[Document title]

VISVESVARAYA TECHNOLOGICAL UNIVERSITY

“JNANA SANGAMA”
BELAGAVI-590018, KARNATAKA

Report on
COMPUTATIONAL FLUID DYNAMIC ANALYSIS OF PROPELLER THRUST
Submitted in partial fulfillment for the requirements for the award of
BACHELOR OF ENGINEERING
In
MECHANICAL ENGINEERING

Submitted by:
STUNDENT
NAME (USN)
VIII Semester
Internship carried out
at
COMPANY NAME
Address

Internal Guide External Guide

Name Name
Designation Designation
Organization Organization

DEPARTMENT OF MECHANICAL ENGINEERING

BMS INSTITUTE OF TECHNOLOGY AND MANAGEMENT
Yelahanka, Bengaluru-560064
2021-2022

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B.M.S. INSTITUTE OF TECHNOLOGY AND MANAGEMENT

(Affiliated to Visvesvaraya Technological University, Belagavi, Karnataka) #6443,
Doddaballapura Main Road, Avalahalli, Yelahanka, Bengaluru-560064
DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE

This is to certify that the Internship Report on “TITLE” submitted by

“STUDENT NAME” bearing USN respectively is a bonafide student of B.M.S.
Institute of Technology and Management, has successfully completed the
Internship programme in partial fulfillment for the award of Bachelor of
Engineering in Mechanical Engineering prescribed by Visvesvaraya
Technological University, Belagavi during the academic year 2022 - 23. The
Internship report has been approved as it satisfies the academic requirements in
respect of seminar prescribed for the Bachelor of Engineering degree.

Signature of Internal Guide Signature of HoD

GUIDE NAME Dr. K M Sathish Kumar
Assistant Professor Professor and Head
Dept. of Mech Engg, BMSIT&M Dept. of Mech Engg,
BMSIT&M

Dr. Mohan Babu G N

PRINCIPAL
External Viva

Name of the Examiners: Signature with

date

1.

2.

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COMPANY CERTIFICATE (Colour Xerox)

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DECLARATION

I hereby declare that the Internship work entitled “TITLE” has been independently
carried out by me at COPMANY NAME, Place under the external guidance of
External guide Name, Designation, Company Name and under the internal
guidance of Internal guide Name, Designation, Department of Mechanical
Engineering, BMS Institute of Technology and Management in partial fulfillment of
the requirement for the award of Bachelor of Engineering in Mechanical Engineering
prescribed by Visvesvaraya Technological University, Belagavi during the academic
year 2022-23.

I further declare that I have not submitted this report either in part or in full in any
other university for the award of any degree.

STUNDENT
NAME USN

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ACKNOWLEDGEMENT

I would like to extend my supreme gratitude to Larsen & Toubro Construction Equipment

Limited, Doddaballapur, for providing such an opportunity to me to broaden the

perception on how the real world in the field of mechanical engineering & manufacturing

looks like as well as organizing the whole internship program and its effort to make sure

that the whole internship program to achieve its desired goals.

I would also like to express my special thanks to Mr. Avinash C, Production head of

machine works LTCEL, Mr. Jagan Mohan, Human Resources, Mr. Keshava Salian,

Maintenance Dept, Hydraulic Works & Mr. Sajith Jayabalan, Intern guide who despite his

busy schedule, took time to help me in my day-to-day activities during the intern time.

I extend my grateful thanks to workers in the factory shop who were cooperative and

shared their knowledge to improve my theoretical knowledge to the real w

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TABLE OF CONTENTS

SI. No. Title

1. Introduction
2. Equipment Manufactured at LTCEL
3. Manufacturing Process
4. Bay 1
• 600T Hydraulic Press Brake
• Sacem A & B Machines
• Shot Blasting
• Paint Booth
• Paint Oven
5. Bay 2
• Himalayan Roll Bending Machine
• Cloos Robot
• CNC Double Column Horizontal Boring Machine
• IGM Robot
• Juaristi CNC Horizontal Machining Centre
• Wheel Loader Lift Arm Full Welding & Rear Chassis Welding

