FOUR WEEKS TRAINING REPORT

AT
DAWN MOTORS PRIVATE LIMITED

PROJECT REPORT

SUBMITTED BY
BAJRANGI
&
JIVESH VERMA
June 2021

PUNJAB TECHNICAL UNIVERSITY

JALANDHAR, INDIA
FOUR WEEKS TRAINING REPORT
AT
DAWN MOTORS PRIVATE LIMITED

PROJECT REPORT
SUBMITTED BY
BAJRANGI
&
JIVESH VERMA
University Roll no. 1917654/1917655
Under the Supervision of
DR. HARMESH LAL
DR. SURJIT KUMAR GANDHI

PCTE INSTIUTE OF ENGINEERING & TECHNOLOGY

June 2021
PUNJAB TECHNICAL UNIVERSITY
JALANDHAR, INDIA
 ACKNOWLEDGEMENT

I Express my sincere gratitude to Dr. Harmesh lal , Head of Department Mechanical Engineering,
PCTEIET, Baddowal, Ludhiana, Punjab, for his continuous encouragement and supervision
throughout the course.

I would like to place on record my deep sense of gratitude to Er. Divanshu Gupta , Dept. of
Mechanical Engineering, PCTEIET, Baddowal, Ludhiana, Punjab for their generous guidance, help
and useful suggestions.

I also wish to extend my thanks to Mr. Bobby, for their kind help and guidance for operating the
machines and providing useful information.

I am extremly thankful to Dr. Surjit Kumar Gandhi, Director, PCTEIET, Baddowal, Ludhiana Punjab,
for providing me infrastructural facilities to work in.

I would also like to extend my thanks to my loving parents for helping me, supporting me and
encouraging me to perform this work.

BAJRANGI
&
JIVESH VERMA
 TABLE OF CONTENTS

1) INTRODUCTION........................................................................................5
2) INFRASTRUCTURE..................................................................................11
3) FORGING....................................................................................................14
4) HEAT TREATMENT..................................................................................17
5) MACHINE SHOP........................................................................................18
6) CNC MACHINING.....................................................................................34
7) INSEPECTION AND TESTING................................................................39
8) MAINTENANCE.........................................................................................43
9) TABLE OF CA FORK(PROJECT).............................................................44
 INTRODUCTION

Company Profile

Dawn Engineering Enterprises, established in

the year 1976, is a known name in the industry
as a dependable manufacturer & supplier of a
vast & flawless range of Tractor Parts,
Commercial Vehicle Parts and Forged
Components. Their product line is appreciated
and demanded in the
market for its world-class quality standards and high reliability. Our quality auditors
check these products before their dispatch, to ensure that our customers get only quality
assured range of products. Offering Forged Tractor Parts, Tractor Linkage Parts, Lift
Arm Assemblies, Steering Control Levers, Tractor Forks, Commercial Vehicle Parts,
Auto Forks, Joint Flanges, Three Point Linkage Assemblies, Gear Box Components,
CNC Turning Components, PTO Components, Sheet Metal Components, Ram Cylinder
Arm etc.

The unit of Dawn Group is located in the northern region of INDIA, in the well known
city of Ludhiana, which is famous for it's engineering and manufacturing capabilities in
the state of Punjab. Our company is located on the Chandigarh Road. It is
approximately 18 Kms. away from the Ludhiana Junction and approximately 19 Kms
away from the main bus stand of Ludhiana city. They are easily accessible from either
of the points. Company has also got two more units located in Ludhiana and Bhopal.

The company is working as a supplier of original equipment & parts for almost all the
major tractor manufacturing companies and commercial vehicle manufacturing
companies. As for forging, DAWN Group has a complete in house solution for forging
 products with Hot Drop Forged hammering capacity from 0.5 ton to 1.5 tons (0.5, 1.0,
1.25, 1.50 and 2 tons), independent die development facilities like VMC and Wire Cut
with competent staff, latest hardware and software technology for CAD / CAM purpose
and in house heat treatment and shot blasting shop.

Over the years, we are considered as one of the reliable and trusted source of precisely
engineered Tractor Parts. The two most important factors of our company that have
helped us satisfy the diverse needs and demands of the clients are our ultramodern
production facilities and skilled workforce. Our strict adherence to set industrial
guidelines and stringent quality control system in our production process enables us to
produce an excellent range of tractor parts for the clients

Mission
Dawn has a single mission on mind i.e. client satisfaction. They deliver the best solutions to
their clients while giving them options to weigh up latest options available. The company is
run keeping mutual concerns in mind such as integrity, honesty, excellence and genuine
improvements. Every individual at Dawn Group is determined to provide quality products
and is committed towards clients and deadlines as well. By honoring our obligations, Dawn
Group is strong minded enough to pull off the missions set earlier and to help their clients be
the most cutthroat and the best in the industries / fields they are from.

Vision

“Dawn Group is a committed for customer satisfaction through quality products, timely
delivery and continuous improvement through quality management system and
procedure”.

Their clients are like the members of DAWN family and they assist them in the very best
manner to have profits and business expansion.

