JNEC,Aurangabad

INTERNSHIP REPORT
by

RAKHI A. TOSHNIWAL

PRN NO.20213220181137210089

Under guidance of

A. P. Phatale

DEPARTMENT OF

ELECTRONICS & TELECOMMUNICATION ENGINEERING

MGM’s JAWAHARLAL NEHRU ENGINEERING

COLLEGE, AURANGABAD

2020-21

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INTERNSHIP REPORT
submitted in partial fulfillment of the requirements for

the award of the degree of

Bachelor of Technology

in

Electronics & Telecommunication Engineering

by

RAKHI A. TOSHNIWAL

PRN NUMBER

(20213220181137210089)

Under guidance of

A.P.Phatale

DEPARTMENT OF ELECTRONICS & TELECOMMUNICATION

ENGINEERING

MGM’s JAWAHARLAL NEHRU ENGINEERING

COLLEGE, AURANGABAD

2020-21

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MGM’s JAWAHARLAL NEHRU ENGINEERING COLLEGE, AURANGABAD

DEPARTMENT OF ELECTRONICS & TELECOMMUNICATION ENGINEERING

This is to certify that Internship Report submitted by RAKHI A. TOSHNIWAL

having PRN (20213220181137210089) is her work during the internship and
submitted in partial fulfillment of the requirements for the award of the degree of
Bachelor of Technology in ELECTRONICS & TELECOMMUNICATION
ENGINEERING of Dr..Babasaheb Ambedkar Technological University, Lonere
during the academic year 2020-21

GUIDE HOD PRINCIPAL

A. P. PHATALE S. N. PAWAR Dr. H. H. SHINDE

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Acknowledgement

I am very glad to represent project report on “Product Of Tool Room Work” fully
designed, fabricated and tested in our six month internship as part of our curriculum.
I have tried my level best to focus upon each and every parameter. In concern with
this topic the detail, necessary figure, definition, tabular analysis has been
enumerated in very easy, simple, compact and lucid manner.
I have been able to achieve this task by dynamic guidance and constant
inspiration where a great use in working of this project of Mr.K.V.GUJAR sir.
I also extend my sincere thanks to Mr.D. P. Telange sir whose support,
cooperation, and motivation provided to me during the training for constant
inspiration, presence and blessings. I have no wards to express my gratitude towards
his kind, persistent inspiration, parent advice and outstanding treatment while
clarifying my confusion.
I am also grateful to our honorable staff of Madhurved Industries for providing
numerous facilities and guidance due to which this difficult task turned in a
convenient task.
The permission granted to me the honorable HOD Mr. S. N. Pawar sir to do the
internship in greatly in acknowledged.
I express my sincere gratitude to honorable Mr. K.V.GUJAR and administration
for providing me an opportunity to undergo six month internship in Madhurved
Industries.

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Index

LIST OF FIGURES .................................................................................................................. vi

LIST OF TABLES ................................................................................................................... vi
CHAPTER 1 .............................................................................................................................. 1
Abstract .................................................................................................................................. 1
CHAPTER 2 .............................................................................................................................. 2
Introduction of Company ....................................................................................................... 2
Profile............................................................................................................................ 2
Facilities ........................................................................................................................ 2
Products......................................................................................................................... 3
Our Manufacturing Machinery List .............................................................................. 4
Departments .................................................................................................................. 4
Customers List:- ............................................................................................................ 5
Regested office:- ........................................................................................................... 5
CHAPTER 3 .............................................................................................................................. 6
Internship Discussion ............................................................................................................. 6
Objective:-..................................................................................................................... 6
Job description:- ............................................................................................................ 6
Process:- ........................................................................................................................ 7
CNC Machining .......................................................................................................... 10
Type of CNC machines............................................................................................... 10
CHAPTER 4 ............................................................................................................................ 13
Weekly Overview of Products ............................................................................................. 13
4.1 Dies:- ..................................................................................................................... 13
4.2 Jig/ Fixture:- .......................................................................................................... 15
4.3 Gauge:-.................................................................................................................. 17
CHAPTER 5 ............................................................................................................................ 20
Conclusion ............................................................................................................................ 20

