SECAB INSTITUTE OF ENGINEERING AND TECHNOLOGY

VIJAYPUR- 586101

DEPARTMENT OF MECHANICAL ENGINEERING

An internship report on
‘‘TOOL ROOM DEPARTMENT”

Carried at

“AARNA ENGINEERING PVT. LTD.”

Specialist in all types of precision machining.

Submitted in partial fulfilment of the requirement for the award of

the degree of

MECHANICAL ENGINEERING

UNDER THE GUIDENCE

OF Mr. AKASHAY

AWATADE SUBMITTED

BY

SAFFAN
KUMASGI
(2SA16ME064)
 SECAB INSTITUTE OF ENGINEERING AND TECHNOLOGY

VIJAYPUR- 586101

CERTIFICATE
This is to certify that the internship entitled “TOOL ROOM DEPARTMENT at
AARNA ENGINEERING PVT.LTD”, carried out by M/r SAFFAN KUMASGI USN:
2SA16ME064, his a bonafide student of SECAB INSTITUTE OF ENGINEERING
AND TECHNOLOGY, VIJAYAPURA in partial fulfillment for the award of bachelor
of engineering in mechanical engineering of the VISVESVARAYA
TECHNOLOGICAL UNIVERSITY, BELAGAVI during year 2020-2021. It is certified
that all corrections/suggestions indicated for internship report. The internship
work prescribed for the said degree. Report has been approved as it satisfies
the academic requirement in respect of internship work prescribed for
bachelor engineering degree in mechanical engineering.

GUIDE HOD PRINCIPAL

AKASHAY AWATADE DR. SYED ABBAS ALI DR. ZAKIR ALI

 /• -= 'D •
EAN A RE N
0IN E RAI N 0

Date: 1*’ April 2021

CERTIFICATE

Th is i5 to certify that Mr. Saffan Kumasgi, Roll No. 2SA16ME064, B.E Mechanical, SECAB
^. b”|ITUDE of Engineering and Technology Vijayapur, has undergone Internship Training under
r guidance of Mr. Akashay Awatade, Tool Room Head, from 02-Mar-2021 to 3i-Mar-2021
at
.- rna Engineering, Bhosari, Pune.
 ACKNOWLEDGEMENT

I am pleased to submit the report on the project I conducted during my

internship at Aarna Engineering’s Pvt. Ltd.

I am deeply indebted to Mr. Akashay Awatade for their valuable

Suggestions, Scholarly guidance, constructive criticism and constant
encouragement at every step of the Project.

I would also like to express my deepest gratitude to Dr. Syed Abbas Ali
Head of Mechanical Engineering Department and I am also thankful to my
project guide MR. Akashay Awatade for constant guidance, co-operation and
practical approach, which provided me the much-needed impetus to work
hard. I also thank all other persons who directly and indirectly contributed in
successful completion of Project.

My gratitude is also towards the management of Aarna Engineering Pvt.

Ltd. for giving me opportunity to work in their esteemed organization.

SAFFAN KUMASGI
B.E MECHANICAL ENGINEERING
VIJAYAPURA
 ABSTRACT

The period of one month, as an intern in Aarna Engineering Pvt. Ltd.

Provided many new directions to my knowledge. It exposed me to the actual
working environment of a firm. I got a feel of actual working on shop floor and
Tool Rome department, which involved a lot of practical difficulties and skills. It
also gave me a very good opportunity to put my theoretical knowledge to
actual practice.

Optimisation of the process cycle was undertaken by which I

learnt various manufacturing and designing process. While doing this project I
came to know of the various practical problems faced during designing of new
product and also the vision to solve the problem.

During this period, I understood the scope of function, job

responsibility of various engineering design department. I also came to know
that how the firm and its different constituents’ function in tandem for
improving the process of particular product.

I came in contact with some machinery, which was completely

unknown to me, and the most important thing to learn was co-operation and
co-ordinate effort of various persons at different levels in different
departments to achieve goals.