Core Values

Honesty & Integrity Customer Delight

Innovation & Creativity Transparency
 PRODUCTS

Tractor Parts & Agriculture Implements:

Commercial Vehicle Parts:

Two Wheeler Parts:

Scaffolding Accessories:
Frameworks Accessories:

Flanges:
 CLIENTS

Tata Motors Limited Escorts Limited Eicher Motors Limited Mahindra & Mahindra
Limited

Swaraj Mazda Limited Royal Enfield Limited Bharat Heavy International Tractors
Electricals Limited Limited

SAME DEUTZ- Tafe Motors & Tractors Panjab Tractors International Car
FAHR Limited Limited Limited Motors Limited
 INFRASTRUCTURE

Dawn Group industries of a state-of-the-art infrastructure with world-class facilities. All its
manufacturing plants possess sophisticated and hi-tech machines which helps in the production of
fully finished Transmission and Differential components with finest quality.

Forging

 Forging Hammers
 Standard Room 2 Ton Capacity Hammer
 1.5 Ton Capacity Hammer
 1 Ton Capacity Hammer
 0.5 Ton Capacity Hammer
 Induction Heater for Billet heating

Presses for trimming and punching

 Screw Presses
 Mechanical Presses for
 Knuckle Joint Presses

Tool Room for forging and Trimming Die

 Shapers
 Planner
 VMC
 Lathe Machines
  Wire Cut Machine for Trimming dies
 Software for Cad/Cam

For Machining Facility or Production

 C.N.C. Vertical Milling Centers

 CNC Turning Center
 Broaching (Spline Broaching, Key way Broaching and Round
 Broaching)
 Copy Turning.
 Boring, Cylindrical Grinding, Center-less Grinding, Angular Grinding,
Surface Grinding
 Milling of Both Types Horizontal and vertical
 Sheet Metal Forming, Shearing and Cutting etc.
 CNC Plasma Cutting

Heat Treatment

The Heat Treatment Facility at Dawn is well equipped with modern state of the art Sealed Quenched
Furnaces, Carburizing Furnace, Induction Hardening machines, Rotary Hearth Furnaces and
Isothermal annealing plant etc.The heat treatment is further supported by well-equipped laboratories
comprising of Automatic Micro Hardness Tester, Microscopes and Jominy hardenability testing
equipments.

Grinding

At Dawn Grinding Operations are carried on various CNC and Conventional grinding machines of
various make to achieve optimum level of accuracy as per the customers’ specifications.
 FORGING SHOP

Forging involves heating of a metal stock to a desired temperature; enable it to acquire sufficient
plasticity followed by the operations like hammering, bending & piecering etc. to give it the desired
shape. The forging process is very important and has indispensable position among the various
manufacturing processes generally adopted in the workshops due to some reasons i.e. it refines the
structures of metal, it renders the metal stronger by setting the direction of the grains & it effects
considerable saving in time the labour and material as compared to the production of same by cutting
from a solid stock and then shaping it.

Fig. Drop forging

 Working Procedure in Forging Shop

Material cutting: - This is the first step which is involved in forging. After the material is
received & inspected it is sent for the material cutting. In material cutting operation the material is cut
in accordance with the required dimensions. The material cutting is done on band saw machines
which are fully automatic in operation. After the material cutting is done the material is sent into the
forging shop.

Heating: - This is the second step which is involved. In this step the material is heated to the
forging temperature in the furnace. The forging temperature is 1250-1300 degrees. The furnaces
which are used are oil-fired furnaces & they can be either pusher type or batch type. After the material
is heated it is sent to the forging machines. The process of heating the stock can be divided into two
stages:-

First stage (Preheating zone): - In this stage the temperature to which the stock is heated is 500-700
degrees.

Second stage(Full heating zone): -In this stage the temperature is 1260-1300 degrees.

Forging: - In this step the material is forged on either a drop hammer or a forging press or on the
up-setter. The type of the machine which is to be used depends upon the shape & size of the
component to be forged.

Trimming: - In this operation the excess & unwanted material is removed from the forged
component. After forging operation is done then the forged component is passed to the trimming press
for the material removal.
Various hammers present in shop with specifications

1. Friction Drop Hammers : 4

1 Ton- 2 no
2 Ton- 2 no

2. Horizontal Upsetter: 1
600 Ton

3. Mechanical Presses: 4
400 Ton, 500 Ton

630 Ton, 1300 Ton

Temperature Measurement Instruments Used in Forging Shop

1. Thermocouple
2. Optical Pyrometer

The thermocouples are located at suitable heating zones inside the furnace & they measure the
temperature of the heating zone & this temperature is represented on the digital temperature indicator
to the operator.

Furnace oil used in forging shop

The furnance oil which is used in the furnances is the residual furnace oil. Fuel consumption in the
furnances is 100 liters.
 HEAT TREATMENT

NORMALIZING

Normalizing operation is done so as:-

a) To improve the machinability.

b) To modify the refine the grain structure.
c) To obtain relatively good ductility without reducing the hardness and strength.

