ORIENT PAPER MILLS

AMLAI

VOCATIONAL TRAINNING PROGRAME (MECHANICAL WORKSHOP)

SUBMITTED TO: ASHUTOSH MISHRA

SUBMITTED BY: AKSHAT RATHI

Introduction

Orient Paper Mills, Amlai are an industry that is in field of paper and tissue production. The plan and erection work of the company started in the year 1961 which was completed in 1963. The companys production work was started in the year 1964. The company is located in a small town Amlai which lies in Distict Shahdol i.e. the border of Madhya Pradesh and Chhattisgarh. The area of the company lies in Madhya Pradesh. The two major point kept in consideration while selecting the location of the industry were Water availability Wood and transport facility availability from nearby areas

The main raw material used for the production of the paper is wood (bamboos), which was easily available in the area. The presence of river Sone in the area was another factor that added in the favor of the plant being set up in the area. Water is very essential in a paper mill as it most important requirement for the processing to convert the bamboo fiber into finished paper. The plant was set up in 1964 with American collaboration which initially had a capacity of 250 tons per day. Now with a tissue and pilot along with it has an overall capacity of 340 tons per day.

Mechanical workshop
Mechanical workshop is the most important section of any factory or mill. Workshop helps a great deal in the maintenance and production of temporary parts used in the various machines. In OPM also mechanical workshop has an important role. In OPM mechanical workshop have mainly four shops viz. Machine shop Fabrication shop Welding shop Moulding shop

Machine shop
Machine shop is the shop where the machine tools are used for metal cutting. Machine too is a power-driven metal cutting machine which changes the shape of the material or job by producing chips. In general it produces the required shape on the raw material by performing some metal removal operation on it. Machine tools are classified on various bases. But generally machine tools used in any workshop are lathe, milling, boring, drilling, grinding and shaping machine. Any machine tool basically, possesses the following part: 1. Machine tool bed, frame or structure 2. Slides and slide ways 3. Spindles and bearings 4. Power source 5. Transmission linkage

In OPM, the workshop possesses 25 machine tools which is been operated by over 50 workers. The workers are scheduled as per the shift. Every shift contains eight hours of work. The machine tools and their numbers in the workshop are mentioned below.

MACHINE Lathe machine Grinding machine Drilling machine Milling machine Knife grinding machine Boring machine Slotting machine Shaping machine Hydraulic machine

NUMBER OF MACHINE 10 04 02 02 02 01 01 01 02

These machines tools are bought from various companies like Hindustan Motors Tools, Batliboi Tools, Kirloskar Enterprise and some of the machines are also imported from Russia and America. One of the biggest lathe machines of bed length 12-14 feets is imported from a Russian company. The knife grinding machines both linear and circular are bought here from an American company naming HANCHETT U.S.A. To operate these machines skilled operators after training of minimum 1 year are placed. These operator or workers are been supervised by specialized staff members. There are 8 workshop staff members under whom the workers are engaged to work. The staff has a general shift of 8 am 5 pm.

Lathe Machine
A lathe machine is a machine tool which spins a block of material to perform various operations such as cutting, sanding, knurling, drilling or deformation with tools that are applied to the work piece to create an object which has symmetry about the axis of rotation. Lathes are used in woodturning, metalworking, metal spinning and glass working. Lathes can be used to shape pottery, the most well-known design being the potters wheel. Most suitably equipped metal working lathes can also be used to produce most solids of revolution, plane surfaces and screw threads or helices. Ornamental lathes can produce three dimensional solids of incredible complexity. The material is held in place by either one or two centers, at least one of which can be moved horizontally to accommodate varying material length. Examples of object that can be produced on a lathe include candlestick holder, cue sticks, table legs, bowls baseball bats, crankshafts and camshafts. When a work piece is fixed between the headstock and tailstock, it is said to be between centers. When a work piece is supported at both ends, it is more stable, and more force may be applied to the work piece, via tools, at right angle to the axis of rotation, without fear that the work piece may break loose. Work is said to be fixed only to the spindle at the headstock end, the work is said to be face work. When a work piece is supported in this manner, less force may be applied to the work piece, via tool, at right angle to the axis of rotation, lest the work piece rip free. Thus, most work must be done axially, towards the headstock, or at right angles, but gently.

MILLING MACHINE

Next to lathe, the milling machine is regarded as the most versatile of all the machine tools. Practically all the shapes and sizes of both the inside and the outside of work piece can usually be machined by one or another milling method. Milling is unique adaptable and economical methods of producing a wide variety of machining operations in the manufacture of only a few parts to an almost unlimited production quantity. Milling offers the additional advantage of providing methods of repetitively creating accurate parts for interchangeable manufacture.