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LIST OF FIGURES

Fig 2.1: Images of Press tool ……………………………..………………………3

Fig 3.1:CNC milling machine………………………………….……….………11

Fig 3.2 CNC lathe machine ……………………………………...……………..11

Fig 3.3:-CNC router machine……………………………………...……………12

Fig 4.1:-Process flow of Dies……………………………………….…….….…13

Fig 4.2:-Types of Dies……………………………………………………....…..13

Fig 4.3:- Basic set up for Die……………………………………………...…....14

Fig 4.4:- Feeler gauge…………………………………………………………..18

Fig 4.5:-Radious gauge…………………………………………………………19

LIST OF TABLES

Table 2.1 Machineries in plants …………………………………………………4

Table 2.2 Our customers list……………………………………………...………5

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CHAPTER 1
Abstract
This report is a summary of all the work experience I have been able to gather
during my six month industrial program at Madhurved Industries.

The report contain some of the product of tool room worksfully designed,
fabricated and tested in interenship.

This report is separated into chapters with each chapter from chapter 2 to chapter
4 starting everything I have learnt in each department for simplified reasons. This
report also contain what I taught by various analysts I worked with and informations
I got from text book,online during my internship.

This report is restricted to tools and dies.The procedures for making the tools and
dies are shown in the this report.

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CHAPTER 2
Introduction of Company
• Profile

Madhurved Industries is one of the leading medium scale companies. Our

company was established in the year 5 March 2008, as a manufacturer of Precision
Press Tools, Press Parts, Dies, Jigs & Fixtures, Gauges and Special Purpose
Machines for the Auto Industries, as well as for replacement markets. We are
committed to tough challenges in the form of stringent specifications & rigorous
quality standards set by our valuable customers –this has been confronted by
dedication, commitment and excellence in work.

Today we are manufacturing above products with multi-manufacturing

technology under one roof for major suppliers of two industries. We are well
equipped to serve the customers as per their needs and urgency. We, the team at
Madhurved Industries, function in perfect synchronization with the customer and are
capable of achieving highest quality standards set by the customer, because we
believe that the satisfied customer is an investment and a perfect product is the bond
for such continued relationship.

We assure you of our best services & commitment to high degree of quality
& reliability in the products, and anticipate our association with your company.
• Facilities

Vision Technologies has installed multi-manufacturing technology with

backward integration of the plant to have highly flexible manufacturing facilities for
Precision Press Tools, Press Parts, Dies, Jigs, Fixture &Gauges and Special Purpose
Machines.

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Fig 2.1: Images of Press tool

• Products

➢ Dies
➢ Fixtures
➢ Gauges

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• Our Manufacturing Machinery List

Table 2.1 Machineries in plants

• Departments

➢ Assembly shop
➢ Machine shop
➢ Purchase dept.
➢ Inspection & testing
➢ Processing
➢ Finance & accounts
➢ Store

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• Customers List:-

Table 2.2 Our customers list

• Regested office:-

Plot No.:SS-45-46, Truck Terminal, KamgarChowk, M.I.D.C. Waluj

Aurangabad – 431 136 Maharashtra, INDIA

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CHAPTER 3
Internship Discussion
• Objective:-

Tool and die makers are a class of machiniste in the manufacturing industries.
Variations on the name include press tool, toolmaker, die maker, moldmaker or tool
jig and die-maker, or fitter, depending on which area of concentration or industry an
individual works in.
Tool and die makers work primarily in toolroom environments sometimes
literally in one room but more often in an environment with flexible, semipermeable
boundaries from production work. They are skilled artisans (craftspeople) who
typically learn their trade through a combination of academic coursework and hands-
on instruction, with a substantial period of on-the-job training that is functionally
an apprenticeship (although usually not nominally today). They make dies,fixtures,
gauges and other tools used in manufacturing processes.
• Job description:-