Generally , the normalizing temperature is 920-930 `c and is done in batch furnance. Then the
component is placed at that temperatute Upto 1 hour or as per reuirement and then it is air cooled till
the temperature Reaches the room temperature.

ANNEALING

Metallic materials consist of a microstructure of small crystals called “grains” or crysatallites. The
nature of the grains (i.e. grain size and composition) determines the overall mechanical behaviour of
the metal. Heat treatment provides an efficient way to manipulate the properties of the metal by
controlling rate of diffusion and the rate of cooling with in the microstructure. Annealing is a
technique used to recover cold work and relax stresses within the metal.

Annealing typically results in a soft ductile metal. When an annealed part ia allowed to cool in the
furnace, it is called a “full anneal” heat treatment. When an annealed part is allowed to cool in the
furnace and allowed to cool in air. It is called a “normalizing” heat treatment. During annealing, small
grains recrystallize to form larger grains.

Isothermal annealing
In this process the components is heated as per desired temperature 640C hold for 30 minutes and
cooled fast below hypoeutecoid steel temperature for sufficient period for completion of
transformation and then cooled to room temperature at air.

It shows following advantage over conventional annealing

 Improved machinability
 Improved surface finish

MACHINE SHOP

After Forging and Pre Heat Treatment the next process in making a part is machining, where the exact
dimensions of the part is obtained. Machining is any of various processes in which a piece of raw
material is cut into a desired final shape and size by a controlled material-removal process

Much of modern day machining is carried out Computer numerical control (CNC), in which
computers are used to control the movement and operation of the mills, lathes, and other cutting
machines.

Types of Machining operation

There are many kinds of machining operations, each of which is capable of generating a certain part
geometry and surface texture.

Turning:- In turning a cutting tool with a single cutting edge is used to remove material from a
rotating workpiece to generate a cylindrical shape. The speed motion is provided by rotating the
workpiece, and the feed motion is achieved by moving the cutting tool slowly in a direction parallel to
the axis of rotation of the workpiece.

Drilling:- Drilling is used to create a round hole. It is accomplished by a rotating tool that typically
has two or four helical cutting edges. The tool is fed in a direction parallel to its axis of rotation into
the workpiece to form the round hole.
Boring:- In boring, a tool with a single bent pointed tip is advanced into a roughly made hole in a
spinning workpiece to slightly enlarge the hole and improve its accuracy. It is a fine finishing
operation used in the final stages of product manufacture.

Milling:- In milling a rotating tool with multiple cutting edges is moved slowly relative to the
material to generate a plane or straight surface. The direction of the feed motion is perpendicular to
the tool's axis of rotation. The speed motion is provided by the rotating milling cutter.

Broaching :- Broaching is a machinig process that uses a toothed tool, called a broach, to remove
material. There are two main types of broaching: linear and rotary. In both processes the cut is
performed in one pass of the broach, which makes it very efficient.

Lathe Machines Used in Industry

A lathe machine is used for the shaping and machining of various work pieces.
Explanation of the standard components of most lathes:

Bed: Usually made of cast iron. Provides a heavy rigid frame On which all the main
components are mounted.

Ways Inner and outer guide rails that are precision machined parallel to assure accuracy of
movement.

Headstock: mounted in a fixed position on the inner ways, usually at the left end. Using a chuck, it
rotates the work.

Gearbox: inside the headstock, providing multiple speeds with a geometric ratio by moving levers.

Spindle: Hole through the headstock to which bar stock can be fed, which allows shafts that are up to
2 times the length between lathe centers to be worked on one end at a time.

Chuck: 3-jaw (self centering) or 4-jaw (independent) to clamp part being machined.

Chuck: allows the mounting of difficult workpieces that are not round, square or triangular.

Tailstock: Fits on the inner ways of the bed and can slide towards any position the headstock to fit the
length of the work piece. An optional taper turning attachment would be mounted to it.

Tailstock Quill: Has a Morse taper to hold a lathe center, drill bit or other tool.

Carriage: Moves on the outer ways. Used for mounting and moving most the cutting tools.

Cross Slide: Mounted on the traverse slide of the carriage, and uses a handwheel to feed tools into the
workpiece.

Tool Post: To mount tool holders in which the cutting bits are clamped.

Compound Rest: Mounted to the cross slide, it pivots around the tool post.

Apron: Attached to the front of the carriage, it has the mechanism and controls for moving the
carriage and cross slide.

Feed Rod: Has a keyway, with two reversing pinion gears, either of which can be meshed with the
mating bevel gear to forward or reverse the carriage using a clutch.

LeadScrew: For cutting threads.

Split Nut: When closed around the lead screw, the carriage is driven along by direct drive without
using a clutch.

Quick Change Gearbox: Controls the movement of the carriage using levers.
Steady Rest: Clamped to the lathe ways, it uses adjustable fingers to contact the workpiece and align
it. Can be used in place of tailstock or in the middle to support long or unstable parts being machined.

