ACKNOWLEDGMENT

We are thankful to Mr. Kundan Singh, General Manager, Metal & Steel factory,
Ishapore for giving us this opportunity to carry out this Vocational training.

We would like to express our deep regards great admiration to Mr. Sumanta Basak, Head
of section of Department of Human Resource & Development for his erudite assistant
support and inspiration which were instrumental in this successful completion and
submission of this training.

We wish to show our appreciation to Mr. Mukesh Kumar Yadav, Head of Section of
Department of Tool Room for his enthusiasm patience and insightful comments on whole
process of making test piece for Izod, Charpy and Gas pin.

We wish to like thanks Mr. Debyendu Das, Head of Section of Department of Cartridge
Case Section for his helpful information, practical advice, in depth knowledge and insightful
comments on the whole process of making cartridges from blank.

We would like to express our thanks to Mr. Sushanta Mondal, Head of section of
Department of Gun Machine Shop for guiding us in turning and machining process and
various production processes.

We are very grateful and would like to express our thanks to Mr. Madan Kumar Sharma,
Head of Section of Department of Mechanical Maintenance for guiding us through the
concept and importance of MM shop in industry and helps us with lots of information.

Place: Ishapore Asif Rahaman

Date: 31st Oct 2023

Abhi Bhattacharjya

Arnab Hazra
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 Metal & Steel Factory, Ishapore
धातु एवं इ ात िनमाणी, ईशापोर
ISO9001:2015, ISO14001:2015, ISO45001:2018, ISO50001:2018

Certificate
This is to certify that Asif Rahaman(Roll No. – 34900721068), Abhi Bhattacharjya(Roll
No. – 34900721002) and Arnab Hazra(Roll No. – 34900721009) of 5th semester
undergraduate student in the Department of Mechanical Engineering, Cooch Behar
Government Engineering College, West Bengal, has successfully completed Vocational
Training programme on 31st October 2023 under the guidance of Mr. Sumanta
Basak(HoS/HRD), Mr. Mukesh Kumar Yadav(HoS/TR), Mr. Debyendu
Das(HoS/CCS), Mr. Sushanta Mondal(HoS/GMS) and Mr. Madan Kumar
Sharma(HoS/MM) of this organization during the period from 3rd October 2023 to 31st
October 2023.

Mr. Sumanta Basak Mr. Mukesh Kumar Yadav

HoS/HRD HoS/TR

Mr. Debyendu Das Mr. Sushanta Mondal

HoS/CCS HoS/GMS

Mr. M.K Sharma

HoS/MM

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 TRAINING SCHEDULE

STUDENTS NAME SECTION NAME TIME PERIOD

Tool Room 03/10/23-09/10/23

Asif Rahaman Ammunition & Cartridge

10/10/23-16/10/23
Case Section
Abhi Bhattacharjya

Arnab Hazra Gun Machine Shop 17/10/23-25/10/23

Mechanical Maintenance
26/10/23-31/10/23
Section

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 CONTENTS
1. FACTORY PROFILE
Introduction ....................................................................................................................5
Location ...........................................................................................................................6
Historical Background .....................................................................................................6
Production Facilities & other Info ............................................................................... 7-9
2. TOOL ROOM
Introduction ............................................................................................................ 10-11
Machines used in the section .................................................................................. 11-17
Milling Machine ...................................................................................................... 17-19
Band Saw Machine .................................................................................................. 19-20
3. CARTRIDGE CASE SHOP
Introduction ..................................................................................................................21
Heat Treatment Processes ...................................................................................... 22-23
Cartridge case operations ....................................................................................... 24-34
4. GUN MACHINE SHOP
Introduction ..................................................................................................................35
Different operations in the section ......................................................................... 36-38
Machines used in the section ................................................................................... 38-39
Flow chart ......................................................................................................................40
5. MECHANICAL MAINTENANCE
Introduction ..................................................................................................................41
Type of Maintenance .....................................................................................................42
Machines used for repairing ................................................................................... 42-44
Flow chart .....................................................................................................................45
5. CONCLUSION .......................................................................................................46

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 FACTORY PROFILE

Metal & Steel Factory, Ishapore is the main producer of basic Ferrous and Non- Ferrous raw
material for military hardware. Present day military hardware requires use of metals of high
strength coupled with superior toughness. Combination of both these properties requires use
of alloy steel of Super-ultra clean quality.

MSF has facilities for state-of-the-art steel making in the form of Electric Are Furnace, Ladle
Furnace Vacuum Degassing & Electro Steel Re melting ensuring production of Ultra clean
steel.

A high-capacity PLC-Controlled 2650T

Forging Press with fully integrate and
double manipulators gives shape to the
products like Gun Barrels & other
components of Artillery and Tank Guns. A
state of art CNC-Controlled Radial
Forging Press of 1250T for catch hammer
can forge various sections and profiles
with high degree of isometric mechanical
properties, near-net finish, and
repeatability.

The Factory also possesses a hot rolling mill, a high precision 2 hi / 4 hi combination cold
rolling mill (setup in 2006) for making thin strips of ferrous and non-ferrous material with
online x-ray and mechanical gauging system.

Precision controlled heat treatment facilities impart high Mechanical Properties in the metal,
making it capable of performance under conditions of high stress. Such integrated facilities
for making, shaping & treating of Super-Ultra clean alloy steel-grades makes it possible to
cater to any metallurgical need.

Production of steel cartridge cases starting from making of deep drawing quality steel
(HSLA Grade) for forming the finished products is the major strength of the factory. MSF is
the leader in this field. Electric induction Brass Melting Furnaces produces high quality
60:40 with/without Pb Brass Billets/Pigs, Mn-brass etc.

Quality intelligence personnel with sophisticated machinery consisting of Ultrasonography,

Laboratory Chemical Testing. Computer aided Spectrographic, XRF Spectrometry,
Hydrogen Gas Analyser, and 3D coordinator for precision dimensional measurement etc.

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 LOCATION

Metal & Steel Factory, Ishapore is situated in West Bengal on the Eastern Bank of River
Hooghly (Ganges) at a distance of 28 KM from Kolkata and is connected by Rail and Motor-
Road. Nearest Airport Terminal is Netaji Subhash Chandra Bose Airport, Dum Dum.

HISTORICAL BACKGROUND

The factory has its origin as part of Gun & Shell Factory at Cossipore - then known as
"Foundry and Shell Factory"- in the year 1872, when metallurgical operations by way of
melting and rolling of Cartridge Brasses were first taken up. Subsequently in the year 1892,
manufacture of steel was taken up when open-hearth steel making furnace was
commissioned. With this, the first authentic production of steel was introduced in India. The
Steel Rolling Mills were installed later on, in 1896. Further expansion of metallurgical
activities necessitated shifting of metallurgical plants to Ishapore.

Relocated to its new site at Ishapore in the Year 1905, the Factory continued to function as a
part of the Gun & Shell Factory, Cossipore. In 1920 it became an independent unit in the

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family of Ordnance Factories and had come to be known as "Metal & Steel Factory, Ishapore
(MSF)"

MSF has been the cradle of military-metallurgy in India. The facilities & expertise available
in carrying out development of products and investigation of failures by the attached
inspectorate led to the formation of Technical Development Establishment (Metals) in the
year 1951 which was upgraded in the year 1956 to the Defence Metallurgical Research
Laboratory (DMRL) within its premises. DMRL was later on shifted to Hyderabad in the
year 1963 after bifurcation into DMRI and CI (Metals).

PRODUCTION FACILITIES

The development of new weapon systems calls for stringent metallurgical property
requirements for the special Alloy Steels and Non-ferrous Alloys that go into making of
weapon systems. Special characteristics of the Defence Materials are the multiplicity of
specifications, adherence to high quality standards and special metallurgical properties.
Quantity of supply ranges from fifty Kilograms to hundreds of MT. In fulfilling these
requirements, MSF has played a unique role in quick development and product ionisation of
new armaments in the country. In addition, MSF has taken adequate care and advance action
in order to not only be competent but also to be at the forefront in quality standards and latest
in technological advantages by developing core competencies in the following areas:

Manufacture of highly specialised steels through the latest technology i.e., ESR & LF-VD
for tank gun barrel like T-72, 130mm, 155mm and all types of steel blanks required for sister
factories for various types of cartridge cases for 30mm Sarath, 23mm Schalke, 73mm,
76.2mm and 125mm ammunition. This factory has established the capability for the
manufacture of the specialised forgings for Arjun Tank. Various types of steel cartridge
cases and blanks. In addition to above, MSF has got the following Production facilities:

Steel Making:

Melting: 20Ton Basic Electric Arc Furnace with cored-wire Ca-Si Injection, Argon
purging and Slide Gate Teeming, Bottom Pouring facilities.