6. Bay 3
• Vertical Turret Lathe
• 4T Front Chassis & Rear Chassis Fit up
• DP Test
• Role of Inspection & Testing
7. Process Flow of Fabrication Bay ______
8. Assembly
• Workstation - 0
• Workstation - 1
• Workstation - 2
• Workstation - 3
• Workstation - 4
• Workstation - 5

9. Conclusion

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INTRODUCTION

Company Background:

Larsen & Toubro Limited is one of the largest and most respected companies in India's
private sector with its headquarters situated in Mumbai. L&T construction is a division
of Larsen & Toubro, a major Indian technology, engineering, construction,
manufacturing & financial services conglomerate, with global operations. L&T
addresses critical needs in key sectors - hydrocarbon, infrastructure, power, process
industries & defence for customers in over 30 countries around the world. L&T is
engaged in core high impact sectors of the economy & our integrated capabilities span
the entire spectrum of design to deliver, with over 60 years of a strong customer focused
approach and a continuous quest for world class quality. L&T has unmatched
capabilities across technology, Engineering Construction and Manufacturing and
maintain leadership in all its major lines of business.

Company Vision:
L&T shall be a world class company with high standards of governance, dedicated to
excellence in Products, Process & People. L&T shall be a company delighting customers
by delivering on- time highly reliable products which enable them to succeed. L&T shall
be a company with high safety standards, caring for safety of people, committed to social
responsibility & environmental protection. People involved shall have the passion to
continual learning & engage themselves to the highest level of involvement. L&T shall
embrace an inclusive culture that incorporates a strong & well-articulated set of values &
behavioural expectations. That the supply chain shall be of world class standard with
highest level of seamless integration bringing in quality, cost & volume flexibility. L&Ts
business model shall drive entrepreneurial zeal, growth with scale & speed X financial
performance shall reward involved stakeholders.

Company Mission:

L&T shall manufacture a premium range of globally competitive construction equipment

& hydraulic systems for domestic & international markets. L&Ts focus would be to attain
market leadership through sustained growth, quality through product reliability & on-time
delivery ol our products to our customers. L&T shall be committed to provide a safe
working environment, promote team working & improve employee engagement. L&T

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shall embrace the lean manufacturing philosophy in our operations and improve our
operating profit margins.

Company Quality Policy:

L&T, at machinery works, shall manufacture, and deliver a range ol construction, mining
and road building equipment and their adjacencies catering to the requirements of the
customers in these industries to achieve a profitable growth and are committed to derive
and achieve the quality objectives in relation to quality, cost, delivery, safety, profitability,
satisfy applicable requirements and continually improve the quality management system.

Values and Ethics:

Larsen and Toubro stress the need for having professional ethics and giving nice
customer treatment. As L&T is a global company, it has a wide variety of customers under
its belt, people of different tastes, languages etc.

Being such a vast company with over 80 years of experience, I &T’s main philosophy is
built on fair and transparent governance and business. It keeps a high weightage on
individual dignity and following professional ethics, honesty, and respect, both within and
outside the company. The company stresses that success can only be achieved and
maintained only if everyone within and outside the company is treated with respect and
dignity, irrespective of any caste, creed, colour, religion, or feature.

L&T also places a strong emphasis on creating a safe, sexual harassment- free workplace
for women. It advises strongly, all-male employees to be treating female employees with
dignity, respect, and equality.

L&T keeps a high emphasis also on confidentiality, of all business-related matters. This is
essential as the risk of miscommunication or leaking of price-sensitive information and
plans, cannot be taken lightly. All L&T employees are considered as "insiders” and are
expected to not leak any sensitive information to a third party, for the potential risks stated
above.

L&T is passionate about the customer's needs hence, it stresses the need for the first-line
managers, the people who may interact with customers, to be nice and civic, so that trust
can be gained starting from the low level. It also keeps all professional transactions with
stakeholders transparent, fair and value based.

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MANUFACTURING PROCESS:

The manufacturing unit consists of five bays where the first three bays are Fabrication

bays and the remaining two are Assembly bays.

