INDUSTRIAL TRAINING PROJECT

REPORT ON
―CNC TURNING‖

SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR

Six Month Industrial Training at

Mahindra and Mahindra Limited | Swaraj Division

(From _____ to ________)

SUBMITTED BY

PRABHDEEP SINGH GUJRAL

Branch: MECHANICAL ENGINEERING

Roll No. 131087

Univ. Roll No. 1311655

Mechanical Department

GURU NANAK DEV ENGINEERING COLLEGE

LUDHIANA, INDIA
 ACKNOWLEDGEMENT

The author is highly grateful to Dr. Manohar Singh Saini, Principal, Guru Nanak Dev
Engineering College (GNDEC), Ludhiana, for providing this opportunity to carry out the six
month industrial training at Mahindra and Mahindra Limited | Swaraj Division.

The constant guidance and encouragement received from Dr. Sehijpal Singh Khangura,
HOD- Mechanical Engg Department, GNDEC Ludhiana has been of great help in carrying
out the project work and is acknowledged with reverential thanks.

The authors would like to express a deep sense of gratitude and thanks profusely to Ms. Neha
Rajgopal (HR) and Mr. H.S. Baweja (HOD- Machine Shop) of the Company. Without the
wise counsel and able guidance, it would have been impossible to complete the report in this
manner.

The help rendered by Mr Gurwant Singh Gill, Supervisor for experimentation is greatly
acknowledged.

The authors express gratitude to other faculty members of Mechanical department of GNDEC
for their intellectual support throughout the course of this work.

Finally, the authors are indebted to all whosoever have contributed in this report work and
friendly stay at Mahindra and Mahindra Limited | Swaraj Division.

PRABHDEEP SINGH GUJRAL

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 TABLE OF CONTENTS

Chapter 1: INTRODUCTION TO THE COMPANY

Chapter 2: INTRODUCTION TO THE VARIOUS SHOPS
 Light machine Shop
 Heavy Machine Shop
 Heat Treatment Shop
CHAPTER 3: PROJECT WORK
 Project 1
 Project 2

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 INTRODUCTION TO THE COMPANY

 ABOUT SWARAJ

Punjab Tractors Limited (PTL) was promoted by Punjab State Industrial Development
Corporation Limited (PSIDCL) with the objective of promoting new industrial projects in the
state of Punjab on 27th June, 1970 at Chandigarh. In 1970, the Government of Punjab
acquired Swaraj tractor's design and established Punjab Tractors Limited (PTL). The unit
wentintoproductionin1974.The tractors were based completely on indigenous design and
resulted as the effort of six years of designing ,development and field proving effort the
Central Mechanical Engineering Research Institute (CMERI), a national laboratory under the
Council Of Scientific and Industrial Research (CSIR) of the Govt. of India. The tractors were
produced and sold under the brand name- Swaraj. In 2007, Mahindra & Mahindra Ltd.
Acquired a majority stake in PTL, and in February 2009, it was merged into M&M as the
Swaraj Division of Mahindra& Mahindra.

The Swaraj Division of Mahindra & Mahindra Ltd. (M&M), Farm Equipment Sector (FES),
is a part of theUSD15.9billion Mahindra Group. The brand is known for producing tractors
that are rugged , powerful and reliable .With over 600 dealers across India, Swaraj today is a
Rs.3,000 crore company today with over 5,000 employees . Swaraj Division is the second
tractor company in India to have won the prestigious Deming Prize Award .The Swaraj
Group has achieved ISO14001:2004 & OHSAS18001:2007 certification and TS16949
certification for Swaraj Automotives Ltd.

 ABOUT MAHINDRA

Founded in 1945 as a steel trading company, Mahindra & Mahindra entered automotive
manufacturing in 1947 to bring the iconic Willys Jeep onto Indian roads. Over the years, the
company has diversified into many new businesses in order to better meet the need so fits
customers. M&M follows a unique business model of creating empowered companies that
enjoy the best of entrepreneurial independence and Group-wide synergies.
This principle has led its growth into a US$15.4 billion multinational group with more than
144,000 employees in over 100 countries across the globe.

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 The federated structure of the company enables each of its businesses to chart its own future
and simultaneously leverage synergies across the entire Group‗s competencies. In this way,
the diversity of its expertise allows it to bring its customers the best in many fields.
The Mahindra Group comprises ten business sectors—After market , Automotive & Farm
Equipment, Defense Systems ,Financial Services, Hospitality, Information Technology ,Real
Estate & Infrastructure, Sys tech , Two Wheelers and Mahindra Partners—with a presence in
18 industries. In 2012, Mahindra featured on the Forbes Global 2000 list, a listing of the
biggest and most powerful listed companies in the world.

 BRAND NAME–SWARAJ

Being a bold and courageous venture based on indigenous design , research &technology,
SWARAJ was appropriately chosen as the brand name. Self reliance and building up of
Indian engineering capabilities, remains the enduring spirit behind PTL.

 Swaraj Division(Plant1)
The flagship company of Swaraj Enterprises, Plant 1hasbecomeaTrailblazer of sorts making a
consistent profit over the years. The first batch of tractors was rolled out on
November14,1973. Commercial production started in April 1974.

Fig.1.1 Swaraj Division (Plant-1)

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  Swaraj Division (Plant2)

Punjab Tractors Limited established another run it in 1981 at a capital layout of 2.6 crores
named Swaraj Combine Division (Nownamedas Plant 2) to manufacture India's first self
propelled Harvester Combine-SWARAJ 8100. The division is located in village Chappercheri,
Distt. Mohali.

Fig.1.2 Swaraj Division (Plant 2)

 Swaraj Foundry Division

This division is supplying automotive castings to other divisions of Swaraj, Swaraj
Engines Limited & also to some outside customers .The foundation stone for expansion of
foundry division was laid on 28 February 2008.The Foundry division is into expansion phase
and this expansion from 10,000 ton per annum to 25,000 ton per annum would bring new
business and strengthen our position in the industry .This project of Rs.32crores with
enhanced technology would help the Foundry Division to make crankcase & cylinder-head
for engines and transmission housing fourteen tire group.

Fig.1.3 Swaraj Foundry division

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  Swaraj Engines Ltd

PTL in collaboration with KIRLOSKAR OIL ENGINES LTD floated a new company-
SWARAJ Engines Ltd.-to manufacture diesel engines in 1987.PTL contributed 38%ofthe
finances for setting up the company; Kirloskar Oil Engines Ltd. contributed 13%and 49%of
the finances came from the public. Swaraj Engines Ltd. Was established in Industrial Area
Phase-IX, Mohali, Distt, Mohali.

Fig.1.4 Swaraj Engines Ltd

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  RESEARCH & DEVELOPMENT CENTRE

The emphasis on R&D is validated by a long list of new products it has introduced and
established. An R&D complex has been setup in order to meet the increased production target of
tractors and the growing need of improving the product line. This complex has the following
facilities:
 Advanced Research &Development needs for Tractor, harvester combines and
forklifts.
 Swaraj centre for HRD training of Management Staff, Supervisory Staff & Workers.
 Spare Part Division for Tractors, Harvester Combines.

Fig.1.6 Swaraj Research & Development

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 PRODUCT PROFILE

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 INTRODUCTION TO THE VARIOUS SECTIONS OF PLANT

The manufacturing of Tractor is performed in various steps. It is manufactured after passing

through various processes in various shops. Firstly, various operations on various parts are
performed in the L.M.S. (Light Machine Section) and H.M.S. (Heavy Machine Section). In
H.M.S. generally there are four major heavy parts that are given proper machining operations.
These include Gear Box Casing, Differential Housing, Trumpet Housing and Rear Cover.
Similarly, in L.M.S. the light parts are given proper machining. These include various parts such
as Gears, Shafts, Cage Assembly casing etc.

In Heat Treatment Shop, the light parts such gears, shafts etc are given the heat treatment to
ensure their strength. Firstly the part after passing through various operations in L.M.S. is taken
to the Heat Treatment Shop. Here the part is kept in the furnace for suitable time period up to
certain high temperature. Then it is taken to the Quenching tank where it is dipped in the oil
tank. After that it is taken to washing tank for washing of dirt and oil etc. Then it is taken to the
Assembly line.