Secondary Steel Refining: 20 Ton capacity Ladle Furnace - Vacuum Degassing (LF-
VD) and 10 Ton capacity Electro Slag Re-melting (ESR) units in conjunction with 15
Ton EAF.

Press: 2650 Ton ZDAS Forging Press, with rail bound manipulator for heavy forgings.

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 Hummer Forging: 5 Ton MASSEY pneumatic Hammer and battery of other
Pneumatic Hammers (1Ton, 10 CWT) for medium and smaller section forgings and
tools.

Rolling: 28 inches 2-high reversing LAMBERTON make Bar Mill with Manipulator
and Roller. High 550 mm X 1500mm MORGARDSHAMMER Billet Rolling Mill.
Double Duo Rod Rolling Mill of 10 inches diameter stands. Bright bar processing
facilities.

Drop Stamping: 10 Ton double acting forging machine, battery of Drop Stamp
Hammers (1Ton. 15 CWT. 7 CWT).

Heat Treatment: Bogie-hearth Electric Annealing and normalizing Furnaces. Pit type
Electric Furnace with quenching facilities for hardening and tempering. Brass Melting:
Battery of Electric Induction Brass Melting furnaces comprising of 2 Nos. 540 kgs.
GEC make Brass melting furnaces. Four Nos. 300Kgs and three nos. 500K AJAX
Watt medium frequency melting furnaces.

Cold Rolling: Cold Rolling Mills for rolling of brass slabs. Extrusion: 1250 Ton
Hydraulic Direct Extrusion Press for brass rods/tubes and Draw Benches. Cupping and
Deep Drawing: Cupping and Deep drawing of Brass and Steel, Chemical Passivation
and finishing. Die Casting and Flow Forming Machines.

DEFENCE FACTORIES ALL OVER INDIA

There are 41 Ordnance Factories geographically distributed all over the country at 24
different locations. A visual idea of how our factories and headquarters are [ distributed can
be had from our location map. Indian Ordnance Factories is a giant industrial setup which
functions under the Department of Defence Production of the Ministry of Defence. Indian
Ordnance Factories, headquartered at Kolkata, is a conglomerate of 41 Factories, 9 Training
Institutes, 3 Regional Marketing Centres and 4 Regional Controller of Safety.

8|Page
Today OFB along with its 41 factories spread over India provide strict adherence to quality
standard (all the units are ISO-9000 certified) original as well as adaptive research &
development to make need-based refinement and modifications project engineering
capability a strong base for industrial training facilities ready market access due to
convenient location a broad and versatile production base with multi-technology capabilities
state of the art manufacturing facilities large reservoir of skilled and professionally qualified
manpower and managerial personnel.

The plant and technologies have been so chosen as to ensure high degree of quality and
reliability and is a unique blend of old and the most modern state-of- the-art CNC
technologies. The manufacturing process covers wide spectrum of engineering Mechanical,
Electrical, Metallurgical, Chemical, Textile, Leather, Optics and Electronics.

NAME OF STATES/UNION NUMBER OF FACTORIES

TERRITORIES
Maharashtra 10
Uttar Pradesh 9
Madhya Pradesh 6
Tamil Nadu 6
West Bengal 4
Uttaranchal 2
Andhra Pradesh 1
Chandigarh 1

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 TOOL ROOM

The tool room in a metal and steel factory is a dedicated area where various tools and
equipment are stored, maintained, and repaired. It plays a crucial role in supporting the
production process by ensuring that all necessary tools are in good working condition and
readily available for use factory.

Here are some key features and functions typically found in a tool room of a metal and steel

1. Tool Storage: The tool room provides organized storage for a wide range of tools,
including hand tools, power tools, cutting tools, measuring instruments, dies, Molds, jigs,
fixtures, and other accessories. Tools are typically arranged in labelled drawers, cabinets,
racks, or shelves for easy identification and accessibility.

2. Inventory Management: The tool room maintains an inventory of all tools and
equipment, keeping track of their availability, condition, and usage. This helps in managing
stock levels, ensuring timely reordering, and minimizing tool shortages or downtime.

3. Tool Maintenance: Regular maintenance and servicing of tools are carried out in the tool
room. This includes cleaning, lubrication, calibration. and repairs to ensure optimal
performance and extend the lifespan of the tools. Skilled technicians or toolmakers may be
responsible for these tasks.

4. Tool Issue and Return: The tool room acts as a central hub for tool distribution. Workers
or departments can request specific tools as needed, and the tool room personnel allocate the
tools and maintain a record of the tools issued to each individual or department. When tools
are returned, they are inspected, cleaned, and prepared for future use.

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5. Tool Repair and Modification: In addition to routine maintenance, the tool room may
have facilities for repairing and modifying tools. Skilled toolmakers can troubleshoot and fix
damaged tools or make necessary alterations to meet specific production requirements. This
can involve welding, grinding, machining, or other fabrication processes.

6. Tool Calibration and Quality Control: Precision measuring instruments used in the
metal and steel industry need regular calibration to ensure accurate measurements. The tool
room may have equipment and procedures for calibrating instruments like micrometres,
gauges, and dial indicators. It may also play a role in quality control by conducting
inspections and verifying tool accuracy.

7. Tool Development and Prototyping: Depending on the capabilities of that old, it may all
involved in the design, development, and prototyping of new tools on modifications to
existing tools. This can include creating prototype testing food performance, and
collaborating with engineering teams to optimize tod designs

The exact setup and organization of a fond room may vary depending on the ire of the
factory, the specific requirements of the quinton poses, and the level of donations present.
However, the primary goal remains the same to me that tools are properly managed,
maintained, and available to support the efficient operation of the metal and steel miniaturing
processes.

Machines used in the Section and their working principle

1. Manual Lathe Machine

It is an electrically operated machine in which there is a Squirrel Cage Motor whose

rotational speed ranges between (1400-1500) RPM. The motor shaft is then connected with a
small driving pulley which is connected through a big driven pulley using V-Belt Drives.
Inside the Headstock, from the driving pulley a Helical Gear train arrangement is attached to
it in which there are also some of the Spur Gears
which plays a role of changing gears. Here for
changing gear, there are 3 levers whose position
can be fixed manually and according to that gear
changes and rotational speed of the main spindle
varies.

Through gear train the power get transmitted to the

main spindle which relates to the Live Centre on
which a 4-Jaw Independent Chuck is mounted.
This 4-Jaw chuck shows self-cantering action, and

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each Jaw can operate independently as there is also a Single Start Lead Screw attached with
it. Now the main spindle rotates through which the Chuck also rotates. From the chuck the
face centre of the job is fixed and from the Tail Stock the Holding Side of the job is fixed.

Now at the bottom of the Headstock there is an another helical gear train arrangement from
which the Feed rod rotates which passes through the Carriage which consist of Compound
Rest which is responsible for axial movement of the carriage, on the compound rest there is a
tool post on which the Single Point Cutting tool (0 or negative Rake Angle) which is a
mixture of Carbon Boron Nitride (CBN) and Tungsten Carbide is fixed and below the
compound rest there is a Cross Slide which is responsible for radial movement of the
carriage. Now carriage achieves longitudinal movement through a Bevel gear train
arrangement whose pinion is attached with a Rack which is above the feed rod such that
through Rack & Pinion arrangement the Carriage.

2.Computer Numeric Control (CNC) Lathe Machine:

Electrically operated CNC machine which runs through a Serve Motor of (80-85) kW power
whose rotational speed ranges between (1-3000) RPM. The shaft which is attached with the
motor is attached with a small driving pulley and from there power got transmitted to a big
driven pulley through 8 V-belt drives. The driving pulley relates to a Helical Gear Train
arrangement which also consist Sper gears who play the role of changing gears.

Here gear changing system is quite different from that of the manual lathe machine, in
manual Lathe machine there were 3 levers for changing gears but here there is a Hydraulic
system for changing gears. So hydraulic oil goes into a piston cylinder arrangement via
cylinder through an Axial Piston Pump at approx. 40 bar pressure and the piston is attached
with a Piston Rod which can perform to-and-fro movement, so the changing spur gears are
on the same shaft and this spur gear system is attached with a Brass plate which is
responsible for movement of gears on the shaft and this brass plate is attached with the
piston rod so with the movement of the piston rod the brass plate moves and along with that
the spur gear system also moves on the shaft such that gear changing happens in this system
and through this the main spindle is able to achieve different rotational speed. At the live
centre for fixing the face centre of the job there is a 4-Jaw Independent Chuck. This 4-Jaw
chuck shows self-centering action and each Jaw can operate independently as there is also a
Single Start Lead Screw attached with it. Now the main spindle rotates through which the
Chuck also rotates. From the chuck the face centre of the job is fixed and from the Tail Stock
the Holding Side of the job is fixed.