BAY 4- Sub assembly bay

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Fabrication Shop:
BAY 1
1. 600 T Hydraulic Press Brake:
A press brake is a machine used to make repeatable, precise, and reliable bends in metal
sheets. Brakes are classified according to tonnage and bed length. They can be fitted with
various types of punches and dies to control the bend of the sheet. Most now come fitted with
an automated back gauge that aids in positioning and holding the sheet, greatly increasing
repeatability.

Figure 11: Hydraulic Press Brake

A press brake is a fabrication machine that is usually used with metal blanks rather than
rods. As such, it is most found in fab shops. Whereas a folding machine is used for light,
thin sheets, press brakes can exert hundreds or even thousands of tons of force, leading them
to be used for huge steel plates and other heavy-duty bending applications. Press brakes can
produce either small parts or very long pieces with minimal tooling. They are useful in both
low and medium production runs. The press brake has 2 axes namely the x-axis and the y-
axis, the x-axis has a maximum distance of 1000mm. The metal sheet to be bent is placed
between the punch and the die. The punch and die arc placed in such a way that they are
aligned in the same vertical axis and the shape of the punch matches that of the die. The

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metal sheet is clamped at both ends to prevent it from slipping during the bending process.
After fixing the metal sheet, pressure is exerted on the punch which bends the metal sheet or
plate against the die.

The force applied is measured in tons, and a machine's capacity 7 is measured in terms of tonnage.

Depending on the means of the job the pressure will be applied.

Every part will not be of the same size and shape. When a new part is to be pressed some changes

must be made in the device to get the shape ot the metal sheet or plate as per the design. This setup

procedure must be done very carefully because it directly affects the quality of the product. The

operator must not take much time in setting the machine up as this may affect the production.

Specifications:

Model EHP 600

Supplier Hindustan Hydraulic Jalandhar
Press Capacity 1992

Length 5220 mm
Distance between Housing 4300 mm

Open Die 625 mm

Maximum Stroke 325 mm

Approach Speed 60 mm/sec

Pressing Speed 6 mm/sec

Return Speed 35 mm/sec

Table Width 400 mm

Motorized Back Gauge 750-800 mm

Control Type DELEM DA58

Table 1: Hydraulic Press Brake Specifications

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2. SACEM A & B Machine:

The SACEM-A has 5 axes as X, Y, Z, W & B where the B axis is the axis of the bed that is
connected to the positioner, so it will rotate 90 degrees so we can do the machining
operations for four directions. The table size of the SACEM-A is 2000mm x 2006mm.
Mainly the 111 drum soil compactor will be placed for machining operations. The SACEM-
A CNC machine centre is an advanced manufacturing machine tool.
This machine can perform various operations. The types and functions of the CNC
Machining Centre are introduced below. The SACEM-A CNC machine tool centre is an
advanced quality, and high surface finish.

Figure 12: SACEM CNC Machine

SACEM-A CNC machine tool centre can perform drilling, milling and boring operations. The

manufacture of prismatic parts in the industry such as wheel loaders, road rollers, excavator buckets

etc., requires different types of operations such as milling, boring, drilling, lapping and many other

related machining operations.

The main purpose of the SACEM-A CNC machine centre is to reduce production time and advanced

mechanisms in the SACEM-A (NC machine centre. The machining centre has a horizontal spindle,

and the tool is mounted on the spindle of the machine, usually a single spindle machine with an

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automatic tool changer. The ATC consists of a replaceable magazine that can store multiple tools and

hold approximately 16 to 100 tools.

To reduce loading and unloading time, an automatic pallet changer (APC) can be installed. Due to

the high material removal rate in the process, the cutting volume is usually large, so the tool

magazine requires a large position on each tool and the relative weight is getting heavier. Some

machine tools also have additional functions for rotating the entire spindle so that the horizontal axis

of the spindle becomes vertical, allowing for different operating techniques.

