Abstract
Hindustan Machine Tools is the major industry of the modem era because of its wide
application in automobile, aer...
Contents
List of Figures

9

List of Tables

10

Chapter 1 Introduction

11

1.1 Background History of HMT

11

1.2 Compan...
1.8 Major Achievements in Last Five Years

21

1.9 Different Department in HMT Ajmer

23

1.10 Machine Tool Ajmer at a Gla...
3.4 HMT Corporate Mission

78

3.5 HMT Corporate Objectives and Goals

78

3.6 Conclusion

79

List of Figures
1.1 Diagram...
2.1 Knee Type Milling Machine FN2

35

2.2 Knee Type Milling Machine FN3

36

2.3 CNC Trainmaster Machining Center VMC 200...
List of Tables
1.1 HMT Centers with their date of establishment

15

1.2 Plan for 2012-2013

22

1.3 MTA at a glance

27

...
INTRODUCTION
1.1 BACKGROUND HISTORY OF HMT
1.

When India achieved independence in 1947, there was hardly any industrial b...
established with the collaboration of the Czechoslovakian firms, M/s Skoda
Export, Praha and German firmWMW, then in East ...
3.

Annex houses civil maintenance, vendor development and sub- contracts, electrical
generation or distribution and conse...
2.

To achieve market leadership in India through ensuring customer satisfaction by
supplying internationally competitive ...
1978

Watch Factory IV

Tumkur

Karnataka

1981

HMT Bearing Ltd.

Hyderabad

Andhra Pradesh

1981

Quartz Analog Watches
...
1.

Unit’s product CNC Double Disc Grinder displayed in IMTEX 1998 at
New Delhi was conferred upon CMTI Trust Award for th...
1.

Manufactures of hydraulic groups for defence, hydraulic assembly for
tractors.

2.

Manufactures of high precision and...
1.2.11 Welfare & Entertainment Activities
1.

There are voluntary organizations like HMT Council of Sports & Cultural
Affa...
1.

ICF (Chennai), C & W (Amritsar), DMW (Patiala),C & W (Jagadhari), DLW
(Varanasi).

2.

Others

1.

Educational Sector ...
GM
Joint
General
Manager
Deputy General
Manager
Assistant General
Manager
Manager

Deputy Manager

Foremen
Fig. no. (1.1) ...
Fig. no. (1.2) Machine Tools and Marketing of HMT
1.7 TECHONOLOGY DEVELOPMENT ON GRINDING MACHINE
17
1.

3 axes CNC Cam Shaft Grinding Machine with Siemens 840D CNC System.

2.

4 axes syringe Needle Grinding Machine with a...
3.

CNC Heavy Duty Vertical spindle reciprocating table

surface grinding

machine for grinding locomotive equalizer beams...
No. of employees

381

332

(-) 49

Table no. (1.2) Plan for 2012-2013

1.9 DIFFERENT DEPARTMENT IN HMT AJMER
1. Human Res...
4.

Materials Department:- Headed by JGM. It is responsible for all kinds of
purchases made by unit. This department also ...
8.

Finance Department:-

Headed by AGM Finance. The functions of this

department include maintenance of all accounts of ...
1.10 MACHINE TOOL AJMER AT A GLANCE
MTA AT A GLANCE
1.

Date of registration

11-01-1967

2.

Commencement of production

...
10.

Other services

1.

offered

Manufacture of Jigs, Fixtures, Toolings, Critical Components,
Wyping Cylinders (for Pres...
4.

The product of H.M.T., however could not orient the local market towards them
due to tough competition but they have n...
(A) BANGLORE

PRODUCT
1.

Heavy duty centre Lathes.

2.

Production Trurret Lathes.

3.

Multi Tools Automatic Lathes.

4....
5.

Moving Column Type Special purpose CNC
Machine.

6.

Copy Milling Machine.

7.

Surface broaching Machine.

8.

Agricu...
2.
1.

Fluorescent Lamps.

Mercury Vapour Lamps.

(E) AJMER

PRODUCT
1.
2.

Internal Grinder.

3.

Tool & Cutter Grinder.
...
CHAPTER 2
DETAILS OF DIFFERENT DEPARTMENTS OF HMT AJMER
29
2.1 MANUFACTURING DEPARTMENT
1.

In all the factories, manufacturing department is main department, because here
products ...
5.

Boring machine.

6.

CNC Trainmaster Machining Center VMC 200T PC.

7.

Pushkar 160.

KNEE TYPE MILLING MACHINE
1.

Pr...
Longitudinal Traverse 560

560

560

Cross Traverse (mm) 275

275

275

Vertical Traverse

375

300

375

2.2

2.2

2.2

(...
Fig. no. (2.2) Knee Type Milling Machine FN3
CNC Trainmaster Machining Center VMC 200T PC
1.

An economical and user frien...
Fig. no. (2.3) CNC Trainmaster Machining Center VMC 200T PC

2.1.2 Round section
1.

Here small rounded components are man...
11.

Linear Dividing m/c.

12.

K-130 Grinding m/c.

13.

Horizontal Milling m/c.

14.

Vertical Milling m/c.

15.

Slotle...
3.

Single lever for unclamping turret and withdrawing indexing pin extra sturdy to
take overload stresses

4.

Dropworm m...
4.

Desired diameter can be operated.

5.

Job is manually hold.

SGM (surface grinding machine)
1.

Used for surface grin...
9.

The cutting tool is either moved into position for the operation or the table is moved
under the cutting tool.

10.

F...
4.

It received pressurized oil form pump and send it to the cylinder by U-connection.

WORKING OF TRACTOR HYDRAULIC LIFTI...
1.