Now for the movement of Carriage there is another Servo Motor inside the carriage whose
shaft relates to a gear train arrangement in which a Bevel pinion which rotates in horizontal

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plane meshes with the Rack which is on the complete length of the Lathe Bed and through
this Rack and pinion arrangement the carriage moves in axial direction. Here there are
Strainers and Magnetic Filter arrangement for Lubrication in different parts. Freon Coolant is
supplied through a motor and pump system at the cutting area. Electromagnetic Brake and
Clutch is there to stop the spindle in case of any electronic system stops.

Main functions of Lathe Machine:

The main functions of a lathe machine include:

1. Turning: The primary function of a lathe machine is turning, which involves rotating the
workpiece while a cutting tool is applied to remove material from the outer surface. Turning
is used to create cylindrical shapes, such as shafts, rods, and tubes.

2. Facing: Facing is the process of machining the end surface of a workpiece to make it flat
and perpendicular to the axis of rotation. A lathe machine can be used to face the ends of
cylindrical workpieces, creating smooth and accurately perpendicular surfaces.

3. Taper Turning: Taper turning is the process of machining a workpiece to create a gradual
reduction or increase in diameter along its length. A lathe machine can be used to accurately
machine tapered surfaces, such as conical shapes or angled surfaces.

4. Drilling: Lathe machines can be equipped with a drill chuck or drill bit holder. allowing
them to perform drilling operations. This enables the creation of holes in the workpiece with
precise dimensions and positioning.

5. Boring: Boring is the process of enlarging or refining an existing hole in a workpiece. A

lathe machine can be used to bore holes with high precision and smoothness, ensuring
accurate dimensions and surface finish.

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6. Thread Cutting: Lathe machines can be used for thread cutting operations allowing the
creation of external or internal threads on the workpiece. This is done using specialized
threading tools or attachments.

7. Grooving and Parting: Lathe machines can be used to create grooves and part-off or cut-
off operations. Grooving involves machining narrow channels or recesses on the workpiece,
while parting is the process of cutting off a section of the workpiece to create separate parts.

8. Knurling: Knurling is a process of impressing a pattern or texture onto the surface of the
workpiece to improve grip or aesthetics. Lathe machines can be equipped with knurling tools
to perform this operation.

9. Facing Off: Facing off is the process of machining a flat surface on the end of a
workpiece. This is often done to create a smooth and perpendicular surface for subsequent
operations.

10. Chamfering and Bevelling: Lathe machines can be used to create chamfers or bevels on
the edges of a workpiece. This involves removing material from the edge at an angle,
resulting in a sloping or rounded surface.

3. Electrical discharge machine (EDM)

An Electrical Discharge Machine (IDM), also known as a spark creston machine or spark
machining center, is a specialized tool used for precision macluning and shaping of hard and
electrically conductive materials FDM works on
the principle of spark erosion, where controlled
electric discharges between an electrode and a
workpiece remose material to create intricate
shapes and features. Here are some key aspects
and functions of an Electrical Discharge Machine

1. Spark Erosion Process: EDM employs a non-

contact machining method where a series of
electric sparks are discharged in a dielectric flank
(typically deionized water) between the
workpiece and an electrode. The high frequency
electrical discharges cause localized melting and
vaporization of the workpiece material,
effectively eroding it away.

2. Two Main Types: There are two primary types of FDM machines

Wire EDM: Uses a thin wire electrode, typically made of brass or coated tungsten, which is
fed continuously from a spool. It cuts through the workpiece in a precise path, guided by
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computer-controlled movements Sinker EDM (also known as Ram EDM or Conventional
FDM) Employs an electrode that is shaped to match the desired cavity or feature. The
electrode is immersed in the dielectric fluid and repeatedly brought into contact with the
workpiece to erode material.

3. Precision Machining: EDM is highly regarded for its ability to machine complex and
intricate shapes in hard materials, including hardened steels, titanium. carbides, and
conductive ceramics. It can produce high-quality surface finishes and tight tolerances.

4. No Direct Tool Contact: Unlike traditional machining methods, EDM does not involve
physical contact between the tool and the workpiece. This allows for machining without
mechanical forces, minimizing the risk of deformation or tool wear and enabling the
machining of delicate or fragile components.

5. Tool and Workpiece Electrodes: In EDM, the electrode is made of a conductive material
and is carefully designed to match the desired shape. For wire EDM, the wire acts as the
electrode, while for sinker EDM, the electrode is preformed to the desired shape and often
made of graphite or copper.

6. Dielectric Fluid: A dielectric fluid is used to cool the machining area, flush away eroded
particles, and provide electrical insulation between the electrode and workpiece. The fluid
also helps in maintaining a stable spark gap and acts at medium for electric discharge. 7.
CNC Control: Modern EDM machines are typically equipped with Computer Numerical
Control (CNC) systems.

4. Shaping Machine:
A shaping machine is a
machine tool used for
shaping or cutting metal and
other materials. The
workpiece is held firmly on
the table and the ram, which
holds the cutting tool, is
allowed to reciprocate over it.
The cutting tool removes
metal from the workpiece
when the ram moves
horizontally in the forward
direction. On the return
stroke, metal is not removed. Shaping machines are commonly used in metalworking
industries for various applications, including creating flat surfaces, slots, and grooves.

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5. Cylindrical Grinding Machines:

Cylindrical grinding machines are widely used in manufacturing industries to create

cylindrical or tapered surfaces on workpieces. These machines consist of several key
components, including the workpiece, the grinding wheel, and the bed or platform that
supports these elements.

The cylindrical grinding process involves mounting the workpiece on the machine's
platform, selecting an appropriate grinding wheel, and then rotating the wheel against the
workpiece. The grinding wheel removes material from the external surface of the workpiece
to achieve the desired shape, size, and surface finish. Cylindrical grinding machines are
highly versatile and can be used for various applications, such as creating precision shafts,
bearings, and other cylindrical components. Their precision and flexibility make them
invaluable tools in manufacturing.

7. Surface Grinding Machines:

Surface grinding machines are

designed for the precise and
efficient grinding of flat surfaces
on workpieces. These machines
consist of a worktable, a grinding
wheel, and a reciprocating or
rotary motion mechanism that
moves the grinding wheel across
the workpiece surface.

The surface grinding process

begins with workpiece preparation
and the selection of an appropriate
grinding wheel. The grinding
wheel is then moved across the workpiece, removing material to achieve a smooth and flat
surface.

Surface grinding is commonly used for finishing and flattening surfaces on various materials,
including metals, ceramics, and plastics. It is crucial in creating components with exceptional
flatness and surface finish, such as precision flat plates and molds.

8. Circular Grinding Machines:

Circular grinding machines, also known as centerless grinders, are specialized tools for
grinding materials with circular cross-sections, such as pipes, tubes, and bars. These
machines feature a grinding wheel, a regulating wheel, and a workrest blade.

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In the circular grinding process, the workpiece is fed between the grinding wheel and the
regulating wheel, while the work rest blade supports and guides the workpiece. The grinding
wheel removes material from the outer surface of the workpiece, shaping it to the desired
diameter and achieving a precise and smooth finish. Circular grinding machines are
particularly efficient for high-volume production of cylindrical workpieces with minimal
setup time, making them ideal for industries like automotive and aerospace.

These three types of grinding machines serve critical roles in various manufacturing
processes, each offering unique advantages for specific applications. Understanding their
operation and capabilities is essential for optimizing manufacturing operations and achieving
high-quality finished products.

9. Milling Machine:

Milling machines are essential assets in manufacturing industries, serving as versatile tools
for a wide range of machining processes. They are employed to remove material from
workpieces, achieving a desired shape or finish. The process of milling involves rotating a
cutting tool, typically with multiple cutting edges, to remove material from the workpiece's
surface, resulting in a precise and well-finished product. Milling machines are employed in
various industries, such as aerospace, automotive, and mold-making, for their ability to
create intricate parts with high accuracy.

Milling Process

 Basic Operations: Milling machines operate on the principle of removing material by

bringing a rotating cutter into contact with the workpiece. The basic milling operations
include:

Face Milling: In this operation, the cutter removes material from the workpiece's flat surface.