In Assembly line various parts are being assembled into a single unit termed ―Tractor‖. During
assembling the various parts are being fitted according to the stage. This would includes the
assembly of important parts such as Rear Cover, Gear Box, Differential Housing and trumpet
Housing. Firstly the Various sub-parts of the Rear Cover are being fitted. Then the various parts
such as gears, shafts, bearing, oil rings, clutch actuator and circlip etc are fitted into the Gear
Box. After that both the Rear Cover and the Gear Box are taken to the line where Gear Box if
fitted ahead of the Differential Housing whereas the Rear Cover on the Top. Then various things
such as Brakes, P.T.O. Shaft, Cage Assembly, Trumpet Housing etc. are fitted to the Differential
Housing. Then this whole assembly is fitted with the engine against the Gear Box.

After whole assembly is fitted with the Engine, this assembly is taken to the Chassis Paint Area
where it is washed and dry followed by Paint on the chassis.

Then the tractor reaches to the Final stage where certain electrical and other accessories such as
Battery with Battery cover, Steering Wheel, radiator etc are fitted. Proper level of Engine oil is
also filled into the Differential and Gear Box. Greasing of various parts is also performed with

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Grease Gun. After that the Tractor is taken out of the line after taken it out from the hooks. This
stage is termed as ―Dismounting Stage‖.

Then the Testing of the Tractor is performed which include the checking for vibrations, noise,
brakes, oil level and other factors that effects the performance of tractor.

The plant also contains a Maintenance shop which after the working and maintenance of various
machines and hoists installed in the Machine shop and the assembly shop. The plant also caters a
Tool Room in which the snap gauge and fixtures for some machine used in the light machine
shop are made. Go & No-Go plug gauges are also made in Tool Room according to component
designed.

The Hydraulic section of the plant caters the assembly of the control valve and response valve
used in the hydraulic section of the tractor. These components are then sent to the assembly line
where they are installed in rear cover assembly and work as sensor for the tractor.

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 LIGHT MACHINE SHOP

 Introduction

LMS is the largest section of the factory. All transmission components like shafts and gears
used in tractors are manufactured here. L.M.S comprises of 117 machines. Except the bevel
gear generator & gear shaver, which have been imported from WMW & Churchill of
Germany respectively, all other machines are from HMT Ltd. Femco CNC turning machine
are also installed. The old machines uses tool made up of high speed steel whereas new
machines uses tool made up of tungsten carbide. Total of 160 highly experienced operators
and inspectors manned this shop.

 Types of machines:

S.No. M/C Description Job Operations

Bull Gear Line

1. ECO-5 CNC Bull Gear Turning

2. Broaching machine Bull Gear Cutting Internal Spline

3. Gear hobbing machine Bull Gear Cutting Outer Spline

4. Deburring machine Bull gear For removing rough edges

5. Shaving machine Bull Gear Shaving or finishing

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 Shaft Line

6. Center Facing machine BP shaft Facing, Centering

7. Femco Turning machine BP shaft Rough, Finish turning (first 4

steps)

8. Femco WNCL-30 BP shaft Rough, Finish turning (next 6

steps)

9. COOPER BP shaft Spline cutting

10. HMT H400 BP shaft Gear cutting

11. Shaving machine BP shaft Shaving

Cage Assembly

Right cage Drilling, Chamfering,

12. VMC-40
Grooving, Tapping, Facing

Cage assembly Boring (both sides)

13. Boring machine

14. Cylindrical Grinding Cage assembly Grinding

machine

15. HMT HMC-320 Cage assembly Cross drilling

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 Other Machines

16. Lichberr (HMT) Hobbing Gear cutting

17. Cooper Gear idle cluster Cutting

18. Parisuda AHG 80 CNC Intermediate shaft Grinding

19. HMT Radial drill drilling

20. GCI 300 CNC Bevel Gear Grinding

21. VMC-500 vertical Milling, Drilling

milling machine

22. WIDMA drilling Drilling

machine

23. SPILOTE Copy turning Lathe

24. PS-180 Gear shaper(not Spline cutting

bevel)

25. Spectra grind 600 Grinding

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  DIFFERENT MANUFACTURING OPERATIONS IN LMS:

1. Facing: It is the operation of finishing the ends of the work to make the ends flat and
smooth and to make the piece of required length.

2. Under cutting: It is similar to grooving operation but is performed inside a hole.

3. Chamfering: It is operation of beveling the extreme end of the work pieces, chamfer is
provided for better look.

4. Rough turning: In this operation max Metal is removed and very little over size
dimensions are left for further machining.

5. Finish turning: Here minimum metal is removed and very fine finish is obtained on the
work surface.

6. Grooving: It is operation of turning the groove or neck in order to terminate a thread or

to provide adequate clearance enable nut to pass freely on threaded work piece to remove
burs and to protect the work piece from being damaged.

7. Knurling: It is the process of embossing a diamond shaped regular pattern on the surface
of the work piece using a special knurling tool.

8. Broaching: It is the method of metal removal by a tool that has successively higher
cutting edges in a fixed path. Each tooth removes a fixed amount of material.

9. Drilling: It is the process of making hole in an object by forcing a grind means to abrade
to wear away by abrasion or to sharpen. In grinding the metal is removed by the means of
rotating abrasive wheel it is rotating a rotating tool called drill.

10. Boring: It is the process of enlarging a hole that has already been drilled.

11. Grinding: It is generally used for sharpening the cutting tool, grinding threads and better
surface finish etc.

12. Shaping: The process of cutting gears on the shaper is known as Shaping. The tool used
in shaping for teeth‘s cutting is a multi-point cutting tool.

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 13. Hobbing:

Hob: - Hob is a cutting tool used for cutting gears or similar form gears by the generating
principle. A Hob resembles a worm in appearance its cutting teeth on the outside of a
cylindrical body following a helical path corresponding to the thread of a worm. It is useful
to think of a hob as a cylinder with a series of racks being parallel to the hob axis or nearly
so and each one slightly displaced axially with respect to the preceding racks. As the hob
rotates in fixed rotation with the blank each row of teeth successively cuts the next portion
of the gear tooth spaces. Hobs can be broadly classified as: -

 Single start

 Double start

 Triple start.

Hob material: -

 High speed steel (HSS) - M2

 HSS with 8% cobalt (M35)
 Power metallurgy (ASP 30)
 Carbide
 Tool steel.

14. Gear shaving: Gear shaving is a metal cutting operation for finishing the gear cutting
process.

Shaving is a low pressure, free cutting, finishing operation applied to a hobbed gear to
achieve the following:-

1. Correct eccentricity and errors in index, helix angle and tooth profile.

2. Improve tooth surface finishing.

3. Maintain tooth size.

4. Eliminate tooth-bearing conditions by producing a crowned tooth form.

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Process Flow (For Shaft):-

Facing & centering

1st Turning

2nd Turning

Straightening (For long shafts)

Green grinding or (Soft grinding)

Shaping

Spline cutting (Hobbing)

Gear tooth rounding/roofing (GTR)

Deburring

Bench Drilling

Shaving

Heat treatment

External (Cylindrical) Grinding

Internal Grinding

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Process Flow (For Gears):-

1st Turning

2nd Turning

Broaching

Gear Cutting (Hobbing)

Shaping

Gear tooth rounding/roofing (GTR)

Deburring

Bench Drilling

Shaving

Heat treatment

Internal Grinding

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  OPERATION OF EACH MACHINE

1. Facing & centering Machine:-

This machine perform the facing & centering operation of forged component
 Facing done to maintain the total length & reference length of component.
 Centre drilling done for holding, inspecting & further processing of component.

Centre Drill
Main Motor
Milling Cutter
Component
Auto cantering Clamping Vice
Operator
Door
Panel

1.1 Function of Machine parts:-

PPanel

S. No. Part Name Function

1 Main Motor To rotate the milling Cutter.

It has different buttons & switches to control the operation of

2 Operator panel
machine by operator.
Auto centering
3 To automatic centre the component & clamp the component.
Clamping vice
To perform the milling operation from both side of component &
4 Milling Cutter
maintain the length of component

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 5 Centre Drill To perform the drilling operation from both side of component.