Following machines are used in tractor hydraulic section :-

1.

CNC turning lathe (PUSHKAR 160).

2.

CNC internal gr...
X – axis

0.008 / 100 mm

Z – axis

0.015 / 300 mm

Repeatability

+/-0.003 mm

Table no. (2.2) Main Data of CNC Turning L...
1.

HDMS is a part of manufacturing department where heavy parts of machine are
manufactured like machine bed, machine bod...
Max. Load on table

10000 kg

Rapid X & Y axes

7000 mm per min.

Rapid Z-axis

5000 mm per min.

Feed X, Y & Z axes

5-40...
5.

Special angular milling head.

6.

Isolation transformer.

7.

Electric cabinet with panel AC.

8.

Chip conveyor with...
CNC system

SIEMENS
Table no. (2.5) Main Data of VMC 800 M

HMC 760 (HORIZONTAL MACHINE CENTRE)
Made by

HMT

Pallet size
...
z-axis travel

1000 mm

B-axis travel

360 degree

No. of tools stations

40

Positioning accuracy

0.01 mm

Repeatability...
1.

CNC Turning Center

-STC 25/Pushkar 200

2.

CNC Train Master Lathe

-T 70 PC/100CNC

3.

CNC Train Master Machining C...
Fig. no. (2.4) Crank Shaft Grinder

Technical description of machine
1.

Swing diameter

-540 mm

2.

Distance between cen...
2.

Grinding wheel clamping flange

3.

Puller of grinding wheel flange

4.

Balancing arbor

5.

Change pulley to be used...
HYDRAULIC CYLINDRICAL GRINDER (K–130)

Fig. no. (2.5) Hydraulic Cylindrical Grinder
Technical description of machine
1.

H...
Table

1.

Max. travel

-310 mm

2.

Min. travel (automatic)

-2 mm

3.

Max swivel on either side

-10

4.

Speed infinit...
Working principle of the hydraulic system
1.

The pressurized oil is delivered by pump at a service pressure of 12 kg./cm2...
CNC GDS-22

585/660/760 mm

18.5/22/37 kw

Table no. (2.8) Main Data of CNC Double Disc Grinder

Special executions
1.

Va...
3.

The machine has been designed to provide optimum grinding performance at
lowest operating cost.

4.

Lower cost with f...
1.

H F internal grinding spindles.

2.

MARPOSS inprocess gauging

3.

Dynamic wheel balancer.

4.

Air gap and crash con...
Fig. no. (2.7) Function of GCL
1.

This machine specially designed for grinding of cylindrical rods with accuracy of
the o...
Special Executions
1.

Fully automatic loading and unloading system/ transfer line

2.

Oblique dresser for OD and grindin...
1.

3-axes CNC Camshaft grinder with SINUMERIK 840d CNC system.

2.

4-axes / 6-axes CNC Crankshaft journal machine with c...
Max. Swing In Chuck

350 mm

Input Resolution

0.0001 mm

Max Cutting Speed

60 m/sec

Work Spindle Speed

10-1000 rpm
Tab...
6.

To increase resistance to wear, heat & corrosion.

7.

To produce a hard surface on a ductile interior.

HARDENING OR ...
1.

Ensure that the temp of furnace <200 deg. C

2.

Load the component taking care that they do not strike each other as ...
ANNEALING OPERTION
PROCEDURE:1.

Ensure that the furnace temp < 200 deg. C.

2.

Load the component taking care that they ...
1.

One of the most important part of production process is measuring and inspection.

2.

All the components produced on ...
TOOL MAKERS MICROSCOPE
1.

The working of this machine is like that of universal measuring machine except
that:-

Least co...
3.

Height gauges (make mistook Japan).

4.

surface plates cast iron and graphite.

2.5 MAINTENANCE DEPARTMENT
1.

It is ...
1.

Only old machines are taken in field of reconditioning complete machine is
dissembled and different faults are repaire...
4.

Reconditioning maintenance – This type of maintenance dissemble of machine is
same as preventive maintenance but it’s ...
(d)

Spin - 68
Used In – Lubrication of Grinding Machine, Hydraulic Tank, Lathe Machine.

(e)

Ser. Way 68
Used In – Guide...
Used In – Bearings
(o)

Sherol - h
Used as – Coolant Oil
Colour – White
Formula – (Water + Oil) 40 : 1

2.6 FOUNDARY DEPAR...
8.

Metal melting equipment includes various types of melting furnaces such as
cupola, pit furnace, crucible furnaces etc....
16.

Gaggers.

17.

Spray-gun.

18.

Nails & wire pieces.

19.

Bellows.

20.

Clamps, cotters & wedges.

FLASKS
1.

The c...
7.

Pouring of molten is generally done directly by them instead of transferring the
molten metal to ladles.

8.

But in t...
1.

Moulding Machines.

2.

Sand Slingers.

3.

Core making & core baking equipments.

4.

Power riddles.

5.

Mechanical ...
Fig. no. (2.9) Induction Furnace Melting Process of Cast Iron

PARTS OF GRINDING MACHINE PREPARED IN FOUNDARY DEPARTMENT
O...
Fig. no. (2.10) Column

Fig. no. (2.11) Bed

Fig. no. (2.12) Clutch Ring

Fig. no. (2.13) Clutch Cylinder

75
Fig. no. (2.14) Production Flow Chart

CHAPTER 3
CORPORATE PROFILE
3.1 SHAFETY MEASURES
76
1.

Do not wear loose garments they got caught leading to accidents.

2.

Either roll up your uniform releases or bottom u...
20.

Do not attempt to change the speed of the machine when in motion.

21.

