GTDMC

Gujranwala Tools, Dies & Moulds Centre

Submitted By: Owais Ahmed BSME-01093-033 B.Sc. Mech. The University of Lahore

Internship Report

Gujranwala Tools Dies and Moulds Centre

GTDMC have the following departments: 1. Marketing, Planning & Purchase PPC 2. Design Department 3. 3d Scanning, Inspection & CMM 4. Machining Department 5. Maintenance

Marketing, Planning & Purchase Control PPC

Objectives of this department are as follows: 1. Meeting the customer 2. Discussing about the job 3. Finalizing the rates for the work 4. Keeping the customer updated about their work This department is the first step to any job that enters GTDMC. They have to welcome the customer and discuss about the job and finalize the overall prize of the job and give the final date on which the job would be completed expectedly. After this they forward the job to the design section for making its 3d design on which the machining could be started. Later on they need to keep the customer updated that at which step their job have been gone and furthermore how much time it would take them to finish it.

Design Department
Objectives of this department are as follows: 1. Making 2D designs of the job given to them. 2. Making 3D designs of the job given. 3. Making surfaces and improving the design of the job given after 3D scanning. Softwares used by this department are: 1. 2. 3. 4. 5. 6. 7. Catia Pro E Delcam Master CAM Auto CAD Creo Parametric Geo Magic Studio

Overall the softwares have the same work to do but main differences are given below: Catia Pro E Delcam Auto CAD Geo Magic Better Analysis /Assembling, Strong surfaces. Easy Assembling Is not Parametric (Modification is difficult) Used mostly for 2D drawings Used for making surfaces on #D scan data

3D Scanning, Inspection & CMM

Objectives of this department are as follows: 1. 3d Scanning 2. Inspection & Quality Control 1. 3D Scanning Most of the products to be manufactured are too complicated to be designed without any scan data or 3d scan, so those products are scanned in this department. This technology is known as Reverse Engineering. Scanning may be of two types 1. Contact Scanning (Using External Probe) 2. Non-Contact Scanning (Using Laser) This department uses 2 machines for this purpose.

a. CMM
The word CMM means Co-ordinate measuring machine. This machine uses a probe for the purpose of scanning in which it takes different co-ordinates of the product and generate a 3d model for those coordinates in the computer. Its model is METRIS LKV 20.12.10 Its bed size is 1.2m x 2m x 1.3m ( L x W x H ).

b. Portable CMM Arm

It is a 3D laser scanner used for scanning the parts. It creates a point data in computer of the product from where the laser light passes. This point data can be easily converted into surfaces and 3d model of the product using different software such as Geomagic. Its model is METRIS 3DS. Its specifications are 1. Dia. 2400mm. 2. Accuracy 28 micron (0.028mm) 3. Weight 10kg 4. Height 7m 2. Inspection & QC Another work under this department is of inspection. They do two types of inspections. a. External Inspection This means that the customer does not want GTDMC to make die or mould of their product rather just to inspect their product against the original one.

b. Internal Inspection This means to inspect each and every die and mould before it goes out to the customer. The QC inspectors have to inspect every piece under the following points. 1. Extra or missing programming 2. Accidents 3. Geometrical Dimensions 4. Surface Inspection For the purpose of inspection they also use both the scanning machines CMM and Portable CMM Arm. Both the scanning machines also have the ability to do inspection using different software like PowerINSPECT.

Machining Department
Objectives of this department are as follows: 1. Machine the job out of the solid block. For this purpose this department uses different machines that are: 1. CNC Milling Machines a. PARPAS THS 100X (5-Axis) b. PARAPS 32XS (5-Axis) c. DAHLIH HC 2000 (4-Axis) d. DAHLIH MCV 720 (3-Axis) e. DAHLIH MCV (3-Axis) 2. Wire cut (WEDM) a. BAOMA XKG 2005 b. CHMER CW 530HF c. CHMER CW 1060HF
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3. Electric Discharge Machines (EDM) a. JS EDM 90A CNC EB600L b. JS EDM 120A CNC EB900L c. CHMER 75N CM 655C d. CHMER 75N CM 655C e. CHMER 75N CM 865C 4. 5. 6. 7. CNC Turning Center DOOSAN PUMA 280LM Surface Grinders Surface Texturing Die Fitting Machine WETORI IDS - 100S 3515

Softwares used in this department are: 1. Catia 2. Delcam 3. Pro E 4. Auto CAD 5. Edge CAM The word CNC means Computer Numeric Control. The CNC milling machines used here are fully automatic with tool changer ability and auto program resume. WEDM means Wire cut Electric Discharge Machine. In these machines a wire is used to cut the block to a specific dimension or to cut out a piece form a die where the ordinary tooling is not possible. The current passes through the wire and due to high voltage and heat the wire starts cutting the material.

The wire cuts used have the following specifications: i. BAOMA XKG 2005 Wire used = Molybdenum Wire Dia. = 0.18 mm Reversible WEDM (Wire Reused) Coolant = Distilled water with chemical

Ii. CHMER CW 530HF & 1060HF Wire use = Brass Wire Dia. = 0.25 mm Single use wire Coolant = Distilled water with chemical Auto Size (Code)

EDM means Electric Discharge Machine. EDM is used where the tooling cannot be done and the surface are is more for wire cut. EDMs used in this department are automatically controlled by computers and have a fully graphical interface. Coolant used in EDMs is Kerosene Oil.
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Turning center is used mostly for working on cylindrical parts. It is usually known as lathe machine. Specifications of the DOOSAN PUMA 280LM are: Muscular Function (Milling) 12 tools (Auto Changer) Chuck RPM 5000 Muscular RPM 1500 to 2000 Hydraulic Tail stock Milling Centre Feet Switches o Spindle feet switch o Tail Stock feet switch Two terms commonly used 1. Absolute Programming Means start point to end point. Which means the machine will have the entire program from zero till end in its memory.

2. Increment Programming This means Point to point. Means that the machine will remember just its very last point and will forget the previous ones.

Maintenance
Objectives of this department are as follows: 1. Weekly checkup and maintenance of machines if needed. 2. Monthly checkup and maintenance of machines if needed. 3. Troubleshooting of any machines. The maintenance department has to check the machines weekly & monthly to check if there is any problem which they observe mechanically or electrically and repair it on the spot.

If any machine gives some problem so its their duty to repair it. For example during my internship duration a Surface Grinder Machine (SG) went wrong and its bed stopped working. Now the department first studied the relevant books for the machine and this problem. Then they concluded that there is some problem under the bed bearings.

They lifted the bed up and there they saw that the bearings pipe was broken. They opened it and repaired it and placed it back. So the machine started working properly again.

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Conclusion
The flow of the job which I learnt that comes in GTDMC is as follows: 1. 2. 3. 4. 5. 6. Marketing and PPC 3D Scanning (If needed) Design Department Machining Department Inspection Sampling

During my internship in GTDMC I have learnt a lot about: New technology machine like 5-axis CNC machines, CNC turning centers, WEDMs, 3D scanners. Have learnt how to manufacture a job completely from zero till end. How to inspect a die, mould or a job. 3D scanning of a job. Making 2D & 3d design of the job given. Programming on PowerMILL and Edge CAM. Operating WEDMs EDMs. Operating CNC machines. Operating Turning Centre. Troubleshooting of any machine and its maintenance.

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