2. Turning Machine (Twin Chuck) :-

This machine performs the turning, facing, drilling, boring, & chamfering, operation of
forged component.

Chuck
Machine Doors Control Panel
Turret

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 Electrical panel

Spindle Motor

Hydraulic unit Coolant tank

2.1 Function of Machine parts:-

S. No. Part Name Function

Head Stock Contains Chuck Mounted on a threaded nose spindle for

1
Assembly. providing rotation to the job.

2 Spindle Assembly To provide desired cutting torque and rpm.

3 Turret Carries various tools and uses the tool when called.

Electrical Panel To house servo drives, relays, contactors, MCB, MPCB &
4
Assembly power supply unit.

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 Operator Panel Used to house CNC controller and other control push buttons &
5
Assembly selector switches.
To provide fluid power for clamping & de-clamping of
6 Hyd. Power Pack
component.
Circulates Lubrication oil to the various parts of the machine as
7 Lubrication Unit
& when required.
To reduce overheating of tool/inserts & component & to remove
8 Coolant Unit
the chips.

9 Panel AC Unit Maintain the optimum temperature of the electrical panel.

Used to maintain the set operating voltage in case of line

10 Stabilizer
fluctuation.
Carries chips away to the chip trolley and coolant to the
11 Chip Conveyor
coolant tank.

 Machine Reference

a) Put the machine in the jog mode.

b) Open the machine door.
c) Move the tool carrying axis (Z axis) axially towards the job axis (-) by 50mm.
d) Move the tool carrying axis (x axis) radially towards the job axis (-) by 50mm.
e) Put the machine in Reference (ZRN) mode.
f) Move the tool carrying axis radially and axially away (+) from the job axis one by one.

Check the program as per job & run the machine in auto mode.

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Turning Machine (Femco) :-

This machine performs the turning, facing, drilling, boring, & chamfering, operation of
forged component.

Operator Control Panel Chuck Tool Tail Stock

Component

Electrical Panel

A.C. Unit

Hydraulic Unit

Chip Conveyor
Coolant Unit

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 2.2 Function of Machine parts:-

S. No. Part Name Function

Head Stock Contains Chuck Mounted on a threaded nose spindle for providing
1
Assembly. rotation to the job.

Tail Stock Houses a revolving centre which moves in and out to hold the job firmly
2
Unit and parallel to the axis.

3 Rest It Support the job and help to prevent any slacking to ensure parallelism.

Spindle
4 To provide desired cutting torque and rpm.
Assembly

5 Turret Carries various tools and uses the tool when called.

Electrical
To house servo drives, relays, contactors, MCB, MPCB & power supply
6 Panel
unit.
Assembly
Operator
Used to house CNC controller and other control push buttons & selector
7 Panel
switches.
Assembly
Hyd. Power
8 To provide fluid power for clamping & de-clamping of component.
Pack

Lubrication Circulates Lubrication oil to the various parts of the machine as & when
9
Unit required.

Coolant To reduce overheating of tool/inserts & component & to remove the

10
Unit chips.
Panel AC
11 Maintain the optimum temperature of the electrical panel.
Unit

12 Stabilizer Used to maintain the set operating voltage in case of line fluctuation.

Chip Carries chips away to the chip trolley and coolant to the coolant
13
Conveyor tank.

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  Machine Reference

a) Put the machine in the jog mode.

b) Open the machine door.
c) Move the tool carrying axis (Z axis) axially towards the job axis (-) by
50mm.
d) Move the tool carrying axis (x axis) radially towards the job axis (-) by
50mm
e) Put the machine in Reference (ZRN) mode,
f) Move the tool carrying axis radially and axially away (+) from the job
axis one by one.

 Check the program as per job & run the machine in auto mode.

3. Hobbing Machine:-

This machine performs the gear cutting (Hobbing) operation on components.

Control Panel
Magazine Arbor Hob Tail Stock
Table Fixture
Hob Head

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 Electrical Panel

Hydraulic Motor

Rapid Motor
Chip Conveyer Cooling Tank

3.1 Function of Machine parts:-

S. No. Part Name Function

1 Bed Assembly Provides a seating to the fixture for mounting the job.

Cutter Head
2 Contains spindle head assembly.
Assembly

3 Spindle Assembly To provide desired cutting torque and rpm.

Electrical Panel
4 To house relays, contactors, MCB, MPCB & power supply unit.
Assembly
Operator Panel Used to house control push buttons, Indicators and selector
5
Assembly switches
Hydraulic Power To provide fluid power for hydro motors and linear cylinders used
6
Pack for Magazine rotation ,Tailstock up down, Table Slides

7 Chip Conveyor To transfer chips to the chip trolley and the cutting oil to the tank

Component Allows to load multiple components in order to eliminate Loading

8
Magazine and Unloading Time

9 Cutting Oil To reduce overheating of Hob & component & to remove the chips.

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Formula for setting the Indexing Gear Train:-

FOR SIMPLE TRAINS

MACHINE CONSTANT X NUMBER NO. OF TEETH ON

OF STARTS OF HOB DRIVER GEAR
=
NO. OF TEETH ON
REQUIRED NO. OF TEETH
DRIVEN GEAR

FOR COMPOUND TRAINS

NO. OF
MACHINE NO. OF
TEETH
CONSTANT X TEETH IN
IN
NUMBER OF DRIVER
DRIVER
STARTS OF HOB GEAR 1
GEAR 2
= X
NO. OF
NO. OF
TEETH
REQD. NO. OF TEETH IN
IN
TEETH DRIVEN
DRIVEN
GEAR 1
GEAR 2

FOR HELICAL TRAINS

DIFFERENTIAL M/C CONST. X

HELICAL
SINE (HELIX ANGLE)
GEAR ≈
∏ X NO. OF STARTS (OF HOB) X
RATIO
MODULE
where
∏=3.1416

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 4. Shaper:-

This machine performs the gear cutting operation. In this operation a rotating component is fed
against a reciprocating cutter.

Spindle head Arbor Cutter Fixture

Operator Cutting oil Cam unit
panel Component
Tank

4.1 Function of Machine parts:-

S. No. Part Name Function

1 Machine Table It provides a seating to the fixture for mounting the job.

It is fixed on machine table & its main function is to hold the

2 Fixture
component
Spindle Head
3 It provides desired cutting torque and rpm.
Assembly

4 Operator Panel It contains different control switches to operate the machine.

Electrical Panel
5 To house relays, contactors, MCB, MPCB & power supply unit.
Assembly

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 To reduce overheating of Cutter & component & to remove the
6 Cutting Oil
chips.
It contains cam & arm which is used to set the desired numbers of
7 Cam Unit
cut & cutting stroke length.

8 Arbor Its main function is to hold the cutter

9 Cutter It is main cutting tool which is use to cut the material.

4.2 Formula for setting the Indexing Gear Train:-

(G/N) = (A/B) X (C/D)

Where G= Number of teeth to be cut

N= Number of teeth on the cutter
A, B, C & D= Number of teeth on gears of the train.

5. Shaving Machine:-

This operation is performing to remove the irregularity from the

gear Tooth flank which are generated during hobbing /shaping
operation.

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 Lubrication Crowning
Hydraulic unit unit guide angle
setting shaft

Cutter Drive motor

Cutter Head

Tail stock

Machine Table

Cutting oil
Tank
Taper
adjustment
shaft

Tail stock

Steady Rest

Head stock

5.1 Function of Machine parts:-

S. No. Part Name Function

It provides a seating to the head stock, tails stock, steady rest. &
1 Machine Table
it has transverse movement during shaving operation.
Head stock & tail The main function of these units is to hold the component at the
2
stock time of operation.

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 3 Steady Rest It provides support to the component.

Cutter Head This unit is used to mount the cutter & provide desired angle to
4
Assembly cutter.