Don’t keep unwanted instruments/tools on the ...
3.3 HMT CORPORATE VISION

Fig. no. (3.1) HMT Corporate Vision
3.4 HMT CORPORATE MISSION
1.

To establish ourselves as one ...
3.

To globalise our operations by developing a mix of international markets and
businesses.

4.

To ensure a satisfactory...
References
[1] Catalogue of Hindustan Machine Tools Limited Ajmer.
[2] Production Technology by R. K. Jain.
[3] Introducti...


82
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  1. 1. Abstract Hindustan Machine Tools is the major industry of the modem era because of its wide application in automobile, aerodynamic sector etc. For the manufacturing of machine tools highly equipped and modern machinery are develop in 21st century like CNC’s, which have been illustrated in the project report. The process of making a grinding machine generally requires study of materials and its behavior in presence of heat, a overview of material used in making a grinding machine is given. In the steps for manufacturing a class first grinding machine the important aspects is reading the drawing and carry out the corresponding operation to get the desired grinding machine, in the report a job piece 305 E outer is analyzed with its cycle time and many such calculations are carried out Last but not the least, rather the most prominent think being the quality control aspect on industry and this enable an individual or organization to keep a check over the manufacturing material this aspect have been discussed in the culmination chapter. 1
  2. 2. Contents List of Figures 9 List of Tables 10 Chapter 1 Introduction 11 1.1 Background History of HMT 11 1.2 Company Profile 12 1.2.1 Technology Base 12 1.2.2 Factory Layout 12 1.2.3 Marketing Standing 13 1.2.4 Productivity and Quality 13 1.2.5 HMT Corporate Mission 13 1.2.6 Product and Service 14 1.2.7 Unit Business 15 1.2.8 Others Services Offered 16 1.2.9 Participation to IMTEX 16 1.2.10 Outsourcing/Subcontracting 17 1.2.11 Welfare and Entertainment Activities 17 1.3 Award Won By HMT 17 1.4 Major Costumers of HMT 18 1.5 Hierarchy in the Organization 18 1.6 HMT Machine Tools Limited Marketing Network 20 1.7 Technology Development on Grinding Machine 21 2
  3. 3. 1.8 Major Achievements in Last Five Years 21 1.9 Different Department in HMT Ajmer 23 1.10 Machine Tool Ajmer at a Glance 26 1.11 Current Scenario 27 1.12 Location of HMT Ajmer 27 1.13 Marketing of HMT 28 Chapter 2 Details of Different Department of HMT Ajmer 33 2.1 Manufacturing Department 33 2.1.1 Medium Machine Shop 33 2.1.2 Round Section 37 2.1.3 Tool Room 39 2.1.4 Tractor Hydraulic 40 2.1.5 Heavy Duty Machine Shop 44 2.2 Assembly Department 47 2.3 Heat Treatment 60 2.4 Metrology Department 63 2.5 Maintenance Department 65 2.6 Foundary Department 69 Chapter 3 HMT Corporate Profile 76 3.1 Safety Measures 76 3.2 Future Vision 77 3.3 HMT Corporate Vision 78 3
  4. 4. 3.4 HMT Corporate Mission 78 3.5 HMT Corporate Objectives and Goals 78 3.6 Conclusion 79 List of Figures 1.1 Diagrammatic Representation of Hierarchy in the Organization 19 1.2 Machine Tools and Marketing of HMT 20 4
  5. 5. 2.1 Knee Type Milling Machine FN2 35 2.2 Knee Type Milling Machine FN3 36 2.3 CNC Trainmaster Machining Center VMC 200T PC 37 2.4 Crank Shaft Grinder 49 2.5 Hydraulic Cylindrical Grinder 51 2.6 Double Surface Grinder 54 2.7 Function of GCL 56 2.8 Internal Cylindrical Grinding Machine 58 2.9 Induction Furnace Melting Process of Cast Iron 73 2.10 Column 74 2.11 Bed 74 2.12 Clutch Ring 74 2.13 Clutch Cylinder 74 2.14 Production Flow Chart 75 3.1 HMT Corporate Vision 78 5
  6. 6. List of Tables 1.1 HMT Centers with their date of establishment 15 1.2 Plan for 2012-2013 22 1.3 MTA at a glance 27 2.1 Main Data of Knee Type Milling Machine 35 2.2 Main Data of CNC Turing Lathe Pushkar 160 43 2.3 Main Data of CNC Internal Grinding Machine GI 100 44 2.4 Main Data of CNC Plano Milling Machine 45 2.5 Main Data of VMC 800 M 46 2.6 Main Data of HMC 760 47 2.7 Main Data of KTM 47 2.8 Main Data of CNC Double Disc Grinder 53 2.9 Main Data of Center Less Grinder 57 2.10 Main Data of CGM 58 2.11 Main Data of Internal Grinder 59 CHAPTER 1 6
  7. 7. INTRODUCTION 1.1 BACKGROUND HISTORY OF HMT 1. When India achieved independence in 1947, there was hardly any industrial base in the country. 2. Right from the prior H.M.T. has played an important role in providing the much needed industrial base as well as a launching pad for the growth & development of the country. 3. HMT was conceived by the Government of India in 1949, and was incorporated in 1953, with the objective of producing a limited range of machine tools, required for building an industrial edifice for the country. 4. HMT Limited was established in 1953 in technical collaboration with M/s Orleikon of Switzerland. 5. Over the years, new products have been added to its manufacturing range. 6. It has technical collaboration with over 30 leading International Engineering Companies for manufacture of various products HMT’s diversified product range includes Machine Tools, Watches, Tractors, Printing Machine Press, Di-Casting and Plastic Injection, Moulding Machines, Food Processing Machinery, CNC Systems, Bal Screws etc. 7. This Unit was established as Machine Tool Corporation of India limited in January 1964 keeping in view the Government Policy of differing new industries in under developed areas of the country and achieving self reliance in production of Grinding Machine Tools which were imported. 8. This Unit was started 1970-71 with a production of Rs. 8.64 Lack faces with difficulty in procurement of quality Machine Tool Casings a captive Foundry Plant was installed in 193 with a capital of about Rs.2 Crore. This Unit was subsequently merged with HMT Ltd. On 1st April 1975 as sixth Machine Tool Plant with this merger; the Unit got backup support of HMT. The basic plant was 7