I sincerely hope that all my efforts put forward in recording this

project is helpful to all my fellow students and future students to guide them in
the field of manufacturing and designing.
 CONTENTS
Internship Dissertation Report…..............................................................ii

Certificate…........................................................................................iii

Acknowledgement................................................................................iv

Abstract…............................................................................................v

Contents.............................................................................................vi

List of Figures....................................................................................vii

List of Tables.....................................................................................viii

Abbreviations......................................................................................ix

CHAPTER 1: Introduction to Company

1.1 Company profile…........................................................................2 1.1.1.

Vision.................................................................................2

1.1.2. Mission...............................................................................3

1.1.3. Philosophy..........................................................................3

1.2 Overall Layout…..........................................................................4

1.3 Introduction of machineries at company............................................5

1.3.1 List of machines and utilities....................................................5

1.3.2 CNC lathe machine…..............................................................6

1.3.3 VMC (Vertical milling machine)..................................................7

1.3.4 M1TR machine…...................................................................8

1.3.5 Surface grinder.....................................................................9

1.3.6 Drilling cum tapping machine…...............................................10

1.3.7 Heavy duty milling machine….................................................11

1.3.8 Bench grinder.....................................................................12

1.3.9 Conventional lathe machine….................................................13

1.3.10 Band saw cutting machine…..................................................14

1.4 Introduction to monitoring and measuring instruments........................15

1.4.1 List of measuring equipment’s................................................15

1.4.2 Vernier Caliper....................................................................16

1.4.3 Digital Caliper.....................................................................17

1.4.4 External micrometre.............................................................18

1.4.5 Digital height gauge..............................................................19

1.4.6 Vernier Depth Gauge….........................................................20

1.4.7 Dial Bore Gauge…...............................................................21

1.4.8 Dial Indicator......................................................................22

1.4.9 Surface Plate…...................................................................23

1.4.10 Universal Bevel Protractor.....................................................24

1.4.11 Radius Gauge…..................................................................25

1.4.12 Feeler Gauge…...................................................................26

1.4.13 Screw Pitch Gauge..............................................................27

1.4.14 Try Square….......................................................................28

1.4.15 Steel Ruler..........................................................................29

1.5 Introduction to Products

1.5.1 List of Products..................................................................31

1.5.2 Product Description…..........................................................32

1.5.3 Polishing Die…...................................................................32

1.5.4 Metallic Shaft......................................................................34

1.5.5 Ratchet Bolt…....................................................................36

1.5.6 Bearing Housing…..............................................................38

1.5.7 Coupler.............................................................................40

1.5.8 Polishing Shaft....................................................................42

3.8 Cost Estimation.........................................................................45

3.9 Conclusion...............................................................................48

Conclusion of Project….........................................................................49
 LIST OF FIGURES

Figure TITLE Page

No. No.
1.17 Surface Plate 23
1.18 Universal Bevel 24
Protractor
1.19 Radius Gauge 25
1.20 Feeler Gauge 26
1.21 Screw Pitch Gauge 27
1.22 Try Square 28
1.23 Steel Ruler 29
2.1 Polishing Die 32
2.2 Metallic Shaft 34
2.3 Ratchet Bolt 36
2.4 Bearing Housing 38
2.5 Coupler 40
2.6 Polishing Shaft 42
3.1 Coupler 46
3.2 Drawing of Coupler 47
4.1 Metallic Shaft Fixture 54
4.2 Metallic Shaft Fixture 55
with Shaft
4.3 Metallic Shaft 55
 LIST OF TABLES:

Figure Page
No.
TITLE No.
1.1 Overall Layout 4
1.2 List of Machines and 5
Utilities
1.3 List of Measuring 15
Equipment
2.1 Description of Die 33
2.2 Description of Metallic 35
Shaft
2.3 Description of Bolt 37
2.4 Description of Housing 39
2.5 Description of Coupler 41
2.6 Description of 43
Polishing Shaft
3.1 Old Machining Time 48
for Coupler
3.2 Optimised Machining 50
Time for Coupler

LIST OF FLOWCHARTS:
Figure Page
No.
TITLE No.
1.1 Old Process of 48
Manufacturing of
Coupler
1.2 Optimised Process of 49
Manufacturing of
Coupler
 LIST OF ABBREVIATION

 CNC - Computer Numerical Control.

 VMC – Vertical Milling Cutter.

 OD – Outer Diameter.

 ID – Inner Diameter.

 PCD – Peripheral Circular Diameter.

 MM – Millimetre.

 SPM – Special Purpose Machine.

 MTM – Multi-tasking Machines.

 MS – Mild Steel.