5 Operator Panel It contains different control switches to operate the machine.

Electrical Panel To house servo drives, relays, contactors, MCB, MPCB & power
6
Assembly supply unit.
It contain cutting oil which are use to reduce overheating of
7 Cutting Oil Tank
Cutter & component & to remove the chips.
Crowning guide
8 This shaft is used to adjust the crowning of component.
angle setting shaft
Taper adjustment
9 This shaft is used to adjust the taper of component.
shaft

10 Cutter It is main cutting tool which is use to cut the material.

The main function of lubrication unit is to reduce friction

11 Lubrication Unit
between slides & other moving surface.
To provide fluid power for hydro motors and linear cylinders
12 Hydraulic Unit used for Head stock & tail stock movement, cutter clamping/de-
clamping, table transverse movement & door movement.

To separate metal chips from oil and transfers the same to the
13 Magnetic separator
chip trolley.

6. Grinding Machine

6.1 CNC Cylindrical Grinding Machine:-

Coolant
Doors Operator Spindle Chip Chiller
Tank
Panel unit conveyer Unit
30|P a g e Grinding
Wheel
6.1.1 Function of Machine parts:-

S. No. Part Name Function

1 Bed assembly It provides a seating to the head stock, tails stock, steady rest.

Head stock & The main function of these units is to hold the component at the
2
tail stock time of operation.

3 Steady Rest It provides support to the component.

Wheel head
4 It mounts Grinding Wheel.
Assembly
Spindle
5 It provides desired cutting torque and rpm to the grinding wheel.
Assembly
It contains different control switches & buttons to operate the
6 Operator Panel
machine.
In Process It checks the current size of component & provides required
7
Gauge (IPG) feedback.
Consists of a probe that touches with job to know the current
8 Flagging Unit
position.
Electrical Panel To house servo drives, relays, contactors, MCB, MPCB & power
9
Assembly supply unit.
It contains Coolant which is used to reduce overheating of
10 Coolant Tank
Grinding wheel and component & to remove the grinding dust.
It is used to Clean the coolant by separate the grinding dust from
11 Filtration Unit
the coolant.
It maintains the optimum temperature (max. 30˙ c) of the
12 Panel AC Unit
electrical panel.
It is made of abrasive material, it cut the metal by rotating the
13 Grinding wheel
opposite direction of component & provide good surface finish.
Lubrication The main function of lubrication unit is to reduce friction between
14
Unit slides & other moving surface.
To provide fluid power for hydro motors and linear cylinders used
15 Hydraulic Unit
for Head stock & tail stock movement & IPG movement.

16 Magnetic To separate metal dust from coolant and transfers the same to the

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 separator dust tray.

Used to maintain the temperature of the spindle oil /hydraulic oil

17 Chiller Unit
or coolant.

 Machine reference.

a) Put the machine in the jog mode.

b) Move the Wheel head head towards the job axis (-) by 50mm.
c) Put the machine into the Reference mode or home position.
d) Move the wheel head away from the job (+) till it reaches zero position (X/Y
axis).
e) Put the machine in Jog mode again.
f) Move the work head (+Z) direction by 50mm (Z axis).
g) Put the machine in the reference mode or home position.
h) Move the work head (-Z) till it reaches the zero position.
i) Put the machine in the MDI mode.
j) Start the wheel through command / pressing the wheel ON button.
k) Put the machine in Automatic mode.
l) Run the wheel dressing program till the whole wheel is dressed.
m) Put the machine back in the jog mode.
n) Bring the diameters of the job in front of the IP gauge by moving the Z axis.
o) Slide in the IP gauge manually using the switches on the panel and on top of the
IP gauge & check the reading.
p) Put the machine in Automatic mode.
q) Run the warm program.

6.2 CNC Internal Grinding Machine:-

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Operator Diamond Chiller Filtration Hydraulic
Control Wheel
Dresser Unit Coolant Unit
Panel Machine Wheel Head Unit
Chuck Unit Tank
Doors
Unit

6.2.1 Function of Machine parts:-

S. No. Part Name Function

1 Bed assembly It provides a seating to the head stock, & wheel head.

2 Work Head assembly Its mount the chuck which hold the job with the help of jaws.

Wheel head
3 It mounts the Grinding Wheel.
Assembly

4 Spindle Assembly It provides desired torque and rpm to the grinding wheel.

It contains different control switches & buttons to operate the

5 Operator Panel
machine.
Electrical Panel To house servo drives, relays, contactors, MCB, MPCB &
6
Assembly power supply unit.
It contains Coolant which is used to reduce overheating of
7 Coolant Tank Grinding wheel and component & to remove the grinding
dust.
It is used to Clean the coolant by separate the grinding dust
8 Filtration Unit
from the coolant.
It maintains the optimum temperature (max. 30˙ c) of the
9 Panel AC Unit
electrical panel.

10 Grinding wheel It is made of abrasive material; it cut the metal by rotating the

33|P a g e
 opposite direction of component & provides good surface
finish.
The main function of lubrication unit is to reduce friction
11 Lubrication Unit
between slides & other moving surface.
To provide fluid power for hydro motors and linear cylinders
12 Hydraulic Unit used for chuck clamping/de-clamping & wheel guard
movement.
13 Used to maintain the temperature of the spindle oil /hydraulic
Chiller Unit
oil or coolant.

 Machine Reference.

a) Put the machine in the jog mode.

b) Move the job head towards the wheel axis (-Z) by 50mm
c) Put the machine into the Reference or zero return mode.
d) Move the job head away from the wheel (+Z) till it reaches zero position.
e) Put the machine in Jog mode again.
f) Move the Wheel head towards (-X) by 50mm.
g) Put the machine into the Reference or zero return mode.
h) Move the work head away (+X) till it reaches the zero position.
i) Put the machine in the MDI mode
j) Start the wheel through command / pressing the wheel button
k) Put the machine in Automatic mode.
l) Run the warm up program (If required)

34|P a g e
 HEAVY MACHINE SHOP
All heavy casting of tractors is machined in this shop with the help of variety of special
machine (SPM). These machines are tailors made by IIMT to suit component requirements.
In addition, facilities of this shop include general-purpose turning, drilling and milling
machines. About 20 SPM and 30 GPM are installed in a covered area of 47,000 sq. Ft. At a
cost of 20 million, 2600 tones of castings are machined every year on a two-shift basis.

COMPONENTS MACHINED IN THE SHOP:

1. Gearbox housing (Material R-33, Casting, 180-230 BHN, 76-Kg wt.).

2. Differential housing.

3. Rear cover.

4. Trumpet housing

 Types of machines:

Sr.No. M/C Description Operations

Gear Box Housing

1. HMC (multipurpose machine), HDC Milling, Drilling, Dowel

holes

2. Duplex milling machine (cutter 500 Milling

mm, total length made –490 mm, 26
inserts 1 viper (inserts for rough cut,
viper for finish)

35|P a g e
 3. HMC 500 Internal milling, drilling CD
hole (39 mm for outer, 24.2
for inner),

4. Boring machine Rough Boring

5. Boring machine Finish Boring

6. Turning Lathe Turning

7. Cross hole Drilling

8. HMT HDC-S Drilling (4 holes for

connecting rod 2 inner 2
outside)

9. HMT HMC 500 S Drilling, Spot facing

10. Turning Finish turning

11. Radial drilling machine Drilling, Reaming, Tapping,

Chamfering

Trumpet Assembly

12. Two way boring machine Rough Boring

13. RAYAUTO (7 tools work at a time) Rough turning, Facing

36|P a g e
 14. Boring machine Finish Boring

15. HMT SBCNC 35 Finishing (outer face)

16. SPM Drilling, Tapping

17. TICO multipurpose machine Milling, Drilling, Tapping

Rear Cover Assembly

18. Free Spindle SPM Milling(1 Vertical,2

horizontal)

19. CNC milling machine Milling

20 Horizontal HC 630 CNC Drilling, Boring, Milling

21. VA 50 Drilling, Milling, Tapping

22. XLO Boring (one way)

37|P a g e
Equipment List:-Process Flow (FOR DIFFERENTIAL):-

Milling , Drilling , Tapping on bottom face of differential

Milling , Drilling , Tapping on top face of differential

Rough Milling and fine Milling on front and rear face

Milling on left and right trumpet mounting face

Rough boring and fine boring of trumpet mounting Holes

Rough and Fine boring of Tail Pinion Carrier and PTO bore

Drilling and tapping of trumpet mounting holes on left and right side of differential

Drilling and Tapping of gear box mounting face and rear face of differential

Washing of Componenets

Material feeding to Assembly

38|P a g e
 Operation of each machine

7. VMC (Vertical Machining Center)

This machine performs milling, drilling and tapping on bottom face of differential.