  8. 8. established with the collaboration of the Czechoslovakian firms, M/s Skoda Export, Praha and German firmWMW, then in East Germany. 9. Today, HMT is a Multi-Product, Multi Technology Engineering Complex with strengths comprising of: 1. 16 Manufacturing Units / 22 Product Division 2. Assets Worth over US$ 250 Million 3. ISO-9000 accreditation 4. The widest range of machine tools, ranging from General- purpose lathes to CNC turning machine centers. 5. Source of qualified and experienced Manpower. 1.2 COMPANY PROFILE 1.2.1 Technological base 1. Unit has Machine Shops well equipped with 186 nos. precision machines, such as CNC Machining Centres, CNC Lathes, Jig Boring, Honing, Superfinishing Machines & different types & sizes of Grinding, Planing, Milling & Lathes. 2. Apart from these, Unit is also having Measuring Centre, Material Testing Laboratory, CAD Centre and Foundry. The Unit has highly skilled and dedicated work force of 380 employees (101 Officers and 278 Workers). 3. The Unit has qualified and experienced Design & Engineering Personnel to fulfil requirement of Business Operations to the entire satisfaction of customers. 1.2.2 Factory layout 1. Unit has two workshop Buildings-Building 1-1 Houses assembly, Painting, heavy Parts, and High technology centre and test floor. 2. Building1-2 houses small parts, medium parts, tool room and special accessories, tool crib, tractor hydraulics, heat treatment shop and plant maintenance departments. 8
  9. 9. 3. Annex houses civil maintenance, vendor development and sub- contracts, electrical generation or distribution and conservation. 4. Stores building houses central stores, material planning and training centre. 5. Pattern shop Building houses pattern shop and machine shop of training centre. 6. Foundry shed houses moulding, machining, sand-plant, core making, knock out, short lasting areas. 7. Store foundry block houses personnel, engineering, designing, information technology centre, industrial engineering, servicing and G.M.’s office. 8. Administrative building houses purchase, sales and finance department. 1.2.3 Market standing 1. The unit pioneered manufacturing technology for grinding machine in India, which was a milestone for country’s journey towards self-reliance. 2. Unit has positioned itself as “Centre of excellence for Grinding Solution”. 3. It caters to requirement of sun rising user sectors like Automobile, Auto Ancillaries, Tractors, Bearings. 4. It also caters to requirement of General Engineering, Defense & Power Sectors. 5. Reliability and precision are hallmark to have a fleet of 7500 machines working in every corner of country & abroad. 1.2.4 Productivity and quality 1. Great emphasis is given on Productivity and Quality in HMT. The unit has achieved substantial progress in implementation of productivity improvement activities i.e. KAIZEN, ISO-9000, Total Customer Satisfaction, TQM, Multi-trade training, Good House Keeping through 5-S, Waste Elimination, Small Group Activities etc. 2. Unit was the first to receive the ISO-9000 Certification in Rajasthan and second in HMT Units, on 24.2.1994. The unit has the distinction of getting “National Productivity Award” (instituted by National Productivity Council if India), in Machine Tool Category for the year 1986-87 from the Hon’ble President of India. 1.2.5 HMT corporate mission 1. To establish ourselves as one of the Worlds companies in the engineering field having strong international competitiveness. 9
  10. 10. 2. To achieve market leadership in India through ensuring customer satisfaction by supplying internationally competitive products and services. 3. To achieve sustained growth in the earnings of the group on behalf of shareholders. 4. To produce and market engineering goods and services of world class excellence for satisfying the aspiration of the stake holders through total performance leadership, consistent with the national socio-economic needs and priorities. 1.2.6 Product and service YEAR Table no. (1.1) HMT Centers with their date of establishment UNITS/DIVISION LOCATION STATE 1953 Machine Tools I Banglore Karnataka 1961 Machine Tools II Banglore Karnataka 1962 Watch Factory I Banglore Karnataka 1963 Machine Tools III Pinjore Haryana 1965 Machine Tools IV Kalamessery Kerala 1967 Machine Tools V Hyderabad Andhra Pradesh 1971 Tractor Division Pinjore Haryana 1971 Die Casting Division Banglore Karnataka 1972 Printing Machine Division Kalamessery Kerala 1972 Watch Factory II Banglore Karnataka 1973 Precision Machine Division Banglore Karnataka 1975 Machine Tools VI Ajmer Rajasthan 1975 HMT (International) Ltd. Banglore Karnataka 1975 Watch Factory III Sri Nagar Jammu & Kashmir 1. Following products and services are provided by HMT :10