Specifications:

Model MSPC 200/600 NC

Supplier SACEM, SPAIN
Year of purchase 1995-1996
Spindle diameter 202mm
Tool fastening taper MAS BT50

Spindle speed range l-1000rpm

X axis {column cross transverse} 5000mm
Y axis {Head stock vertical transverse} 3500mm
Z axis {Column longitudinal transverse} 6000mm
Table rotation 4 X 90 degrees
Table size 2000mm X 2006mm
Max load 25000kg

Indexing accuracy 3 seconds

Type of control HEIDENHAIN TNC416B
Working feed for X, Y, W, Z 2-2500mm/min
Rapid feed for X, Y, W, Z 10000m m/m in
Speed for rotary table 0-21-1.5 rpm
Rapid speed for rotary table 3 rpm
Axis and spindle INDRAMARTIC AC drive

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3. Shot Blasting
A shot blasting machine is a mechanical method of propelling abrasive using a centrifugal
wheel to remove surface and other impurities from the surface of steel applications.
Generally, blasting prior to finishing sene> three primary purposes. They are:

• It cleans and descales surfaces

• Adds texture to enhance paint adhesion
• Property reduces maintenance costs by increasing coating life Applications of
blast rooms de-rusting and surface preparation before thermal spray and painting.
The gun makes the grain propel at 6-bar pressure and the size of the grain is 1 mm in
diameter. The main feature of the blast room system is that the operator is inside the room
during the blasting process. A protective suit and a helmet protect the operator from
abrasive impact, and a fresh air supply provides sufficient ventilation through the blaster’s
helmet. Blast rooms are used for big components or components where automatic blasting
would be too expensive. In combination with nozzle manipulators installed in the blast
room, surfaces can be automatically processed and areas that are hard to access can be
blasted manually. Thus, flexibility is maintained while reducing the number of blasters
needed.

Figure 13: Shot Blasting

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4. Paint Booth
A paint booth is a significant component of many industrial manufacturing plants. It
can improve results, pull contaminants out, and help achiex e a smoother, cleaner
coating. Some designs can even blow paint o\ er uncoated areas to create a more
uniform finish. Abide by regulations. \ ou can play nice with the Environmental
Protection Agency and meet or exceed their requirements regarding the dangerous
chemicals involved in paint spraying Plus, it can keep your employees safer by
limiting their exposure. A paint booth works by manipulating the principles of
negative and positive air pressure. Spray painting booth ventilation relies on the
balance of the exhaust fan and the air replacement fan. If just the exhaust fan is on,
the booth takes on negative pressure, since more air is being removed than pushed in.
If the door opens, it will try to pull in as much air as it can from the outside, yanking
in dirt and debris along with it. If just the replenishing fan is on, you'll get the positive
air pressure in the booth, and it will tiy to push that air outward when the door is open
Contaminants and debiis will get swept away from it, keeping the inside cleaner.

Figure 14: Wheel Loader undergoing Spray Painting

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To create an effective working environment, these two fans work together to remove and
replace the air at comparable rates with a slightly positive booth, you can keep dirt and
debris out even as the door is opened. This method of keeping negative particles out is
effective at keeping rooms clean-so effective, in fact, that you can find it employed in
healthcare spaces. Two factors can significantly affect the success of a paint booth- your
filters and volume change. If a filter gets filled up completely with overspray, the exhaust
fan will struggle to pull air through it, without an exit point, the booth can become over-
pressurized. As for the volume, you simply have to keep in mind that adding an item into
the booth will reduce the amount of space that needs to be pressurized. If you pump the
same amount of air into a filled booth as you would when it was empty, you'll over
pressurize it.

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5. Paint Oven:
Paint Drying Ovens also referred to as Dryers or Paint Curing Ovens or Paint Baking Oven
removes the moisture from water - based coatings and adhesive. Paint drying Oven are also
removing water from the surface or interior of products with the help of thermostatic
controls in case of electrical heating and temperature controllers operating solenoid valves
in case of steam, gas, and oil heating.

Figure 15: Paint Oven

The object will be kept for a minimum of 20 minutes at 80 degrees Celsius.