Electrical panel
FRL unit Tool magezine Operator panel
Pallet

Function of Machine parts:-

S. No. Part Name Function

1 Main Motor To rotate the machine spindle

It has different buttons & switches to control the operation of

2 Operator panel
machine by operator.
Auto Clamping
3 To automatic clamp the component
pallet
4 Machine Spindle To provide desired cutting torque and rpm to machining tool
Allows to load multiple tools in order to eliminate Loading and
5 Tool Magazine
Unloading Time
6 Chip Conveyor Carries chips away to the chip trolley
Circulates Lubrication oil to the various parts of the machine as
7 Lubrication Unit
& when required.
8 Hydraulic unit For clamping of component

39|P a g e
 9 Panel AC Unit Maintain the optimum temperature of the electrical panel.
Used to maintain the set operating voltage in case of line
10 Stabilizer
fluctuation

8. VMC (Vertical Machining Center)

This machine perform milling , drilling and tapping on bottom face of differential.

Electrical panel Hydraulic Unit Tool Magazine

Operator panel Pallet

8.1 Function of Machine parts:-

S. No. Part Name Function

1 Main Motor To rotate the machine spindle

It has different buttons & switches to control the operation of

2 Operator panel
machine by operator.
Auto Clamping
3 To automatic clamp the component
pallet
4 Machine Spindle To provide desired cutting torque and rpm to machining tool
Allows to load multiple tools in order to eliminate Loading and
5 Tool Magazine
Unloading Time

40|P a g e
 6 Chip Conveyor Carries chips away to the chip trolley
Circulates Lubrication oil to the various parts of the machine as &
7 Lubrication Unit
when required.
8 Hydraulic unit For clamping of component
9 Panel AC Unit Maintain the optimum temperature of the electrical panel.
Used to maintain the set operating voltage in case of line
10 Stabilizer
fluctuation

 SPECIAL PURPOSE MACHINES

1. Rough Milling and fine Milling on front and rear face (SPM)

This machine performs milling operation on front and rear face of differential housing.

Operator panel Pallet Cutter Hyd. Motor Spindle Motor

41|P a g e
S. No. Part Name Function

Main Motor
1 To provide desired cutting torque and rpm to machining spindle
(2 No‘s)

2 Rapid motor To move machine bed in forward and back word direction rapidly

3 Feed motor To move machine bed in forward and back word direction slowly

Operator It has different buttons & switches to control the operation of machine
4
panel by operator.
Auto
5 Clamping To automatic clamp the component
fixture
Cutter
6 To provide desired cutting torque and rpm to machining cutter
Spindle
Hydraulic
7 For clamping of component
unit
Lubrication Circulates Lubrication oil to the various parts of the machine as & when
8
Unit required.

2. Milling on left and right trumpet mounting face

This machine performs milling operation on left and right trumpet mounting face of
differential housing.

Operator panel
Cutter Pallet
Hyd. Unit
Spindle Motor

42|P a g e
S. No. Part Name Function

Main
1 Motor (2 To provide desired cutting torque and rpm to machining spindle
No‘s)
Rapid
2 To move machine bed in forward and back word direction rapidly
motor

3 Feed motor To move machine bed in forward and back word direction slowly

Hydraulic
cylinders To move Head A and Head B closer and farther so as to machine two
4
(left and different dimensions
right)
Operator It has different buttons & switches to control the operation of machine by
5
panel operator.
Auto
6 Clamping To automatic clamp the component
fixture
Cutter
7 To provide desired cutting torque and rpm to machining cutter
Spindle
Hydraulic
8 For clamping of component
unit
Lubrication Circulates Lubrication oil to the various parts of the machine as & when
9
Unit required.

10 FRL Unit To provide lubrication to cylinders

3. Rough boring and fine boring of trumpet mounting and bull pinion shaft Holes
This machine performs milling operation on left and right trumpet mounting face of
differential housing.

43|P a g e
 Operator panel
pallet Feed motor Hyd. Unit Chip conveyorl
FRL. Unit

S. No. Part Name Function

1 Main Motor To provide desired cutting torque and rpm to machining spindle

2 Rapid motor To move machine bed in forward and back word direction rapidly

3 Feed motor To move machine bed in forward and back word direction slowly

Hydraulic
4 For clamping of component
cylinder
It has different buttons & switches to control the operation of
5 Operator panel
machine by operator.
Boring Bar (4
6 To provided desired dia of bore
No‘s)
Circulates Lubrication oil to the various parts of the machine as &
7 Lubrication Unit
when required.

8 FRL Unit To provide lubrication to cylinders

4. Rough boring of Tail Pinion Carrier and PTO bore

44|P a g e
 Operator panel Pallet Boring bar
Spindle Motor
Electrical panel

S. No. Part Name Function

To provide desired cutting torque and rpm to machining

1 Main Motor (3 No‘s)
spindle
To move machine bed in forward and back word
2 Rapid motor
direction rapidly
To move machine bed in forward and back word
3 Feed motor
direction slowly
It has different buttons & switches to control the
4 Operator panel
operation of machine by operator.

5 Boring Bar (3 No‘s) To provided desired dia of bore

6 Booster For clamping of component

Circulates Lubrication oil to the various parts of the

7 Lubrication Unit
machine as & when required.

8 FRL Unit To provide lubrication to cylinders

45|P a g e
 5. Fine boring of Tail Pinion Carrier and PTO bore

Hyd cylinder

Lub. Unit

Operator panel
Electrical panel Pallet
Boring Bar
Spindle Motor

S. No. Part Name Function

1 Main Motor (3 No‘s) To provide desired cutting torque and rpm to machining spindle

To move machine bed in forward and back word direction

2 Rapid motor
rapidly
To move machine bed in forward and back word direction
3 Feed motor
slowly

4 Hydraulic cylinder For clamping of component

It has different buttons & switches to control the operation of

5 Operator panel
machine by operator.

6 Boring Bar (3 No‘s) To provided desired dia of bore

Circulates Lubrication oil to the various parts of the machine as

7 Lubrication Unit
& when required.

8 FRL Unit To provide lubrication to cylinders

46|P a g e
 6. Rough and. Fine boring of Tail Pinion Carrier and PTO bore

Feed motor Spindle motor Operator panel

Pallet
Hyd unit

S. No. Part Name Function

To provide desired cutting torque and rpm to machining

1 Main Motor (6 No‘s)
spindle
To move machine bed in forward and back word direction
2 Rapid motor
rapidly
To move machine bed in forward and back word direction
3 Feed motor
slowly

4 Hydraulic cylinder For clamping of component

It has different buttons & switches to control the operation of

5 Operator panel
machine by operator.

6 Boring Bar (6 No‘s) To provided desired dia of bore

Circulates Lubrication oil to the various parts of the machine

7 Lubrication Unit
as & when required.

8 FRL Unit To provide lubrication to cylinders

47|P a g e
 7. Drilling of trumpet mounting holes on left and right side of differential

Lub unit Electrical panel

Hydraulic cylinder

Hyd unit

Spindle motor

Spindle motor Operator panel

Operator panel

S. No. Part Name Function

1 Main Motor (2 No‘s) To provide desired cutting torque and rpm to machining spindle

To move machine bed in forward and back word direction

2 Rapid motor
rapidly

3 Feed motor To move machine bed in forward and back word direction slowly

4 Hydraulic cylinder For clamping of component

It has different buttons & switches to control the operation of

5 Operator panel
machine by operator.
Drilling Spindles (54
6 To provide desired cutting torque and rpm to machining tool
No‘s)
Circulates Lubrication oil to the various parts of the machine as
7 Lubrication Unit
& when required.

