CONTEN CHAPTER 1: ABOUT THE COMPANY 1.1 Vision 1.3 Specialized in 1.4 Products 1.5 Infrastructure 1.5.1 List of Machineries 1.5.2 List of Instruments. 1.6 Clients CHAPTER 2: ABOUT THE DEPARTMENT 2.1 Manufacturing processes 2.2 Machining proc 2.2.1 Conventional process 2.2.2 Non-Conventional process 2.3 Measuring tools CHAPTER 3: TASKS PERFORMED 3.1 Geometric Dimensioning and Tolerance 3.2 Surface Roughness and Symbols 3.3 Engineering Drawing 3.4 Process Planning 3.5 Assembly section 3.5.1 Sugarcane juice machine Pg. No.1 Pg. No.l Pg. No.2 Pg. No.2 Pg. No.3 Pg. Nod Pg. No4 Pg. No.4 Pg. No.4 Pg. No.5 Pg. No.5 Pg. No.6 Pg. No.6 Pg. No.17 Pg, No.21 Pg. No.24 Pg. No.24 Pg, No.25 Pg. No.26 Pg. No.43 Pg. No.43 Pg, No.35.2 Wire striping machine CHAPTER 4: OUTCOMES 4.1 Specific outcome 4.2 Conclusion Pg. No.44 Pg. No.45 Pg. No.45 Pg. No.46 Pg. No.47An Isometric Drawing 28 The block suspended in a glass box. 29 The creation of an orthographic multiview drawing. 29 A multiview drawing and its explanation. 30 An object needing only two orthogonal views. 30 An isometric view with dimensions. 30 An isometric drawing that does not show all details. 31 "Sectioning" an object. 32 Sectioning the object in figure 3.8. 32 Sectioned isometric and orthogonal views. 32 Drawing Tools. 33 Pillow-block (Freehand sketch). 33 Disassembled Pillow-block. 34 Pillow Block. 34 Pillow Block. 35 Section"A-A". 35 The top "outside" view of the bearing. 36 Full and sectioned isometric views. 36 Front view and half section. 36 Half section without hidden lines. Cross section. 38 Dimensioned Drawing. 38 Example drawing with a leader. 39Example of appropriate and inappropriate dimensioning. Simple Object. Surface datum example. Surface datum example. Exampled of a dimensioned hole. Example of a directly dimensioned hole. Example of a directly dimensioned hole. LIST OF TABLES CaptionCHAPTER 1: ABOUT THE COMPANY People Mechanics is engaged in the manufacturing vertical, The industries we serve include, but are not limited to, the Construction, Aerospace, Automobile and Hydraulic Industries. They have experienced and energetic team of professionals with a nothing's too difficult philosophy. The company is keen to make its mark in the manufacturing Industry by providing 100% results. They achieved name by Manufacturing Expertise, State-of-the-Art Machine, wide range of Materials & Services, Exceptional Quality Control. With a proven understanding of the design, technology and manufacturing process, we create solutions that provide our customers with a competitive advantage. Vision Their vision is to continuously provide 100% customer satisfaction by supplying quality products on time delivery with promised lowest cost. As they are unique they state thei vision in three verticals. 1, To Customers: 100% satisfaction. Prime Quality. On time Delivery. 2. To Vendors: Permanent Orders, Last long Relationship. On Time Payment. 3. To Employees : To make our people wealth . To make our people Skilful. Respecting Diversity.1.2 Mission Their business is dedicated to providing superior products and services to their customers. They believe their customers are the most important part of their business now and in the future. People Mechanics Committed: To Customers: Unmatched quality, and support to every customer. To Vendors: Foster the relationships with our vendors. We foster an open, collaborative culture where dedication, Passion, ideas second to none. 1.3 Specialized in © Designing of jigs and fixture. * Manufacturing manual and robotic welding jigs and Fixtures. * Aerospace components. * Construction machines. * Hydraulic and pneumatic cylinders.é. es1.5.1 LIST OF MACHINERIES v bY D.R.O. Milling (LAGUN): MNTR, ISO 40, Bed Length 1000mmX400mmX350mm. LATHE (Rajkot) : Medium Duty, SOB-300mm, CO2 Welding M/C: 250A CNC Turning Centre: ~LOKESH TL-20 OD — 200mm(Max), Length 400mm(na Micrometric Cylindrical Grinding M/C: OD 350mm(Max), Length 1000mm(Max)ID 200mm(Max.Apprx), Dia 16mm (min). Gear Hobbing M/C: (Up to 8 Modules) Future Project. 