Traditionally, working from engineering drawings developed by the toolmaker,

engineers or technologists, tool makers lay out the design on the raw material
(usually metal), then cut it to size and shape using manually controlled machine
tool (such as lathes, milling machines, grinding machines, and jig grinders), power
tools (such as die grinders and rotary tools), and hand tools (such
as files and honing stones).
Art and science (specifically, applied science) are thoroughly intermixed in their
work, as they also are in engineering. Manufacturing engineers and tool and die
makers often work in close consultation as part of a manufacturing
engineering team. There is often turnover between the careers, as one person may
end up working in both at different times of their life, depending on the turns of their
particular educational and career path. There was no codified difference between
them during the 19th century and earlier parts of the 20th century; it was only
after World War II that engineering became a regulated profession exclusively

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defined by a university or college engineering degree. Both careers require some

level of talent in both artistic/artisanal/creative areas and math-and-science areas.
Since the advent of computing in the manufacturing fields
(including CNC, CAD, CAM, and other computer-aided technologies), tool and die
makers have increasingly added IT skills to their daily work. Today's tool and die
makers are generally required to have all of the traditional skills plus substantial
digital skills; these formidable requirements make the field challenging to master.
• Process:-

➢ Die making
Die making is a subdiscipline of tool making that focuses on making and
maintaining dies. This often includes making punches, dies, steel rule dies, and die
sets. Precision is essential in die making; punches and die steels must maintain
proper clearance to produce parts accurately, and it is often necessary to have
components machined with tolerances of less than one thousandth of an inch.
➢ Tool making
Tool making typically means making tooling used to produce products. Common
tooling includes metal forming rolls, cutting tools (such as tool bits and milling
cutters), fixtures, or even whole machine tools used to manufacture, hold, or test
products during their fabrication. Due to the unique nature of a tool maker's work, it
is often necessary to fabricate custom tools or modify standard tools.
➢ Overlap of die making, tool making, and mold making
One person may be called upon for all of the above activities, and the skills and
concepts involved overlap, which is why tool and die making is often viewed as one
field and is also why mold making is often viewed as a subset thereof (rather than a
totally separate field).
➢ Toolrooms and toolroom methods
A toolroom in the original sense of the word is a room where tools are stored; a
tool crib. In larger companies, the tools stored there must be checked in and out, and
there may be a person assigned to attend the area. In a factory, the toolroom refers
to a space where artifacts are made and repaired, particularly tools for use throughout

