Final Report (Akash)

CONTENTS
Title Page no
CHAPTER1:DISCRIPTION OF THCOMPANY 1-5

1.1:Title of the company
1.2:products and service details
1.3: Achivements of vijayalaxmi group of companies
CHAPTER2:INTRODUCTION 6-7
2.1:Introduction On CNC And VMC Machine
2.2: Computer numerical control (CNC)
2.3:vertical milling machine (VMC)
CHAPTER3:PROJECT DETAILS 8-10
3.1: Project Title
3.2:Raw Material Details
3.3:Raw Material Diagram
3.4:Port Cell Diagram
CHAPTER4:INSPECTION 11-12
4.1:Raw Material Inspection
4.2:Working Job Details
4.3:98024 1st Side Finish Turn
4.4:98024 2nd Side Finish Turn
CHAPTER5:PROCEDURE 13-17
5.1:Job Procedure
5.2:selection of machine for each operation
CHAPTER 6:G Codes And M Codes 18
6.1:G Codes
6.2:M Codes
CHAPTER 7: OPERATIONS 19-23
7.1: Explanation Of Operation
7.2: Line Inspection Report
7.4: Safety
7.5: Industrial Safety
CHAPTER 8: FINAL INSPECTION 24-28
8.1: Measuring Instruments
8.2: Measuring Procedure
8.3: Gauges
CHAPTER 9: DISPATCH 29
CHAPTER 10:CUSTOMER FEEDBACK 30
CONCLUSION 31
INTERNSHIP ON CNC MACHINING AND IT’S OPETRATION
CHAPTER:1
DISCRIPTION OF THE COMPANY
1.1 TITLE OF COMPANY-VIJAYALAXMI GEARS:
Established in 2009, Vijayalaxmi Gears has made a name for itself in the list of top supplies of
in India. The supplier company is located in Hubballi, Karnataka and is one of the leading
sellers of listed products.
Vijayalaxmi Gears is listed in Trade India's list of verified sellers offering preme quality of etc.
Buy in bulk from us for the best quality products and service
Vipyalam group consists of three companies operating from Hubballi, Karnataka India.
Vijayalaxms Gear we are into state-of-art of CNC machining having more than 15 years of
experience in complex component machining at affordable cost our end to end solution is
aspirated by Top 100 Companies in India & abroad.
Our product line includes Alternator (AC Generator) with dedicated manufacturing setup and
also maintenance team for after sales.
History of company - Vijayalaxmi Group of industries was started in the year. 1996, the
company is into the state of art of CNC machining from more than 15 years and is being
manufacturing complex component machining at affordable cost.
Vijayalaxmi is an ISO 9001:2015 certified company. Vijayalaxmi Gears are providing super
quality service for machining, electrical motor winding, alternators, gen sets and much more
components.
Vijayalaxmi group of industries are the class-l contractors, authorized service centre for
Crompton greaves and are also into the trading of diesel gen sets, they are also in hiring of gen
sets for various nationalized banks.
Vijayalaxmi has four units in Hubballi, Karnataka at following addresses,
1) Vijayalaxmi Gears, Unit-I, G2&G3, Industrial Estate, Gokul Road, Hubballi 580030.
2) Vijayalaxmi Gears, Unit-II, R-23, M.T. Sagar Industrial Estate, Gokul Road, Hubballi-
580030,
Dept of Mechanical Eng : Klecet Chikodi Page 1

3) Vijayalaxmi Gears, Unit-III, No 36/2, Dasanur, Jodalli Village, Tq: Kalghatgi,

Dharwad-580114. 4) Vijayalaxmi Gears, Unit-IV, Plot No: 14, KIADB Industrial Area,
Rayapur, Dharwad.
4) Vijayalaxmi Gears, Unit-IV, Plot No: 14, KIADB Industrial Area, Rayapur,
Dharwad.
1.2 PRODUCTS AND SERVICE DETAILS:
Products/Service Range
 CNC Machining Job Works
 AC Generators 5KVA To 40KVA
Typical Components Manufactured On Job

 Automobile Components
Work Basis
 All Types Of Precision CNC Turning
Components.
 Drive Shaft
1.3 ACHIVEMENTS OF VIJAYALAXMI GROUP OF COMPANIES:
1) Best Vendor for year- 2007, Customer: Spicer India Ltd.
2) President's award for Best Vendor- 2011, Customer: Spicer India Ltd.
3) Best VSME Supplier for year-2013, Customer- Spicer India Ltd.
4) Best VSME Supplier for year-2014, Customer- Spicer India Ltd.

