Beruflich Dokumente
Kultur Dokumente
[1]
PREFACE
Industrial training is part and parcel of every technical
course and gives a face or form to all the theoretical
knowledge we gain in our classroom. We get to have a
virtual experience of the processes, methods, objects and
phenomenon which used to be just an imaginary picture in
our minds. It also gives an exposure to the environment of
the industries and workshops which are virtual components
of our professional life. We too were provided with this
opportunity this summer.
[2]
INTRODUCTION
Fulcrum of Indian Industrial Development:
HMT synonymous with excellence in precision
engineering is a multi product company established in
1953. Built on a strong foundation of technical know how
acquired from world leaders in machine tools such as
Oerlikon, Manurhin, Glidemeister, Liebherr, Rino Berardi,
Fritz Werner, Pegard, Waldrich Coburg etc. HMTs machine
tools expertise has been developed to such an extent that
HMT can design and develop any kind machine. Having
established as a machine tool manufacturer, HMT
diversified into other product lines.
From simple lathes to multi-station transfer lines from
stand alone CNC machine to flexible manufacturing
systems, leading to factory automation, HMTs broad range
of machine tools cover General Purpose Machine, Special
Purpose Machines and CNC machines, meetings the
application needs to every engineering industry.
Pioneering the concept of CNC technology in India
HMT has the destination of being the first company to
successfully manufacture its own CNC system in
association with Siemens.
HMTs commitment to the development of the
machine tools technology is clearly reflected in the fact that
HMT has as many as seven exclusive machine tool units,
spread across the country. Each superbly equipped to meet
[3]
[4]
PATTERN SHOP
A pattern may be defined as a replica or facsimile
model of the desired casting which, when packed or
embedded in a suitable moulding material, produces a
cavity called mould. This cavity, when filled with molten
metal, produces the desired casting after solidification of
the poured metal. Since it is a direct duplication, the pattern
very closely conforms to the shape and size of the desired
casting, except for a few variations due to the necessary
allowances.
The most commonly used pattern materials in the
industry are 1) wood (e.g. teak, deodar etc.), 2) metal (e.g.
aluminium, cast iron, bronze etc.), 3) thermocol, 4)rubber,
5)epoxy resin.
[7]
[8]
FOUNDARY SHOP
HMTs foundary shop comprises of two units:
One is the captive foundary, meant for the small
production of casting having weight upto 4 tonnes.
The capacity of this foundary is 1000 MT per annum.
And the other is meant for mass production of
comparatively smaller tractor and machine
components. The capacity of this foundary is 2000 MT
per annum.
Melting Department:
The process of melting in HMT is carried out in
induction furnaces at a temperature of about 1400-1450 C
Process:
At first the induction furnaces are coated with fine
cement clay. Now metal scrap is inserted in the furnace and
slag coagulant is added to it. The requisite amount of coke
is added to it. The current is supplied to copper coils
provided in the furnace which induce current in the metal
scrap and the scrap gets heated up, when the melting
temperature is reached the molten metal is collected in
ladles and taken to the pouring zone. When this process is
being carried out the copper coils are regularly cooled with
[9]
coolant (water) so that the coils donot melt due to the high
temperature generated in the coils.
The foundary of HMT has three furnaces, two, each
having capacity of 3MT and one of 1.5MT. The two types
of induction furnaces are: Main frequency Induction Furnace(50Hz)
Medium frequency Induction Furnace(250Hz)
11000 Volts
Primary Voltage
440 Volts
Power Voltage
440 KW
Power Rating
5 KA
Melting Power
Frequency
50 Hz
Lining Thickness
95 mm
Power Factor
0.9
Fettling:
Fettling is the process by which the pattern obtained is
given the desired finish by various processes. Before
fettling, the casting obtained is subjected to removal of
projections, chips, core, runner, riser etc. by the
following processes:
Decoring
Chipping
Shot blasting (for heavy pattern)
Wheel abrasion (for small pattern)
Decoring:
Decoring is the process of removing the fused sand.
Chipping:
Chipping is the process of removing the runner, riser
etc.
[12]
[13]
Spindle Section:
This section is concerned with the manufacturing of
small cylindrical parts or spindles which may be hollow,
solid, shell type etc. according to machines requirement.
The jobs concerned are larger in size as compared to other
sections. This section manufactures all the head related obs.
This machine requires for the purpose include lathe
[14]
[15]
Cylindrical Grinding Machine:This is used to grind cylindrical jobs with the motion
of grinder itself. This job is held in the jaw chuck.