  11. 11. 1978 Watch Factory IV Tumkur Karnataka 1981 HMT Bearing Ltd. Hyderabad Andhra Pradesh 1981 Quartz Analog Watches Banglore Karnataka 1982 Watch Factory V Ranibagh Uttar Pradesh 1983 Stepper Motor Division Tumkur Karnataka 1985 Ball Screw Division Banglore Karnataka 1986 CNC System Division Banglore Karnataka 1991 Central Re-Conditioning Banglore Karnataka 1. Machine Tools 2. Project Consultancy 3. Tractor & Agricultural Implements 4. Watches 5. Bearing 6. Printing Machinery 7. Software & IT Services 8. Imports 1.2.7 Unit business 1. Manufacture of Machine Tools 1. Wide range of CNC conventional, General Purpose & Special purpose Grinding Machines (Cylindrical, Centreless, Internal, Crank Shaft, Duplex, Horizontal & Vertical, Tool & Cutter). The product strategy is mainly focussed on Auto & Auto-ancillary, Engineering and Defence segments. 11
  12. 12. 1. Unit’s product CNC Double Disc Grinder displayed in IMTEX 1998 at New Delhi was conferred upon CMTI Trust Award for the best innovative design of the year. 2. CNC Turning Centres. 3. CNC Training Machine (Lathe & Machining Centre). 4. Other machines like Super Finishing, Knife Edge Grinding, Gap Grinding, Cot Grinding, Coil Winding, Needle Sharpening, Rotary Table Vertical Surface Grinding, etc. 5. Reconditioning/CNC Retrofitting of Machine Tools. 6. Job Orders/Customer Component Manufacture 1. Hydraulic Groups for Defence. 1. Unit got National Award for excellence in indigenisation of Defence Stores in the category of Mechanical Engineering for the year 1993-94. This award was for development and supply of Hydraulic Unit for T-72 Tank.Hydraulic 1. Lifts for Tractors. 2. High Precision Components/ operations on job work basis for Automobile Industry and BHEL. 3. Jigs & Fixtures. 4. Wyping Cylinders for Bank Note Press. 5. Supply of Castings. 6. Unit has bagged an order worth Rs.5 crore for supply of Flange Connectors to M/s.Bhava Atomic Research Centre, Mumbai. 1.2.8 Others services offered 12
  13. 13. 1. Manufactures of hydraulic groups for defence, hydraulic assembly for tractors. 2. Manufactures of high precision and critical items and assemblies. 3. Manufactures of jigs and fixtures and tooling for various machinery. 4. Supply of casting. 5. Reconditioning and retrofitting of old machines. 6. Chemical, mechanical and meteorological tests. 7. Checking and calibration of instruments and machines. 8. Training to outsiders /students/customers. 1.2.9 Participation to IMTEX 1. Unit has been participating in every IMTEX with innovative products. 2. Unit’s product CNC Double Disc Grinder displayed in IMTEX 1998 at New Delhi was conferred upon CMTI Trust Award for the best innovative design of the year. 3. Unit is developing 6 Axes CNC Centreless Grinding Machine, Model GCL140 TG-CNC/610x305(6A) for display in IMTEX 2007. 1.2.10 Outsourcing/Subcontracting 1. To win over the problems caused by continuous reduction in manpower, increase in overhead expenditure and fierce market competition due to globalization of economy, the Unit has been strategizing for inhouse manufacture of only critical components and offloading sheet metal fabricated parts, B & C class fully machined parts, special accessories group assemblies, fettling of castings, scraping, making of packing cases, etc. to subcontractors. 2. In the process 14 subcontractors locally and 15 outside Ajmer have been developed. 13
  14. 14. 1.2.11 Welfare & Entertainment Activities 1. There are voluntary organizations like HMT Council of Sports & Cultural Affairs, HMT Senior Club, HMT Ladies Club, HMT Employees Cooperative Credit & thrifts Society, etc. 2. Through these organizations, various activities are undertaken for the welfare and entertainment of the employees. 1.3 AWARD WON BY HMT 1. National Productivity Award, in Machine Tools Category for the year 1986-87. 2. National Award for R & D efforts in Mechanical Engineering Sector in 1990. 3. ISO-9001 Certification on 24th February, 1994. HMT Ajmer was the first Unit to receive this Certification in Rajasthan and second in HMT Units. 4. National Award for excellence in indigenization of Defense Stores in the category of Mechanical Engineering for the year 1993-94. This Award was for development & supply of Hydraulic Unit for T-72 Tank. 1.4 MAJOR COSTUMERS OF HMT 1. Automobile sectors 1. Bajaj Auto, Ashok Leyland, Hero Honda, Maruti, Mahindra & Mahindra. 2. Bearing industries 1. Timken India, SKF Bearing, NEI, KCI Bearing, HMT Bearing. 2. Defence 1. Ordnance Factory Ambernath, Khamaria, Ambajari, Katni, Kanpur,V.F.& GCF Jabalpur, Nuclear Fuel Complex (NFC), H.V.F. Avadi, A.H.Q, Base Repair Depot (BRD), HAL, Army Base Workshops (ABW). 2. Railways 14
  15. 15. 1. ICF (Chennai), C & W (Amritsar), DMW (Patiala),C & W (Jagadhari), DLW (Varanasi). 2. Others 1. Educational Sector (Engg. Colleges, Polytechnics, ITI’s etc.) 2. Power Sector (BHEL, NTPC, State Electricity Boards etc.) 3. Refractory Industries (TATA Refractory, Bharat Refractory etc.) 4. Tool Rooms and Training Centers. 1.5 HIERARCHY IN THE ORGANIZATION 1. The organizational hierarchy of HMT MTL Ajmer is based on functions. General Manager leading the unit, assisted by the General Manager, Directly controls in different department. 2. The organization hierarchy consists of seven management levels in all. They are listed below in descending order: 1. General Manager 2. Joint General Manager 3. Deputy General Manager Assistant 4. General Manager 5. Managers 6. Deputy Managers 7. Foremen 15