HYDRAULIC PRESS
A hydraulic press is a hydraulic mechanism for applying a large lifting or compressive force. It is the hydraulic equivalent of a mechanical lever, and is also known as a Bramah press after the inventor, joseph Bramah. Hydraulic presses are the most commonly-used and efficient form of modern press. The hydraulic press depends on the Pascals principle: the pressure throughout a closed system is constant. At the end of the system is a piston with a small cross-sectional area driven by a lever to increase the force. Small-diameter tubing leads to the other end of system. A fluid, such as oil, is displaced when either piston is pushed inwards. The small piston, for a given distance of movement, displaces a smaller amount of volume than the large piston, which is proportional to the ratio of areas of the heads of the piston. Therefore, the small piston must be moved a large distance to get the large piston to move significantly. The distance the large piston will move is the distance that the small piston is moved divided by the ratio of the areas of the heads of the pistons.

GRINDING MACHINE
The grinding machine consist of a power driven grinding wheel spinning at the required speed and a bed with a fixture to guide and hold the work piece. The grinding head can be controlled to travel across a fixed work piece or the work piece can be moved while the grind head stay in fixed position. Very fine control of the grinding head or table position is possible using a vernier calibrated hand wheel, or using the features of numerical control. Grinding machine remove material from the work piece by abrasion, which can generate substantial amounts of heat; they therefore incorporate a coolant to cool the work piece so that it does not overheat and go outside its tolerance. The coolant also benefits the mechanist as the heat generated may cause burn in some cases. In very high-precision grinding machine the final grinding stages are usually setup so that they remove about 200 nm per pass - this generates so little heat that even with no coolant, the temperature rise is negligible.

DIFFERENT TYPES

These machines include the: Belt grinder, which is usually used as a machining method to process metals and other materials, with the aid of coated abrasive. Sanding is the machining of wood; grinding is the common mane for machining metals. Belt grinding is a versatile process suitable for all kind of application like finishing, deburring, and stock removal. Bench grinder, which usually has two wheels of different grain size for roughing and finishing operations and is secured to a workbench. It is used for shaping tool bits or various tools that need to be made or repaired. Bench grinders are manually operated.

Cylindrical grinder which include the center less grinder. A cylindrical grinder may have multiple grinding wheels. The work piece is rotated and fed past the wheel to form a cylinder. It is used to make precision tool.

Surface grinder which include the wash grinder. A surface grinder has a head which is lowered, and the work piece is moved back and forth past the grinding wheel on a table that has a permanent magnet for use with the magnetic stock. Surface grinder can be manually operated or have CNC controls.

Tool and cutter grinder and the D-bit grinder. These usually can perform the minor function of the drill bit grinder, or other specialist tool room grinding operation.

Gear grinder, which is usually employed as the final machining process when manufacturing a high precision gear. The primary function of these machines is to remove the remaining few thousandths of inch of material left by other manufacturing methods.

DRLLING MACHINE
The earliest drills were Bow drill which date back to the ancient Harappans and Egyptians. The drill press as a machine tool evolved from the bow drill and is many centuries old. It was powered by various power sources over the centuries, such as human efforts, water wheel and windmills, often with the use of belts. With the coming of the electric motor in the late 19 th century, there was a great rush to power machine tool with such motor, and drills were among them. The invention of the first electric drill is credited to Arthur James Arnot and William Blanch Brain, in 1889, at Melbourne, Australia. Wilhelm Fein invented the portable electric drill in 1895, at Stuttgart, Germany. In 1917, Black & Decker patented a trigger-like switch mounted on a pistol-grip handle.

TYPES There are many types of drill: some are powered manually, others use electricity or compressed air as the motive power and a minority is driven by an internal combustion engine. Drills with a percussive action are mostly used in hard material such as masonry or rock. Drilling rigs are to bore holes in the earth to obtain water and oil. Oil wells, water wells, or holes for geothermal heating are created with large drilling rigs. Some types of hand-held drills are also used to drive screws. Some small applications that have no motor of their own may be drill-powered, such as small pump, grinder, etc.

BORING MACHINE
Boring machine, device for producing smooth and accurate holes in a work piece by enlarging existing holes with a bore which may bear a single cutting tip of steel, cemented carbide, or diamond or may be small grinding wheel. Single-point tools, gripped in a boring head attached to a rotating spindle, are moved circularly against the sides of the existing holes. The diameter of the hole swept out by the tool is controlled by adjustment of the boring head.

Grinding-wheel cutters have a planetary motion, rotating rapidly about their own axes, which in turn slowly rotate with the boring head about the spindle axis; the hole diameter is controlled by adjusting the distance between the wheel axis and the spindle axis.

Boring machine used in tool making shops has one vertical spindle and a work-holding table that can be moved horizontally in two directions perpendicular to each other so that holes can be accurately spaced. On some machines the spacing error is less than 0.002%. In mass-production plants, special boring machines with multiple spindles are common.