[16]
Gear Teeth Grinding Machines:It is used for grinding the teeth of the gears. In this
machine gear teeth are grinded by a worm type grinding
wheel. Here the tooth profile are checked with a machine
called gear tooth profile tester.
Components Manufacturing:
Blocks, rectangular strips, gibs, pump body, stop
block, adjustable plate, clump levers etc.
[18]
[19]
MATERIAL TESTING
1) UNIVERSAL TESTING MACHINE:
It has component load scale, oil pump, hydraulic press,
main piston, fixed cross head, & movable cross head. It
has range according to load applied:
a) 0-1 tons
b) 0-4 tons
c) 0-10 tons
It is generally used to determine:
Proportional & elastic limit
Yield point
Ultimate tensile strength
Percentage elongation & reduction of area
Working:
It is generally used to perform tensile test which is
widely used in the design of material for structure & other
purposes. Here, test piece is pulled out at a constant rate
gradually increasing the axial pull, till the rupture take
place. The tensile test for ductile material is generally,
carried out with the help of a Universal Testing Machine on
the specimen made from material to be tested.
[20]
2)SPECTROSCOPE:
It is a method of qualitative analysis of material with
the help of electricity. Argon gas is being used as it
prevents oxidizing of piece. Here piece is not destroyed.
This is used for chromium, ammonium, nickel, tungsten,
manganese, zinc, tin, lead etc. the spectrum is directly
compared with a chart as it is moved by caliper & is then
compared. It is used to find what materials are present.
4)POLISHING MACHINE:
In this machine polishing of material is done. In this
belts are present on which abrasive powder is applied. In
this machine belt is passed over two pulleys & which is
driven by motor.
6)SPECTOMETER:
It is basically computerized control program in which
material is kept under observation than software is there
which give composition of each element present in the
material.
7) PORTABLE MICROSCOPE:
It is a method used for analysis of the structure without
cutting. And also it is used for determining the
composition of element present in the material. It is used
for the analysis of the structure.
[23]
10)
PRECAUTION:
The indenter & anvil should be clean & well placed.
The surface of the specimen should be flat, clean, dry,
& smooth &should be placed perpendicular to the
indenter.
[24]
M CODES
M00 Program Stop
M01 Optional (Planned) Stop
M02 End of program
M03 Spindle CW
M04 Spindle CCW
M05 Spindle OFF
M06 Tool change
M07 Coolant #2 ON
M08 Coolant #1 ON
M09 Coolant OFF
M10 Clamp
M11 Unclamp
M12 Unassigned
M13 Spindle CW & Coolant ON
M14 Spindle CCW & Coolant ON
M15 Motion +
M16 Motion M17 Unassigned
M18 Unassigned
M19 Oriented spindle stop
[25]
[26]
G CODES
G00 Rapid Positioning
G01 Linear Interpolation
G02 CW circular Interpolation
G03 CCW circular Interpolation
G04 Dwell
G05.1 Q1 Ai Nano contour control
G05 P10000 HPCC
G07 Imaginary axis designation
G09 Exact stop check
G10/G11 Programmable Data input/ Data write cancel
G12 CW Circle Cutting
G13 CCW Circle Cutting
G17 X-Y Plane selection
G18 X-Z Plane selection
G19 Y-Z Plane selection
G20 Programming in inches
G21 Programming in mm
G28 Return to home position
G30 2nd reference point return
G31 Skip function
[27]
[28]
[29]
1) Double Housing Planer:This is the heavy type of planer and is used for heavy
cuts by double cutters. Its length is 3000mm. It consists of
two columns, one on each side of bed. The cross rail is
fitted between the two housings which can accommodate
one or two heads, according to the specifications.
[30]
Machines installed
Horizontal Boring Machine
[31]
[33]
TOOL ROOM
This department keeps various kinds of tools which
are useful during manufacturing of heavy pats. Most of the
tools are measuring devices such as vernier caliper,
micrometer etc.
[35]
Types of Micrometer:
Outside Micrometer (aka micrometer caliper),
typically used to measure wires, spheres, shafts and
blocks.
Inside Micrometer, used to measure the diameter of
holes.
Depth Micrometer, measures depths of slot and steps.
Bore Micrometer, typically a three-anvil head on a
micrometer base used to accurately measure inside
diameters.
Tube Micrometer, used to measure the thickness of
tubes.