  16. 16. GM Joint General Manager Deputy General Manager Assistant General Manager Manager Deputy Manager Foremen Fig. no. (1.1) Diagrammatic Representation of Hierarchy in the Organization 1.6 HMT MACHINE TOOLS LIMITED MARKETING NETWORK 16
  17. 17. Fig. no. (1.2) Machine Tools and Marketing of HMT 1.7 TECHONOLOGY DEVELOPMENT ON GRINDING MACHINE 17
  18. 18. 1. 3 axes CNC Cam Shaft Grinding Machine with Siemens 840D CNC System. 2. 4 axes syringe Needle Grinding Machine with automatic loading & unloading. 3. 2 axes CNC wheel head mounted rotary diamond profile dresser. 4. Heavy Duty CNC Cylindrical Grinding Machine with swing dia 840 mm and job weight 2000 kg. 5. Heavy Duty Internal Grinding Machine for bore dia up to 600 mm & length 300 mm. 6. Automatic CNC machines for engine valve. 7. Grinding line for inner tube and piston rod of shock absorbers. 8. Oblique dresser for OD and face grinding simultaneously. 9. Machine for grinding axle of heavy vehicles. 10. MTA was earlier making conventional grinding machines. 1. Business was going down as trend was shifting towards CNC machines. 2. 1996 onwards we started focusing within house efforts on development of CNC versions of all products to cope up with the emerging trend and market demand. 3. Subsequently high value CNC machines and SPM grinders became priority area. 4. In last five years we developed no. of such products which increased our turn over with simultaneous decreasing manpower. 1.8 MAJOR ACHIEVEMENTS IN LAST FIVE YEARS 1. Development of 8 axes CNC CRANK SHAFT JOURNAL AND PIN GRINDING MACHINE as Import Substitution. 2. CNC Centreless grinding machine for grinding bearing race dia. upto 300 mm as import substitution. 18
  19. 19. 3. CNC Heavy Duty Vertical spindle reciprocating table surface grinding machine for grinding locomotive equalizer beams to M/s.CLW, Chittaranjan. 4. CNC Heavy Duty Cylindrical grinding machine with 3000kg weight capacity, swing 840mm & ABC 3000mm . Highest value order executed in history of MTA as import substitution at a price of Rs.330 lakhs for BHEL Haridwar. 5. CNC Heavy Duty Internal Grinding machine model GI400(SPM) for grinding carbide bush ID up to 400mm with diamond grinding wheel for M/S Flow Serve, Chennai. 6. CNC Heavy Duty Double Disc Grinding machine with Shot Gun Type Feeder for Grinding both faces of Large bearing races as import substitution for M/s Timken, Jamshedpur. 7. Robotics loading and un loading of con rods on CNC double disc grinding machine to M/s.Mushashi Auto, Gurgaon. PLANS FOR 2012-13 ACTUAL ESTIMATE GROWTH (%)/ PLAN FOR 2010-11 2011-12 VARIATION 2012-13 Particulars Value in ` Lakhs Production 1945 2836 46 4000 Sales (I) 2162 2624 21 3942 Sales (X) 47 77 64 58 Sales (T) 2209 2701 22 4000 Gross Margin (PBDIT) -505 116 +621 L 657 Opening Pending Orders 4013 5434 +1421 L 5434 19
  20. 20. No. of employees 381 332 (-) 49 Table no. (1.2) Plan for 2012-2013 1.9 DIFFERENT DEPARTMENT IN HMT AJMER 1. Human Resource Department:- Headed by Joint General Manager (HRM) this department is setup with an aim of conservation and proper utilization of human resources and is also responsible for maintaining the cordial relations between employees and management. The other important functions of this department are performance appraisal and different welfare activities for the employee. 2. Manufacturing and Assembly Department:- Headed by JGM (manufacturing). HMT Ajmer’s manufacturing environment is highly advanced; this department also looks after utilizing only the latest production techniques in all phases of manufacturing maintenance. This assembly of machine is done stages, much as sub assembly. Group assembly and final assembly of individual components. There subassemblies after inspection pass on group assembly, which consists of head stock assembly, saddle, gearbox, tail stock assemblies etc. this group then reaches to the final assembly to be fitted on the bed. Electrical are also inter faced and the machine is ready for final testing and printing of plant and equipment. 3. Service & Inspection Department:- Headed by DGM. This department is responsible for inspection & Servicing of the M/C’s. This department is concerned with the inspection of various components and machines being manufactured. The inspection is carried out in various stages, beginning from the inspection of individual components at different stages of manufacturing followed by the inspection of the whole machine while included final runs etc. Inspection of incoming material is also handled. 20 -