Follow Rest: Bolted to the lathe carriage, it uses adjustable fingers to bear against the workpiece
opposite the cutting tool to prevent deflection.

TYPES OF LATHES
There are three general types of lathe machines:-

Engine lathes. These are probably the most popular among the lathe machines. In fact, no
machine shop is seen without this type of lathe. The good thing about engine lathes is that it can be
used in various materials, aside from metal. Moreover, the set-up of these machines is so simple that
they are easier to use. Its main components include the bed, headstock, and tailstock. These engine
lathes can be adjusted to variable speeds for the accommodation of a wide scope of work. In addition,
these lathes come in various sizes.

Turret Lathes. These types of lathes are used for machining single workpieces sequentially. This
means that several operations are needed to be performed on a single work piece. With the turret
lathes, sequential operations can be done on the work piece, eliminating errors in work alignment.
With this set-up, machining is done more efficiently. Correspondingly, time is saved because there is
no need to remove and transfer the work piece to another machine anymore.

Special Purpose Lathes. As the name implies, these lathes are used for special purposes such
as heavy-duty production of identical parts. In addition, these lathes also perform specific functions
that cannot be performed by the standard lathes. Some examples of special purpose lathes include the
bench- type jewelers’ lathes, automatic lathes, crankshaft lathes, duplicating lathes, multispindle
lathes, brakedrum lathes, and production lathes among others

Various types of operations perfoemed on lathes

Facing

Facing is the process of removing metal from the end of a workpiece to produce a flat surface. Most
often, the workpiece is cylindrical, but using a 3or 4 jaw chuk you can face rectangular or odd-shaped
work to form cubes and other non-cylindrical shapes.When a lathe cutting tool removes metal it
applies considerable tangential (i.e. lateral or sideways) force to the workpiece.

Turning

Turning is a machining process in which a cutting tool typically a non-rotary tool bit describes
a helical toolpath by moving more or less linearly while the workpiece rotates. The tool's axes of
movement may be literally a straight line, or they may be along some set of curves or angles, but they
are essentially line. Usually the term "turning" is reserved for the generation of external surfaces by
this cutting action.

Chamfer

Chamfer is a beveled edge connecting two surfaces. If the surfaces are at right angles, the chamfer
will typically be symmetrical at 45 degrees.

"Chamfer" is a term commonly used in mechanical and manufacturing engineering Special tools such
as chamfer mills and chamfer planes are available.

Boring
A boring is the process of enlarging a hole that has already been drilled or cast, by means of a single
point cutting tool . Boring is used to achieve greater accuracy of the diameter of a hole, and can be
used to cut a tapered hole. Boring can be viewed as the internal-diameter counterpart to turning which
cuts external diameters

Reaming

Reamer is a type of rotary cutting tool used in operation . Precision reamers are designed to enlarge
the size of a previously formed hole by a small amount but with a high degree of accuracy to leave
smooth sides. There are also non-precision reamers which are used for more basic enlargement of
holes or for removing burrsThe process of enlarging the hole is called Reaming.
 DRILLING
Drilling is a cutting process that uses a drill bit to cut or enlarge a hole of circular cross-section in
solid materials. The drill bit is a rotary cutting tool, often multipoint. The bit is pressed against the
workpiece and rotated at rates from hundreds to thousands of revolutions per minute. This forces the
cutting edge against the workpiece, cutting off chips from the hole as it is drilled.

Types of Drilling Machines

There are many different types or configurations of drilling machines, but most drilling machines will
fall .into four broad categories: upright sensitive, upright, radial, and special purpose.

Upright Sensitive Drill Press

The upright sensitive drill press is a light-duty type of drilling machine that normally incorporates a
belt drive spindle head. This machine is generally used for moderate-to-light duty work. The upright
sensitive drill press gets its name due to the fact that the machine can only be hand fed. Hand feeding
the tool into the workpiece allows the operator to "feel" the cutting action of the tool. The sensitive
drill press is manufactured in a floor style or a bench style.

Fig. Upright sensitive drill press

Upright Drill Press

The upright drill press is a heavy duty type of drilling machine normally incorporating a geared drive
spindle head. This type of drilling machine is used on large hole-producing operations
that typically involve larger or heavier parts. The upright drill press allows the operator to hand feed
or power feed the tool into the workpiece. The power feed mechanism automatically advances the tool
into the workpiece. Some types of upright drill presses are also manufactured with automatic table-
raising mechanisms.

Fig. Upright drill press

Radial Arm Drill Press

The radial arm drill press is the hole producing work horse of the machine shop. The press is
commonly refered to as a radial drill press. The radial arm drill press allows the operator to position
the spindle directly over the workpiece rather than move the workpiece to the tool. The design of the
radial drill press gives it a great deal of versatility, especially on parts too large to position easily.
Radial drills offer power feed on the spindle, as well as an automatic mechanism to raise or lower the
radial arm. The wheel head, which is located on the radial arm, can also be traversed along the arm,
giving the
machine added ease of use as well as versatility. Radial arm drill presses can be equipped with a
trunion table or tilting table. This gives the operator the ability to drill intersecting or angular holes in
one setup.