ABOUT COMPANY:
We partner your thinking to provide superb quality service for machining, electrical motor
winding, alternators, genets and much more. let us introduce ourselves vijayalaxmi group
consists of three companies operating from hubli, karnataka india.
GROUP OF COMPANIES & KEY BUSINESS ACTIVITIES:
 VIJAYLAXMI GEARS - Exclusive vendor of dana anand india pvt.ltd. & dana
fairfield ltd. since from 1996
Total employee strength- 240
 VIJAYLAXMI INDUSTRIES - Manufacturers of alternators and dg sets, lt&ht motor

generator winding,dc motr winding,traction motor winding, institution delaer for escorts
tractors & escorts silent gensets.
Total employee strength - 20
 NKR ENGG.SOLUTIONS PVT.LTD.,&NKR AGENCIES - Hiring of generators

and reconditioning of generators
Total employee strength – 25
 VIJAYALAXMI TRADERS - Premium distributor for acc cement for dharwad

district and authorised dealer for jk &dhanalaxmi cement
Total employee strength – 20
TOTAL EMPLOYEE STRENGTH OF THE GROUP – 305

COMPANY PHOTOS:
HO & UNIT-1
15000 SQ.FT
MACHINERIES :
1. CNC Turnings centres : 53
2. VMC’s : 5
3. Gear Hobbing : 5
4. Surface broaching : 4
5. SPM machines : 9
6. External grinding machines : 2
7. Laser marking machines : 2
8. Dot matrix marking machines : 7
9. Air Compressor : 7
10. Bench grinders : 3
11. DG sets: 3
12. Conventional drilling machines: 8
13. Conventional lathe machines : 3
14. Tool and cutter grinder : 1
15. Bend saw : 1
Total machines- 114

CHAPTER:2
INTRODUCTION
2.1 INTRODUCTION ON CNC AND VMC MACHINE
2.1.1 COMPUTER NUMERICAL CONTROLE (CNC):
Computer numerical control is the numerical control system in which a dedicated computer is
built into the control to perform basic and advanced CNC functions. CNC controls are also
referred to as software CNC systems because most of their control functions are implemented
by the control software programs. CNC is a computer assisted process to control general
purpose machines from instructions generated by a processor and stored in a memory system.
Fig 2.1 Computer numerical control
ADVANTAGES OF CNC SYSTEMS
 CNC machines can be used continuously and only need to be switched off for
occasional maintenance.
 These machines require less skilled people to operate unlike manual lathes/milling
machines etc.
 CNC machines can be updated by improving the software used to drive the
machines.

 Training for the use of CNC machines can be done through the use of “virtual
software”.
2.1.2VERTICAL MACHINING CENTER (VMC):
Vertical Machining has been around in its most basic form for more than 150 years. Yet, it’s
still one of the newest forms of machining technology (turning/lathes is the oldest).
The process of “milling” entails a rotating cutter, or drilling bit, and a movable work table,
which the work piece is affixed to.
The cutter is attached to and rotated in a housing called the “spindle.” Through the sharpness of
the tool and force of the table pushing the material into the cutter, the material yields and is cut
or shaved away as desired.
Fig 2.2 Vetical Milling Machine
ADVANTAGES OF CNC SYSTEMS:
 Simpler structure. The simple structure of VMCs makes it easy to clamp the work
piece in the necessary position
 Better cooling efficiency. Gravity works with the VMC design.
 Easier setup and operation.
 Smaller space requirements.
 Higher accuracy.
CHAPTER:3
PROJECT DETAILS
3.1 PROJECT ON
PRODUCTION AND PROGRAMMING OF “PENTAIR WATER COMPONENT”
Procedure of production and programming of Pentair water component according to customer

diagram.
PART NAME: PORT
 Model: 98024W
 Head Code: K4EE
 Material: SAE351
 Heat Code: CF3M
 Origin Date: 27-11-2009
 Customer: Pentair Water India Pvt. Ltd Verna Goa.
3.2 RAW MATERIAL DETAILS
 A raw material, also known as a feedstock, unprocessed material, or primary