Peripheral Milling: Material is removed from the outer surface of a workpiece.

Slot Milling: Cutting narrow slots or channels into the workpiece.

End Milling: Cutting performed on the edges of a workpiece, often to create contours or
shapes.

Drilling: Milling machines can also be equipped with drill bits to create holes in the
workpiece.

 Cutting Tools

Milling machines utilize a variety of cutting tools, including end mills, face mills, and ball-
nose cutters. These tools are selected based on the specific requirements of the machining
task, such as precision, speed, and material removal rate.
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Types of Milling Machines:

Milling machines can be categorized into several types, each tailored to specific applications
and requirements:

1. Vertical Milling Machine

The vertical milling machine has its spindle aligned vertically, allowing the cutter to descend
directly onto the workpiece. It is commonly used for drilling, pocketing, and contouring
operations. This machine is popular in workshops due to its compact design and ease of use.

2. Horizontal Milling Machine

In contrast to the vertical milling machine, the horizontal milling machine features a
horizontally oriented spindle. It is ideal for heavy-duty operations and is commonly used for
slotting, facing, and end milling applications. This type of machine is particularly suitable
for larger workpieces.

3. Universal Milling Machine

Universal milling machines combine both vertical and horizontal milling capabilities. They
provide a high degree of versatility and are often utilized for complex machining tasks that
require multiple angles and orientations. Engineers find them beneficial for various
production requirements.

4. CNC (Computer Numerical Control) Milling Machine

CNC milling machines are highly advanced, as they are controlled by computers to precisely
execute complex machining tasks. CNC milling machines are known for their exceptional
precision and repeatability, making them crucial in industries where intricate components
and tight tolerances are a necessity.

5. Planer Type Milling Machine

Planer type milling machines are characterized by their rigid construction and the ability to
produce large, flat surfaces. They are often used in industries requiring heavy-duty milling,
such as manufacturing of large machinery and components.

Milling machines are essential assets in the manufacturing industry, allowing engineers to
achieve precision and efficiency in shaping materials. This report has provided an overview
of the milling process and various types of milling machines commonly found in factories.
Engineers and technicians must choose the appropriate milling machine based on the specific
requirements of the project to ensure the highest quality and productivity in their operations.

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10.Bandsaw Machine:

A bandsaw machine is a versatile and essential tool in manufacturing and woodworking,

designed for precision cutting of various materials. It operates using a continuous looped
blade with teeth that cut through the material. This machine is characterized by its flexibility,
allowing straight and curved cuts, making it a fundamental asset in many industrial settings.

Components of a Bandsaw Machine:

Frame: The frame provides structural support and houses the internal components of the
bandsaw machine. It ensures stability during operation.

Blade: The blade is the cutting tool, typically a long, narrow strip with teeth. It is mounted
on the wheels and continuously runs to perform the cutting action.

Motor: The motor powers the bandsaw blade, providing the necessary energy for cutting.
The motor's power varies based on the machine's size and the materials it's intended to cut.

Guides: Blade guides are adjustable components that maintain the blade's proper alignment,
preventing it from deviating during cutting. These guides are essential for maintaining
cutting accuracy.

Table: The table provides support for the workpiece during the cutting process. It can be
adjusted vertically and tilted to accommodate different cutting angles.

Feed System: The feed system controls the rate at which the workpiece advances into the
blade. This component is essential for controlling the speed and precision of the cutting
process.

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Working of a Bandsaw Machine:

The operation of a bandsaw machine involves the following steps:

Blade Installation: Start by selecting the appropriate blade for the material and cut type. The
blade is installed and correctly tensioned to ensure it remains rigid during the operation.

Workpiece Preparation: The workpiece is prepared by securely clamping it to the table to

prevent movement during the cutting process. Proper alignment and support of the
workpiece are crucial for clean and accurate cuts.

Machine Setup: The machine is powered on, and the blade is allowed to reach the desired
cutting speed. Blade tracking and guide alignment are adjusted to ensure the blade remains
on the intended cutting path.

Cutting Operation: The operator slowly feeds the workpiece into the blade using the feed
system. Steady pressure and a consistent feed rate are maintained to achieve a smooth and
accurate cut. The operator monitors the process to prevent binding and overheating

Finish and Cleanup: Once the cutting operation is complete, the workpiece is removed, and
any additional finishing operations may be performed, such as sanding or deburring.

Bandsaw machines are versatile and efficient tools that can be found in various industrial
applications. They offer precision and flexibility, making them indispensable for cutting a
wide range of materials, from wood and metal to plastics and composites. Proper operation,
maintenance, and adherence to safety protocols are essential to maximize their utility and
ensure safe working conditions.

Band Saw

20 | P a g e
 CARTRIDGE CASE SECTION (CCS)

Input Material. A blank which comes from the M.M.E. (Metal Mill Extrusion) Section made
up of alloy which is basically a mixture of many metals. Elements in the respective

Alloy: - Carbon, Silicon, Sulphur, Phosphorous, Manganese, Nickel, Chromium, Copper,

Aluminium.

Note- Nitrogen content should be restricted to 50 PPM (Parts Per Million). This is based on
requirement indicated in the Factory's purchase order placed on V.I.S.L. (Visvesvaraya Iron
& Steel Limited, Bhadarvathi, Karnataka) whose parent company is SAIL (Steel Authority
of India).

Mechanical Properties of the Blank

1. Ultimate Tensile Strength (U.T.S.)- (34-41) kgf/mm²

2. Elongation-35% minimum

3. Charpy Impact V-notch test of 2mm deep notch- 150 kgf/cm² (minimum) in longitudinal
direction.

4. Charpy Impact V-notch test of 2mm deep notch- 90 kgf/cm² (minimum) in transverse
direction.

Charpy V-notch test is a standardized high strain rate test which determines the amount of
energy absorbed by a material during fracture.

Grain Size- Grain size (or particle size) is the diameter of individual grains of sediment. It
should be between (7-16) units.

Decarb Test-Decarburization occurs during the interaction between the carbon atoms in steel
and the atmosphere of an endothermic atmosphere furnace.

Hardness is measured at greater and greater depths perpendicular to the part surface until a
constant hardness is observed. So the zone of complete decarburization should not be deeper
than 0.25 mm.

Ultrasonic Test- It is done in materials to determine whether there are flaws or defects
present in a material, and also to determine the thickness of a material and in this test the
material should be 100% free from flaws.

21 | P a g e
Some of the Heat Treatment processes used in complete manufacturing of
Cartridge Case: -
1. Hardening- It is a process consists of heating the components above the critical
(normalizing) temperature, holding at this temperature for one hour per inch of thickness
cooling at a rate fast enough to allow the material to transform to a much harder, stronger
structure.

2. Tempering- It is a process of reheating the steel at a relatively low temperature leading to

precipitation and spheroidization of the carbides present in the microstructure.

3. Annealing-It is a heat treatment process that changes the physical and sometimes also the
chemical properties of a material to increase ductility and reduce the hardness to make it
more workable.

4. Spherodizing- It is a form of heat treatment for iron-based alloys, commonly carbon

steels, in order to convert them into ductile and machinable alloys.

Blank Operation in M.M.E. section (in short)

1.Pickling of strips: Pickling is the process of preserving edible products in an acid solution.

Acid-𝐻 𝑆𝑂

Acid Strength- (8-10) % in water Temperature (80 to 90) °C

pH of Acid-(6-7)

Dipping Time in Acid Solution-(2-3) minutes

22 | P a g e
Hot Water (pH)-(6-7)

Dipping Time in water-(2-3) minutes

2. Cold Rolling Operation by rolling mill to size (13.6-13.8) mm thickness.

3. Flattening Operation by Flattening Machine.

4. Ultrasonic Testing for crack detection.

5. Hardening in Heat Treatment Section- Load the compound in a furnace. Rate of heating
is (100-150) °C/hr, Temperature-960°C (maximum) for 1 hr.

6. Spherodizing, Annealing, Tempering- Rate of Heating- 100°C/hr Temperature- 710 °C

(maximum), Soaking Time-28hr, Under Furnace Cooling.

7.Mechanical Press of 500/400 Ton

23 | P a g e
8. Surface Machining

9. Inspection by Quality Audit (QA)- Inspection of Surface machined blanks.

10. Annealing- Load the component in Furnace. Temperature- (640-660) °C, Soaking Time-
2.5 hrs, Hardness after Anealing-(95-115) VPN (Vicker's Pyramid No.)

Cartridge Case Operations in Cartridge Case Section (C.C.S.)

