilitating inspection.
CNC milling
Machine 4
CNC
CNC milling
milling Machine 5
Machine 3
CNC
Cnc milling milling
Machine 2 WORKERS Machine 6
CNC
CNC
milling
milling
Machine 7
Machine 1
Quality and
Planning
department inspection
department
Marketing Dispatch to
customer
department
Customer
order FIG 3.14: OPTIMIZED MILLING SECTION
CHAPTER 4
REFLECTION NOTES
The internship training is experienced the real life situations in industrial
organizations and their related maintenance environments and accelerating the
learning process of how knowledge could be used in a realistic way.
In addition to that, industrial training also makes one understand the formal
and informal relationships in an industrial organization so as to promote
favorable in.
The exposure to practice and apply the acquired knowledge in the
maintenance works industrial training also provides a systematic introduction
to the ways of industry and developing maintenance activities.
There is strong evidence that industrial training is highly beneficial to students
development, and it is highly valued.
The students are well equipped to manage the period of industrial training
successfully and undoubtedly gain useful experience of applying their
specialist and technical skills, as well as developing their personal and
communications skills.
This internship also helps students to prepare for the work environment and
also teach the ergonomics of organizations in the real world.
An internship is the great way to develop specific skills and knowledge as well
as make contacts to network, build confidence and enhance your resume. In this
chapter I will reflect on all the experience and influences that I had in this internship
program. because reflecting summarizing and analyzing the skills acquired and/or
work during this period is as important as the internship itself as it provides clear
picture of the things to be done for the way forward in our professional life.
REFERENCES