1.5.2 LIST OF INSTRUMENTS. Vernier (Analog): 0-300mm, LC 0.02mm, 2. Vernier Height Gauge: 0-300mm, LC0.02mm 3. Plunger Dial Gauge (Mitutoyo): 0-10mm, 0.01mm, 0.001mm OD 4. Micrometer: 0-25mm, 25-S0mm, 50-75mm, 75-L00mm, 100-125mm,125- 150mm,150-175mm, 175-200mm, 200-225mm, 225-250mm, 250-275mm, 275-300mm 5. Bore Gauge: 18-300mm 6. Bevel Protractor, Radius Gauge, Calipers, Pitch Gauge Ete. 1.7 Clients regqgO S SAFRAN ae ~ WASALS on imeeCHAPTER 2: ABOUT THE DEPARTMENT 2.1 Manufacturing Processes Manufacturing is the backbone of any industrialized nation. Manufacturing and technical staff in industry must know the various manufacturing processes, materials being processed, tools and equipments for manufactu 2 different components or products with optimal proces plan using proper precautions and specified safety rules to avoid accidents. Beside above, all kinds of the future engineers must know the basic requirements of workshop activities in term of man, machine, material, methods, money and other infrastructure facilities needed to be positioned properly for optimal shop layouts or plant layout and other support services effectively adjusted or located in the industry or plant within a well-planned manufacturing organization. The complete understanding of basic manufacturing processes and workshop technology is highly difficult for anyone to claim expertise over it, The study deals With several aspects of workshops practices also for imparting the basic working knowledge of the different engineering materials, tools, equipments, manufacturing processes, basic concepts of electro- mechanical controls of machine tools, production criteria’s, characteristics and uses of various testing instruments and measuring or inspecting devices for checking components or produets manufactured and in various manufacturing shops in an industrial environment, It also describe demonstrates the use of different hand tools (measuring, marking, holding and supporting tools, cutting ete.), equipments, hinery and various methods of manufacturing that facilitate shaping or forming the different existing raw materials into suitable usable forms. It deals with the study of industrial environment which involves the practical knowledge in the area of ferrous and non-ferrous materials, their properties and uses. It should provide the knowledge of basic workshop processes namely bench work and fitting, sheet metal, carpentry, pattern making, mould making, foundry, smithy, forging, metal working and heat treatment, welding, fastening, machine shop, surface finishing and coatings, assembling inspection and quality control, It emphasizes on basic knowledge regarding composition, properties and uses of different raw materials, various production processes, replacement of orimprovement over a large number of old process s, new and compact designs, better accuracy in dimensions, quicker methods of production, better surface finishes, more alternatives to the existing materials and tooling systems, automatic and numerical control systems, higher mechanization and greater output. 2.2 Machining Processes Machining is a process in which a piece of raw material is cut into a desired final shape and size by a controlled material-removal process. There are two types of machining Process © Conventional Machining Process. * Non-Conventional Machining Process. 2.2.1 Conventional Machining Process. It is nothing but the process in which the material is removed by the direct contact between tool and work piece. The energy is utilized to rotate either work piece or tool, and the cutting tool should be harder than work piece. © Lathe * Drilling Machine © Milling Machine © Grinding Machine 1 Lathe A lathe is a machine which is used for shaping wood & metals (ferrous and non-ferrous), phosphorous bronze, copper, nylon etc. : LATHE (Rajkot) : Medium Duty, SOB-300mm,Operations in lathe © Facing: Facing is used to make a flat surface at the end of the work piece. The work part should be rotating and the implied feed should be radial. © Contour turning: In this operation of lathe machine the too! is not fed in a straight path. Instead the tool follows a contour. A contoured form is ereated in the turned part. © Form turning: In this method a special shaped tool is used. The tool is inserted radially. © Taper turning: Like contour turning the tool is not fed parallel to the