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the rest of the factory, jigs for setups, and other parts to assist workers and, as an
extension, production. In engineering and manufacturing, toolroom activity is
everything related to tool-and-die facilities in contrast to production line activity.
Originally a toolroom was literally in one room, but like emergency room, the
term has been figuratively extended in both substantive and adjectival senses to all
such places and the methods used there, regardless of the physical space. The name
was originally styled tool room or tool-room, but toolroom is now the norm in
engineering and machining.
➢ Making, repairing, and storing tools
The simplest sense of the word “Toolroom” refers to the storage of tools. A
broader use of the term includes reference to a space where tools are made, repaired,
inventoried, and/or distributed for use within the factory. This extension of the latter
sense reflects the development of greater systemization in manufacturing. During
the 19th century, there gradually developed a division of labor whereby the people
who made, repaired, kept records of, stored, and retrieved tools were not necessarily
the same people who used the tools to do the manufacturing work itself. Examples
of such division of labor had existed in prior centuries, but most manufacturing had
been done on a craft basis, where there had been no need for the idea of a toolroom
separate from the rest of the workshop.
The simplest sense above can also be conveyed by the word toolcrib (sometimes
styled tool-crib or tool crib).
➢ Tool-and-die facilities and methods
In engineering and manufacturing, a toolroom is everything related to tool-and-
die facilities and methods, in contrast to the factory floor and production line
activity. For people not familiar with these fields, in order to understand the
specialist usage, some explanation is needed:
Within the general field of machining there is a rough but recurring division
between (a) toolroom practice and (b) production practice (the making of large
numbers of duplicate parts). It is the difference between manufacturing itself and the
tool-and-die work that is done in support of the manufacturing. Anecdotal examples
of similar distinctions can probably be found here and there throughout human
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history, but as a widespread part of the "fabric" of material culture, this distinction
(and the terminology with which to talk about it) has evolved since the Industrial
Revolution, and most especially since the advent of armory practice and later mass
production.
A good, simplistic way to summarize the change in ideas is to compare the
making of a certain product in different time periods. In 1750, a rifle was made in a
workshop by a craftsman using hand tools, and if he needed a new tool, it is likely
that he would make it himself using the same tools and methods that he would use
to make his product, the rifle (smithy, files, woodcarving knives, etc.) This type of
craftsmanship can still be done today, but it is expensive in terms of skilled labor
time per unit of output, and therefore it implies small total output volume and high
unit price. However, today the way to make rifles in large quantity with low unit
price is to first do the tool-and-die work (toolroom work) (that is, make, or have
someone else make, machine tools, jigs, and fixtures), and then use those specialized
tools to mass-produce the rifles in an automated way that involves no toolroom
methods.
Another example, instead of comparing different centuries, simply compares
different methods of toolpath control that could be chosen today: If you need a
certain hole location on each part for your drill bit, will you dial it carefully by
hand many times (once for each part produced), or will you dial it carefully by
hand only once while making a drill jig for subsequent drilling to be quickly and
effortlessly guided by.
The manufacturing of small batches has often presented the biggest challenge to
this division of methods. When only a small batch of output is demanded, will one
(a) produce each piece using "custom" methods (handcrafting or toolroom-style
layout and machining), which drives up unit cost; or (b) maintain the capital-cost-
intensive toolroom-production division, which also drives up unit costs in its own
ways? In other words, is it worth one's time to make a fixture, and is it worth tying
up a drill press's availability by setting it up for dedicated use with that fixture? The
drill press may be needed tomorrow for a different part, with a different setup. For
100 parts, the costs of making a fixture and tying up a machine's availability are
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justified. For 5 parts, maybe one should just make each of the 5 using toolroom-style
layout and toolpath control.
The evolution of IT and its integration into manufacturing is changing the
questions and equations still further. For example, CNC and robotics have led the
way to rapid prototyping and instant manufacturing, which shift the toolroom-
production division by giving an up-front toolroom investment the flexibility to be
quickly and easily used for any product design, with batch size irrelevant.
In large corporations there may be a very distinct division of labor between
toolroom work and production machining, with different employees for each,
whereas job-shop work is often a blend of toolroom work and production work,
because each project requires some of both, and the same employees may "wear each
hat" in sequence.
• CNC Machining
CNC – Computer Numerical Control
CNC machining can be defined as a process in which pre-programmed computer
software dictates the movement of factory machinery and tools. As a result,
manufacturers can produce parts in less time, reduce waste and eliminate the risk of
human error.
This manufacturing process is used to control a wide variety of complex
machinery, which will be discussed in this article. Essentially, CNC machining
makes it possible for three-dimensional cutting to be completed by following one set
of prompts.
• Type of CNC machines
➢ CNC Milling machine

One of the most common types of CNC machines, a CNC mill utilizes computer
controls to cut various materials. Mills can translate specific programs of numbers
and letters in order to move the spindle in various ways.
Many mills use what is known as G-code, which, as mentioned, is a standardized
programming language recognized by most CNC machines. A CNC mill can have a

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wide array of functions, such as face milling, shoulder milling, tapping, drilling and
turning. Most CNC mills come in three to six-axis configurations.
A CNC mill is very large compared to other tools and can be quite costly. Some
CNC milling machine manufacturers include Okuma, HAAS and DMG Mori.

Fig 3.1:-CNC milling machine

➢ CNC Lathe

A lathe is a CNC machine that functions to cut work pieces as they are rotated.
CNC lathes can make precise cuts quickly by using various tools.
These CNC machines are quite effective in the precision they offer compared to
manual lathes. They often have fewer axes than CNC milling machines, and are
therefore smaller in size and more compact.
CNC lathes come with similar controls to those of CNC mills and can read both
G-code and other proprietary programming languages. Some of the most common
CNC lathe machine manufacturers include HAAS, Mori Seiki and Okuma. The
framework of CNC lathes is similar to manual lathes.