 Commodity, is a basic material that is used to produce goods, finished products, energy,
or intermediate material that are feedstock for future finished products.
 The raw material is sent by the customer and the raw material is made with metals like
Mild steel, stainless steel, aluminum, brass and carbon steel.
 The raw material of Pentair water component 98024 is made up of stainless steel. A
picture of raw material is shown above.
 All raw material have a heat code shown below, the heat code of Pentair water
component is 98024W.

Fig 3.2 Raw material
3.3 RAW MATERIAL DIAGRAM

Fig 3.3 Raw Material Diagram
RAW MATERIAL FLOW CHART:

3.4 PORT CELL DIAGRAM:
Fig 3.4 Port Cell
CHAPTER:4
INSPECTION
4.1 RAW MATERIAL INSPECTION
A raw material inspection is to select materials or item for a manufacturing or processing at

factory at a first stage.Insecption and tests on all aspects of materials as physical,chemical,
AIM”s inspector determine or verify materials the requirements of a specification, regulation
contrat are meet.
Our raw material inspections are a vital step in that process, helping to ensure that your supplier
is to meeting your specifications and giving you insight into the nature of raw materials
 Identity.
 Safety.
 Suitability for your product.

Ultimately, our aim is to give you confidence that you are producing a safe ,high quality
product that meets the expectation of customers and regulatory bodies.
If any defects found it will be sent back to the customer and they will reforge it and send it
back to us. One of defect is shown below.
Fig 4.1 Raw Material
4.2 WORKING JOB DETAILS:
After raw material inspection we have to pass the material with few operation and we have to
turn it according to customers diagram or requirements with exact measurements are with given
tolerance.

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CHAPTER 5
5.1 JOB PROCEDUCE
FLOW CHART
PROCEDURE

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5.2 SELECTION OF MACHINE FOR EACH OPERTAION:

As shown in the above chart we have used cnc machine (computer numerical controle) and
vmc (vertical machineing center) for all operation.
5.2.1 MACHINE DETAILS:
COMPUTER NUMERICAL CONTROL (CNC):
Cnc machining is a term commonly used in manufacturing and indusbal applications, but endly
what does the acronym cnc stand for and what is a cnc machine?
The term cnc stands for computer numerical control, and the cnc machining definition is that is
a subtractive manufacturing process which typically employs computerized controls and
machine custom-designed part.
This procace range of materials, including metals, plastica tools to remove layers of material
from a stock piece-known as the bank or work piece and produces wood, glass, foam, and c
machining and cnc postes a in a variety of industries, such as large cnc aerospace parts when
speaking in terms of the machine self, the cnc machine definition is that represents the actual
programmable machine that is capable of autonomously performing the operations of cnc
machining note the contrast between the processes cnc machining definition) versus the
machine (cnc machine definition)
CNC TURNING :

Tuming is a machining process which employs single-point cutting tools to remove material
from the rotating work piece in cnc tuming, the cnc machine-typically a lathe or turning
machine feeds the cuting tod in a linear motion along the surface of the rotating work piece,
removing material wound the circumference und the desired damater is achieved to produce
cylindrical parts with eemal and internal features such as slota, lapers, and threads operational
capabilities of the turning process include boning, facing proeving, and thread cutting.
CNC MILLING :
It's is a type of machining that uses cutters to shape a workpiece, often on a moveable tabletop,
although some milling machines also feature movable cutters. milling started out as a manual
task performed by humans, but most milling these days is done by a cnc mill, which utilizes a

computer to oversee the milling process. cnc milling offers higher precision, accuracy, and
production rates, but there are still some situations when manual milling comes in useful.
manual milling, which requires a lot of technical skill and experience, offers shorter turnaround
times. it also has the added benefit that manual mills are cheaper and the user doesn’t need to
worry about programming the machine.
CNC DRILLING:
Drilling is the cutting process in which the workpiece does not move, making the cutter move,
aligning the cutter center with the hole center, and making the cutter rotate. CNC Drilling is
primarily done on CNC machines including CNC milling machines and lathes.
CLASSIFICATION OF CNC MACHINE:

VERTICAL MACHINING CENTER (VMC):
 Vertical machining center with automatic pallet change can be applied to do complex
machining such as milling, drilling, boring, reaming and facing operations etc. The
exchange mechanism directly on the base; easy to install, good water resistance and to
avoid waste of space.
 Repairs and maintenance are also very convenient and simple. For the quantitative
needs of modular production and product accuracy and machining speed requirements,
machine with APC (Automatic Pallet Changers) is the best choice.
 Automatic pallet changer increases labor productivity, enables work piece clamping,
releasing and gauging on the pallet outside the machine’s working space while parts are
being machined on the other pallet.
 The pallet changers are not only cutting cost in manufacturing but also helping
customer to improve and monitor quality.

CHAPTER:6
TABLE OF IMPORTANT G CODES & M CODES
• G00 Rapid Transverse

• G01 Linear Interpolation
• G02 Circular Interpolation, CW
• G03 Circular Interpolation, CCW
• G17 XY Plane,
• G18 XZ Plane,
• G19 YZ Plane
• G20/G70 Inch units
• G21/G71 Metric Units
• G40 Cutter compensation cancel
• G41 Cutter compensation left
• M00 Program stop

• M01 Optional program stop
• M02 Program end
• M03 Spindle on clockwise
• M04 Spindle on counterclockwise
• M05 Spindle stop
• M06 Tool change
• M08 Coolant on
• M09 Coolant off
• M10 Clamps on
• M11 Clamps off

CHAPTER:7
OPETRATIONS
7.1 EXPLANATION OF OPERATION:

We have to make the work piece according to customers diagram or specifications so we pass
the raw material with few processes. 1 side Facing, Rough boring and Rough Q/D 2nd side
Rough boring and Finish boring. 3d side Rough turn, Finish turn.
7.1.1 1st SIDE ROUGH TURNING, ROUGH BORE, FINISH TURN AND BORE
The first Operation of 1 side is facing in which we roughly remove the material from the face
or front side. Then in rough boring and Rough O/D we roughly remove the material from Outer
Diameter and Inner Diameter.

Fig 7.1 1st Side Finish Turn

7.1.2 2nd SIDE BORE RADIUS, OD GROOVE, ROUGH THREADING, FINISH

THREADING
In the 2nd side we roughly remove the material from the 2nd side of the raw material in Inner
diameter and then pass it through a Finish turn in which the material will be finished with the
smooth surface in the Inner diameter.
Fig 7.2 2nd Side Finish Turn

7.1.3 3rd SIDE NOTCHING, BUFFING AND ENGRAVING:
In the 3rd side roughly remove the material from outer diameter and then pass it through a
finish turn in which the material will be finished with the smooth surface in the outer diameter.
Fig 7.1 Buffing
Fig 7.2 Finished Product

7.2 LINE INSPECTION REPORT (LIR)

Fig 7.1 LIR Sheet
7.4 SAFETY

Fig 7.1 5s System

7.5 INDUSTRIAL SAFETY
Fig 7.6 Industrial Safety

CHAPTER:8
FINAL INSPECTION
It is an inspection in the manufacturing process, and refers to the inspection performed in the
final stage of manufacturing process. in this fest, whether the complete goods meet the
requirements as product or not is determined in order to prevent the loss in customer
confidence, various problems, and damages in advance. on top of that, the manufacturing
process includes acceptance inspection and inspection between processes, both of which are
performed for such constituent items as purchased raw materials, processed parts, and
assemblies, and they are not done for complete goods. in the final inspection, the whole of the
product including the requests from customers is inspected.
8.1 MEASURING INSTRUMENTS
1. Snap Gauges Outer Diameter
2. Plug Gauges Inner Diameter
3 Thread Gauges Thread pitch
4.Height Gauge Height

