Beruflich Dokumente
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Submitted By:
AJAY KUMAR SAMARIYA
IV year (MECHANICAL)
ACKNOWLEDGEMENT
We feel profound happiness in forwarding this industrial training report as an image of sincere
efforts. It is almost in evitable to ensure indebt ness to all who generously helped by sharing their
valuable experience & devoting their precious time with us, without whom this industrial
training report would never have been accomplished.
Only theoretical Knowledge is not sufficient for absolute mastery in any field. Theoretical
knowledge given in our book is not of much use without knowing its practical implementation. It
has been experienced that theoretical knowledge is volatile in nature; however practical
knowledge makes solid foundation in our mind.
To accomplish this aspect the Rajasthan Technical University has included Industrial training for
the student of degree in the ending of VI semester. We accomplished our Industrial training on
24th May 2012 to 25th June 2012 succeeding chapters give details about what we have learnt
from the prestigious Organization.
CONTENTS:-
Introduction
HMT at a glance
Important parts
Applications
Major customers
When India achieved independence in 1947, there was hardly any industrial base
in the country. Right form the prior H.M.T. has played an important role in providing the
much needed industrial base as well as a launching pad for the growth & development of
the country.
HMT was conceived by the Government of India in 1949, and was incorporated
in 1953, with the objective of producing a limited range of machine tools, required for
building an industrial edifice for the country.
This Unit was started 1970-71 with a production of Rs. 8.64 Lack faces with
difficulty in procurement of quality Machine Tool Casings a captive Foundry Plant was
installed in 193 with a capital of about Rs.2 Crore.
This Unit was subsequently merged with HMT Ltd. On 1 st April 1975 as sixth
Machine Tool Plant with this merger; the Unit got backup support of HMT. The basic
plant was established with the collaboration of the Czechoslovakian firms, M/s Skoda
Export, Praha and German firm WMW, then in East Germany.
1.1 HMT AT A GLANCE
Date of Registration 11-01-1967
Headed by Joint General Manager (HRM) this department is setup with an aim of
conservation and proper utilization of human resources and is also responsible for
maintaining the cordial relations between employees and management. The other important
functions of this department are performance appraisal and different welfare activities for
the employee.
Patterns provide the exterior (mould) or interior (core)shape of the finished casting and
are produced in wood,metal or resin for use in sand mould and core making.Patterns are
usually made in two halves.
Sand casting is the most common production technique, especially for ferrous castings.
Sand is mixed with clay and water or with chemical binders and then packed or rammed
around the pattern to form a mould half. The two halves are joined together to make the
mould - a rigid cavity that provides the required shape for the casting, as shown in Fig.
6 below.
Variations on this technique include the use of plaster in place of sand and the recently
invented Patternless process (CDC 2000), where the mould is machined directly out
of a sand block without the need for a pattern.
Cores are produced by blowing, ramming or in heated processes, investing sand into a
core box. The finished cores, which can be solid or hollow, are inserted into the mould
to provide the internal cavities of the casting before the mould halves are joined. Sand
cores are also widely used in diecasting, where permanent metal moulds are employed.
Electric induction furnaces are the most common type used for batch melting of
ferrous, copper and super alloys. This method involves the use of an electrical current
surrounding a crucible that holds the metal charge. Furnace sizes range from < 100 kg
up to 15 tonnes.
For production of super alloys and titanium, melting may be undertaken in a vacuum
chamber to prevent oxidation
1.2.2.4 Casting and separation
Molten metal is poured into moulds using various types of ladles, or in high volume
production, automated pouring furnaces. Metal is poured into the runner (a channel into
the mould cavity) until the runner bush is full. The riser provides an additional
reservoir of feed metal to counteract the shrinkage that occurs as the casting begins to
cool.
When the metal has cooled sufficiently for the casting to hold its shape, it is separated
from the mould by mechanical or manual methods. Where sand moulds are used, the
process is often referred to as shakeout or knockout, and large amounts of dust may be
generated
1.2.2.4 Removal of runners and risers
After casting, these extraneous pieces of metal are removed and often collected for re-
melting. In ferrous castings and larger non-ferrous castings, they may be removed by
knocking off, sawing or cutting using an arc air or oxy-propane torch. In die-castings,
they are often snapped off manually.