8 Hydraulic Unit Acts as reservoir for oil

48|P a g e
 8. Tapping of trumpet mounting holes on left and right side of differential

Hyd cylinder

Spindle motor

Operator panel Spindle motor Hyd unit

S. No. Part Name Function

To provide desired cutting torque and rpm to

1 Main Motor (6 No‘s)
machining spindle

2 Hydraulic cylinder (2 No‘s) To move machine bed in left and right direction

To move machine bed in forward and back word

3 Feed motor
direction slowly

4 Hydraulic cylinder For clamping of component

It has different buttons & switches to control the

5 Operator panel
operation of machine by operator.
To provide desired cutting torque and rpm to
6 Tapping Spindles (52 No‘s)
machining tool

7 Boring Bar (Dia 30) To provided desired dia of bore

Circulates Lubrication oil to the various parts of the

8 Lubrication Unit
machine as & when required.

9 Hydraulic Unit Acts as reservoir for oil

49|P a g e
 9. Drilling and Tapping of gear box mounting face and rear face of differential

Hyd cylinder

Tapping spindle
Hyd unit
Spindle motor Tapping spindle Operator panel

S. No. Part Name Function

To provide desired cutting torque and rpm to machining

1 Main Motor (4 No‘s)
spindle
Hydraulic cylinder (2
2 To move machine bed in left and right direction
No‘s)

3 Hydraulic cylinder For clamping of component

It has different buttons & switches to control the

4 Operator panel
operation of machine by operator.
Drilling Spindles (23 To provide desired cutting torque and rpm to machining
5
No‘s) tool
Tapping Spindles (23 To provide desired cutting torque and rpm to machining
6
No‘s) tool
Circulates Lubrication oil to the various parts of the
7 Lubrication Unit
machine as & when required.

8 Hydraulic Unit Acts as reservoir for oil

50|P a g e
 10. Drilling and Tapping of gear box mounting face and rear face of differential

Spindle motor

Machine bed Carriage wheel Gear change lever

S. No. Part Name Function

Spindle Motor (01

1 To provide desired cutting torque and rpm to machine spindle
No‘s)
To hold the tool and transfer required RPM from motor to
2 Spindle
tool
Hydraulic motor (01
3 To move machine head in up/down direction (Vertically)
No‘s)

4 Rotary Switch To change the speed of spindle (RPM)

Machine Bed
5 Used as work table , job is placed on it
(Stationary)

6 Spindle Weight To provide desired cutting torque and rpm to machining tool

7 Feed Change lever To change the feed

8 Depth control lever To adjust the depth of operation

9 Carriage wheel To move spindle in left / right direction (Horizontally)

To change the gear of spindle rotation (Clockwise , Neutral ,

10 Gear Change lever
Anticlockwise)
51|P a g e
 HEAT TREATMENT SHOP

The heat treatment shop lays a very important role in the automobile Industry. Various parts such
as axles, gears, shafts etc. if not heat- treated will not work for a longer time. Heat treatment
shop at STD is adjoining the LMS. Most of the parts of tractors and Mazda manufactured in
LMS are heat treated here. The shop is equipped with several heating furnaces and testing
machines. The shop is manned by skilled staff and workers.

All Transmission components after undergoing machining operation are subjected to heat
treatment. Heat treatment is done so as to improve hardness and strength of these components
viz gears and shafts.

TYPES OF FURNACES

o Pit Type-Carburizing is done to increase carbon content

o Sealed Quenched Type- Certain reactions are allowed to take place resulting in
formation of carbon by products. The reagents used are mainly N2, LPG and methanol.

All other gears and shafts manufactured in L.M.S. are heat-treated.

TYPES OF FURNACES AND MACHINES

MACHINE NAME NO OF MACHINES

1. Gas Carburizing Furnace 8

2. Induction Hardening Machine 1

3. Quenching Tank 2

4. Shot Blasting Machine 2

5. Tempering Machine 3

6. Lapping Machine 2

7. Hydraulic Press 2

8. Cutting Machine 1

9. Hardness Testing Machine 3

10. Sealed Quenched Furnace

52|P a g e
LIST OF COMPONENTS GIVEN HEAT TREATMENT ARE:-

1. Gear z-28. 19. Gear z-35

2. Intermediate shaft 20. Bull pinion shaft
3. Dog gear z-36 21. Input shaft without gear.
4. Dog gear z-32 22. Input shaft gear z-21, 23,24.
5. Dog gear z-32 23. Hi/low intermediate shaft
6. Input gear z-50, 52,53 24. Sleeve small.
7. Sleeve big. 25. Bull gear.
8. Input shaft. 26. PTO slide
9. Lever. Ring gear. 27. PTO internal gear
10. Drive shaft. 28. Bull gear
11. PTO fix. 29. PTO slide.
12. Sleeve52/16. 30. Output shaft.
13. Lay shaft. 31. Sleeve-68
14. Idler cluster 32. Gear PTO z-56
15. Internal gear. 33. Sleeve-37Bp shaft.
16. PTO gear z-37 34. PTO rear shaft
17. HOB (for intermediate shaft)

18. Gear z-28,25 loader special

STEPS IN WHICH THE COMPONENTS OPERATED IN THE HEAT TREATMENT PLANT

ARE:-

(1). PUNCHING OF THE COMPONENTS:-

Machine name: - punching machine.

Operation: - Punching.

Tool used: - Number punch.

About operation: - All the components are given codes or numbers first.

The punching machine is hydraulically operated.

53|P a g e
The jobs are held in the fixture and then with help of a punch different codes are punched on the
jobs.

(2). FIXTURE PREPARATION:-

After punching, fixture preparation is done. In this operation the fixture prepared according to
the size, shape and quantity of the components. The fixtures are very large in size and can carry
numbers of gears, shafts and other small components.

(3). WASHING OF THE COMPONENTS:-

This is done in the washing tank to remove the oil from the component, which is on them
because of machining. For washing of the component water and caustic soda is used. Caustic
soda is used because oil cannot be removed by water alone caustic soda is useful in removal of
oil from the surface of the components. In washing tank there are number of nozzles through
which water and caustic soda mixture strikes over the surface of the component at high pressure,
this high pressure helps in removal of oil and other impurities.

(4). CARBURISING:

This is the phenomenon by which carbon penetrate the steel. Iron at temperature above its critical
temperature has affinity for carbon. The carbon is absorbed into the metal to convert outer
surface into high carbon steel. The depth of case depends upon the time and temperature of
treatment. The atomic size of iron (Fe) is less than that of atomic size of carbon (c) so, the
temperature inside the furnace is set according to the requirement. In GCF there is a drip feed
panel through which the quantity of isopropanol is controlled. In carburizing isoprpanolis used
for making carbon at high potential. The percentage of isopropanol is controlled with the help of
drip feed panel. When the liquid from the drip feed panel enters the furnace it at once burst into a
gas having carbon at very high potential. Since carbon has property to flow from high potential
towards the low potential therefore it is helpful for the penetration of carbon into steel. When the
temperature inside the furnace reaches about 930 c, the penetration of carbon in the steel started.
This penetration of carbon into steel at temperature 930 c is called active carburising.

(5). QUENCHING:

Quenching or rapid cooling done above the critical temp by immersion in cold water or other
cooling medium is a hardening treatment. It increases the strength of the metal and increases the
wear resistance, but makes the metal brittle and has low ductility

54|P a g e
(6). WASHING: -

After quenching the washing of the component is done. The washing is done to remove oil dust
and small chips from the surface of the components. The mixture of water and caustic soda is
used for washing.

(7). TEMPERING: -

Tempering consist of reheating below the critical temperature. The quenched metal is tempered
to restore some of the ductility and to reduce the brittleness. Increased toughness is obtained at
the expense of high strength.

55|P a g e
 PROJECT
1
TO DEVISE A COMPONENT CYCLE OF INPUT SHAFT
FOR PROCESSES CARRIED OUT IN MACHINE SHOP
FROM THE FORGED COMPONENT TO THE FINISHED
COMPONENT.