1. Obtaining Annealed Blank from M.M.E. Section.

2. Pickling, Phosphating, Saponification

a. Pickling in (5-10) % HCL solution, temperature-(50-70) °C for (20-40) minutes

dipping.

b. Dip in hot water temperature-(50-70) °C for (2-4) minutes.

c. Dip in cold/running water for (2-4) minutes.

d. Dip in Zinc Phosphate [pH-(2-5)], temperature-(80-90) °C for (20-40)

minutes.

e. Dip in cold/running water for (2-4) minutes. f. Dip in Saponification, temp-(80-90)

°C for (20-30) minutes.

Here Zinc Phosphate [ZnPO4] acts as self-lubricant, it facilitates next cold draw
operation and due to this, tiny pores got generated in the component so through
Saponification, soap particles get poured into those tiny pores and this soap solution
also acts like lubricant.

3. Stamping- It is a mechanical process in which the blank is pressed against a Die with
(250-500) Ton of force.

4. High Temperature Annealing in Electrical Furnace

Temperature- (640-660) °C

Rising time-4 hrs [25°C to 650°C]

Soaking Time-3.5 hrs [Grain Structure improves and Stress Relief]

Furnace Cooling for 4hrs [650°C to 100°C]

Cooling in Still Air [100°C to Room Temperature]

5. Pickling, Phosphating, Saponification

24 | P a g e
 a. Pickling in (5-10) % HCL solution, temperature-(50-70) °C for (20-40) minutes
dipping.

b. Dip in hot water temperature-(50-70) °C for (2-4) minutes.

c. Dip in cold/running water for (2-4) minutes. d. Dip in Zinc Phosphate [pH-(2-5)],
temperature-(80-90) °C for (20-40) minutes.

e. Dip in cold/running water for (2-4) minutes.

f. Dip in Saponification, temp-(80-90) "C for (20-30) minutes.

Here Zinc Phosphate [ZnPo4] acts as self-lubricant, it facilitates next cold draw
operation and due to this, tiny pores got generated in the component so through
Saponification, soap particles get poured into those tiny pores and this soap solution
also acts like lubricant.

6. Cupping- It is a mechanical process in which the blank is pressed against a Die with 250
Ton of force. λ 2mm

7. High Temperature Annealing in Electrical Furnace

Temperature- (640-660) °C

Rising time-4 hrs [25°C to 650°C]

Soaking Time-3.5 hrs [Grain Structure improves and Stress Relief]

Furnace Cooling for 4hrs [650°C to 100°C] Cooling in Still Air [100°C to Room
Temperature]

8. Pickling, Phosphating, Saponification

a. Pickling in (5-10) % HCL solution, temperature-(50-70) °C for (20-40) minutes

dipping.

b. Dip in hot water temperature-(50-70) °C for

(2-4) minutes.

c. Dip in cold/running water for (2-4) minutes.

d. Dip in Zinc Phosphate [pH-(2-5)],

temperature-(80-90) °C for (20-40) minutes.

e. Dip in cold/running water for (2-4) minutes.

f. Dip in Saponification, temp-(80-90) °C for (20-30) minutes.

25 | P a g e
 Here Zine Phosphate (ZnPo acts as self-lubricant, it facilitates next cold draw
operation and due to this, tiny pores got generated in the component so through
Saponification, soap particles get pored into those tiny pores and this soap solution
also acts like lubricant.

9. First Draw- It is a mechanical process in which the blank is pressed against a Die with
250 Ton of force.

10. Upsetting- It is a mechanical process in which the blank is pressed against a Die with
300 Ton of force.

11.High Temperature Annealing in Electrical Furnace

Temperature- (640-660) °C

Rising time-4 hrs [25°C to 650°C]

Soaking Time-3.5 hrs [Grain Structure improves and Stress Relief]

Furnace Cooling for 4hrs [650°C to 100°C]

Cooling in Still Air [100°C to Room Temperature]

12. Pickling, Phosphating, Saponification

a. Pickling in (5-10) % HCL solution, temperature-(50-70) "C for (20-40) minutes

dipping

b. Dip in hot water temperature-(50-70) °C for (2-4) minutes.

c. Dip in cold/running water for (2-4) minutes.

d. Dip in Zinc Phosphate [pH-(2-5)], temperature-(80-90) °C for (20-40) minutes.

e. Dip in cold/running water for (2-4) minutes.

f. Dip in Saponification, temp-(80-90) "C for (20-30) minutes.

Here Zine Phosphate (ZnPO4] acts as self-lubricant, it facilitates next cold draw
operation and due to this, tiny pores got generated in the component so through
Saponification, soap particles get pored into those tiny pores and this soap solution
also acts like Lubricant.

13. Second Draw- It is a mechanical process in which the blank is pressed against a Die
with 250 Ton of force.

26 | P a g e
14. Degreasing- Metal degreasing or degreasing is a process aimed at removing any residual
grease from a particular element. "Removal of all grease residues" is not simply a matter of
careful cleaning, but rather the destruction of every single oily molecule. It is followed by
Washing and Drying.

15. Surface Hardening in Induction Heating Furnace

Temperature- (940-980) °C Approx hardening time 42 sec/component.

Heat the component then Quench in Water.

Water Temperature= 33 °C approx.

After Hardening, hardness of the component is checked through Vicker's Pyramid Test, and
it should be in the range of (145-250).

Hardening is done to get uniform distribution of Carbon throughout the component such that
there will be uniform strength in the component.

16. Tempering in Electric Resistance

Temperature- 690 °C.

Soaking Time-(30-45) minutes.

After Tempering, hardness of the component is checked through Vicker's Pyramid Test and
it should be in the range of (119-140).

The process has the effect of toughening the component by lessening brittleness and
reducing internal stresses.

17. Pickling, Phosphating, Saponification

a. Pickling in (5-10) % HCL solution, temperature-(50-70) °C for (20- 40) minutes dipping.

b. Dip in hot water temperature-(50-70) °C for (2-4) minutes.

c. Dip in cold/running water for (2-4) minutes.

d. Dip in Zinc Phosphate [pH-(2-5)], temperature-(80-90)

°C for (20-40) minutes.

e. Dip in cold/running water for (2-4) minutes. f. Dip in

Saponification, temp-(80-90) °C for (20-30) minutes.

Here Zine Phosphate [ZnPo4] acts as self-lubricant, it

facilitates next cold draw operation and due to this, tiny
pores got generated in the component so through
27 | P a g e
Saponification, soap particles get poured into those tiny pores and this soap solution also acts
like lubricant.

18. Third Draw- It is a mechanical process in which the blank is pressed against a Die with
300 Ton of force.

19. Trimming and Deburring- Trimming is a manufacturing process that is used as a

finishing operation in order to remove flash. Deburring is a material modification process
that removes sharp edges, or burrs, from a material, and leaves the material with smooth
edges. Both operation are performed on Lathe Machine.

20. Low Temperature Annealing in Electrical Resistance Furnace

Tempearture-380 °C

Rising Time- 1.5 hr.

Soaking Time- 1hr.

After heat treatment furnace cooling occurs for 2.5 hr (380°C to 40°C)

21. Pickling, Phosphating, Saponification

a. Pickling in (5-10) % HCL solution, temperature-(50-70) °C for (20-40) minutes dipping

b. Dip in hot water temperature-(50-70) °C for (2-4) minutes.

c. Dip in cold/running water for (2-4) minutes.

d. Dip in Zine Phosphate [pH1-(2-5)], temperature-(80-90) °C for (20-40) minutes.

e. Dip in cold/running water for (2-4) minutes. f. Dip in Saponification, temp-(80-90) °C for
(20-30) minutes.

Here Zine Phosphate [ZnPo] acts as self-lubricant, it facilitates next cold draw operation and
due to this, tiny pores got generated in the component so through Saponification, soap
particles get poured into those tiny pores and this soap solution also acts like lubricant.

22. Final Draw-It is a Hydraulic process in which the blank is pressed against a Die with
500 Ton of force.

23. Trimming and Deburring- Trimming is a manufacturing process that is used as a

finishing operation in der to remove flash. Deburring is a material modification process that
removes sharp edges, or burrs, from a material, and leaves the material with smooth edges.
Both operations are performed on Lathe Machine.

28 | P a g e
24. Heading and Indenting- Heading is a method of forming metal in progressive steps into
net shaped or near net shaped parts. Indentation is a widely used technique to probe the
mechanical properties, such as hardness and elastic stiffness of solid state materials, via
measuring their surface response to penetration of a probe with known geometry and
imposed load.