Fig 3.2 CNC lathe machine

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➢ CNC Router

A CNC router is a machine that is very similar to the commonly used handheld
router utilized for cutting various materials. This type of CNC machine can aid in
the cutting of steel, wood, aluminum, composites, plastic and foam.
A CNC router is similar to a CNC mill. It comes with the ability to use computer
numerical control to route tool paths that enable the machine to function. CNC
routers reduce waste and increase productivity by producing various items in a much
shorter amount of time than other machines.
Most routers can operate on a particular material in all three dimensions, and are
great for smaller projects and the creation of prototype models and complex designs.
You can also find three axis, four axis, five axis and six axis routers.

Fig 3.3 CNC router machine

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CHAPTER 4
Weekly Overview of Products
• 4.1 Dies:-

Process Flow for Design & Manufacturing of Die:-

Design
Trial out Part
drawing
release

Assembly
Raw
material

Material
Inspection preparati
on

Pre-
Polishing
machining

Bench
Grinding
work

Precisio
Heat n
treatment machini
ng

Fig 4.1 Process flow of Dies

Types of sheet Metal Dies (Press Tool):-
Press tool
(DIES)

Cutting Non-cutting Integrated

Bending

Forming

Drawing

Fig 4.2 Types of Dies

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Details of Different parts of the Die:-

The complete die set consists of a punch, die and some other accessories which
are described in this section later. Perfect alignment of punch and die is most
important for satisfactory working of punch. Accessories of die set provides the
require alignment and rigidity to the system and improves accuracy of the system
performance. These accessories are the finished parts, removal of waste. The die
accessories are shown in below figure.

Fig 4.3 Basic set up for die

1. Simple Dies: Simple dies are also known as single operation dies as a single
operation is performed for each stroke of the die press. These are generally used for
very simple operations listed under cutting or forming dies.

2. Compound Dies: Compound dies are those dies wherein more than one operation
takes place on a single station. These dies are mostly used for cutting operation and
hence addressed as cutting tools. These dies allow simultaneous cutting of internal
as well as external part features in a single stroke in some cases. Compound dies are
always more accurate and economical as compared to single operation or simple
dies. The figure adjacent provides example of a compound die operation. In this
operation a washer is prepared by one stroke of the press. This washer is
manufactured by simulation blanking as well as piercing operations.

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3. Combination dies: Combination dies are used for operations involving more than
one operation on a work station. The major difference between compound dies and
combination dies is that in these dies a cutting operation is combined with with a
bending or drawing operation, and hence the name “combination dies”.

4. Progressive Dies: Progressive dies also known as follow on dies have a series of
operations. At every station on the work piece, an operation is performed during the
stroke of press. However, in between the two presses, the work piece gets transferred
to the next station and is worked there. In this operation thus, each press operation
develops a finished piece. The figure adjacent provides an example of progressive
dies. The initial sheet metal is fed as coil strip and at same station different operations
like punching, blanking, notching, etc. occur with each stroke of series of punches.
The piercing punch cuts a hole in the stroke, whereas the blanking punch blanks out
portion of metal in which hole had been pierced in previous station. Thus, with each
first stroke, when a hole will be punched, each stroke of press produces finished
washer.

5. Transfer dies: Transfer dies have similar working phenomenon like progressive
dies. Here also the stroke is fed progressively from one station to another. However,
here the already cut blanks are fed mechanically to other station. Thus, transfer dies
provide different stations for operations. Here, the work piece is progressively
modified at each station until the final operation ejects the finished part.

6. Multiple Dies: Multiple dies also known as gang dies ate those dies which
produce tow or more piees at each stroke of press. In these dies a number of simple
dies are ganged together to produce tow or more parts via each stroke of the press.
• 4.2 Jig/ Fixture:-

A jig and fixture maker is under the faction of a tool and die maker/toolmaker.
The standard differentiation of jigs from fixtures is that a jig guides the tool for the
operation being carried out while a fixture simply secures the work. The terms are
sometimes used interchangeably. A jig and fixture maker needs to know how to use
an assortment of machines to build these devices such as having skills in welding

