ADAMA SCIENCE AND TECHNOLOGY

UNIVERSITY
SCHOOL OF MECHANICAL CHEMICAL AND MA-
TERIAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

INTERNSHIP REPORT

HOSTING COMPANY-ADDIS MACHINE AND SPARE PART

MANUFACTURING INDUSTRY
Prepared by - Bethlehem Dawit UGR/16878/11

ACADEMIC ADVISOR - Mr. Kuba

INTRODUCTION
Thinking about hands on career in the manufacturing industry, one way to get started is to
serve as an intern. So I prefer Addis machine and spare part manufacturing industry to get
some knowledge and real-world experience in the manufacturing environment.

Addis machine and spare part manufacturing industry company is located in Addis Ababa,
Lideta sub-city, kebele 07 around Mexico square. It covers an area of 92,979 square meters.
The company was established in 1945 by an agreement between Ethiopia and the
Czechoslovakian government with an initial cost of 2,000,000ETB. It was further expanded
in 1977with the cost of 82,000,000ETB and started working with Ethiopian defense for am-
munition (mostly bullets), square parts, medals, badges, and work woods. It is called with
different names like “Hebret machine tools engineering complex” or “Addis engineering”.

WORK FLOW
I work from Monday to Friday during regular working hours.The First and the second
weeks was an introductory weeks that where I was given a tour around the company and I
understood the general workflow and sections of the company. And this is how the system
flows.

1.Customer
The customer comes with either a drawing or a sample of the desired part.

2.Marketing
In the marketing department the where the entire cost of the product is estimated. If the
countermen found the estimated cost affordable, he/she will go further with the process and
pay 50% of the total cost. The cost is estimated based on the type of material and its diffi-
culty to produce.

3.Production
The production process starts in the designing room where the sample part is analyzed; the
designer will measure the dimension of the sample material with calipers and other measur-
ing tools. Then it’s converted into a 3d drawing then back to a 3rd angle projection view us-
ing CATIA V5software. In addition that the technological procedure is written in this room
which is the description of what process should be done to achieve the desired part. If the
desired part is going to precision an Nc code is generated for the CNC machine to work read
or manually inserted using an input device in the CNC machine.

4.Production planning and control

This department administers and controls the production process and checks whether it's go-
ing according to schedule and plan or not.
Before the product could go to quality control it would be checked on the heat treatment
class for better strength and surface finishing.

5.Technological procedure
These are a series of procedures that are operated on every produced
a.Operation on lathe machines

A lathe machine is a kind of machine tool, which fixes the workpiece on the main shaft and
rotates at high speed to process the cutting tool's in feed motion. A lathe machine tool that is
driven by an electric motor to rotate the spindle through a belt and gear transmission system,
which drives the workpiece on the spindle chuck to rotate and then uses the turning tool
fixed on the tool post to perform turning. The main workpiece is round rods. The cutting
work includes turning end faces, inner and outer diameters, and arc, taper, drilling, boring,
eccentricity, embossing, cutting, grooving, and turning thread.
In lathe machines the cutting tool is fixed and the workpiece rotates along the chucks ax-
is.Lath machine can do turning, facing, boring, threading (internal or external), grooving
(parting), reaming, and tapering.

b.Operation on Milling machines

A milling machine removes material from a work piece by rotating a cutting tool (cutter)
and moving it into the work piece. Milling machines, either vertical or horizontal, are usu-
ally used to machine flat and irregularly shaped surfaces and can be used to drill, bore, and
cut gears, threads, and slots.

c.Operation on slotting machine

Slotting is the process of cutting grooves or slotting workpieces.The slotting machine uses a
high load to remove material from a piece.The spindle is usually oriented vertically. And it
is responsible for cutting motion which has the cutting tool. It usually operates in a recipro-
cating manner.

d.Operation on Shaping machine

Shaping machines use huge load per stroke and also it removes much chipper stroke as we
compare it with lathe and milling machine. They are generally used for producing flat sur-
faces. In shaper machine cutting motion is given to reciprocating cutting feed motion to the
workpiece.
Cutting tools in the shop
There are different cutting tools but the most commonly applied to their works are:
• Side and face cutter (splaying cutter)- this type of cutter has a cutting edge on the periph-
eral and side of the teeth for cutting shoulder and slot.
• Slitting saw- for cutting deep slots or for parting off.
But horizontal milling cutters are specified by the name, the material, the width, the diame-
ter, and the hub size of the cuter such as,
• End mill- commonly used for facing, slotting, and profile milling.
• Rough cut end mill- for rapid metal removal.
• Slot drill- for producing pocket without drilling a hole beforehand.
• Face milling cutter- for heavy cut
e.Operation on CNC machines

CNC Milling Machines

CNC milling machines are machine operated cutting tools that are programmed and man-
aged by Computer Numerical Control (CNC) systems to accurately remove materials from a
workpiece. The end result of the machining process is a specific part or product that is cre-
ated using a Computer Aided Design (CAD) software.

CNC Lathe Machines

CNC lath machines are like CNC milling machines that are operated with Computer Numer-
ical Control (CNC) systems and provided with precise design instructions, CNC Lathes are
machine tools where the material or part is clamped and rotated by the main spindle, while
the cutting tool that work on the material, is mounted and moved in various axis.

Starting from week 3 I began to work on part design in Catia V5 and CNC programming.

Writing a CNC Program

CNC programming (Computer Numerical Control Programming) is utilized by manufactur-
ers to create program instructions for computers to control a machine tool. CNC is highly
involved in the manufacturing process and improves automation as well as flexibility.

Step 1 – Eliminate Assumptions

Use a header to set model commands that affect machine motion and offsets.
• G90 & G91 - Absolute vs. Incremental coordinates
• G80 - Cancels canned cycles
• G40 - Cancels cutter compensation etc..
Step 2 – Establish The Coordinate System
• G54-G59 – Work Coordinate System Offsets
• T and H – Tool Numbers and Length Offsets
• M03,M04 & M05 - Turning the spindle On and Off
• M08 & M09 - Coolant On and Off
Step 3 – Program Tool paths
• M03, M04, and M05 – Spindle switch
• G00 – Rapid Move
• G01 – Linear Cutting Move
• G02 and G03 – Arc Cutting Move
Step 4 - End Safely
• M30 - Raise Tool out of the way. Be safe for power up.

Design in CATIA V5
• Open Catia V5 software and go to File-New-Part.
• Create a point at the center axis with co-ordinates x=0,y=0,z=0.
• Go to Toolbar-Insert-Sketcher-Positioned sketch.
• In Sketcher Positioning select yz-plane and in projecting point select center point of
the origin.
• Sketch the geometry with Profile toolbar.
• Profile toolbar: The commands located in this toolbar allow you to create simple ge-
ometries (rectangle, circle, line, etc.) and more complex geometries (profile, spline,
etc.).
• Operation toolbar: Once a profile has been created, it can be modified using com-
mands such as trim, mirror, chamfer, and other commands located in the Operation
toolbar.
• Give appropriate constrain to the geometry.
• Constraint toolbar: Profiles may be constrained with dimensional (distances, angles,
etc.) or geometrical (tangent, parallel, etc.) constraints using the commands located in
the Constraint toolbar.
• Check for Sketch solving statues it should be iso-constrained.
• Now check for Sketch Analysis.There should be no warning and any sign of errors.