Fig. Radial arm drill press

Milling

Milling is the machining process of using rotary cutters to remove material from a workpiece
advancing (or feeding) in a direction at an angle with the axis of the tool. It covers a wide variety of
different operations and machines, on scales from small individual parts to large, heavy-duty gang
milling operations. It is one of the most commonly used processes in industry and machine shops
today for machining parts to precise sizes and shapes.

Types of Miliing Machines

Milling machines are a very versatile machine tool. Milling machines are capable of machining one or
two pieces as well as large volume production runs. The milling machine can produce a variety of
surfaces by using a circular cutter with multiple teeth that progressively produce chips as the cutter
rotates as shown in figure.
 Fig. Carbide face mill used on a vertical milling machine.

The advantage of having a circular milling cutter with multiple teeth has led to the design of a large
variety of milling machine types. These different milling machine types can be classified as Knee and
Column, Fixed Bed, Bridge Type, and Special. All of these classifications can have either a vertical or
horizontal spindle configuration. Further classifications of milling machines are made on the basis of
the type of computer numerical control the machine uses.

Knee and column type milling machine

The knee and column type milling machine is a very versatile machine. This type of milling machine
is found primarily in job shops and tool and die shops.

The most distinguishing characteristic of this type of machine is the knee and column configuration .

This type of milling machine is unique in that the table can be be moved in all three directions.

The table can be moved longitudinally in the X-axis as well as in and out on the Y-axis. Since the
table rides on top of the knee, the table can be moved up and down on the Z-axis. There are several
different types of knee and column type milling machines, but they all have the same characteristic.
The knee slides up and down on the column face.
Fig. Horizontal knee and column type milling machine.

Fig. Vertical knee and column type milling machine

Universal knee and column milling machine
The universal knee and column milling is very similar to the plain knee and column milling machine.
The largest difference being the swiveling table housing. The swiveling table housing allows the table
to be swiveled at an angle to the axis of the spindle .

Fig. Universal horizontal knee and olumn milling machine machine with the swivel table.

Vertical knee and column type milling machine

A vertical type knee and column milling machine has the spindle located vertically, parallel to the
face of the column, and perpendicular to the top of the table.

The ram style knee and column type milling machine is a light duty milling machine. This type of
machine is well suited for a variety of tool room work as well as other light duty operations. The head
is mounted on a ram that can be swiveled or brought forward. This allows the head to be brought into
an operating position over most of the table.
 Fig. Ram style knee and column type vertical milling machine.

Broaching

Broaching is a machining process that pushes or pulls a broach over or through the surface being
machined. Its high-production, metal-removal process is sometimes required to make one-of-a-kind
parts.. Early broaching applications were cutting keyways in pulleys and gears. Today, almost every
conceivable type of form and material can be broached. It represents a machining operation that,
while known for many years, is still in its infancy. New uses for broaching are being devised every
day.

Broaching is similar to planing, turning, milling, and other metal cutting operations in that each tooth
removes a small amount of material.

Fig. Cutting action of a broaching tool.

The broaching tool has a series of teeth so arranged that they cut metal when the broach is given a
linear movement as indicated in figure 1. The broach cuts away the material since its teeth are
progressively increasing in height.

Fig. Typical push keyway broaching tools and a shim

Properly used, broaching can greatly increase productivity, hold tight tolerance,and produce precision
finishes. Tooling is the heart of broaching. The broach tool's construction is unique for it combines
rough, semi-finish, and finish teeth in one tool.

Fig. Parts of a broaching tool.

There are two types of broaching procedures: internal broaching and external broaching. For exterior
broaching, the broach tool may be pulled or pushed across a workpiece surface, or the surface may
move across the tool. Internal broaching requires a starting hole or opening in the workpiece so the
tool can be inserted. The tool, or workpiece, is then pushed or pulled to force the tool through the
starter hole.
Almost any irregular cross-section can be broached as long as all surfaces of the section remain
parallel to the direction of broach travel (Figure 4). Helical cuts can also be produced by twisting the
broach tool as it passes the workpiece surface.

Fig. Different types of broaches.

In conclusion, it may be said that the broach tool and the broaching process are versatile and
important and that anyone who works in the field of metals, woods, or plastics should be familiar with
them.

Grinding
Grinding is an abrasive machining process that uses a grinding as the cutting tool. A wide variety of
machines are used for grinding: Grinding is used to finish workpieces that must show high surface
quality and high accuracy of shape and dimension

A Grinding machine, often shortened to grinder, is a machine tool used for grinding which 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 workpiece via shear deformation.

. As the accuracy in dimensions in grinding is on the order of 0.000025 mm, in most applications it
tends to be a finishing operation and removes comparatively little metal, about 0.25 to 0.50 mm depth.
However, there are some roughing applications in which grinding removes high volumes of metal
quite rapidly. Thus, grinding is a diverse field.