25. Degreasing- Metal degreasing or degreasing is a process aimed at removing any residual
grease from a particular element. "Removal of all grease residues" is not simply a matter of
careful cleaning, but rather the destruction of every single oily molecule. It is followed by
Washing and Drying.

26. Mouth Annealing in Rotary Induction Furnace

Temperature- (700-740) °C

It is a continuous process done before performing taper operation on the mouth.

Before performing this operation Vicker's Hardness Test is perform on it:- At 140mm from
base it ranges between (130-140). At 110mm from base it should be minimum 200. Distilled
water is also used to cool the component.

27. Low Temperature Annealing in Electrical Resistance Furnace

Temperature- 380 °C.

Rising Time- 1.5 hr.

Soaking Time- 1hr.

After heat treatment furnace cooling occurs for 2.5 hr (380°C to 40°C)

28. Pickling, Phosphating, Saponification

a. Pickling in (5-10) % HCL solution, temperature-(50-70) "C for (20-40) minutes dipping.

b. Dip in hot water temperature-(50-70) "C for (2-4) minutes,

c. Dip in cold/running water for (2-4) minutes.

d. Dip in Zinc Phosphate [pH-(2-5)], temperature-(80-90) "C for (20-40) minutes.

e. Dip in cold/running water for (2-4) minutes. f. Dip in Saponification, temp-(80-90) °C for
(20-30) minutes.

29 | P a g e
Here Zinc Phosphate [ZnPo4] acts as self-lubricant, it facilitates next cold draw operation
and due to this, tiny pores got generated in the component so through Saponification, soap
particles get poured into those tiny pores and this soap solution also acts like lubricant.

29. Tapering-Taper Turning operation is performed on the workpiece on the mouth part
through Lathe Machine.

30.Low Temperature Annealing in Electric Resistance Furnace

Temperature-(370-390) °C

Soaking Time-2hr

Furnace Cooling-4hr

Then cooling in still air up to room temperature.

31. Head Diameter Cutting-This operation is performed on Lathe Machine.

32. Head Turning- This operation is performed on a Multi Spindle Semi-Automatic Lathe
Machine in which 5 operations are performed followed by Turning→ Drilling→ Facing →
Grooving → Chamfering.

Here in drilling 2 types of drills are used

(1) Spade Drill

(2) Twist Drill

Multi Spindle Semi-Automatic Lathe

This machine is used for Head Turning
operation in this there is a Main Motor of
11kW Power from the motor power goes
to a set of Spur Gears and from there
through a hollow shaft a Sun and
Planetary gear train system is attached
with 6 planetary gears whose speed is
almost 850RPM, on the hollow shaft there
is a V-pulley which is connected with a
feed system through (a, b, c, d) gear train
arrangement. Feed system drives the Cam
Shaft through Worm and Worm Wheel
arrangement, Cam Shaft drives the
hexagonal turret which provides axial movement of the tool and cross slide movement which
provides radial movement to the tool.
30 | P a g e
Main motor also drives the lubricating pump as there are 3 pumps for lubrication: -

a. Cutting Oil for Machining.

b. Circulating Oil for Gear lubrication.

c. Fresh Oil for bearing & Slide interfaces.

As here there are 6 spindles so there would be 6 clutches for it, additionally 2 clutches are
fitted for turret movement (both radial and axial) and 1 more Electromagnetic Clutch is fitted
for feed system. Here for indexing the mechanism that would be followed is the
Geneva Mechanism.

33.Thread Milling: Thread milling is the metalworking operation need to create internal
and external threads of different sizes through the circular movement of a rotating tool. It is
done through Thread milling machine/ CNC Thread Milling Machine, feed ranges between
(150-200) RPM.

34.Degreassing- Metal degreasing or degreasing is a process aimed at removing any residual

grease from a particular element. "Removal of all grease residues" is not simply a matter of
careful cleaning, but rather the destruction of every single only molecule It is followed by
Washing and Drying

35. Final Length Trimming- This operation is performed on a Lathe Machine in which
final length of the component is achieved i.e. (164-165) mm. Cycle Time-19
components/min.

36. Machining of Mouth Part- This is also performed on a Lathe Machine in this final
shape of the mouth part is achieved.

37. Deburring- Deburring is a material modification process that removes sharp edges, or
burrs, from a material, and leaves the material with smooth edges. This operation performed
on Lathe Machine

38. 100% visual & Dial Inspection by Quality Control

It is a completely manual process, in which majorly 17 dimensions of the Cartridge Case are
checked through different types of Gauges.

a. Total Length- [164-165] mm Head Dia width:

b. Head Diameter- [39.66-40.00] mm

c. Screw Thread (No-go)

d. Screw Thread (Go)

31 | P a g e
e. Fire Hole Diameter- [3-3.3] mm

f. Chamber Diameter before platting

g. Under Head Diameter- [39.66-40.00] mm

h. Flange Thickness- [4.30-4.50] mm

i. Recess Depth- [2.60-2.72] mm

j. Depth of Primer- [15.00-15.43] mm

k. Recess Diameter- [16.24-16.48] mm

L. Base Thickness- [17.70-19.00] mm

m. Groove Diameter- [34.16-34.50] mm

n. Mouth Thickness- [1-1.2] mm

o. Mouth inside Diameter- [29.20-29.34] mm

p. Width of Groove- [3.5-3.8] mm

q. Core Diameter of Thread [Go/No-go]

39. Rectification- Re-machining is done on any defected component if possible.

40. Lot Stamping- A stamp is given at the base of

the Cartridge Case which consist of Lot No., Year
of manufacturing & Name of Manufacturer. It is
done through Laser CNC Machine.

41. Coating- Electroplating is done on the case of

Zine through chromatising, as Zinc is a highly
Corrosive resistance material and Chromium is a
high heat resistance material.

42. Joint Sample selection by SQAE & QC for testing as per specified limit

This involves several test such as:-

(i) Visual/Dimension Gauging

(ii) Chemical Composition Test

a. Carbon

b. Silicon

32 | P a g e
c. Sulphur

d. Phosphorous

e. Manganese

f. Nickel

g. Chromium

h. Copper

i. Aluminium

Note- Nitrogen content should be restricted to 50 PPM (Parts Per Million). This is based on
requirement indicated in the Factory's purchase order placed on V.I.S.L.(Visvesvaraya Iron
& Steel Limited, Bhadarvathi, Karnataka) whose parent company is SAIL (Steel Authority
of India).

(iii) Mechanical Test

In this Ultimate tensile strength of the material is tested at different height from the mouth of
the Cartridge Case.

(iv) Zinc Coating Thickness

Outer Surface- 15µm (minimum)

Inner Surface-9 pm (minimum)

(v) Corrosion Resistance Test- No corrosion should be on the base metal as well as on the
Zinc.

(vi) Adhesion Test- The adhesion strength is a measure of how strong the bond between two
materials is. This can be done in terms of load, stress, energy or work required to break the
interphase.

(vii) Hardness Test- Checked through Vicker's Hardness Test

43. Acceptance of Proof Report from SQAE

44. Scrutiny of all documents by SQAE & release of Quality Audit Control (QAC)

45. Packing and Identification of LOT Nos.

Packing is done manually, and Cartridge Cases are packed in Low Density Polymer (L.D.P.)
Bag with Silica Gel packet in it to absorb moisture, to protect it from getting Rust.

46. Despatch to consignee a sorting to given order.

33 | P a g e
 GUN MACHINE SHOP

GMS Play a crucial role for production and manufacturing various military artillery &
various military components. Not only military components GMS also
produce Railway axle.

Input material- Black Forged material received from New Gun Forge (N.G.F.), Radial
Forging Shop (R.F.S.), (B.S.F).

Productions of G.M.S.

o Barrel (E.g.- T-90, Arjun, Sharang, Soltam, Dhanush etc.)

o Recoil Buffer
o Through Tube
o Fin Cylinder Tube
o Nozzle Front
o Pinaka
o Barrel Casing
o Railway axle

34 | P a g e
 Operations involved in machining of Barrels
1. End Parting & Facing: It is not a necessary process, after forging from (N.G.F.), (R.S.F.)
end parting and facing operation is performed there and after that the job will come to Heavy
Machine Shop (H.M.S.) for machining but before machining if it is found that the end
parting and facing haven't done properly there than through Band Saw Machining it is done
properly in H.M.S. Section.

2. Centering: After End parting and facing, centering is

done on both the end face of the machine. A Calliper is
used here through which arcs are drawn on the face of
job from the periphery to know the centre then through a
90° drill, a small hole is produced at the centre with
depth of drilling (25-26) mm.