  21. 21. 4. Materials Department:- Headed by JGM. It is responsible for all kinds of purchases made by unit. This department also maintains a Central store and looks after appropriate levels. 5. Planning Department:- Headed by JGM(EQ). The main functions of the planning department are as under: 1. Time calculations for each operation. Job card booking of workers in shifts. 2. To prepare monthly progress reports for the production activities carried out in shop. 3. To calculate manpower and machines available, accordingly new machines are ordered and component. 4. 5. 6. Counting of products and components. Prepare machines and sectional layouts Design Department:- Headed by JGM. Its functions are: 1. Design & development of products. 2. Vendor development for new items. 3. Drawing of component, group assembly, special assembly etc. along with master part list (BOM) for machines. 4. Deciding the type of material required for each component grade such as casting alloy etc. 5. 6. 7. Testing & trials of machines. Marketing of special purpose machine. Foundry Department:- Headed by JGM Foundry. This department is administratively under HMT Ajmer, but functionally under executive director. 21
  22. 22. 8. Finance Department:- Headed by AGM Finance. The functions of this department include maintenance of all accounts of the Company. The balance sheet is finally prepared which is sent to the head office for the preparation of combined balance sheet. The costing section of this dept. is responsible for the computing of each product of that the selling price may be determined accordingly. 9. Sales Department:- It is headed by JGM(Sales). This dept. is divided into 3 sections viz. Sales, Spares and Reconditioning. These functions of sales sections are the execution of sales order and to bid for contracts through tenders. The function of service section is to provide after sales & also looks after customer’s complaints and supply of spares. 10. Security Department:- This is headed by Junior Security officer. Main function of this dept. is preventions of theft, sabotage and maintenance of industrial security within the HMT compound including Township. 11. Quality Assurance Department:- Dy. General Manager heads this department. This department also looks after the feedback received from marketing division so as to make improvement accordingly. 22
  23. 23. 1.10 MACHINE TOOL AJMER AT A GLANCE MTA AT A GLANCE 1. Date of registration 11-01-1967 2. Commencement of production 3. Merger with HMT 4. Land area – total 178 acres (720900 m2) 1. Plant & foundry 62 acres (251100 m2) 1. Covered 2. Covered area of plant 3. Uncovered 31848 m2 4. Township 102803 m2 1970-71 01-04-1975 148297 m2 116 acres (469800 m2) 5. No. of quarters TYPES I Total : III IV V VI 48 136 II 48 24 12 3 1 6. Power required 2.13 lakh Units/month 7. No. of employees(as on 1.4.2011) 381 8. No. of machines 198 9. Product Wide range of CNC, General Purpose & Special purpose Grinding range of grinding &Machines (Cylindrical, Centreless, Internal, Crank Shaft, Duplex, training machines Roll Camber, Key Stone, Horizontal & Vertical Surface, Tool & Cutter), Needle Sharpening M/c., CNC Turning Centers, CNC Training Machine (Lathe & Machining Centre). 23
  24. 24. 10. Other services 1. offered Manufacture of Jigs, Fixtures, Toolings, Critical Components, Wyping Cylinders (for Presses), Group Assemblies, Hydraulic Groups. 2. Carrying out critical, high precision operations on Job Work basis. 3. Reconditioning & retrofitting of old machines at HMT Works and at customers’ Works. 4. Manufacture of Hydraulic Lift Mechanism for tractors. 5. Supply of castings. 6. Chemical, mechanical & metrological tests, checking & calibration. 7. Training to outsiders/customers. Table no. (1.3) MTA at a glance 1.11 CURRENT SCENARIO 1. The Unit achieved a turnover of Rs.3274 Lakhs during 2005-06 against previous year's turnover of Rs.2526 Lakhs i.e. a growth of 30%. 2. However, keeping in view the present encouraging market conditions, the Unit has planned a challenging Sales Turnover of Rs.40 Crores during 2006-07 i.e. growth of 22% Y-O-Y basis. 3. As the order position continues to be encouraging, Unit is confident to achieve current year's Sales target. 1.12 LOCATION OF HMT AJMER 1. The H.M.T. Ajmer is situated near Ajmer Dairy 6 Km. from Ajmer City of Ajmer-Beawar Road. 2. It's foundation stone was laid on December 16, 1966 and production was started in 1970. 3. It produced various types of Grinding Machine, Lathe Machines of various sizes. 24
  25. 25. 4. The product of H.M.T., however could not orient the local market towards them due to tough competition but they have nicely attached the foreign market. 5. The H.M.T. were highly appreciated by Foreign Experts in many industries trade fair organized in India and Abroad. 1.13 MARKETING OF HMT 1. H.M.T. has a type marketing network throughout the country. 2. While each business group has a central marketing division, each factor has also a unit Sales Department. MARKETING DIVISON 1. Machine Tools - Bangalore 2. Watches - Bangalore 3. Tractors - Chandigarh SALES AND SERVICE CENTES 1. Agra, Ahmedabad, Bangalore, Bhilai, Bhopal, Bhubaneshwar, Bombay, Calcutta, Chandigarh, Coimbtore, Cochin, Guwahati, Hyderabad, Indore, Jabalpura, Jaipur, Kanpur, Karnel, Luckhnow, Madras, Mohali, Nagpur, New Delhi, Patna, Puna, Ranchi, Srinagar, Tumkur. HMT INTERNATIONAL LIMITED 1. Head Office Bangalore 2. Overseas Branches Australia, Kenya, USA 3. Overseas Offices Algeria, Indonesia, Nigeria. Malasiya HMT FACTORIES IN INDIA 25
  26. 26. (A) BANGLORE PRODUCT 1. Heavy duty centre Lathes. 2. Production Trurret Lathes. 3. Multi Tools Automatic Lathes. 4. Single Spindle Automatic. 5. CNC Single Spindle Automatic. 6. Angular Wheel Read Grinders. 7. CNC Cylindrical Grinders. 8. Radial Drilling Machine. 9. Multi Spindle Drilling Machine. 10. Facing & Centering Machine. 11. Die Casting and Plastic. 12. Injection Moulding Machine. 13. Gear Mobbing Machines. 14. Gear Shaping Machines. (B) PINJORE PRODUCT 1. Knee Type Mechanical Controlled Milling Machine. 2. Ram Type Turret Milling Machine. 3. CNC Milling Machines. 4. Horizontal & Vertical Machining Centre. 26