 SS – Stainless Steel.
 CHAPTER 1
INTRODUCTION TO COMPANY

INTRODUCTION TO SHIVMAY ENGINEERINGS PVT. LTD.

1.1 COMPANY PROFILE:

Aarna Engineering Pvt. Ltd. is a private industry incorporated on 28th

March 2019. It is classified as non-government company. This industry is
involved in manufacturing of general-purpose machinery.

Aarna Engineering Pvt. Ltd. has a state of the art in house precision tools
and die manufacturing facility comprising of next generation VMC 4 th axis.
Tools are designed and developed in house for regular use as well as new
product development work with strict adherence to quality.

The industry has high precision VMC, CNC and other tool room
machineries for machining of tools and dies which ensures high quality tools
and dies in terms of consistency and repeatability.

1.1.1. Company’s Vision:

 The vision is to reliable long term manufacturing partner of

modern industrial companies in India and contribute substantially
to the development of innovative and high added value industries.

 To be the preferred partner, sharing expertise and delivering value on-

time always. To nurture a performance culture and develop our people.
To innovate to grow and diversify our business.
1.1.2. Company’s Mission:

 To achieve sustainable growth by using the better technology in

product development and manufacturing and better process driven
methodologies offering value added services to our customers.

 To produce and continually develop quality products at a

competitive price while fostering a climate where environmental
technologies can thrive.

 Always strive to service our customer with the utmost integrity, and
to their complete satisfaction.

1.1.3. Company’s Philosophy:

 Hire high quality motivated people.

 Give our people high quality equipment and tools to work with.
 Provide a clean and safe working environment.
 Provide opportunities and encourage personal growth.
 Offer training and guidance where needed.
 Allow people to make decisions within their area of responsibility.
 Get out of their way and let them do their jobs.
1.2 OVERALL LAYOUT:

Description Data
Company name Aarna Engineerings Pvt. Ltd.
Incorporation 28th march 2019.
Founder Mr. Bhupesh Meher.
Location Parmar industrial complex,
Chinchwad,Pune – 411019.
No. of Employees 15
Annual Turnover 10 cr.
Products
1. Metallic shafts.
2. Polishing dies.
3. SPM parts.
4. Press tools.
5. Lock and Hinges mold.

Product Receiving Sectors

1. Railway sector.
2. Textile sector.
3. DRDO Sector.

Raw Material Supplier

1. RK Engineering.
2. Ferromet Steels
3. Saffron Steels Pvt. Ltd.

Table 1.1: Overall layout

 1.3 INTRODUCTION TO MACHINERIES:

1.3.1 List of machines and utilities-

Sr. No. Identificatio Equipment Make/ Range / Year of

n No. Description Model Capacity Mfg.
1 SEPL01 CNC LX20TL3 ᴓ300x500M 2019
(LMW Make) M
2 SEPL02 VMC VF4i 1270X508X6 2019
(HAAS Make) 35MM
3 SEPL03 M1TR ARGO Make 250X1250M Oct-18
M
4 SEPL04 Surface Tos Make 600X200MM 1983
Grinder
5 SEPL05 Drilling cum PRASHANT 25 M. M. 2019
Tapping
Machine
6 SEPL06 Heavy Duty VERNIER 300X1200M −
Milling Make M
Machine
7 SEPL07 BENCH KISMAT 8”X3/4” 2019
GRINDER
8 SEPL08 Conventiona KRUPA 7.5” 2019
l Lathe
9 SEPL09 Double YUVA UP TO Jan-19
Column ᴓ175MM
Band Saw
Cutting
Machine
10 SEPL10 AIR CHICAGGO 10.2 BAR 2019
COMPRESSO PNEUMATIC MAX
R
Table 1.2: List of machines and utilities
1.3.2 CNC (Computer Numerical Control) Lathe Machine-

Figure 1.1: CNC machine

General information of machine:

 CNC Lathes are machine tools where the material or part is clamped
and rotated by the main spindle, while the cutting tool that work on the
material, is mounted and moved in various axis.
 This type of machine is commonly used in metalworking, woodturning.
 Accuracy of CNC lathe is more than manual lathe.
 CNC program is generated in the NC form using G- codes & M-codes.
 Capacity of given machine is ∅300×500𝑚𝑚.
 Company of manufacturing - LMW.
1.3.3 VMC (Vertical Milling Machine)-

Figure 1.2: VMC machine

General information of machine:

 It is Vertical milling centre machine with computer numerical control.