The provision of a Painting Drying Oven ensures:

• Speeding up of the paint drying operation

• Improved quality of products
• Increase in the durability of the product
• Economizing the cost of painting the product
• Dust - free product

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1. Himalaya Roll Bending Machine:

This type of machine has linear guidance for the two bottom rolls. Its geometry has the
minimum distance between the bending points resulting in higher bending accuracy. The
top roll remains fixed & the bottom rolls move vertically. Two bottom rolls are power
driven by planetary gearboxes with electric or hydraulic system. Energy saving is ensured
in the machine by a hydraulic system that can work at less than full capacity when jobs
less than maximum thickness are rolled. Many shapes like oil tankers & elliptical shells
can be made.
When rolling a steel plate, the plate is placed between upper & lower rollers and the three
cutting points exposed on the metal sheet by the three rolls can make the plate bend into a
curved or closed circle. Therefore, forming process of sheet metal can be regarded as a
three-roll bending machine to make a continuous three point bending process.

Figure 17: Himalaya Roller Bending Machine

During this process, one end of the metal plate is fed into three roller plates between the
upper & lower roller and then the top roller brings downwards displacement on the metal
plate, which makes the plate under it generate a certain plastic bending deformation due
to compression. Lower roller under positive and negative rotation alternately and rolled
plate move back and forth, two lower roller rotation and friction drive plate and roller
move Meanwhile, the upper roller continues to add downward pressure roller, the upper

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roller moves back and forth on the plate.

Specifications:

Model RRH 165

Supplier Himalaya Machinery Ltd Baroda

Year of Purchase 1989

Asset Number CP 87033
Year of Gradation 2019
Operating Width 3000 mm
Thickness of Rolling 38 mm at 36 kgf/sqmm YS

Top Roller Diameter 510 mm

Bottom Roller Diameter 460 mm

Table 3: Roller Bending Machine Specifications

2. CLOOS ROBOT:

The CLOOS robot contains 11 axes, where the robot arm houses 6 axes motion and

cartesian 5 axes motion. When the job is placed on the positioner the program will be

inserted in the display of CLOOS robot 1 & then it will be commanded through a teacher

pendant, so then it will execute the program for the given job. Optical guidance will

sense that there are two CLOOS robots (I & II) in the fabrication bay, assigned

specifically for welding operations. This is a CNC operated robot, wherein we can input

the pre-written commands via USB or manually enter them into the robot. The robot

which performs the MiG welding, also called arc welding. The weld will occur by using

the Cu wire which will be the size diameter of 1.2 mm. It uses 85% of Argon & 15% of

CO2 as shielding gas for the welding operation.

Key Features:

• Combo of single & tandem torch welding which results in increased

productivity.
• Consistency in quality.
• Laser cam for volumetric compensation.

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Figure 18: Cloos Robot

3. CNC DOUBLE COLUMN HORIZONTAL BORING MACHINE:

A horizontal boring machine is a specialized machine tool that bores holes in a horizontal

direction in relation to the floor. There are three main types including floor, table, and

planer. Boring machines can process extremely large and heavy parts and allows

operators to reach hard to machine geometries and small cavities. A horizontal boring

machine consists basically of a bed, column, saddle, ram, and spindle. The X-axis is the

longitudinal travel of the machine on the bed. The Y-axis is the vertical travel of the

saddle along the row. The Z-axis and axis are the inward and outward strokes of the

plunger and boring tool spindle, respectively. The saddles are connected to the

counterweight placed in the column by a wire through a pulley at the top of the column to

eliminate its own weight. Each shaft is precisely driven by a ball screw or rack and

pinion. Larger parts require larger capacity and increased rigidity to support heavier table

loads. The CNC double machining centres are designed for extreme cutting capacity,

offering the benefits of solid box way constructions, high speed/high torque spindle

options, spacious work envelopes, and a patented double column bridge-type design.

