Arun

Industrial Training at
STAR WIRE IND, LTD.

Submitted in partial fulfilment of the requirements for the award of degree of
Bachelor of Technology
in
Mechanical engineering
by
Submitted by (ARUN)
(Roll No- 18038013502)
2018-2021
Under supervision of
MR.RAM NARESH YADAV
Department of Mechanical Engineering

Shri Ram College of Engineering & Management, Palwal, Haryana
J. C. BOSE UNIVERSITY OF SCIENCE & TECHNOLOGY, YMCA

FARIDABAD-121006
July 2021
COMPANY PROFILE
Star wire India limited is a public incorporated on 4-july-1963. Founded by Mahender

Kumar Gupta . Directors are Rekha Gupta ,Abhishek Gupta, Samir Gupta, and Mahima
Gupta.
It is classified is Non-government Company and is registered at registrar of companies,

Delhi. Its authorized share capital is Rs. 350 million . It is involved in manufacturing of basic
iron & steel.
Star Wire (India) Limited, one of the leading Mini Steel Plant is engaged in the
manufacturing of Alloy Steels, Stainless Steel and Special Steels for diversified
engineering application in shape of castings, forging and rolled products. Plant is fully
equipped with modern equipment’s and testing facilities which have created confidence and
ability for manufacturing various sophisticated grades of steel conforming to international
and National standards.
Vision: -
We, the proud members of the Starwire family, shall strive vigorously to delight our
customers and stakeholders who are our very purpose, by pursuing excellence and
innovation through committed team work. To this end we shall promote continuous
learning, achievement orientation and ethical business practices, which will make us
shine as a global player.
Mission: -
To retain and reinforce our position as a leading Indian manufacturer of Alloy

Steels, Stainless Steel and Special Steels for diversified engineering application in
shape of casting, forging and rolled products and aggregates and meet the
aspirations of customers in domestic and export markets. This will be achieved
through responsive service, empowered employees, vendor partner and satisfied
investors.
STAR WIRE DEPARTMENT
 Valve steel Shop
 Forging shop
 Bullet proof division
 Foundry machine shop (casting)
 Aerospace
 12000-ton press
 VAR (Vacuum Arc Remelting)
 Steel melting shop (SMS)
 Rolling mill
 Non-destructive testing (NDT)
 Electro slag Remelting furnace (ESR)

INTRODUCATION OF GANTRY MILLING MACHINE
Milling is the process of machining using Rotary cutter to remove material by advancing a
cutter into a work piece. This may be done varying direction on one or several axis cutters
head speed and processor milling cover a wide variety of different operation and a machine
on scale from small individual parts two large heavy duty gang milling operation
FIGURE. Gantry milling machine

Axis of gantry milling machine
 Universal head
X- 14000mm
 Angular head
Y- 6000mm
 Vertical head
Z- 1150mm
 Dummy plate
W- 800mm
 Control panel
A-180-degree rotatory
C-270-degree rotatory  Air Compressor
Parts of gantry milling machine  Hydraulic power pack- capacity 1200 litre oil
CNC SYSTEM- 840_D_SL Siemens,  chip conveyor – 2 horizontal, 1 vertical
 Cross rail  oil chiller.
 Ram
 Spindle
 Automatic head loading magazine

Operation performs on a gantry milling machine
 Face milling-
 Side milling
 Angular milling
 Slotting
 Threading
 Drilling
Face milling- Face milling is a machining process in which the milling cutting is placed
Figure. Face milling cutter

Perpendicular to the work piece. The milling cutting is essentially positioned “face
down” towards the top of the work piece. When engaged, the top of the milling
cutting grinds away at the top of the work piece to remove some of its material.
Side milling- The process of milling surfaces that are at right angles to the axis
of rotation of the cutter with a side milling cutter
Figure. Side and face mill cutter.

Angular milling- Angle milling, also known as angular milling,
FIGURE. Angular mill cutter
Parallel nor perpendicular to the axis of the cutting tool,

which means the surface to be machined is at an angle to the
axis of the revolving milling cutter.
Slot Milling- Groove or slot milling is an operation in which side and face milling is
often preferred to end milling. Slots or grooves can be short or long, closed or open,
straight or non-straight, deep or shallow, wide or narrow.
Figure. Slot mill cutter.
Tool selection is normally determined by the width and depth of the groove and to
some extent
Thread milling Thread milling is a metalworking process to cut threads at different sizes
through the circular ramping movement of a rotating tool, the thread pitch is created by
the lateral movement in one revolution. Different from tapping, thread milling is
primarily applied to large workpieces.
Figure. Thread mill cutter.

Drilling-Drilling is a cutting process that uses a drill bit to cut a hole of circular
cross-section in solid materials. The drill bit is usually a rotary cutting tool, often
multipoint. The bit is pressed against the work-piece and rotated at rates from
hundreds to thousands of revolutions per minute.
Figure. Drilling
Function of VERTICAL MILLING CENTRE :-
CNC mill follows precise set of instruction to drill or machine identical parts. CNC milling
machine used computerized control and translated codes from CAD and Cam software to
perform automated machine function on a workpiece
Advantage of CNC milling machine
 The metal is removed at a faster rate as the kettle has got multiple cutting edge
and rotate at a higher speed
 It is possible to perform machine by mounting more than one cutter at a time

 The table of the machine can be moved to an accuracy of .02 mm
Inspection :-
 Ultrasonic test
 Brinell hardness test
 Surface roughness off machining area
 Toughness
 Grinding
 Upper- and lower-part blue matching
Dispatch:-
After all these process castings were dispatch.

Foundry Process Flow Chart
Perioding Process
Raw Material Pattern Making
Methoding Process Mold Making Process (chemical
Process
composition)
Temperature check
Mold Removing
Process
Dimension
Inspection Machining Marking Process NDT Process Fettling Process
Packing Dispatch

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Industrial Training at

STAR WIRE IND, LTD.

Department of Mechanical Engineering

J. C. BOSE UNIVERSITY OF SCIENCE & TECHNOLOGY, YMCA

Star wire India limited is a public incorporated on 4-july-1963. Founded by Mahender

It is classified is Non-government Company and is registered at registrar of companies,

To retain and reinforce our position as a leading Indian manufacturer of Alloy

 Valve steel Shop

 Bullet proof division

 Foundry machine shop (casting)

 VAR (Vacuum Arc Remelting)

 Steel melting shop (SMS)

 Non-destructive testing (NDT)

 Electro slag Remelting furnace (ESR)

FIGURE. Gantry milling machine

CNC SYSTEM- 840_D_SL Siemens,  chip conveyor – 2 horizontal, 1 vertical

 Cross rail  oil chiller.

 Automatic head loading magazine

Figure. Face milling cutter

Figure. Side and face mill cutter.

FIGURE. Angular mill cutter

Parallel nor perpendicular to the axis of the cutting tool,

Figure. Slot mill cutter.

Figure. Thread mill cutter.

Advantage of CNC milling machine

 It is possible to perform machine by mounting more than one cutter at a time

 Brinell hardness test

 Surface roughness off machining area

 Upper- and lower-part blue matching

After all these process castings were dispatch.

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