 The cutting head in this milling machine is vertical and is a particular
type of milling machine where the spindle runs in a vertical axis known
as the “z” axis.
 VMC machine is basically 3 axis machines, although 4th and 5th axis
can be attached separately.
 We can load at a time 24 tools in machine.
 Bed size of given machine is 1270×508×635𝑚𝑚 with 4th
axis of attachment of ∅310𝑚𝑚.
1.3.4 M1TR Machine-

Figure 1.3: M1TR machine

General information of machine:

 A Ram turret milling or a M1TR Milling has a stationary spindle and the
table is moved both perpendicular and parallel to the spindle axis to
accomplish cutting.
 Turret mills often have a quill which allows the milling cutter to be raised
and lowered in a manner similar to a drill machine.
 Angular drilling and tapping operations can also be performed on
this machine.
1.3.5 Surface Grinder-

Figure 1.4: Surface Grinding machine

General information of machine:

 Grinding is an abrasive machining process that uses a grinding wheel

as the cutting tool.
 A grinding machine is a type of machining using an abrasive wheel as the
cutting tool.
 Each grain of abrasive on the wheel's surface cuts a small chip from the
work piece via shear deformation.
 It is used for surface finishing in this industry.
1.3.6 Drilling cum tapping machine-

Figure 1.5: Drilling cum Tapping machine

General information of machine:

 Drilling is a workshop practice that involves the process of cutting or

expanding hole of circular cross-section in solid materials.
 The drill is the executing tool that works the rotary action of its bit.
 This forces the cutting edge against the work piece, cutting off chips
(swarf) from the hole as it is drilled.
1.3.7 Heavy duty Milling Machine-

Figure 1.6: Milling machine

General information of machine:

 The milling machines are also known as the multi-tasking machines

(MTM) which are multi-purpose machines capable of milling and turning
the materials as well.

 The milling machine has got the cutter installed up on it which helps in
removing the material from the surface of the work piece.

 It is used for roughing in this industry.

1.3.8 Bench Grinder-

Figure 1.7: Bench Grinder

General information of machine:

 A bench grinder is a bench top type of grinding machine used to drive

abrasive wheels.

 Depending on the bond and grade of the grinding wheel, it may be

used for sharpening cutting tools such as tool bits, drill bits, chisels.

 It is also used for debarring of work piece using different grades of

wheel.
1.3.9 Conventional lathe-

Figure 1.8: Lathe machine

General information of machine:

 Lathe machine is also termed as “Mother of all machine tools”.

 A lathe is a machine that rotates the piece on the axis in order to

perform various operations like cutting, facing, knurling, deformation
and turning.

 Woodturning and metalworking are common operations performed

with a lathe machine.
1.3.10 Double column Band Saw cutting machine-

Figure 1.9: Band Saw Cutting machine

General information of machine:

 A band saw is a power saw with a long, sharp blade consisting of a

continuous band of teeth metal stretched between two wheels to cut
material.

 They are used principally in Metalworking but may cut a variety of

materials.

 This machine is used for cutting of MS, EN24, D2, Brass and Aluminium
rods in this industry.
1.4 INTRODUCTION TO MONITORING AND MEASURING
EQUIPMENTS:

1.4.1 List of measuring equipment-

Sr. No. Instrument Make Range Calibration

Description (mm) Frequency
(Months)
1 Vernier Baker 0-200 12
Caliper
2 Digital Baker 0-300 12
Caliper
3 External Baker 0-25 12
Micrometr
e
4 Digital Baker 0-300 12
Hight
Gauge
5 Depth Baker 0-150 12
Caliper
6 Dial Bore Baker 0-10 12
Gauge
7 Dial Baker 0.01-0.8 12
indicator
8 Surface GMT 75X630X6 12
plate 30
9 Universal Kristel 0-360 12
Bevel
Protractor
10 Radius Kristel R1-7 12
Gauge
11 Feeler NTC 0.03-1 12
Gauge
12 Screw Kristel 0.23-6 12
pitch
Gauge
13 Tri square Crystal 10X70X10 12
100B 0
14 Steel Ruler Kristel 0-600 12
Table 1.3: List of measuring equipment
1.4.2 Vernier Caliper-

 The Vernier caliper is an extremely precise measuring instrument.