axis of rotation of the work part, The tool is fed at an angle. This turning operation gives a conical and taper cylindrical shape. © Cutoff or Parting: In parting operation the tool is fed radially and the end part of the work piece is cut off. © Boring: A single point tool head fed linearly to the end of the work piece (on the inside diameter). © Threading: A pointed tool is used at the outside surface of the work piece with linear feed to create a thread. © Drilling: Drilling and reaming is done by feeding the lathe tool along the axis of the rotating job part. © Knurting: It is a metal forming method which creates a regular cross hatched pattern. It is not a machining process. It does not involve any cutting of the metal. © Grooving: The term grooving usually applies to a process of forming a narrow cavity of a certain depth, on a cylinder, cone, or a face of the part.Tolerance achieved in lathe: 100 microns (0.1mm) Average roughness value can be achieve in lathe 1.6 above Turning operations cannot be done after heat treatment. Can be done by using certain special tips up to certain extent of 35-40Hre Types of tool material used in lathe © Carbide © High speed steel (HSS) © Diamond Types of Lathe Machine * Speed Lathe! Wood Lathe © Engine lathe * Tool room lathe © Capstan lathe and turret lathe © Special purpose lathe © Wheel lathe © Automatic lathe © CNC lathe © Crank shaft lathe © Vertical lathe 2.2.1.1(a) CNC Turning © Turing done by programming according to the desired shapes in drawing * Its preferred over conventional when there is complex shapes in turning which cannot be achieved in conventionalFig.2.2: CNC Turning Centre: Z-Mat TL-20 OD 200mm(Max), Length 400mm(max) Advantages of CNC Machine CNC Machines have following advantages — CNC machines can be used continuously 24*7 throughout the year and only need to be switched off for occasional maintenance. Less skilled/Arained people can operate CNC machines unlike manual lathes / milling machines ete. which nee illed engineers. Time saving when compared to conventional turning Normally used for batch or mass productions Modern design software allows the designer to simulate the manufacture of his/her idea. There is no need to make a prototype or a model. This saves time and money. Tolerance achieved in CNC Machines: up to 10 microns (0.01mm) Average roughness value can be achieved is 0.82.2.1.2 Drilling Machine Drilling is an operation of producing a cylindrical hole of required diameter and depth by removing metal by the rotating edges of a drill MOTOR eo moron switch, , VARIABLE SPEED CONTROL TOOL HEAD \ = <. JA QUILL FEED HAND LEVER QUILL FEED RATE Ss ar SELECTOR———___» . = “DIGITAL READOUT r 7 QUILL FEED HANDWHEEL— = & SPINDLE” ‘TABLE casera TABLE LOCKS CRANK HANDLE <——— RAM at <— pam Locks a RAM ADJUST “~— HANDLE TABLE STOP DOGS VERTICLE a KNEE TRAVERSE CRANK BASE———"| SADDLE TRAVERSE ‘CRANK Fig.2.3: DRO Drilling Machine Operations Performed in Drilling Machine Drilling Drilling is the operation of producing a cylindrical hole of required diameter and depth by removing metal by the rotating edge of a cutting tool called drillReaming Reaming is an accurate way of sizing and finishing a hole which has been previously drilled by a multi-point cutting tool known as reamer. Boring Boring is the operation enlarging the diameter of the previously made hole. Counter boring Process of enlarging a drilled hole along part of the length of the hole by drilling with a greater diameter Countersinking Countersinking is the operation of making a cone shaped enlargement at the start iz of the hole, The included angle of the conical surface may be in the range of 45° to 90° Spot Faci Spot facing is the operation of smoothing and squaring the surface around a hole. It is done to provide proper seating for a nut or the head of a screw. Tapping Tapping is the operation of cutting internal threads by means of a cutting tool called ‘tap’ Trepanning Trepanning is an annular groove producing operation which leaves a solid cylindrical core in the centre Tolerance achieved in Drilling Machine: 100 microns (0.1mm) in drill bits 20 microns (0.02) in reamers ‘Types of drilling Machine 1. Portable drilling machine (or) Hand drilling machine Sensitive drilling machine (or) Bench drilling machine 3. Upright drilling machine 4. Radial drilling machine5. Gang drilling machine 6. Multiple spindle drilling machine 7. Deep hole drilling machine 2.2.1.3 Milling Machine Milling is the process of machining using rotary cutters to remove material by advaneing a cutter into work piece. VERTICAL HORIZONTAL ‘A has @ VenricaL wean e oun © TAmue & Sanne © CROBEFEED HANOLE G VERTICAL Peed Crane ARNE Fig. 2.4: Milling Machine Operations performed in Milling Machine Plain mill As the name implies, this operation used to get plain surface. In this milling, the cutting tool axis is parallel to the machining surface or the face of the machiningEnd milling: In this operation, the cutting tool axis is perpendicular to the machining surface or the face of the machining surface. It is used to perform pocket milling, small slotting operations Gang milling: In this operation more than one milling cutters which are in different shapes and size are used for machining. To get the desire shape in one pass. Straddle milling: In this operation, two or more parallel vertical surface machined in a single pass. In this milling the work piece is situated between the two cutters which can machined the surface vertically. Slotting:” In this operation slots are cut by a cutter on the work piece. The slots are in various shapes like circular, rectangular ete. and sizes according to the requirement. Angular milling: In this operation, surfaces which are at an angle to the axis of the cutter, is machined by the rotary cutter. Tolerance achieved in milling machine: 100 microns ‘Types if Milling Machines 1. Column and knee type milling machine © Vertical milling machine * Horizontal milling machine © Universal milling machine 2. Fixed bed milling machine Simplex milling machine © Duplex milling machine Triplex milling machine 3. Planner milling machine 4. Special milling machine* Tracer milling machine © CNC milling machine. Average roughness value that can be achieved is 0000 and it’s above Tolerance can be achieved is ~ (+ or - 0.1mm) 2.2.1.3(a) CNC Milling Machine . eee Machine will operates on predefined program according to the desired shape Types — Horizontal and Vertical Milling Machine Types based on axis ~3Axis, 4Axis, SAXis Complex shapes can be achieved which cannot chieved in conventional chieved up to 0.01 mm(10 microns) Average Roughness value ~ 0.8 Tolerance that can be achieve is -0.01mm(10 microns) Flatness can be VMC( Vertical milling Centre) Here Spindle is placed vertical y (perpendicular) to the job Horizontal milling centre Spindle is placed horizontal Normally the industries uses the 3Axis Machine 2.2.1.4 Grinding Machine 2.2.1.4(a) Surface Grinding © Grinding is an abrasive machining process that uses a grinding wheel as the cutting tool © The Grinding wheel is made up of abrasive particles © Surface grinding is used to produce a smooth finish on flat surfaces.Types of surface grinding machines are: 1. Horizontal spindle and reciprocating table 2. Vertical spindle and reciprocating table ‘A: rotation of grinding wheel B: reciprocation of worktable ‘C: down feed of grinding whee! ‘A: rotation of grinding wheel 1: table rotation 6: table reciprocation D: down feed of grinding whee!cess is 0.3 and above ge roughness can be achieved in this pro’ ed is 0.002mm (2 microns) Avera: Tolerance can be achiev js 0.002mm (2 microns) Flatness can be achieve ! 2.2.1.4(b) CYLINDRICAL GRINDING This machine is used to grind external cylindrical surface and inner cylindrical surfac Types of Cylindrical grinding machine Plain centre type cylindrical Universal cylindrical surface grinder veNe Centre less cylindrical surface grinderWORK REST Schematic representation of Universal cylindrical surface grinder Normally in industries Universal cylindrical surface grinder are used due to i flexibility when compared to other two The Average Roughness value can be achieved 0.3-0.8 Maximum tolerance that can be achieved in the machine is .002mm The grinding surfaces may be straight, tapered, steps, or ID grinding Centre less cylindrical surface grinder used, when the job can’t hold betweer the 2centres, and when concentricity is not required 2.2.1.4.