Grinding machine main parts

The grinding machine consists of a bed with a fixture to guide and hold the work piece, and a power-
driven grinding wheel spinning at the required speed. The speed is determined by the wheel’s
diameter and manufacturer’s rating. The user can control the grinding head to travel across a fixed
work piece, or the work piece can be moved while the grind head stays in a fixed position. Fine
control of the grinding head or tables position is possible using a vernier calibrated hand wheel, or
using the features of numerical controls.

Grinding machines remove material from the work piece by abrasion, which can generate substantial
amounts of heat. To cool the work piece so that it does not overheat and go outside its tolerance
grinding machines incorporate a coolant. The coolant also benefits the machinist as the heat generated
may cause burns. In high-precision grinding machines (most cylindrical and surface grinders), the
final grinding stages are usually set up so that they remove about 200 nm (less than 1/10000 in) per
pass - this generates so little heat that even with no coolant, the temperature rise is negligible.

Types of Grinder

Suface Grinder

Fig. Sufrace grinder

These machines include the :

 Belt grinder:- which is usually used as a machining method to process metals and other
materials, with the aid of coated abrasives. Sanding is the machining of wood; grinding is the
common name for machining metals. Belt grinding is a versatile process suitable for all kind of
applications like finishing, deburring, and Stock removal.
 Bench grinder:- which usually has two wheels of different grain sizes for roughing and finishing
operations and is secured to a workbench or floor stand. Its uses include shaping tool bits or
various tools that need to be made or repaired. Bench grinders are manually operated.

 Cylindrical grinder:- which includes both the types that use centers and the centerless types. A
cylindrical grinder may have multiple grinding wheels. The workpiece is rotated and fed past the
wheels to form a cylinder.It is used to make precision rods, tubes, bearing races, bushings, and
many other parts.
 Surface grinder:- which includes the wash grinder. A surface grinder has a "head" which is
lowered, and the workpiece is moved back and forth past the grinding wheel on a table that has a
permanent magnet for use with magnetic stock.
 Tool and cutter grinder:- These usually can perform the minor function of the drill bit grinder,
or other specialist tool room grinding operations.
 Gear grinder:- which is usually employed as the final machining process when manufacturing a
high-precision gear. The primary function of these machines is to remove the remaining few
thousandths of an inch of material left by other manufacturing methods .
 CNC MACHINING

NC & CNC
Numerical control (NC) is a method of automatically operating a manufacturing machine based on a
code letters, numbers and special characters.

The numerical data required to produce a part is provided to a machine in the form of program, called
part program or CNC (computer numerical control).

The program is translated into the appropriate electrical signals for input to motors that run the machine.

A CNC machine is an nu.merical control machine with the added feature of an on board computer. The
computer is referred to as the machine control unit (MCU)

CNC LATHES
They cut metal that is often turning at fast speeds.

CNC lathes are able to make fast, precision cuts using indexable tools and drills with complicated
programs.Normally, they cannot be cut on manual lathes.

They often include 12 tool holders and coolant pumps to cut down on tool wear
 Fig. Cnc lathe

CNC Turning Centers

CNC Turning Centers are capable of executing many different types of lathe cutting operations
simultaneously on a rotating part.

Fig. CNC Turning Centers

Advantages of CNC Machines

Ease of Use
a) CNC machines are easier for beginners

b) Operation of several CNC machines at same time.

c) Some CNC machines don’t need any operator

d) Call their operator in case of the emergencies.

High Efficiency

a) operate almost continuously 24 hours a day, 365 days a Year.

Expanding Options

a) Expand the machine's capabilities with Software changes and updates.

No Prototyping

a) New programmes provide elimination build a prototype, save time and money.

Precision

a) Parts are identical to each other.

Reduce Waste

a) Reduce waste as errors allows minimize wasted material.

Disadvantage of CNC Machines

a) costs quite a lot more than conventional machinery.

b) does not eliminate the need for expensive tools.

c) expensive to repair.

Vertical Machining Center(VMC)

A Vertical machining center (VMC) is a machining center with its spindle in a vertical orientation.
High-end VMCs are high-precision machines often used for tight-tolerance milling, such as fine die
and mold work. Low-cost vertical machining centers are among the most basic CNC machine tools. A
low-cost VMC is often a new machine shop’s first machine tool purchase.

Fig. Vertical Machining Center

Most CNC milling machinesare 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, and 2.5D surfaces such as relief sculptures. When combined with the use of conical tools
or a ball nose cutte, it also significantly improves milling precision without impacting speed,
providing a cost-efficient alternative to most flat-surface hand-engraving work.
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). Horizontal milling machines also have a C or Q axis, allowing the
horizontally mounted workpiece to be rotated, essentially allowing asymmetric andeccentric turning .
The fifth axis (B axis) controls the tilt of the tool itself. When all of these axes are used in conjunction
with each other, extremely complicated geometries, even organic geometries such as a human head
can be made with relative ease with these machines. But the skill to program such geometries is
beyond that of most operators. Therefore, 5-axis milling machines are practically always programmed
with CAM.
 INSEPECTION AND TESTING

Vernier Scale
A vernier scale is a device that lets the user measure more accurately than could be done by
reading a uniformly-divided straight or circular measurement scale. It is scale that indicates where the
measurement lies in between two of the marks on the main scale.