 The reading error is 1/20mm = 0.05mm
 This instrument may be used to measure outer dimensions of objects
(using the main jaws), inside dimensions (using the smaller jaws at
the top), and depths (using the stem).
 A Vernier scale on a calliper has a least count of 0.1 mm.

Figure 1.10: Vernier Caliper

1.4.3 Digital Caliper-

 The Digital Caliper is a precision instrument that can be used to measure

internal and external distances extremely accurately.
 Unlike dial calipers and Vernier calipers, Digital calipers do not have a
rack and pinion mechanism.
 They send a signal to a chip within the caliper, which generates the
readings shown on the LCD display.
 Digital calipers contain a "reading hold" feature, allowing the reading
of dimensions after use in awkward locations where the display cannot
be seen.
 Ordinary 6-in/150-mm digital calipers are made of stainless steel, have
a rated accuracy of 0.001 in (0.02mm) and a resolution of 0.0005 in
(0.01 mm).

Figure 1.11: Digital Caliper

1.4.4 External Micrometre -

 External Micrometres are used for measuring the thickness or

external diameter of small parts.
 They are industry standard measuring tools because of their
high accuracy/resolution and ease of use.
 External micrometre is used for measuring the outer diameter of an
object.
 The smallest value that can be measured by the measuring instrument
is called its least count, while a micrometer has a least count of 0.01
mm.
 Micrometre measuring faces (anvil and spindle) are normally faced with
carbide to reduce wear caused by repeated use.

Figure 1.12: External Micrometre

1.4.5 Digital Height Gauge-

 A Height gauge is a measuring device used for determining the height of

objects, and for marking of items to be worked on.
 Height gauges may also be used to measure the height of an object by
using the underside of the scriber as the datum.
 It is a measuring instrument in which a slider with a measuring Digital
stylus moves relative to a measuring scale on a beam and in which
this motion is along a single vertical axis nominally perpendicular to a
reference plane on the instrument base.

Figure 1.13: Digital Height Gauge

1.4.6 Vernier Depth Gauges –

 Vernier Depth Gauge as the name suggests is used to measure the

depth from the surface of reference of an object.
 Vernier caliper also has depth bar but this cannot be used as the
standard measurement.
 The way of taking measurements of vernier depth gauge is same
as vernier caliper has.
 Digital depth gauges, also called electronic depth gauges, replace
the dial and needle indicator.
 The material’s surface represents the reference plane against which the
depth measurement is made by the instrument.
 It is used to accurately obtain the measurement of the depth of a
bored cavity, recess, hole, groove or other similar openings that were
created below the surface level.

Figure 1.14: Vernier Depth Gauge

1.4.7 Dial Bore Gauge -

 Dial bore gauges are both easy to use and accurate, as well as good for
measuring how deep bores taper.
 They need to be calibrated every time they use.
 Small hole gauges, available in full ball and half ball types, are better
suited to smaller bores, and can be used to see if a bore's shape is off.
 The speed and accuracy of a dial bore gauge can save a lot of time when
used to measure cuts or hole sizes in home remodelling projects.
 They are typically used to measure deck clearances, crankshaft thrust
and straightness, lifter travel and other measurements that involve the
distance between two surfaces or small amounts of component travel.

Figure 1.15: Dial Bore Gauge

1.4.8 Dial indicator -

 Dial indicators are instruments used for making and checking

linear measurements.
 Dial indicators are smaller indicating devices containing a graduated dial
scale and these depend upon gear and pinion or lever magnification
system.
 These are generally used as comparators, i.e., compare a part to
a master setting.
 They are typically used to measure deck clearances, crankshaft thrust
and straightness, lifter travel and other measurements that involve the
distance between two surfaces or small amounts of component travel.

Figure 1.16: Dial Indicator

1.4.9 Surface plate -

 A surface plate is a solid, flat plate used as the main horizontal

reference plane for precision inspection, marking out (layout), and
tooling setup.
 The surface plate is often used as the baseline for all measurements to a
work piece.
 Plates are typically square or rectangular, although they may be cut
to any shape.
 Surface plate must be calibrated regularly to ensure that chipping,
warping, or wear has not occurred.

