Foundry Shop The cast products of BMTF have already established a footprint in the market both for its

quality and competitive price. The foundries are served with In House pattern making facilities equipped with lathe and milling machines both for wooden and metallic patterns. Product of this shop: Manhole cover (Material: Cast Iron) Liner of rice mill (Material: Cast Iron) Brake drum (Material: Cast Iron) Tube well (Material: Cast Iron) Centrifugal pump (Material: Cast Iron) Rural Electrification Board (REB) power transmission lines items (Material: Aluminum)

Pattern making materials: Wood Aluminum

Melting Unit: Cupola Furnace: This type of furnace is used specifically for melting cast iron. Capacity of this furnace is 10 ton. It consists of a large shell of steel plate lined with refractory. The charge, consisting or iron, Coke, flux and possible alloying elements, is loaded through a charging door located less than halfway up the height of the cupola. The iron is usually a mixture of pig iron and scrap (including risers, runners, and spurs left over from previous castings). Coke is the fuel used to heat the furnace. Forced air is introduced through openings near the bottom of the shell for combustion of the coke. The flux is a basic compound such as limestone that reacts with coke ash and other impurities to form slag. The slag serves to cover the melt, protecting it from reaction with the environment inside the cupola and reducing heat loss. As the mixture is heated and melting of the iron occurs, the furnace is periodically tapped to provide liquid metal for the pour.

3x Crucible Furnace: This particular type of furnace can be used for the melting process of Ferrous, Non-Ferrous, different types of Steel Alloy materials, etc. Crucible furnace is very simple in nature. A crucible made of graphite whose outer diameter is approximately 16~20 inch and height is approximately 30 inch and crucible thickness is about 3 inch.

1x Tilting furnace: Although the principle of the principle of this furnace is same as crucible furnace, Tilting furnace is much easier to use. The crucible can be tilted through an arm wheel which made it easier to cast out to molten metal. Aluminum, Copper and their alloys can be melt in this furnace.

Sand molding technique: 1. Unrefined sand is first washed by water and then dried. 2. Second step of sand molding is mixing Bonding agent, refractories etc. with the dried sand to create molding sand. 3. Then this molding sand is placed over the pattern and then jolted, squeezed and rammed. The ramming process is done by Height Breaking Machine.

Die Casting Method: 1. First the dies are heated. This heating process is done by natural gas. When molten metal is casted by gravity casting process which means that the molten metal travels through runner and riser it is fed through the feeder using gravity force. If cold dies are used, long before the molten metal rise through the riser it solidifies. That is why the dies are heated before they are used in casting process. 2. Second step is to pour the molten metal through the feeder. When it is seen that the molten metal coming out through the riser, pouring stops. 3. After some time the two dies are taken apart and the desired parts are brought out.

Surface Cleaning Machine: The parts or patterns that are found after die casting process have rough unfinished edges. These rough edges are cleaned by surface cleaning machine. The pattern is placed inside the machine. The machine has a box which has numerous small holes in its walls. The pattern is placed in that box. When the machine is switched on, numerous small metal sphere or balls comes though these holes and hit the pattern as it is rotated inside the box. These balls are called shots. After some time the pattern is brought out with its surface clean. Although this process is easy to use, it is not precise. For precise operation lathe machine, milling machine, grinding machine is used.

Machine Shop Boring and Milling Machine: Specification Table Size Swiveling Table Max. Shear Dia. Vertical Travel Cross Travel = 500-1050 mm = 50x500 mm = 500 mm = 650 mm = 800 mm

Longitudinal Travel = 800 mm Maag Gear Grinding Machine: Specification Max. outside dia. of gear = 300 mm Min. pitch circle dia. Normal pitch module No. of teeth Max. helix angle = 35 mm = 10-15 mm = 10-120 mm = 45 degree

Centre Lathe Machine: Specification

Distance between the centres = 1003 mm Swing over bed Swing over bed gap = 425 mm = 481 mm

Shear machine: This particular machine can cut shape of round, square, flat plate all at once. Sheet Bending Machine: This machine is use for making pipes from metal sheets. The metal sheet is passed through 3 wheel and it comes out as a pipe. Diameter of pipe can be varied. Specification Width of the plate = 2000 mm