56|P a g e
INPUT SHAFTS are used in gear box housing of tractors. In general all the gears of transmission
are mounted on this shaft which when mate with other gear give power through output shaft. The
shaft consists of splines which help the broached gear to get connected to the shaft. It also
consists of a gear at the outer periphery which meshes it with another shaft. The end of shaft may
also contain groves for bearing fitment. The surface at which bearing is fitted on shaft is to be
grinded for its proper working. Carburising of input shaft is done by which approx 8mm layer of
carbon is deposited on the shaft. It increases the strength of shaft. Shot blasting is done after this
operation and after this the component is send for grinding. The processes done on input shaft
are as follows:

• Facing & centering

• Turning
• Straightening (For long shafts)
• Spline cutting (Hobbing)
• Shaping
• Gear tooth rounding/roofing (GTR)
• Bench Drilling
• Shaving
• Heat treatment
• External (Cylindrical) Grinding
• Internal Grinding
All the operations performed require a change in fixture and tool and accordingly gear train is set
in Hobbing, Shaping, and GTR etc. except in CNC TURNING machine. In CNC turning a whole
program is to be devised for manufacturing the shaft.

ABOUT CNC: -

CNC stands for Computer Numerical Control. A CNC is a mini-computer which is used to
control the machine tool functions and slide motion from stored information. The instructions are
stored in the memory of the mini computer. The instructions are written in the form of program.
A CNC system is the heart and brain of a CNC machine which enables the operation of the
various machine members such as slides, spindles etc. as per the sequence programmed into it,
depending on the machining operations. The main advantage of a CNC system lies in the fact
that the skills of the operator hitherto required in the operation of conventional machine are
57|P a g e
removed and the part production is made automatic. A CNC machine tool is different from
conventional machine tools in a number of respects. The basic design for conventional machine
tool is not suitable for CNC machine. Many design changes are required for CNC machines as
compared to conventional machines tools due to addition al requirements of CNC machines such
as automatic drive system, high rigidity feed drives, ball screw, automatic tool changer (ATC),
chip conveyor, tool magazine. A CNC machine tool responds directly to the program that is in
operation. The accuracy to be achieved depends to a great extent on the various elements of CNC
machine. Also the CNC machines have high accuracy and productivity as the machine is
operated 24 hours, so need special design for its elements.

ADVANTAGES OF CNC MACHINES: -

1. Availability: - CNC machine can be available for work continuously 24 hours a day, 365 days
a year and only need to be switched off for maintenance.

2. User friendly: - CNC machines are user friendly. Less skilled/trained people can operate
CNCs unlike manual lathes/milling machines etc. which need skilled engineers.

3. Conversion of units: - If the takes is prepared in the units of inches then the same system of
units can be converted into SI units within the computer memory.

4. Updated: - CNC machines can be updated by improving the software used to drive the
machines.

5. Diagnostic: - It can diagnose program and can detect the machine malfunctioning even before
the part is produced.

6. Easy supervision: - One person can supervise many CNC machines as once these are
programmed they can usually be left to work by themselves.

7. Easy training: - Training in the use of CNCs is available through the use virtual software.
This is software that allows the operator to practice using the CNC machine on the screen of a
computer like a computer game.

8. Similar quality: - CNC machines are programmed with a design which can then be
manufactured hundreds or even thousands of items. Each manufactured product will be exactly
the same.

58|P a g e
9. Reduce inspection: - The time spent on inspection and in waiting for inspection to begin is
greatly reduced. Normally it is necessary to inspect the first component only. If there is any
difference in the dimensions of the machined component, the program is checked and corrected,
if needed.

DISADVANTAGE OF CNC MACHINES: -

1. High initial cost: - CNC machines are more expensive than manually operated machines.

2. Higher maintenance cost: - Persons trained in electronics along with mechanical and
electrical are required to service and maintain these complex machines.

3. Skilled CNC personnel: - It is very difficult to find a programmer and operator for a CNC,
hence existing personnel must be trained in the programming and operation.

Description of the Control Panel Of CNC Turning Machine:-

59|P a g e
 1. CRT – Displays the information of the running and stored programs.

2. Keypad – Allows to input any value / reading in the machine.

3. Emergency – Allows cutting off all the supplies in case of any abnormality.

4. MPG – Manual Pulse Generator: Allows moving the slides.

5. Feed Rate Override – Allows to Change feed rate to desired percentage of the actual
feed.

6. Rapid Override – Allows changing the rapid rate to the desired percentage of actual
rapid.

7. Spindle override – Allows to change the spindle RPM to desired percentage of actual
RPM.

8. Mode Selector Switch – Allows to put the machine in different modes i.e. auto, jog, etc.

9. Manual Axes Movement -Allows moving the axes in jog mode for setting & other
purposes.

10. Spindle Load Meter – Indicates the load on the spindle.

11. Spindle Manual Speed - Allows running the spindle manually at different speeds.

12. Spindle Rev / Fwd / Stop – Allows to run the spindle in desired direction & stop as
needed.

13. Turret Rotation – Allows running the turret in desired direction to select the required
tool.

14. Conveyor Rotation – Allows run the chip conveyor fwd / rev.

15. Feed Hold – Allows pausing the running operation in case of any problem.

16. Cycle Start – Allows to run the desired program in Auto Mode

17. Protection Locks – Allows locking various functions in order to avoid unauthorized
manipulation.

60|P a g e
AXIS OF MACHINE

The machine moves along its axes of motion. All movements along an axis are either in a
positive or negative direction. Not all machines use the same system to identify axes. The
descriptions used in this manual are commonly used to identify 3-axis mills.

The number of axis in a machine vary according to the functioning

Machine Type No. of Axis

Turning 02 (X & Z)

Hobbing 02 (X & Z)

Grinding 02 (X & Z)

Shaping 02 (X & Z)

VMC 03 (X, Y & Z)

HMC 04 (X, Y, Z & B)

Shaving 05 (X, Y, Z, B & C)

61|P a g e
NOTE: To visualize machine movements correctly, imagine tool motion rather than table
motion.

Types of Codes

G-codes initiate motion commands, canned cycles and various machine and CNC functions.
More than one G-code may be specified per block. If a block contains conflicting G-codes, an
Error message will appear.

Modal G-codes remain in effect until canceled by the appropriate code. Non-modal G-codes
affect only the block in which they are programmed.

The following Table lists non-modal and modal G-codes. (Details covered in Handouts)

62|P a g e
MACHINE REFERENCE

 The reference position is the position from where the machine starts its traverse in any
direction as per the command.

 This position is set by the manufacturer & varies from machine to machine.

 Prior to running the machine in the Auto Cycle , machine reference is a must.

 All the axis of the machine need to de referenced.

63|P a g e
  Reference is also termed as: Homing or Zero Return

DEFINATIONS

 Turret Head: The part of machine in which the tool is held.

 Work piece: The component to be machined.

 Rapid : High Speed Motion from one point to another for Covering idle distance
without any cutting action

 Feed: Relatively slower motion for travelling the tool / Job to perform cutting action.

 Geometry offset: The Values of X / Z to be entered for every tool after touching the tool
/ job in manual mode before starting any work.

 Wear Offset: The values of X / Z to be entered for the required tool for fine adjustments
or for compensation against tool wear.

TAKING OFFSET

 Using the Jog mode, bring the tool near the work piece, using the handle wheel bring it
closer, as such that it touches the face of the job. Now keeping the tool in this position go
to the Geometry offset screen & enter MZ=0

 After this, bring the tool tip near the circumference of the work piece so that it touches it.
Measure the dia. Of the same work piece using a micrometer. Now Without disturbing
the tool position enter the value of the diameter in the geometry offset as, MX= 50 mm
(as per the given dia.)

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TO REDUCE CYCLE TIME OF INPUT SHAFT THE DESIGN CONSIDERATIONS WERE
TAKEN INTO CONSIDERATIONS AND A PROGRAM IS TO BE DEVISED AND
EXECUTED FOR THE SYSTEM

INPUT SHAFT DRAWING

BEFORE MACHINING

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The following program is devised in Fanuc system taking in consideration the various constraints
of the CNC machine like the rpm, rapid etc, and that of the tool i.e. the wear strength, feed rate
etc.