(c) CENTRELESS GRINDINGTypes of Non-traditional Machining + Ultrasonic Machining (USM) + Water-Jet Machining & Abrasive-Jet Machining + Chemical Machining + Electrochemical Machining (ECM) + Electrical-Discharge Machining (EDM) + High-Energy-Beam Mi chining ~—Laser-beam machining (LBM) ~Electron-beam machining (EBM) Why Non-traditional Machining? © Situations where traditional machining processes are unsatisfactory or uneconomical: © Work piece material is too hard, strong, or tough *® Work piece is too flexible to resist cutting forces or too difficult to clamp © Part shape is very complex with internal or external profiles or small holes. © Requirements for surface finish and tolerances are very high © Temperature rise or residual stresses are undesirable or unacceptable2.2.2.1 Water Jet Machining (WJM) Schematic Layout of WIM Accumulator ‘ica WIM is a form of micro erosion. It works by forcing a large volume of water through a small orifice in the nozzle. The extreme pressure of the accelerated water particles contacts a small area of the workpiece and acts like a saw and cuts anarrow groove in the material, *Pros: no need for predrilled holes, no heat, no work piece deflection (hence suitable for flexible materials), minimal burr, environmentally friendly. * Cons: limited to material with naturally occurring small cracks or softer material. + Applications: Mostly used to cut lower strength materials such as wood, plastics, rubber, paper, leather, composite, ete. —Food preparation -Good for materials that cannot withstand high temperatures of other methods for stress distortion or metallurgical reasons. 2.2.2.2 Electrical Discharge Machining (EDM) * EDM is one of the most accurate while quite affordable manufacturing processes* Principle - Electrical discharge machining process works on the basic principle of spark generation and metal removed by spark erosion. ‘* The EDM system consists ofa shaped tool or wire electrode © The part is connected to a power supply to create a potential difference between the work piece and the tool. © When the potential difference is sufficiently high, a transient spark discharges through the fluid, removing a very small amount of metal from the work piece. The dielectric fluid 1) acts as an insulator until the potential is sufficiently high, 2) Acts as a flushing medium, and 3) Provides a cooling medium, Types of EDM 1. Sparking 2. Wire Cutting or Wire EDM 2.2.2.2(a)Sparking * Tool used for sparking is COPPER ‘* Copper is used because it is highly conductive material © Tolerance can be achieved is 0.001mm ‘* Sparking is used when the material has to remove up to particular depth in the job. Servo Motor Too! Blectrode Dielectric Task Dielectric Inter-electrode gap Worl piece Fixtore The above picture is for sparking2.2.2.2(b) Wire Cutting Machine © Type of wire used in process is BRASS © Diameter of the wire is 0.25mm ~ 0.3mm © Tolerance can be achieved is 0.001mm © Average roughness value can we get is 0.8 © Wire cutting is used to cut the material only when the wire is allowed to pass through the job Wire Suppiy Wire electrode Dielectric ‘Supply nn Pulse generator Wire take up wheel Above picture is for wire cutting EDM 2.3 Measuring tools used in Manufacturing Process 1. Vernier calliper 2. Micrometre 3. Dial gauge 4. Bore gauge 5. Vernier height gauge 6. Try squareVernier calliper Vernier callipers have both a fixed main scale and a moving vernier scale. INTERNAL ar METRICIINGH LOCKING ~) BUTTON SCREW Power” zeno DEPTH MEASURING Gucrr SETTING BAe i EXTERNAL Sans Micrometer A micrometer, sometimes known as a micrometer screw gauge, is a device incorporating a calibrated screw widely used for accurate measurement of components in mechanical engineering and machining as well as most mechanical trades, along with other metrological instruments such as dial, vernier, and digital callipers. Dial gauge © A gauge consisting of a circular graduated dial and a pointer actuated by a member that contact with the part being calibrated, © Dial indicators are one of the primary measuring tools used in preci building. jon engine© They are typically used to measure deck clearances, crankshaft