3. Rough Turning: It is basically a Skinning process

which is performed on manually controlled Lathe
Machine in which the black layer from the material is removed. At first the diameter of the
forged material is measured using Calliper and it will come in the range of (240-245) mm.

Length of Bed- 12m.

Average Depth of cut = 8mm.

Feed (0.6-0.7) mm/rev.

Rotational Speed of spindle (25-40) RPM. Average final Job diameter on the facing side-
150 mm.

Diameter of the job on holding side- (210-215) mm.

4. Ultrasonic Testing: Ultrasonic Waves are sent in the

job for detection of any internal cracks and defects.

5. Finish Turning: This process itself consist of 3

processes performed on Computer Numeric Control
(CNC) Lathe Machine. Length 12 m, without steady
capacity-5 Ton, With Steady capacity 5 Ton, Diameter
(80-550) mm.

a. Turning and Taper Turning - Rotational Speed (50-70) RPM. Average Feed (0.4-0.5)
mm/rev. Depth of Cut-(4-6) mm.

b. Facing-Rotational Speed (80-90) RPM, Average Feed=0.4mm/rev, Average Depth of Cut-

2mm.
35 | P a g e
c. Chamfering-Chamfer Angle-30", Chamfer Width (6-7) mm.

6. Deep Hole Drilling: It refers to the drilling of bore holes with high length-to-diameter
ratios. For this operation the tool that we use is Drilling Head (i.e., Solid Bore). It consists of
7 inserts (or) cutting tools. Solid Bore-Lowest Size-56 mm Highest Size 190 mm. Average
Feed 20mm/minutes. Operational Speed (100-120) RPM, Bed Length 30 m.

7. Heat Treatment: After Deep Hole Drilling the job

goes in Gun Heat Treatment Shop (GHT) where
different heat treatment processes like Hardening,
Annealing, Normalising etc. is done.

8. Skinning: After heat treatment the job will come

back to GMS/HMS where the job is loaded on CNC
Lathe Machine and skinning of the black layer is done
which came due to heat treatment.

9. Counter Boring: Counter Boring is the

operation of enlarging one end of an existing hole
concentric with the original hole with square
bottom. For this operation the tool that we use is
Drilling Head (i.e., Counter Bore). It consists of 3
inserts or cutting tools.

10. Surface Finishing: In this process unevenness of the surface is removed through CNC
Lathe Machine. For this operation, Rotational Speed ≥ 100 RPM. Feed (0.3-0.4) mm/rev.
Depth of Cut-(4-5) mm.

11. After ultrasonic test if the job requires further machining, then it will go to CNC Lathe
Machine and further machining is done as per required wall thickness.

12. Inspection and Rectification:

Dimensional inspection is done by
Quality Control (QC), if any extra
material is there then that would be
removed using Band Saw Machine or
through other machining processes. After
Rectification again Inspection happens
and if any Dimensional Inaccuracy is
there which can be rectified then again
rectification process will be done as per
requirement.

36 | P a g e
13. Despatching: After above all steps the job will be sent to Gun Heat Treatment Shop
(GHT) and further to the consignee authority [i.e., Ordinance Factory Kanpur (OFC)].

Machines used in the Shop and their working principle

1. Manual Lathe Machine

It is an electrically operated machine in which there is a Squirrel Cage Motor whose

rotational speed ranges between (1400-1500) RPM. The motor shaft is then connected with a
small driving pulley which is connected through a big driven pulley using V-Belt Drives.
Inside the Headstock, from the driving pulley a Helical Gear train arrangement is attached to
it in which there are also some of the Spur Gears which plays a role of changing gears. Here
for changing gear, there are 3 levers whose position can be fixed manually and according to
that gear changes and rotational speed of the main spindle varies.

Through gear train the power get transmitted to the main spindle which relates to the Live
Centre on which a 4-Jaw Independent Chuck is mounted. This 4-Jaw chuck shows self-
centering action, and each Jaw can operate independently as there is also a Single Start Lead
Screw attached with it. Now the main spindle rotates through which the Chuck also rotates.
From the chuck the face centre of the job is fixed and from the Tail Stock the Holding Side
of the job is fixed.

Now at the bottom of the Headstock there is an another helical gear train arrangement from
which the Feed rod rotates which passes through the Carriage which consist of Compound
Rest which is responsible for axial movement of the carriage, on the compound rest there is a

37 | P a g e
tool post on which the Single Point Cutting tool (0 or negative Rake Angle) which is a
mixture of Carbon Boron Nitride (CBN) and Tungsten Carbide is fixed and below the
compound rest there is a Cross Slide which is responsible for radial movement of the
carriage. Now carriage achieves longitudinal movement through a Bevel gear train
arrangement whose pinion is attached with a Rack which is above the feed rod such that
through Rack & Pinion arrangement the Carriage.

2.Computer Numeric Control (CNC) Lathe Machine:

Electrically operated CNC machine which runs through a Serve Motor of (80-85) kW power
whose rotational speed ranges between (1-3000) RPM. The shaft which is attached with the
motor is attached with a small driving pulley and from there power got transmitted to a big
driven pulley through 8 V-belt drives. The driving pulley relates to a Helical Gear Train
arrangement which also consist Sper gears who play the role of changing gears.

Here gear changing system is quite different from that of the manual lathe machine, in
manual Lathe machine there were 3 levers for changing gears but here there is a Hydraulic
system for changing gears. So hydraulic oil goes into a piston cylinder arrangement via
cylinder through an Axial Piston Pump at approx. 40 bar pressure and the piston is attached
with a Piston Rod which can perform to-and-fro movement, so the changing spur gears are
on the same shaft and this spur gear system is attached with a Brass plate which is
responsible for movement of gears on the shaft and this brass plate is attached with the
piston rod so with the movement of the piston rod the brass plate moves and along with that
the spur gear system also moves on the shaft such that gear changing happens in this system
and through this the main spindle is able to achieve different rotational speed. At the live
centre for fixing the face centre of the job there is a 4-Jaw Independent Chuck. This 4-Jaw
chuck shows self-centering action and each Jaw can operate independently as there is also a
Single Start Lead Screw attached with it. Now the main spindle rotates through which the
Chuck also rotates. From the chuck the face centre of the job is fixed and from the Tail Stock
the Holding Side of the job is fixed.

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Now for the movement of Carriage there is another Servo Motor inside the carriage whose
shaft relates to a gear train arrangement in which a Bevel pinion which rotates in horizontal
plane meshes with the Rack which is on the complete length of the Lathe Bed and through
this Rack and pinion arrangement the carriage moves in axial direction. Here there are
Strainers and Magnetic Filter arrangement for Lubrication in different parts. Freon Coolant is
supplied through a motor and pump system at the cutting area. Electromagnetic Brake and
Clutch is there to stop the spindle in case of any electronic system stops

3. Ultrasonic Testing Machine

It in an electrically operated machine which runs through Battery & have potential to
generate Ultrasonic Waves. In this process at first some oil (or) grease is putted over the job
such that no air can go inside the job as if air get trapped in the job then the velocity of the
ultrasonic waves decreases which will degrade the results of the ultrasonic testing which may
lead to give un-necessary errors.

Range 500 mm, Probe Delay 1.0306

us, Display Delay-0.970 ps, SA 58.60
mm, Gain 74 Db.

In this process there is cable whose one

end relates to the machine & other end
is connected with a probe. Probes are
of 2 types:

a. Normal Probe (90° probe)- Velocity

of wave 5900 m/sec for Mild Steel

b. Angular Probe (35" probe)- Velocity of wave 3200 m/sec for Mild Steel.

4. Start boring/drilling & monitor these things: -

a. Chip Size & Shape

In Deep Hole Drilling the chip should have sharp edge not blunt edge while in Counter
Boring there should be no any variation in thickness of the chip from one end to other end.

b. Coolant Oil Pressure

This should be monitor as by applying certain pressure only the chips can come out of the
job through Boring Head. This should not be more than 25 Bar.

d. Positioning of boring-tube steadies- This is very important as according to job the position
of steady is fixed and if the job position matches with the position of these steadies then only
the job can be held steady and machining can happen firmly.