Fig 8.1 Measuring Instruments
8.2 MEASURING PROCEDURE:
 In final inspection (firewall) the work piece is inspected visually and physically. First
worker will visually check the work piece the physically measure the dimensions. You
have check the work piece height with digital height gauge, o/d or outer diameter with
go, nogo gauges also with micrometer and vernier and you have check groove with no
gauges.
 If the work piece doesn't met the required dimensions, the worker will return it to
operator then the operator set the offset on cnc and turn it to the required dimensions
and sent for dispatch.
TOLERANCE:
 A certain amount of error will inevitably occur between the measured value and the true
value. What is important is to specify the allowable range of errors.
 In terms of measurement, the difference between the maximum and minimum

dimensions of permissible errors is called the "tolerance."
 The allowable range of errors prescribed by law, such as with industrial standards, can
also be referred to as tolerance.

 If "60 (+0.045-0.000)" is written on a drawing, "50" represents the reference dimension,

and +0.045-0.000" indicates the tolerance of the upper and lower limits. In this case the
upper limt & 60.045 and the lower limit is 60.000.
 One of the reasons for establishing tolerances for practical applications is to find a canc
between the processing cost and the intended functions of the object increases in
accuracy lead 10 corresponding increases in processing costs.
 The important point is to ensure that the required functions and quality are achieved,
and tolerances must be set accordingly The tolerance is given by customers in the
drawing like shown below,
8.3 GAUGES:
8.3.1 SNAP GAUGES
The surfaces which define the edges of the aperture are the anvils, which may be made of
separate pieces of hard material such as tungsten carbide for wear resistance. two apertures are
frequently used to provide go/no-go testing and are often arranged such that a part being
measured can pass through the two apertures in sequence.
Fig 8.1 Snap Gauges
8.3.2 PLUG GAUGES:

Plug gauges, in some cases called pin gauges, are metrology tools whose purpose is to gage the
inside diameters of holes that have been drilled or machined into a manufactured part,
component, or assembly.
Fig 8.2 Plug Gauge
8.3.3 THREAD GAUGE
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.
Fig 8.3 Thread Gauge
8.3.4 GROOVE GAUGE

Professional, fast and uncomplicated measuring of grooves of your ropes drives. Groove
gauges are measuring aids and are therefore not subject to the measuring equipment inspection
obligation.
Fig 8.4 Groove Gauge

8.3.5 ENGRAVING
Machine for mechanical engraving from a drawing, stencil, or model. An engraving machine is
used to transfer representations reliefs and other convex artistic originals to soft metal (such as
copper), stone, or wood.
In metalworking the engraving machine is a small copying-milling machine with a pantograph,
carrying a cutting instrument (cutter or graver), which cuts the stamps, inscriptions, and figures
on machined parts. An engraving machine is used in polygraphy to prepare zincographic stereo
types.

Fig 8.5 Engraving Machine
CHAPTER:9
DISPATCH
Dispatch is a procedure for assigning employees (workers) or vehicles to customers. Industries
that dispatch include taxicabs, couriers, emergency services, as well as home and commercial
services such as maid services, plumbing, HVAC, pest control and electricians.
With vehicle dispatching, clients are matched to vehicles according to the order in which
clients called and the proximity of vehicles to each client's pick-up location. Telephone
operators take calls from clients, then either enter the client's information into a computer or
write it down and give it to a dispatcher. In some cases, calls may be assigned a priority by the

call-taker. Priority calls may jump the queue of pending calls. In the first scenario, a central
computer then communicates with the mobile data terminal located in each vehicle
Trucking dispatchers play a major role in transportation logistics. Truck dispatchers orchestrate
freight movement and equipment from one place to another while keeping close
communication with truck drivers. Some dispatching companies help truck drivers to negotiate
and acquire loads and handle paperwork Dispatching trucks require a variety of skills like using
a computer to find and track loads for drivers to speaking multiple languages depending on the
region or number of trucks they manage. Great customer service and good communication are
vital for succeeding in this fast-paced environment
Fig 9.1 Dispatch
CHAPTER:10
CUSTOMER FEEDBACK
When finally the dispatch reaches the customer he will first do the inspection to make sure that
all the dimensions are met the requirement. If the dimensions are wrong he will return the work
piece to company and pays the company after inspection.
Then customer will feedback the company that how are the work pieces are made and describes
about our good or bad service