Figure 1.17: Surface Plate

1.4.10 Universal Bevel Protractor -

 The instrument consists essentially of two straightedges hinged together

by means of the protractor head and capable of being set at any desired
angle.
 The principal feature of this bevel gauge is the circular scale, which
is divided accurately on a glass annulus mounted inside the head.
 A bevel protractor is a graduated circular protractor with one
pivoted arm, used for measuring or marking off angles.
 They are used by toolmakers; as they measure angles by
mechanical contact they are classed as mechanical protractors.

Figure 1.18: Universal Bevel Protractor

1.4.11 Radius Gauge -

 A radius gauge, also known as a fillet gauge, is a tool used to measure

the radius of an object.
 Radius gauges require a bright light behind the object to be measured.
 The gauge is placed against the edge to be checked and any light
leakage between the blade and edge indicates a mismatch that requires
correction.
 A good set of gauges will offer both convex and concave sections, and
allow for their application in awkward locations.

Figure 1.19: Radius Gauge

1.4.12 Feeler Gauge -

 A feeler gauge tool used to measure gap widths.

 A feeler gauge I mostly used in engineering to measure the clearance
between two parts.
 They consist of a number of small lengths of steel of different
thicknesses with measurements marked on each piece.
 They are flexible enough that, even if they are all on the same hinge,
several can be stacked together to gauge intermediate values.
 The lengths of steel are sometimes called leaves or blades, although
they have no sharp edge.

Figure 1.20: Feeler Gauge

1.4.13 Screw pitch Gauge -

 A thread gauge, also known as a screw gauge or pitch gauge, is used

to measure the pitch or lead of a screw thread.
 Thread pitch gauges are used as a reference tool in determining
the pitch of a thread that is on a screw or in a tapped hole.
 This tool is not used as a precision measuring instrument, rather it
allows the user to determine the profile of the given thread and quickly
categorize the thread by shape and pitch.
 This device also saves time, in that it removes the need for the user to
measure and calculate the pitch of the threaded item.

Figure 1.21: Screw Pitch Gauge

1.4.14 Try square -

 A try- square is a woodworking and Metalworking tool used for marking

a straight line and measuring a right angle of channel/job.
 The square refers to the tool's primary use of measuring the accuracy
of a right angle (90-degree angle) to try a surface is to check its
straightness or correspondence to an adjoining surface.
 Try square is so Called because it is to try the square.

Figure 1.22: Try Square

1.4.15 Steel Ruler -

 A steel rule is a straight flat piece of metal, very similar to a ruler.

 They can be flexible or rigid, and are usually 6″ – 12″ in length.
 Steel rulers are generally thinner than a desk ruler, which makes
them more accurate since the measurement markings are closer to
the surface being measure.

Figure 1.23: Steel Ruler

1.5 INTRODUCTION TO PRODUCTS AT COMPANY:

Shivmay Engineering Pvt. Ltd. has a state of the art in house precision
tools and die manufacturing facility comprising of next generation VMC 4 th
axis.
At Shivmay Engineering Pvt. Ltd. Because of availability of high precision
VMC, CNC and other tool room machineries for machining of tools,
manufacturing of precision tools, special purpose machines, dies and press
tools takes place.
Also, product manufacturing and designing work with strict adherence to
quality and reliability. They are the suppliers of the products to three major
sectors i.e., Railway sector, Textile sector and DRDO sector.
Given below is list of the some of the components manufactured at the
industry.

1.5.1 LIST OF PRODUCTS:

A. Polishing Die.

B. Metallic Shaft.

C. Rachet Bolt.

D. Bearing Housing.

E. Coupler.

F. Polishing Shaft.
1.5.2 PRODUCT DESCRIPTION:

1.5.3 Polishing Die-

Figure 2.1: Polishing Die

Sr. No. Description Data
1. Product name Polishing Die
2. Material used EN24
3. Uses Paper-tube industry (Textile
sector)
4. Machines used for
manufacturing 1. Band saw
2. Lathe Machine
3. M1TR
4. CNC lathe machine

5. Operations done on
product 1. Rough turning
2. PCD Drilling
3. OD drilling
4. Hardening
5. CNC finishing
6. Inspection