Thickness of the plate = 23.4 mm Dia. of pipe Maximum Minimum = 2000 mm = 500 mm

Assembly Shop In assembly Shop, different parts of a vehicle are assembled together. Most of the parts are imported. Most frequent vehicles that are assembled here are Assembly Sequences: Assembly sequence differs vehicle to vehicle. Big vehicles that weigh about 3 tons (i.e. truck,bus)are assembled by following this sequence--1. Unboxing 2. Frame 3. Axle Line a) Axle b)Leaf Spring c)Disc Wheel d)Tyre e)Suspension 4. Pipe Line a)Piping Military Trucks Bus Night coach Jeep cars Private cars Pickup Trucks 3 wheel CNG BMTF Power Tiller Motorcycles

b)Harness c)Bracket d)Air Tank e)governor 5. Engine and Transmission Line a)Engine Sub Assembly b)Transmission Sub Assembly c)Radiator d)Pitman 6. Transfer Installation Line a)Transfer b)Propeller Shaft c)Fuel Tank d)Air Cleaner 7. Cabin Installation Section a)Dash Board b)Instrument Cluster c)Steering Column d)Seat e)Triming Medium sized vehicles that weigh about 1.5 tons (i.e. jeep, private car) are assembled by following this sequence 1. Material Handling and distribution Section a)Box Opening b)Checking of CKD Components c)Distribution 2. Spot Welding Section a)Deck b)Cabin c)Door d)body 3. Metal Section a)Gas Welding b)Brazing c)Soldering

d)Finishing 4. Painting Booth 5. Chassis Section a)Axle b)Spring c)Wheel d)Engine Sub Assy 6. Triming Section a)Dash Board b)Pipe c)Glass 7. Final Section a)Setting of Deck and Cabin b)Installation of all Items c)Air Bleed 8. Inspection Section a)Engine b)Clutch and brake c)Horn and lighting d)Painting

All the parts are moved from one section to another by remote control crane. Brand: MARS Country: Switzerland Capacity: 3000 kg

There are some ongoing and finished projects in Assembly Shop. BMTF Power Tiller(finished),3 wheel CNG (ongoing),pickup(ongoing) are among them.

Forging Shop Being equipped with all kinds of forging machines like hammer, presses and special forging machines, BMTF forging shop is probably the most vibrant area in the factory.

Die Casting: The Die Casting Plant of BMTF is capable of producing 1 million die cast parts per year. Thanks to the 630 Ton Buhler Die Casting Machine for its excellence in making quality products. Typical products include electric fan parts, auto and motorcycle spares and bicycle parts etc. The tool room has all the facilities to design and manufacture single and multi-cavity dies. Die Machining Process: 1. Circular Saw: Circular Saw is used to give the rough form of the die from the huge raw material specification: Power: 7.5KW Feed: 8, 10, 13,17,23,30 mm Speed: 60 rpm Cutter Mat.: Carbide 2. Drill Machine: Drill Machine is used create a carrying hole in the die. 3. Shaping Machine: By Shaping machine the edges are shaped. 4. Surface Grinding Machine: After shaping process the block is ready for surface grinding. It is used with utmost precision because it is the final dimension of the dies.

5. Milling Machine: Both dies have a dovetail slideways at the rear end which connects them to gravity forging machine. These slideways are done by milling machine. 6. Layout: This is the process where the die design is imprinted on the die block. Needless to say this the most important part of die making process. 7. Copy/Wire-cut/Idiom Milling Machine: These machines are used to make cavities on the die block according to the design.

The dies used in the forging shop are made of KTV Chrome Vanadium alloys.

Central Tool Department(CTD) Shop In CTD shop there are lathe machine, milling machine, shaper machine, grinding machine, drilling machine, cutting tool sharpening machine(slitting saw cutter) etc.

Cutting Tool Sharpening Machine: After using a cutting tool for a while its edges becomes dull therefore losses it precision. That tool cannot be used until it is repaired. Cutting tool sharpening machine is used for sharpening blunt edged cutting tool. It is a special type of grinding machine specifically for tool sharpening purpose. It has a slitting saw cutter which carries an abrasive wheel which performs the sharpening operation. This wheel can be rotated at different angle and can be positioned at different position. Jig Boring Machine: This type of machine allows the operator to make very precise machining operation. Its work table can be moved by using large hand wheels which has micrometer style readout and vernier. It has an

accuracy of 0.001 mm.

BMTF AT A GLANCE

Bangladesh Machine Tools Factory (BMTF) Ltd. is one of the largest company enterprises of its kind in Bangladesh. It is located at Gazipur about 40km away from Dhaka. The factory has an area of 249.55 acres with a covered area of 60310sq meter. It was commissioned on 11th February 1979. BMTF is a state owned limited company under the management of Bangladesh Army. BMTF is well equipped with variety of high production machineries & equipments for various engineering products. It has basic production facilities like casting, forging, machining, heat and surface treatment etc. It has thirteen large production shops along with administrative building, training school, residential area etc., within the complex. This factory has enormous prospects to open up new avenues with products and services for local & foreign markets. Under the management of Bangladesh Army, BMTF is now reshaping itself to respond to the new challenges. The mechanized foundries of BMTF are the largest in Bangladesh having a combined output of about 5000 tons per year.