Fig. Vernier scale

Micrometer
A micrometer sometimes known as a micrometer screw gauge, is a device incorporating a
calibratedscrew used widely for precise measurement of small distances in mechanical
engineering and machining as well as most mechanical trades, along with other metrological.
Micrometers are usually, but not always, in the form of calipers, which is why micrometer caliper is
another common name. The spindle is a very accurately machined screw. The object to be measured is
placed between the spindle and the anvil. The spindle is moved inward by turning the ratchet knob or
thimble until the object to be measured is lightly touched by both the spindle and the anvil.

Fig, Micrometer
The sleeve through which the spindle moves is graduated with marks 0.025 inch (0.635 mm) apart,
with the number 1 on the sleeve representing 0.1 inch (2.54 mm), 2 representing 0.2 inch complete
turn for each 0.025 inch on the sleeve scale, and the thimble scale is graduated from 0 to 25. Thus use
of the two scales permits a reading to the nearest 0.001 inch (0.025 mm).

Plug gauge
These gauges are referred to as plug gauges; they are used in the manner of a plug. They are generally
assembled from standard parts where the gauge portion is interchangeable with other gauge pieces and
a body that uses the collet principle to hold the gauges firmly. To use this style of gauge, one end is
inserted into the part first and depending on the result of that test, the other end is tried.

Fig. Plug gauge

In figure, the top gauge is a thread gauge that is screwed into the part to be tested, the labeled GO end
will enter into the part fully, the NOT GO end should not. in plug gauge used to check the size of a
hole, the one end is the GO and another endis NOT GO.

Snap gauge
Snap gauges are often used when a large quantity of work pieces must be inspected. The snap gauge
has four anvils or jaws, the first one or pair (outermost) are set using the upper limit (tolerance) of the
part and the inner set adjusted to the lower limit of the part. A correctly machined part will pass the
first set of jaws and stop at the second — end of test. In this manner a part may be checked in one
action, unlike the plug gauge that needs to be used twice and flipped to access the second gauge.
 Fig. Snap gauge

Dial Test Indicator

A dial test indicator, also known as a lever arm test indicator or finger indicator, has a smaller
measuring range than a standard dial indicator. A test indicator measures the deflection of the arm, the
probe does not retract but swings in an arc around its hinge point. The lever may be interchanged for
length or ball diameter, and permits measurements to be taken in narrow grooves and small bores
where the body of a probe type may not reach. The model shown is bidirectional, some types may
have to be switched via a side lever to be able to measure in the opposite direction. These indicators
actually measure angular displacement and not linear displacement; linear distance is correlated to the
angular displacement based on the correlating variables

Fig. Dial indicater

Significance

Metal parts when they are machined and/or welded can become stressed during those processes.
Those stresses can reveal themselves in the from of small fissures or cracks in the metal joints. These
stress fractures at times may be difficult to see with the human eye. A method of employing small
magnetic particles and a fluorescent dye was implemented to highlight any abnormalities of the
machining and joining those metal parts.

Features

After the part is sprayed with the magnetic particle dye solution, a handheld electro magnet is passed
over the part. The magnetic field causes the small particles in the solution to align themselves with
that magnetic field. Generally if the part being tested has no small fissures or cracks, the magnetic
particles simply lay on the surface.

Identification

A testing part that does contain a crack or fracture will hold the solution in that small fissure, and once
the magnetic field is passed over the area, a "line" of particles will form. This identification line will
fill into the fissure and the particles will remain in place due to the magnetic field that was induced.

Some fissures are so small that it may be difficult to identify the abnormality with the human eye. The
dye that is employed in the testing solution is a fluorescent base. This liquid fluorescent base is
readily seen under a black light illumination source. Typically the magnaflux light test is performed in
a darkened area so the black light illumination can be seen.
 MAINTENANCE
Maintenance involves fixing any sort of mechanical plumbing or electrical device should it become
out of order or broken. It also includes performing routine actions which keep the device in working
order or prevent trouble from arising .

Types of Maintenance

Break-down maintenance : The long term continously working on the machines, the machine parts
& its components gets damaged or breakdowndue to wear & tear or due to over running. The
problems may occur due to electrical faults, over-running, noise or vibration etc. We should check the
machines regulerly on time before working on it.

Preventive maintenance : The care and servicing by personnel for the purpose of maintaining
equipment and facilities in satisfactory operating condition by providing for systematic
inspection, detection, and correction of incipient failures either before they occur or before they
develop into major defects.

Corrective maintenance : Corrective maintenance is a task performed to identify, isolate, and rectify
a fault so that the failed equipment, machine, or system can be restored to an operational condition
within the tolerances or limits established for in-service operations.