CONCLUSION:
In the due course of internship, I got a chance to learn what exactly happens in a industry. It
is my immense pleasure to say that the employees in this company has been approachable and
ready to address my queries which has helped me in understanding of process significantly.
The staff in every unit helped me to understand the work environment and how the
management handles the organization for the smooth functioning of Vijayalaxmi Industries.
It also gave a brief description as to how the organization uses the resources efficiently to gain
maximum benefits out of it. I got an idea as how to carry oneself in the professional
environment.
I learnt the way to approach people to gather necessary information keeping their busy work
schedules in mind and learnt some of the time management tricks.
Thus it was a great experience of being an intern in Vijayalaxmi Industries.

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CONTENTS

CHAPTER1:DISCRIPTION OF THCOMPANY 1-5

CHAPTER 10:CUSTOMER FEEDBACK 30

Dept of Mechanical Eng : Klecet Chikodi Page 1

3) Vijayalaxmi Gears, Unit-III, No 36/2, Dasanur, Jodalli Village, Tq: Kalghatgi,

1.2 PRODUCTS AND SERVICE DETAILS:

 AC Generators 5KVA To 40KVA

Typical Components Manufactured On Job

1.3 ACHIVEMENTS OF VIJAYALAXMI GROUP OF COMPANIES:

1) Best Vendor for year- 2007, Customer: Spicer India Ltd.

3) Best VSME Supplier for year-2013, Customer- Spicer India Ltd.

4) Best VSME Supplier for year-2014, Customer- Spicer India Ltd.

Dept of Mechanical Eng : Klecet Chikodi Page 2

GROUP OF COMPANIES & KEY BUSINESS ACTIVITIES:

Total employee strength- 240

 VIJAYLAXMI INDUSTRIES - Manufacturers of alternators and dg sets, lt&ht motor

Total employee strength - 20

 NKR ENGG.SOLUTIONS PVT.LTD.,&NKR AGENCIES - Hiring of generators

Total employee strength – 25

 VIJAYALAXMI TRADERS - Premium distributor for acc cement for dharwad

Total employee strength – 20

TOTAL EMPLOYEE STRENGTH OF THE GROUP – 305

Dept of Mechanical Eng : Klecet Chikodi Page 3

1. CNC Turnings centres : 53

6. External grinding machines : 2

7. Laser marking machines : 2

8. Dot matrix marking machines : 7

10. Bench grinders : 3

12. Conventional drilling machines: 8

13. Conventional lathe machines : 3

14. Tool and cutter grinder : 1

15. Bend saw : 1

Total machines- 114

Dept of Mechanical Eng : Klecet Chikodi Page 5

2.1 INTRODUCTION ON CNC AND VMC MACHINE

2.1.1 COMPUTER NUMERICAL CONTROLE (CNC):

Fig 2.1 Computer numerical control

ADVANTAGES OF CNC SYSTEMS

Dept of Mechanical Eng : Klecet Chikodi Page 6

2.1.2VERTICAL MACHINING CENTER (VMC):

Fig 2.2 Vetical Milling Machine

ADVANTAGES OF CNC SYSTEMS:

Procedure of production and programming of Pentair water component according to customer

3.2 RAW MATERIAL DETAILS

 A raw material, also known as a feedstock, unprocessed material, or primary

Dept of Mechanical Eng : Klecet Chikodi Page 8

Fig 3.2 Raw material

3.3 RAW MATERIAL DIAGRAM

Dept of Mechanical Eng : Klecet Chikodi Page 9

Fig 3.3 Raw Material Diagram

RAW MATERIAL FLOW CHART:

Dept of Mechanical Eng : Klecet Chikodi Page 10

3.4 PORT CELL DIAGRAM:

Fig 3.4 Port Cell

4.1 RAW MATERIAL INSPECTION

A raw material inspection is to select materials or item for a manufacturing or processing at

Dept of Mechanical Eng : Klecet Chikodi Page 11

Fig 4.1 Raw Material

4.2 WORKING JOB DETAILS:

Dept of Mechanical Eng : Klecet Chikodi Page 12

5.1 JOB PROCEDUCE

Dept of Mechanical Eng : Klecet Chikodi Page 13