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 Flow Chart

FLOW 1: Black Forge Material From NGF

Centering

Skin Turning (Benco 12m)

Finishing In CNC (GMS)

FLOW 2: Black Forge Material from NGF

Centering

Skin Turning (Benco 12m)

Ultra Sonic Testing

Cutting As Per Drawing

Ultrasonic Sound Testing

Finishing/GHT

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 MECHANICAL MAINTENANCE SHOP (MM)
Working Mechanical maintenance is the job that maintains mechanical assets working with
little downtime. Regularly planned servicing, periodic checkups, and both scheduled, and
emergency repairs can all be part of machine maintenance. It also comprises the repair or
adjustment of worn, damaged, or misaligned elements Machine maintenance is essential in
every factory or facility that employs mechanical assets. It assists organisations in meeting
production deadlines, reducing costly downtime, and lowering the risk of worker sediments
and injuries.

Type of Maintenance:

There are several types of maintenance strategies that companies use. They are a range of
proactive and reactive methodologies. Depending on how you form your business structure,
maintenance can become costly or affordable, create problems or solve them. The different
types of maintenance strategies include:

1. Preventive Maintenance- Preventive maintenance (PM) is the normal and regular repair of
equipment and assets in order to keep them functioning and avoid costly unplanned
downtime due to unexpected equipment breakdown. A good maintenance strategy
necessitates the planning and scheduling of equipment repair before a problem arises. It is all
about repairing things before they break. Preventive maintenance is classified into four
categories: usage-based, calendar/time-based, predictive, and prescriptive. Each is based on
the notion of planned maintenance, but they are all organised and scheduled differently to fit
the needs of diverse business operations.

2. Corrective maintenance- Corrective maintenance

includes maintenance operations performed to
identify, isolate, and fie a defect in order to return
the equipment, a machine, or a system to operational
status so that it can fulfil its intended purpose.
Troubleshooting disassembly, adjustment, repair,
replacement, and realignment are all examples of
corrective maintenance. Corrective maintenance
jobs can be scheduled or unexpected, and they can
occur for one of three reasons: When condition
monitoring identifies an issue, a probable flaw is discovered during normal inspection, or a
piece of equipment fails....

3. Predetermined maintenance- Predetermined maintenance follows a plan of action

developed by the equipment manufacturer, as opposed to scheduled maintenance carried out
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by a maintenance team. An outstanding example of preset maintenance is when machinery
maintenance is scheduled at regular intervals based on the manufacturer's recommendations.

4. Condition-based maintenance- Condition-based maintenance (CBM) is a maintenance

technique that involves monitoring an asset's real state to decide when a repair is required.
CBM is based on the present and/or futare performance of the equipment rather than on a
predetermined timetable. CBM seeks to decrease maintenance costs and downtime by doing
maintenance only when necessary.

5. Predictive maintenance- Predictive maintenance (PdM) is a strategy that employs data

analysis tools and procedures to spot abnormalities in your operation and potential flaws in
equipment and processes so that they may be fixed before they fail. Predictive maintenance,
in theory, allows the maintenance frequency to be as low as feasible in order to od
unforeseen reactive repair while avoiding the expenses associated will performing too much
preventative maintenance.

6. Reactive maintenance- Reactive maintenance, often known as break down maintenance,

refers to repairs performed after equipment freaks down in order to return it to normal
operational condition. While active maintenance has a role in a well-rounded
maintenance approach, it should not be your default repair method.

Machines used for repairing:

1. Lathe

Conventional Lathe: - A typical lathe is a sort of standard lathe that is used to hold and turn
various materials such as metal, wood, plastic,
and so on against a cutting tool to create a
cylindrical item. It can also conduct a variety of
additional tasks like as grinding, boring,
threading. polishing, reaming, drilling, and carry-
on. It is ideal for small-volume production plants
and machinery repair shops, and it can machine a
broad variety of materials.

CNC (Computer Numerical Control) Lathe: - A CNC lathe is a machine tool that holds the
material or part in place and turns it using the main spindle whereas the cutting tool that
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works on the material is attached and moved on several axes. A basic CNC lathe runs on two
axes with the cutting tool placed in an 8 to.24-station turret]. It is a modification that
combines a standard lathe with a computer system. The workpiece spins quickly within this
technology and a computer- controlled cutting tool processes it to make axisymmetric pieces
with high precision. It may be used to machine a variety of metals and nonmetals.

2.Milling

Vertical Milling: A vertical milling machine is one in which the spindle (which holds the
collies, which in turn holds the cutting lies positioned vertically. It is the most popular
configuration for a CNC mill and may be used for milling, slotting, drilling, or boring. A
mail point cutting tool known as a milling cutter is used in this machine. This machine
features a vertical spindle that is perpendicular to the workpiece. The head may be swivelled
or fixed, and it can travel in any direction. Vertical Milling Machines are used to create a
variety of operations such as smooth surfaces, grooves, and slots.

Universal Milling- A universal milling machine is a sort of knee milling machine that can
execute more operations than a regular mill. It is a milling machine with all movements and
a division head with change gears, allowing it to conduct any sort of milling operation. The f
universal milling machine may be used for a variety of milling operations such as machining
planes, bevels and grooves by employing various milling cutters such as bar milling cutters,
circular milling cutters and angle milling cutters. The processing range of the machine may
be extended by employing the universal milling head, circular table, indexing bead, and other
milling machine attachments.

Shaping- A shaping machine is a machine tool used for shaping or cutting metal and other
materials. The workpiece is held firmly on the table and the ram, which holds the cutting
tool, is allowed to reciprocate over it. The cutting tool removes metal from the workpiece
when the ram moves horizontally in the forward direction. On the return stroke, metal is not
removed. Shaping machines are commonly used in metalworking industries for various
applications, including creating flat surfaces, slots, and grooves.

Slotting- A slotting machine is a reciprocating machine tool in which a crank and connecting
rod mechanism reciprocates the vertical slide containing the cutting tool. On the work table,
the job to be machined is mounted directly or in a vice. To generate splines, grooves, and
other tools, the machine tool eliminates any unwanted material chips from the workpiece.
Slotting machines are primarily used for cutting planes, shaping surfaces, and keyways,
among other things. and are appropriate for single or small- batch manufacturing.

Drilling: - A radial drilling machine is a type of drilling machine that is used to drill holes in
a specified radial distance when the component size is higher in terms of height with respect

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to the work table. It is mainly utilised when the component has a considerable height. Radial
drilling machines are often used to drill holes in large tasks or workpieces Lock

MAINTENANCE OF EAF

1. Check electrode length, if required, adjust

2. Electrode Arm is maintenance free.

3. Electrode lifting cylinder is easy to maintain. Only an overhead erane is required to

remove the 'PIN' of fixing

4. Gantry Arm is maintenance free.

5. Roof lift mechanism needs once in a month of cleaning by compressed air.

6. If the viscosity of the fluid in the hydraulic power pack is high. distilled water is added to
maintain viscosity.

7. After charging check no big skull/ non-metallic under the electrode to avoid electrode
breakage.

8. After charging start FCE at the lower Tap for 5 to 8 min to avoid electrode breakage then
increase tap as per requirement.

9. After melting, check physically if charge melting temp approx. 1550°C take sample and
temperature and flush out initial slag. add lime in furnace as per 'P' opening and flush out
slag. If required, take a sample and when you get tapping temperature try to flush out slag in
FCE and go for tapping 53

10. During tapping. Ensure that purging on adding to be done before tapping /during tapping
as per requirement. Take care during tapping no slag form FCE aim slag free tapping.

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 FLOW CHART OF MM

Preventive Maintenance

MR SECTION

Repair Request

Input – man, tools, Repair Request by

spares, lubricants, MR wings for
consumables, m/c common repair,
documentation heavy machining,
welding etc.

PLANT/MFC/EQP
T/FACILITY

OUTPUT
Productive m/c,
Maintenance history,
spares/Design

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 CONCLUSION

The availability of a suitable platform is essential for the evolution of eagerness and
enthusiasm. Without practical visualization and hands-on experience, the knowledge we gain
from reading remains incomplete. That's why we choose to undergo our vocational training
at Metal & Steel Factory, Ishapore.

In the factory, we have the opportunity to connect our minds with our eyes and
witness various engineering operations, mechanisms, and the work of different employees.
This exposure enhances our understanding of both technical and non-technical principles.
Metal & Steel Factory, Ishapore has made significant contributions in providing us with this
invaluable vocational training experience.

The factory offers a conducive industrial environment and exhibits a professional

attitude that allows us to learn how to perform tasks in an industrial setting. The guidance
and instructions from the experts in each department contribute greatly to our knowledge
acquisition.

We express our gratitude to the entire staff, Jr. Works Managers, Trainees, Charge
man’s and Heads of Sections at Metal & Steel Factory, Ishapore. It is an esteemed
ordnance factory that plays a vital role in ensuring defence security across India.

________________________________

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