6. Measuring
equipment used 1. Digital Vernier Caliper
2. Vernier height gauge
3. Bore gauge

7. Machining time Approx. 2 hours for one job on

CNC machine

Table 2.1: Description of Die

1.5.4 Metallic Shaft-

Figure 2.2: Metallic Shaft

Sr. No. Description Data
1. Product name Metallic Shaft
2. Material used EN24
3. Uses Railway sector
4. Machines used for
manufacturing 1. Band saw
2. Lathe Machine
3. Cylindrical grinding
machine
4. CNC lathe machine
5. VMC machine

5. Operations done on
product 1. Pre-Turning.
2. Hardening.
3. CNC Turning.
4. Grinding.
5. Slot Machining.
6. Inspection

6. Measuring
equipment used 1. Vernier height gauge
2. Snap gauge

7. Machining time Approx. 5 hours for one job.

Table 2.2: Description of Metallic Shaft

1.5.5 Ratchet Bolt-

Figure 2.3: Ratchet Bolt

Sr. No. Description Data
1. Product name Ratchet Bolt
2. Material used SS material
3. Uses In DNA extractor machine
4. Machines used for
manufacturing 1. Band Saw.
2. Lathe Machine.
3. CNC Machine.

5. Operations done on
product 1. Cutting.
2. Drilling.
3. Turning.
4. Hardening.
5. Threading.
6. Inspection.

6. Measuring
equipment used 1. Vernier Caliper
2. Vernier height gauge
3. Ring gauge

7. Machining time Approx. 10 minutes for one

job on CNC machine

Table 2.3: Description of Bolt

1.5.6 Bearing Housing-

Figure 2.4: Bearing Housing

Sr. No. Description Data
1. Product name Bearing Housing
2. Material used EN8
3. Uses Used as bearing coupling in
Paper-tube industry (Textile
sector)
4. Machines used for
manufacturing 1. Band Saw
2. Lathe Machine
3. CNC Lathe Machine
4. VMC Machine
5. M1TR
6. Grinding machine

5. Operations done on
product 1. Cutting
2. Facing
3. Interpole Drilling
4. CNC Turning
5. Drilling
6. Tapping
7. Grinding
8. Inspection

6. Measuring
equipment used 1. Vernier height gauge.
2. Vernier Caliper.
3. Bore gauge.
4. Micrometer.

7. Machining time Approx. 3 hours 40 minutes for

one job

Table 2.4: Description of Housing

1.5.7 Coupler-

Figure 2.5: Coupler

Sr. No. Description Data
1. Product name Coupler
2. Material used EN8
3. Uses For holding Main screw in
Paper-tube industry (Textile
sector)
4. Machines used for
manufacturing 1. Band Saw
2. Lathe Machine
3. CNC Lathe Machine
4. VMC Machine
5. M1TR

5. Operations done on
product 1. Cutting
2. Facing
3. Slotting
4. CNC Turning
5. Drilling
6. Tapping
7. Inspection

6. Measuring
equipment used 1. Vernier height gauge
2. Vernier Caliper
3. Micrometre
4. Threading pitch gauge

7. Machining time Approx. 3 hours 25 minutes for

one job

Table 2.5: Description of Coupler

1.5.8 Polishing Shaft-

Figure 2.6: Polishing Shaft

Sr. No. Description Data
1. Product name Polishing Shaft
2. Material used EN19
3. Uses Paper-tube industry (Textile
sector)
4. Machines used for
manufacturing 1. Band Saw
2. Lathe Machine
3. VMC Machine
4. M1TR
5. Grinding Machine

5. Operations done on
product 1. Cutting
2. Turning
3. Key Slotting
4. Hole Punching
5. Hardening
6. Grinding
7. Inspection

6. Measuring
equipment used 1. Vernier height gauge
2. Vernier Caliper
3. Micrometre
4. Reference square Key

7. Machining time Approx. 3 hours for one job

Table 2.6: Description of Polishing Shaft

3.8 COST ESTIMATION-

1. Designing cost of fixture:

Designing cost is defined as the cost which includes all
the necessary efforts which will be taken for the design. This design has been
made on two designing software’s.
Following are the software’s which are used in designing process along with
time duration and costing.
1. Auto CAD – Rs. 250 /hr. for 2 days.

