Study Area Report SAA Factory

Maintenance section:
Maintenance section is the back bone of any factory. This Maintenance section provides the services to machines, and

electronic components including CNC system and PLC programming to digital integrated circuits. The following are the sections of SAA factory 1. Empty section 2. Loading & Assembling section 3. Packing section 4. Testing section

Empty section:
In this section cases and bullets are manufactured. In this section modular plant is working. This plant is recently installed. It has two lines.
1.

Case line Bullet line

2.

Case line:
This line consists of systems that are

Cupping Press

in this press a coin of bras is mould into a form of cup. Both the sizes 5.56*45mm and 7.62*51mm cases are formed here.

It has stages of initial draw, final draw and heading. It has DC

drive control having 100hp power. It uses adec plc having main 8085 Intel processor. It also consists of optical devices, proximity switches etc.

4-A

Here head turning and piercing is done. It has DC drive control

having 25hp power. It uses adec plc having main 8085 Intel processor. It also consists of optical devices, proximity switches etc.

4-B

Here following processes are done. It has DC drive control

having 40hp power. It uses adec plc having main 8085 Intel processor. It also consists of optical devices, proximity switches etc

4-C

It comprises of high frequency induction heating.

Processes are
a- Body annealing

b- 1st taper c- 2nd taper d- Trimming e- Tip Annealing The material of case is brass. After this, case is sent to loading section.

Bullet line:
It consists of system 7. Here bullets are formed that are installed in front of case after loading. Process is as follows.

1st draw

Final draw.

1st punch. 2nd punch

Lead insertion Lead Press

 Boatail Cannelour Sizing(to set dia due to multiple processes) Bullet line also consists of cupping press before system 7. The material of bullet is GMCS (gilding metal clad steel)

List of machines
These are

Bullet Lachaussee Press

It is plc controlled Siemens S-5 It consists high VFD (variable frequency drive)

Case Lachaussee
It is plc controlled siemens s-5 It consists of high VFD HTR Lachaussee

HTR Bullet Trimming

Here bullet trimming is done by this machine

 Bullet Turn Over Machine Tapering M/C for 30 mm Bore

This machine sets the size of bullet again that has been changed due to previous operations on it.

Sizing M/C

Bullet Lead Core M/C Bullet Rumbler Case Rumbler

Here in this machine lead is pressed into bullet

Lead Ext Press

Case Cupping Press Bullet Cupping Press Piercing M/C Heading M/Cs Indenting M/C Trimming M/C First Draw

2nd Draw

Annealing Furnaces
These are electrically controlled by resistive heating. Nichrome strip is basic element used here.

Washer Air Compressor

Machines in C08:
CNC Grinding Machine
This machine is for both internal and external grinding. This based on FPGA (FIELD PROGRAMABLE GATE ARRAY). That is the latest technology for high speed operations.FPGA works as communicator here. It is controlled by FANUC 16 TI multi axes control using Fanuc plcs.It is heart of machine. The speed of main drive is 1.5 lac rpm.

CNC Grinding( internal )machine:

It uses PLC: sematic S7 C-300. it has control panel of siemens Sinumeric 840d.The speed of main drive is 1.2 lac rpm. It is 3 phase motor. A liquid flows inside machine as coolant.

 CNC Lath:
This machine has 80186 graphical processor. PLC uses 8085 processor. And three fanuc processors for mathematical operations.

CNC JIG BORING , GRINDING(& Milling ) machine.

It done milling and boring operations. One 8085 processor is for main ,one for control and one for scales(X,Y,Z) controlling. It has dedicated PLC.

WIRE CUT:
It is an application of EDM technology. EDM is electric discharge machining. Using wire for cutting materials(hard and soft). It has AGIE control using 8080 A (on current generator card) & 8085(on panel) processors. It is Swiss technology.

Products of SAA factory

Cartridges are the following

7.62 mm
1. weight 9.6 g 2. jacket material CuZn10 3. core material lead

5.56mm
1. weight 4g 2. jacket material CuZn10 3. core material lead

9 mm
1. weight 7.5g 2. jacket material CuZn10 3. core material lead

Conclusions
In SAA factory we observed VFDs, Microprocessors, relays, PLCs, Laths, Furnaces, Microcontrollers, operating panels, Proximity switches, DC to Rc converters, Regulators, thyristors, SCRs etc.