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Figure 19: Horizontal Double Milling Machine

Specifications:

Model MX-5
Supplier Juaristi, Spain
Ram Size 420 mm X 450 mm
Tool Fastening Taper MA403/BT50
Spindle Speed Range Up to 3500 mm
X-axis (Column Long Traverse) 9000 mm
Y-axis (Ram Vertical Traverse) 2000 mm ____________

Z-axis (Ram Axial Traverse) 1250 mm

Floor Plate Size (Table Size) 9000 mm X 1500 mm
Maximum Load 30000 kg
Type of Control Siemens 840 Di
Rapid feed / Working Feed Rate (x) 30000 & 10000 mm/min
Rapid feed / Working Feed Rate (y) 20000 & 10000 mm/min
Rapid feed / Working Feed Rate (z) 20000 & 10000 mm/min_________________
ATC 10 tools in each column
Accuracy / repeatability (x) 0.015 mm / 0.008
0 015 mm / 0.008
Accuracy / repeatability (y) Accuracy /
0,015 mm / 0.008
repeatability (z)

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4. IGM ROBOT:

The IGM robot contains 5 axes. When the job is placed on the positioner, the program

will be inserted in the display of IGM and then commanded through a teach pendant, so

that it executes the program for the given job. The robot will sense the point where to

weld. IGM gas nozzle searching is a tactile sensor for position detection. This tactile

sensor is used to determine the workpiece position or its components and individual parts

by gauging the surface of the workpiece. In each case, the succeeding part of the program

is shifted according to determined deviations. Sensors shifting must be applied for

correction of an arbitrary number of individual points, entire sections of a welding

program or entire programs. A combination with arc scam sensing is feasible I lie control

system supports shilling, rotation and lilting of a program, depending on position change.

Figure 20: IGM Robot

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Specifications:

Model RTi476 S
Supplier IGM, Austria
Year of Purchase 2012
Type of Control Kuka Robot Control
Programming Language K5
Sensing Gas Nozzle & Laser Camera
Power Source Fronius
Welding Type Single & Tandem Welding
Maximum Load 6000 kg
Robot Payload 10 kg
I Axis - 1 + 270 degrees
Axis - 2 + 135 degrees
Axis - 3 + 135 degrees
Axis - 4 + 180 degrees
Axis - 5 + 145 degrees
Axis - 6 + 360 degrees
Robot Working Space 2400 mm
RP 1600 mm
RFP 1600 mm
RP - rotary axis 360 degrees
RFP - rotary axis 360 degrees
Table 5: IGM Robot Specifications

5. JUARISTI CNC HORIZONTAL MACHINING CENTER:

JUARISTI CNC horizontal machining centre is a CNC machining operation machine that

performs various operations such as drilling milling tapping

Figure 21: Juaristi CNC Horizontal Machining Centre

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etc. the JUARISTI CNC horizontal machining centre which have 4 axes which are X, Y, W.

Z. the table rotation of JUARISTI CNC horizontal machining centre is 4'90 degrees, the

maximum load of the JUARISTI CNC horizontal machining centre is 30000kg where the 10T

roller will get machining operations. The axis and spindle drive of the JUARISTI CNC

horizontal machining centre is the INDRAMAT ac driver.

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Specifications:

Model
Ts 205 CNC
Supplier
J-2000 SAL, Spain___________
Year of Purchase
1990-91
Spindle Diameter
205 mm
Tool Fastening Taper
ISO:50
Spindle Speed Range
3-700 RPM
X-axis (Table Cross Traverse) 2500 mm
Y-axis (Head Stock Vertical Traverse) 2000 mm
W-axis (Column Longitudinal Traverse) 1500 mm
Z-axis (Spindle Axial Traverse) 1250 mm
Table Rotation 4 X 90 degrees

Maximum Load 30000 kg

Table Size 2000 mm X 2000 mm

Indexing Accuracy 3 seconds

Type of Control Siemens 840 DI SL
3 - 3000 m/min
Feed Drivers X, Y, W, Z
Raid Drivers X, Y, W, Z 5000 mm/min

Speed for Rotary Table 0 - 1.75 RPM

Rapid Speed for Rotary Table 1.75 RPM
Axis & Spindle Drive INDRAMAT AC Driver

Table 6: Juaristi Horizontal Machine Specifications.

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