Dial Indicator:
Dial indicators, also known as dial gauge and probe
indicators, are instruments used to accurately measure small
linear distances, and are frequently used in industrial and
mechanical processes. They are named as so because the
measurement results are displayed in a magnified way by
means of a dial.
Dial Indicator may be used to check the variation in
tolerance during the inspection process of a machined part,
measure the deflection of a beam or ring under laboratory
conditions, as well as many other situations where a small
measurement needs to be registered or indicated. Dial
indicators typically measure ranges from 0.25mm to
300mm (0.015in to 12.0in), with graduations of 0.001mm
to 0.01mm (metric) or 0.00005in to 0.001in (imperical).
[36]
b) When the rotating spindle lies horizontal w.r.t. the table the
machine is as horizontal (H) milling machine.
c) When the cutting can be done at any angle of the job with the
help of rotary motion of tile table the machine is termed as
universal (U) milling machine.
Thus, these machines are named as FN2V, FN2H, FN2U,
FN3H, FN3V, FN3U, TRM3V, and TRM3H.Now here we
would discuss the features of the three types of milling
machines with their properties:-
[38]
Assembly of Milling Machines:1) First of all the parts are obtained from the foundary and
machined accordingly to give the desired shape to them.
2) The base is leveled properly with proper instruments .
3) Then the column is aligned w.r.t. the base. The column is
attached to the base with the help of guide pins which form a
right fit and later with the help of screws.
4) The knee is then aligned with the base keeping in mind that
the face of the saddle is parallel with the base.
5) Then the saddle is mounted on the knee and aligned properly.
6) The table is then mounted on the saddle with the help of
guides which form a proper fixture with each other.
7) The ball screw is then attached which is responsible for the
vertical movement.
8) The gears and the pulleys are then assembled inside the
column along with other basic components.
9) The electrical assembly is carried out with proper earthing
facility.
10) Then all the accessories are attached to it.
11) Final inspection is done and machine is dispatched.
[39]
CNC SECTION
Introduction
We know that GPMs are semi - automatic machines. They
require an operator for each work piece loaded on machine and in
a limited period. Mass production is not possible in these
machines. Moreover complex shaped jobs require high precision.
They need for flexible automation has always been felt. And this
is an era of machine tool automation. So, flexible automation is
implemented in machine tools in the form of NC and CNC
(Computerized Numerical Control) technology . Today HMT is
producing a lot of CNC variants of conventional machine tools
with the specialized functions and mostly CNC products.
CNC machines are part of the field named mechatronics. This
field is the combination of electronics and mechanical
engineering fields. When they work in combination they are
termed as above. A single CNC machine can perform variety of
machining operations in a sequential order (based upon the
programme). For example drilling , tapping , slotting, milling, etc.
operator is used only for clamping and declamping purpose ( after
feeding the programme ). These machines ensure repeatability of
the dimensions (precision). Accuracy of these machines is in
microns.
A CNC machine may be of three dimensional coordinate system
with XYZ axis. Rest two are available on machines whose table
can rotate and tilt. These are 4th and 5th axis. The axis of the
spindle is termed as Z axis. The axis which crosses Z axis
[41]
Machine Description:Salient features of CNC machines are as follows:1) Bed type machine configuration:Bed type construction with longitudinal and cross movement
to work table and vertical movement to head , provides stable
cutting condition and maximum rigidity. Box type construction of
bed and column with properly ribbed reinforcement minimizes
torsion and flexural deflection.
2) Linear motion with guide ways:Preloaded anti - friction linear motion type. Guide ways in the
entire three provide clearance free guidance for slides during
cutting. Their use significantly reduces the coefficient of friction
and eliminates stick slip and thermal generation during high speed
positioning. In addition they offer high positioning and
outstanding contouring capability.
6) Stepless AC spindle motor:AC spindle motor eliminates the troublesome brush inspections
and replacements required in case of DC motors. Another
advantage of DC motor is that it reduces electricaly consumption.
7) Electronic spindle orientation:The spindle motor has build in encoder for position feedback of
the spindle. Spindle orientation stops spindle in a particular
position. This helps in retracting bars without damaging bores in
boring operations and counter-boring/Facing. Automatic tool
change is also achieved through the features.
8) AC servomotors:All the three axes are driven through AC servomotors. Their
[45]
13)Numeric head counter balance:It offsets the natural weight of spindle head and guarantees
consistent cutting , high speed and highly accurate positioning . It
eliminates head falling.
[48]