INPUT SHAFT

N1

T0100;

T0101;

G00 X20 Z10;

G01 X17.5 Z2 F1;

G01 Z0 F0.2;

G01 X19.5 Z-0.577 F0.2;

G01 Z-62 F0.2;

G01 X25.6 Z-63.76 F0.2;

G01 Z-359.25 F0.2;

G02 X45.60 Z-369.25 R10 F0.2;

G01 Z-393 F0.2;

G01 X43.6 Z-394 F0.2;

G01 X50 F0.2;

G01 X52 Z-395 F0.2;

G01 Z-399 F0.2;

G02X62 Z-404 R5 F0.2;

G01 X72 F0.2;

G01 X74 Z-405 F0.2;

G00 X300 Z100;

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T0100;

N2

T0200;

T0202;

G00 X25 Z-30;

G01 X20 Z-33.5 F1;

G01 X17.5 F0.05;

G04 P3000;

G01 X20 F1;

G00 X50;

G00 Z-370;

G01 X46 Z-373.15 F1;

G01 X43.6 F0.05;

G04 P3000;

G01 X46 F1;

G00 X300 Z100;

T0200;

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AFTER MACHINING

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 PROJECT
2
TO ELIMINATE THE PROBLEM OF CHATTERING ON INPUT
SHAFT AND REDUCE THE LOSS OF MACINING INSERT IN
CNC TURNING

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INTRODUCTION

Cutting tools may fail by brittle fracture, plastic deformation or gradual wear. Turning carbide
inserts having enough strength; toughness and hot hardness generally fail by gradual wear. With
the progress of machining, the tools attain crater wear at the rake surface and flank wear at the
clearance surfaces, due to continuous interaction and rubbing with the chips and the work
surfaces respectively. Among the aforesaid wears, the principal flank wear is the most important
because it raises the cutting forces and the related problems. According to ISO standard 3685 to
tool life testing, the life of carbide tools, which mostly fail by wearing, is assessed by the actual
machining time after which the average value (VB) of its principal flank wear reaches a limiting
value of 0.3 mm

Cutting parameters in turning operation

The three primary factors in any basic turning operation are speed, feed and depth of cut. Other
factors such as kind of material and type of tool have a large influence but these three are the
ones the operator can change by adjusting the controls, right at the machine.

Speed
Speed always refers to the spindle and work piece. When it is stated in revolutions per minute
(rpm) it tells their rotating speed. But the important feature for a particular turning operation is
the surface speed, or the speed at which the work piece material is moving past the cutting tool.
It is simply the product of the rotating speed times the circumference of the work piece before
the cut is started. It is expressed in meter per minute (m/min) and it refers only to the work piece.
Every different diameter on a work piece will have a different cutting speed, even though the
rotating speed remains same.

Feed
Feed always refers to the cutting tool and it is the rate at the tool advances along its cutting path.
On the most power-fed lathes, the feed rate is directly related to the spindle speed and is
expressed in mm per revolution (of the spindle) or mm/rev.

F= f × N (mm/min) (3.2) Here, F is the feed in mm per minute, f is the feed in mm/rev
and N is the spindle speed in RPM.

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Depth of cut
Depth of cut is practically self-explanatory. It is the thickness of the layer being removed from
the work piece or the distance from the uncut surface of the work to the cut surface, expressed in
mm. It is important to note that the diameter of the work piece is reduced by two times the depth
of cut because this layer is being removed from both sides of the work.

MECHANISM OF CUTTING
In general, machining is 3D process for providing an understanding of mechanics of machining,
we simplify the process in to 2D process called orthogonal cutting, as shown in figure 3.2. In the
orthogonal cutting, the work piece is a flat piece and is machined using a wedge shaped tool.

Crack propagation

The following assumptions were made:

1) The tool tip is sharp and no rubbing occurs between the tool and work piece.
2) Plain strain condition such as there is no side spread and therefore the deformation is
two dimensional.
3) The stresses on the shear plane are uniformly distributed.

The resultant force on the chip applied at the shear plane is equal, opposite and collinear to the
force applied which is the force applied to the chip at the tool interface.

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Mechanism of chip formation by shearing
Shearing takes place along a shear zone at an angle. Below the shear plane, the work piece
remains unreformed; above it, the chip that is already formed moves up the rake face of the tool.

Types of cutting tool materials

The ideal cutting tool material should have all of the following characteristics:
• Harder than the work piece it is cutting
• High temperature stability
• Resists wear and thermal shock
• Impact resistant
• Chemically inert to the work material

To effectively select tools for machining, a machinist or engineer must have specific information
about:
• The starting and finished part shape
• The work piece hardness
• The material's strength tensile
• The material's abrasiveness
• The type of chip generated
• The work holding setup
• The power and speed capacity of the material

Cutting tool inserts

Cutting tool inserts are replaceable attachments for cutting tools that typically contain the actual
cutting edge. Cutting tool inserts applications include turning, boring, construction, cut-off and
parting, drilling, grooving, hobbing, milling, mining, sawing, shearing and cutting, tapping,
threading, and brake rotor turning. Cutting tool inserts have much different geometry.

Type of inserts used in turning operation

Inserts are available in several thicknesses and a variety of sizes and shape. The basic shapes are
round, square, triangle, and diamond. Many other shapes, including the parallelogram, hexagon,
and pentagon are also used to obtain specific machining requirements. The most common insert
shapes are shown in fig.

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Inserts with different shape (a) C shape insert (b) D shape insert (c) Round insert (d)
square insert (e) Triangular insert (f) Trigon insert (g) V shape insert (h) K shape insert
Basic insert selection factors

To quickly and easily establish the indexable insert needed for the machining in question some
factors are necessary to consider at the outset: component material, types of operation needed
and conditions. These will determine the in insert type, shape, size, geometry, grade, nose radius.
Selecting the insert should involve initial consideration of the most suitable entering angle and
operational accessibility as well as tool holder size.

1. Component material:
Determine the component material, Condition, hardness and strength as well as machining
factors. The basic CMC group is: P-steel, M-stainless steel, K-cast iron, N-nonferrous metals, S-
heat resistant and super-alloys, H-hardened steel. These group then have sub groups representing
the material variations most commonly encountered. The material mainly affects the choice of
inserts geometry and the insert grade.

2. Operations:
Determine the operations needed for the application. Rough, medium duty and finish machining
make up the basic types. But there are variation of rough machining depending upon demands of
metal removal amount and the surface condition necessary for the subsequent operations; also
semi finish machining as well as various level finishing depend upon regarding tolerances and
surface finish.

3. Machining conditions:
These affect the choice of tool and the application. Basically there are three: good, average and
difficult conditions but there are additional factors that should also be established continuous or
intermittent cuts, work piece surface and condition, machine tool etc. The machining conditions
may influence the insert shape, size, nose radius, geometry and grade.

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Cutting Tool Geometry
For cutting tools, insert geometry depends mainly on the properties of the tool materials and the
work material. The standard terminology is shown in the figure.

ANALYSIS OF PROBLEM:

 High consumption of insert in turning operation of input shaft and leading to less
productivity.
 Repeated changing of inserts of turning tool &chattering problem at the diameter.
 The insert edges get blunt after machining 10-15 components.
 The material to turn is more for each edge of insert than its limit.

ROOT CAUSE:

The material to turn for each edge of insert is more as compared to its wear strength.

IDEA:

To reduce the material for turning for the insert by introducing a roughing cut in the program so
that wear strength of the insert is increased.

SUGGESTED SOLUTION:

BEORE
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G00 X100 Z10 M08;

G01 X72 Z2 F3;

G01 Z-15 F0.5;

G01 X80 F0.2;

….

….

.…

AFTER: Alteration in program

Introduction of roughing cut

G00 X100 Z10 M08;

G01 X75 Z2 F3;

Alteration in program
G01 Z-15 F1.5;

G01 X80 Z2 F3;

G01 X72 F3;

G01 Z-15 F0.3;

G01 X80 F0.2;

….

….

….

BENEFITS

 Increased Productivity
 Reduced Consumption of Inserts
 Ensure good quality

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RESULT:

The insert life is improved and the problem of chattering on the diameter is completely
eliminated; now the single edge of the cutting insert turns 80-100 components thus increasing the
productivity and reducing tool breakage cost.

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