2. Catia V5 – Rs. 400 /hr. for 2 days.

Time taken for designing process = 4 days (8 hrs/day)

Therefore, design cost = 250 x 2 x 8 + 400 x 2 x 8
= 4000 + 6400
Designing Cost = Rs.10,400/-

2. Material Cost:

Material cost means that the cost which is invested to the raw
material used in manufacturing the fixture.
Now, to find mass of the component:

Mass = Volume x Density (Unit = Kilogram)

Weight = Mass x Acceleration due to gravity
(Unit = N – newton)
To find material cost of the component –
Material cost = Weight x Cost of material / kg
Cost of material / kg = Rs.65/-
Calculation for material cost:

1. Bottom Plate-
Dimensions (in mm)- 860 x 560 x 25
Weight = L x W x H x 0.00000785
= 860 x 560 x 25 x 0.00000785
= 94.514 Kg
Material cost = Weight x cost of material / kg
= 94.514 x 65
= Rs. 6144/-
2. Fixture Clamp-1:

Dimensions (in mm)- 155 x 50 x 30

Quantity required – 5 nos.

Weight = L x W x H x 0.00000785
= 155 x 50 x 30 x 0.00000785
= 1.83 kg
Material cost = Weight x cost of material / kg x quantity
= 1.83 x 65 x 5
= Rs. 594/-

3. Fixture Clamp-2:

Dimensions (in mm)- 155 x 50 x 40

Quantity required – 20 nos.
Weight = L x W x H x 0.00000785
= 155 x 50 x 40 x 0.00000785
= 2.44 kg
Material cost = Weight x cost of material / kg x quantity
= 2.44 x 65 x 20
= Rs. 3172/-
Therefore, Total material cost = 6144 + 594 + 3172
= Rs.9,910/-
3. Machining Cost:

It includes following machining operations-

1. Drilling and Tapping- Rs.50 /drill
2. Milling- Rs.100 /hour
3. VMC Machining- Rs.500 /hour
4. Allen bolts (10 nos) – Rs.45/each

Overall cost for above operations:

1. Drilling and Tapping – Rs.2500/-
2. Milling – Rs.2000/-
3. VMC Machining – Rs.25000/-

(Cost breakup of VMC machining)

No. of Resting blocks = 15
No. of Clamping blocks = 10
Total Blocks = 25 nos.
Time taken on VMC = 2 hours
VMC rate = Rs.500/ hour
Cost = 500 x 2 x 25
= Rs. 25000/-
Total Machining cost = 4500 + 450 + 25000
= Rs.29,950/-
❖ Total Cost of Fixture = Designing cost + Material Cost + Machining

Cost
= 10,400 + 9,910 + 29,950
=RS 50,260/-
3.9 CONCLUSION-

Time required for VMC operation without fixture = 30 minutes per job.
Time required for VMC operation with use of fixture = 18 minutes per job.
Now,
Time required for 10 jobs for VMC operation without fixture is
= 30 x 10 = 300 minutes.
Time required for 10 jobs for VMC operation with fixture is
= 18 x 10 = 180 minutes.
Therefore, Time saved with the use of fixture is 120 minutes per 10 jobs.
Number of jobs in an order to company = 500 nos.
Total time saved for 500 jobs i.e., for 50 setups is
= 50 x 120 = 6000 minutes.
Thus, 6000 minutes = 100 hours has been saved due to the design of fixture
per 500 jobs.
Thus, the design and implementation of Shaft fixture is proved to be
productive and effective.
 CONCLUSION OF REPORT

The greatest advantage of the Mechanical Engineering is that it

provides me a unique opportunity to undergo Industrial Internship, which in
many ways enables one to experience the working of industry and enables one
to be moulded for the future.

This was the most exciting, enriching and challenging experience

ever in my engineering curriculum. This internship has certainly helped me in
bridging the gap between theory and practical. It has empowered me to see
how the knowledge gained through textbooks is implemented in practise. This
internship offered an exposure to industrial environment, which cannot be
simulated in the engineering college.
➢ I understood scope and job responsibilities of the various
departments of an engineering organization.

➢ I enabled me to get familiarized with various materials,

process, products and their applications.

➢ I gained insight into the psychology of the workers, their

habits and attitudes.

The opportunity of the work experience has helped me to think from

the quality point of view. The free working environment has helped me to
accept responsibilities and improve my decision-making ability. The project on
which I worked was very helpful to improve my theoretical knowledge and to
teach me how to take responsibility.
THANK YOU!