Condition-based maintenance : Condition-based maintenance shortly described, is maintenance

when need arises. This maintenance is performed after one or more indicators show that equipment is
going to fail or that equipment performance is deteriorating. It was introduced to try to maintain the
correct equipment at the right time.
 TABLE OF CA FORK(PROJECT)

S.No. Operation Control Size Inspection Inspection All Dimensions in mm Clamping Machine Open Total
Name Meter Time Operation Time
Time
1 2 3 4 5
1 Main Drilling 25±.30 VC 25.2 25 25.5 25.1 25.2 10sec 2Min 6sec 2.16sec
R 20±.50 VC 19.60 19.70 19.66 20.0 20 (2pc.)
R BG 18.10 18.08 18.40 18.22 18.24
17.50±1.50 VC 26.3 26.4 26.2 26 26.4
25.00±1.50
2 Facing 72±.50 VC 72.76 72.66 72.34 72.76 72.7 6sec 21sec 7sec 34sec
±0.15 HG 0.02 1.05 0.05 0.03 0.02 (1pc.)

3 Rough Ø25.50±.20 VC+PG 25.5 25.5 25.4 25.5 25.5 11sec 5sec 4sec 20sec
Broching ±0.10 HG 0.10 0.15 0.08 0.10 0.09 (1pc.)
4 Total Length 70.50±.30 VC 70.50 70.46 70.66 70.7 70.42
±0.10 HG 0.07 0.08 0.10 0.08 0.09
5 Champhering 1.50x450 VC+BG 1.50x 1.50x 1.50x 1.50x 1.50x 3sec 14sec 3sec 21sec
Both Side 450 450 450 450 450
6 Final Ø26.50±.033 PG 26.48 26.48 26.48 26.50 26.50
Broching ±0.10 BOR
7 Twining ±0.10 HG 0.09 0.1 0.08 0.1 0.07 3sec 5sec 3sec 11sec
Turning 93.00±0.50 VC 93.7 94 93.8 93.4 93.5
8 Milling R 16 RG 18.44 18.64 18.64 18.74 18.14 43sec 1:22sec 31sec 2:36sec
Operation 18.20/19.0 VC 0.06 0.10 0.09 0.15 0.18 (2pc.)
and Radius ±0.20 HG 10.20 10.10 10.06 10.18 9.96
Cutting 10.00±0.30 HG 69.92 69.88 69.98 69.64 70.20
CD 70±0.50 HG
9 R Grinding R 16 RG 18.34 18.5 18.46 18.2 18.14 2sec 48sec 2sec 52sec
18.00±0.50 VC 70.04 69.96 69.98 70.08 70.02 (1pc.)
CD 70±0.50 HG 0.04 0.05 0.04 0.03 0.04
±0.05 HG+Dial
10 Side Milling 23.00±0.20 VC+HG 23.02 23.18 22.90 23.08 23.08 11sec 1:48sec 5sec 2:4sec
±0.20 0.13 0.15 0.14 0.10 0.13
450±30 BG (2pc.)
11 Gap Milling 66.05±0.20 VC+Gg 66 66.08 66.10 66 66 42sec 56sec 19sec 1:57sec
±0.10 HG 0.08 0.10 0.08 0.10 0.08 (2pc.)
68.35±0.80 HG 68.12 68.10 68.26 68.30 68.24
12 Dub Milling 3.00±0.50 HG 3.30 3.10 2.94 2.98 3.08 29sec 1:43sec 18sec 2:20sec
1030 BG (2pc.)
Cutter dia
R55
13 Dub Dibbring 1x450 visual Bur Removing area 3sec 8sec 3sec 11sec
14 Dub Grinding 1x450 Visual Bur Removing area
check
15 All Dibbring 1x450 Visual Bur Removing area 3sec 15sec 3sec 21sec
check (1pc.)
16 Drilling Ø8.90±0.20 VC+PG 8.96 8.968 8.98 9.06 9.02 6sec 12sec 4sec 22sec
CD 40±0.10 VC+HG 40.04 39.94 39.98 40.08 40.06 (1pc.)
Ref450 10.00±0.30 HG+SPG 10.02 9.96 9.98 9.90 9.88
±0.10 HG 0.09 0.08 0.09 0.10 0.08
17 Champher 1x450 VC+BG 1.2x 1.1x 1x450 1.x450 1.1x 5sec 8sec 3sec 16sec
 Hall Ø8.90 450 450 450 (1pc.)
18 Thearding M 10x1 T.P.G 40.02 40.06 39.98 40.02 40.40 5sec 30sec 4sec 39sec
CD 40±0.1 M 10X1 9.86 9.92 10.02 10.10 10..05 (1pc.)
Ref450 10.00±0.30 VC 0.10 0.09 0.08 0.08 0.07
±0.10 HG
19 Furnishing Ø26.50±.03 PG OK OK OK OK OK
Tool
20 Dial gauze ±0.05 Dial 0.02 0.03 0.01 0.03 0.02
+Radius 10.00 ±0.30 OK OK OK OK OK OK
21 Visual Check 1x450 Visual BOR Ø26.50 Finishing
Check All Thread M10x1
Operation All check=1.5x450
22 Dispatch Daily Dispatch=300+200+180+250 or depends on electricity or machinery