thrust and straightness, lifter travel and other measurements that involve the distance between two surfaces or small amounts of component travel. Bore Gauge A bore gauge is a collective term for the tools that are unique to the process of accurately measuring holes Vernier height g: uge A height gauge is a measuring device used for determining the height of objects, and for marking of items to be worked on Height gauges may also be used to measure the height of an object by using the underside of the seriber as the datum.GD&T Symbol Name Summary Description Straightness Controls the straightness of a feature in relation to its own perfect form Flatness Controls the flatness of a surface in relation to its own perfect form Circularity Controls the form of a revolved surface in relation to its own perfect form by independent cross sections Cylindricity Like circularity, but applies simultaneously to entire surface Profile of a Surface Controls size and form of a feature. In addition it controls the location and orientation when a datum reference frame is used. Profile of a Line Similar to profile of a surface, applies to cross sections of a feature Perpendicularity Controls the orientation of a feature which is nominally perpendicular to the primary datum of its datum reference frame Angularity Parallelism Controls orientation of a feature at a specific angle in relation to the primary datum of its datum reference frame Controls orientation of a feature which is nominally parallel to the primary datum of its datum reference frameCircular run out | Controls circularity and coaxially of each circular A segment ofa sutfice ladependently ebout a conkial datum Total run out Controls circularity, straightness, coaxiiality, and tap aA of a cylindrical surface about a coaxial datum 3.2 Surface Roughness and Symbols Surface roughness often shortened to roughness, is a component of surfe lexture. Roughness plays an important role in determining how a real object w interact with its environment. Roughness is often a good predictor of the performan of a mechanical component, since irregularities on the surface may form nucleati sites for cracks or corrosion. On the other hand, roughness may promote adhesion. Value of Roughness Rainmm | Roughness - grade symbol! Roughness grade number3.3 Engineering Drawing An engineering drawing is a type of technical drawing that is used to convey information about an object. A common use is to specify the geometry necessary for the construction of a component and is culled a detail drawing. Usually, a number of drawings are necessary to completely specify even a simple component, The drawings are linked together by a master drawing or assembly drawing which gives the drawing numbers of the subsequent detailed components, quantities required, construction materials and possibly 3D images that can be used to locate individual items. Although mostly consisting of pictographic representations, abbreviations and symbols are used for brevity and additional textual explanations may also be provided to convey the necessary information. The process of producing engineering drawings is often referred to as technical drawing or drafting. Drawings ty ally contain multiple views of a component, although additional seratch views may be added of details for further explanation. Only the information that is a requirement is typically specified. Key information such as dimensions is usually only specified in one place on a drawing, avoiding redundancy and the possibility of inconsistency. Suitable tolerances are given for critical dimensions to allow the component to be manufactured and function, More detailed production drawings may be produced based on the information given in an engineering drawing. Drawings have a information box or title block containing who drew the drawing, who approved it, units of dimensions, meaning of views, the title of the drawing and the drawing number.STOUT CR 100 (40)We hope you like the object in Figure 3.1, because you'll be seeing a lot of it. Before we get started on any technical drawings, let's get a good look at this strange block from several angles.

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