1.2.2.5 Finishing
The industry recycles a large proportion of mould and core making sand internally for
re-use. This involves processing to remove tramp metal and returns the sand to a
condition that enables it to beused again for mould or core production
Headed by DGM. This department is responsible for inspection & Servicing of the
M/Cs. This department is concerned with the inspection of various components and
machines being manufactured. The inspection is carried out in various stages, beginning
from the inspection of individual components at different stages of manufacturing
followed by the inspection of the whole machine while included final runs etc.
Inspection of incoming material is also handled.
Headed by JGM. It is responsible for all kinds of purchases made by unit. This
department also maintains a Central store and looks after appropriate levels.
Headed by JGM(EQ). The main functions of the planning department are as under: -
Time calculations for each operation. Job card booking of workers in shifts.
To prepare monthly progress reports for the production activities carried out in shop.
To calculate manpower and machines available, accordingly new machines are ordered
and component.
Counting of products and components.
Prepare machines and sectional layouts
Headed by AGM Finance. The functions of this department include maintenance of all
accounts of the Company. The balance sheet is finally prepared which is sent to the
head office for the preparation of combined balance sheet. The costing section of this
dept. is responsible for the computing of each product of that the selling price may be
determined accordingly.
is headed by JGM(Sales). This dept. is divided into 3 sections viz. Sales, Spares and
Reconditioning. These functions of sales sections are the execution of sales order and to
bid for contracts through tenders. The function of service section is to provide after
sales & also looks after customers complaints and supply of spares.
This is headed by Junior Security officer. Main function of this dept. is preventions of
theft, sabotage and maintenance of industrial security within the HMT compound
including Township.
Dy. General Manager heads this department. This department also looks after the
feedback received from marketing division so as to make improvement accordingly
1.3 HMT Grinding Solutions:-
Bed made of high tensile strength cast iron, heavily ribbed for better vibration damping
and shock absorption.
Precision, widely placed V & flat guideways for table with continuous automatic
lubrication. Turcite lining for G17.
Higher powered wheel head for production model for high rate of stock removal.
Precision, V & Flat guideways with turcite for infeed slide for better damping & higher
repeatability.
Auto plunge grinding cycle consisting of rapid approach, coarse feed, fine feed, spark out
and rapid retraction.
Single piece robust construction with long guided sleeve for better rigidity of tailstock.
MACHINE FEATURES
Two axes CNC controlled external cylindrical grinding machine with Siemens / Fanuc
CNC System
Both axes are driven by preloaded ball screw and servo motor
U-MODEL:
\
1.3.1.3 CGM -225 CNC AH
1.3.1.4 CNC CYLINDRICAL GRINDING MACHINE
Offers economic solution for cylindrical grinding applications and angular head grinding
applications.
Can be used for grinding of crankshaft journals in automatic cycle with auto positioning.
Hardness : 35 40 HRC
(sharpening)
Achievable Accuracies:
Hardness : 60 62 HRC
Achievable Accuracies:
Circularity : 0.003
0.6 Ra on face
Achievable Accuracies:
Hardness : 60 62 HRC
Achievable Accuracies:
Circularity : 0.003
Cylindricity : 0.005
Production Rate : 40
Material :M5
Achievable Accuracies:
Circularity : 0.002
Cylindricity : 0.005
Achievable Accuracies:
Circularity : 0.0025
Hardness : 60 - 62 HRC
0.1 mm on face
Achievable Accuracies:
Size Tolerance : IT 7
0.6 Ra on face
Automobile Sector:-
Bajaj Auto
Ashok Leyland
Hero Honda
Honda, Thailand
TELCO
Maruti
Premier Automobiles
Escorts Ltd,
HMT Tractors
Punjab Tractor
Ford India
LML
Hyundai Motors
TV
Auto- Ancillary:-
Munjal Showa
Escorts
MICO
Bajaj Motors
Cooper Metals
International Tractors
SRMT
Sona Steering
Pricol
Kalyani Brakes
TATA Yutaka
TI Diamonds
AUDCO
BPL
Videocon
Voltas
Godrej
Kirloskar Copeland
Himson Textiles
Bearing Industries:-
Timken India
HMT Bearing
SKF Bearing
NRB Bearings
KCI Bearings
NEI
Defence:-
MSF Ishapore
H.V.F. Avadi
A.H.Q
HAL
Value in ` Lakhs
Sales (X) 47 77 64 58