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and in some cases the knowledge of wood working equipment, of course with the
tool room machining skills.
They are often advised by an engineer in building the devices. A wide knowledge
of various materials is needed beyond wood and metal such as plastics. They also
can create, design and build without engineering plans/bluprints.
Jig/fixture makers gain hands on practical experience while monitoring and
making alterations as the manufacturing process is constantly improved and
reviewed with/by engineering. They also can be required to make these adjustments
without engineering help, depending on the size of the company. Some Jigs and
fixtures require electronic and pneumatic actuation, which will involve
knowledge/training in these fields as well.
Properly built jigs and fixtures reduce waste by ensuring perfectly fitting parts.
Jigs and fixtures can be as big as a car or be held in hand. Production needs dictate
form and function. Jigs, fixtures and gages are needed to maintain quality standards
for repeated low and high volume production demands.
Ongoing evolution of computerized design and control technologies, such
as CAD/CAM, CNC, PLC, and others, has limited the use of jigs in manufacturing,
however all the computer run machines need some sort of clamping fixture for
production runs. A common example is that a drill jig is not needed to guide the drill
bits to the hole centers if it is done on a CNC, since it is Computer Numerically
Controlled. However, fixtures are still needed to hold the part[s] in place for the
operation needed. Jigs are currently needed in many areas of manufacturing but
mainly for low-volume production.

Fixture is a work piece-locating and holding device used with machine tools. It
is also used in inspection welding and assembly. Fixture does not guide the cutting
tool, but is always fixed to machine or bench. By using fixture, responsibility for
accuracy shifts from the operator to the construction of machine tool. When a few
parts are to be machined, work piece clamp to the machine table without using
fixture in many machining operations. However, when the numbers of parts are large
enough to justify its cost, a fixture is generally used for holding and locating the
work.
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1. Hydraulic Fixture:-
A clamping system that uses high-pressure liquids to power clamps and hold
a work piece in place. Hydraulically clamped fixtures have many advantages over
manually clamped fixtures. In most cases, these benefits reduce costs for
manufacturers allowing them to justify the initial investment for a hydraulic
clamping system. Hydraulic clamping enables manufacturers to put more
intelligence into the fixture eliminating human error and producing a more stable,
predictable processes no matter who the operator is or what production shift your
machine run.
2.Indexing Fixtures:-
Several components need machining on the different surface such that their
machined surface surfaces or forms are evenly spaced. Such elements are required
to be indexed equally as many as the number of surfaces to be machined. The holding
devices (jigs or fixtures) used are made to carry a suitable indexing mechanism. A
fixture carrying such a device is known as an indexing fixture.
• 4.3 Gauge:-

A gauge or gage, in science and engineering, is a device used to make

measurements or in order to display certain dimensional information. A wide variety
of tools exist which serve such functions, ranging from simple pieces of material
against which sizes can be measured to complex pieces of machinery.

1.Relation gauge:-

Relation Gauges which is manufactured using quality tested raw material. The
offered relation gauges are dimensionally stable with a wide operating temperature.
These are extensively used in various industries for measuring the engineering
components accurately.

2.Spanner gauge:-

A spanner is a type of wrench with an opening and sometimes little teeth: you
can clasp it over the nut or bolt and get a good grip. In the US, the main difference

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between a spanner and other wrenches is the spanner is adjustable and works with
many sizes of nuts and bolts.

3.Feeler gauge:-

A feeler gauge is a tool used to measure gap widths. Feeler gauges are mostly
used in engineering to measure the clearance between two parts.

Fig 4.4 Feeler gauge

4.Go/no go gauge:-

Refers to an inspection tool used to check a work piece against its allowed
tolerances. Its name is derived from two tests: the check involves the work piece
having to pass one test (go) and fail the other (no-go).

5.Radious gauge:-

A radius gauge, also known as a fillet gauge, is a tool used to measure the radius
of an object. Radius gauges require a bright light behind the object to be measured.
The gauge is placed against the edge to be checked and any light leakage between
the blade and edge indicates a mismatch that requires correction.

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Fig 4.5 Radious gauge1

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CHAPTER 5
Conclusion

I would like to conclude my internship report with a sense of satisfactions that

whatever knowledge I have gained in this internship of or curriculum can be indeed
used in the real life situation and it enhanced my view at looking towards things in
a winder perspective. This project imparted me the practical knowledge.

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