  27. 27. 5. Moving Column Type Special purpose CNC Machine. 6. Copy Milling Machine. 7. Surface broaching Machine. 8. Agricultural Machinery. (C) KALAMASSARY PRODUCT 1. 2. Drum Turret Lathe 3. SB Copying Lathe. 4. Programme Controlled Turret Lathe. 5. 1. High speed precision Lathe. Slanted Bed CNC Lathe. Printing Machinery. (D) HYDERABAD PRODUCT (a) MACHINE TOOLS 1. Horizontal boring Machine. 2. Special Purpose Machine. 3. Flow forming Lathe. 4. CNC Horizontal boring Machine. 5. Machine Centres. (b) PRESSES & PRESS BRAKES 1. GLS Lamps. 27
  28. 28. 2. 1. Fluorescent Lamps. Mercury Vapour Lamps. (E) AJMER PRODUCT 1. 2. Internal Grinder. 3. Tool & Cutter Grinder. 4. Crank Shaft Grinder. 5. Roll Chamber Grinder. 6. Vertical Surface Grinder. 7. Duplex Surface Grinder. 8. CNC Trainer Lathe T-70 & VMC 200T 9. LENS Grinding & Polishing Machine. 10. Centreless Grinding Machine. 11. 1. Cylindrical & Universal Grinder. Knife edge Grinding Machine. Hydraulic Cylindrical Grinder K-130 (F) AURANGABAD PRODUCT (DAIRY MACHINERY UNIT) 1. Milk Separator 2. Plate heat exchanger 3. Continuous butterline Machinery 4. Self cleaning milk separator milk and cream pasteuriser. 28
  29. 29. CHAPTER 2 DETAILS OF DIFFERENT DEPARTMENTS OF HMT AJMER 29
  30. 30. 2.1 MANUFACTURING DEPARTMENT 1. In all the factories, manufacturing department is main department, because here products or different parts of machine are prepared. 2. H.M.T. Ajmer also has a manufacturing department which is divided in the following sections. 1. Mfg. H.P. (Manufacturing Heavy Parts) 2. Mfg. S.P. (Manufacturing Small Parts) 1. In manufacturing H.P. heavy parts of a m/c like machine bed, gear box main body etc. are manufactured. 2. In manufacturing S.P. different small components and parts of a m/c like shaft, spindle, gear, bushes, screw etc. are manufactured. 3. Following sections comes in the manufacturing department. 1. Medium Machine Shop (MMS). 2. Round Section (RS). 3. Tool Room (TR). 4. Tractor Hydraulic (TH). 5. Heavy Duty Machine Shop (HDMS). 2.1.1 Medium machine shop 1. In this shop small parts of grinding machine like bush, spindle, shaft, pulley etc. are prepared. 2. Following types of machines are used to manufacture that part:- 1. Centre lathe. 2. Knee type milling machine. 3. Cylindrical grinding machine. 4. Drilling machine. 30
  31. 31. 5. Boring machine. 6. CNC Trainmaster Machining Center VMC 200T PC. 7. Pushkar 160. KNEE TYPE MILLING MACHINE 1. Production milling machine. 2. Wide range of speeds and feeds. 3. Longitudinal automatic programmed cycle. 4. Rapid traverse to minimize idle time. 5. Separate motors for spindle and feed drives. 6. Centralized push button controls for ease of operation. 7. Main spindle runs on precision taper roller bearings. 8. Streamlined construction, rugged and vibration free. 9. 7.5/5l5 kW Motor for heavy stock removal. 10. Power operated feeds and rapid traverses in all directions. 11. Independent main drive and feed drive motors. 12. Wide range of spindle speeds and feeds. 13. Instantaneous braking of spindle and table drives through electromagnetic clutches. 14. High rate of rapid traverses. 15. Light fingertip push button controls. 16. Inching push button for speed and feed drive. Horizontal Universal Vertical Table Size (Length & 1070x230 1070x230 1070x230 Width) (mm) 31
  32. 32. Longitudinal Traverse 560 560 560 Cross Traverse (mm) 275 275 275 Vertical Traverse 375 300 375 2.2 2.2 2.2 (mm) (mm) Main Motor (kw) Table no. (2.1) Main Data of Knee Type Milling Machine . Fig. no. (2.1) Knee Type Milling Machine FN2 32
  33. 33. Fig. no. (2.2) Knee Type Milling Machine FN3 CNC Trainmaster Machining Center VMC 200T PC 1. An economical and user friendly PC based system to meet Training requirements of all Training Centre, Technical and Educational Institutions in CNC machine tools operation & programming. 1. Provides a comprehensive range of CNC functions for both Vertical and Horizontal modes of operation, with a CRT monitor and many more advanced features. 2. PC based CNC system. 3. Compact table top model, most ideal for training institutes. 4. Step less DC drive with RPM and load indication for spindle. 5. Hardened and ground spindle runs in Precision antifriction bearings. 6. Economical CNC system best suited to educational institutions. 7. Recirculating Ball screw and Nut arrangement for all axis. 8. Machine lamp. 33
  34. 34. Fig. no. (2.3) CNC Trainmaster Machining Center VMC 200T PC 2.1.2 Round section 1. Here small rounded components are manufacture. 2. Following m/c are used to manufacture the round parts. 1. Capstan Lathe. 2. Drum Turret Lathe. 3. Turret Lathe. 4. Centre Lathe. 5. Drilling m/c. 6. Radial Drilling m/c. 7. Centre less Grinding m/c. 8. Cylindrical Grinding m/c. 9. BUA31 Grinding m/c. 10. Circular Dividing m/c. 34
  35. 35. 11. Linear Dividing m/c. 12. K-130 Grinding m/c. 13. Horizontal Milling m/c. 14. Vertical Milling m/c. 15. Slotler m/c. Centre Lathe LB 17 1. Manufactured by Chamundi Machine Tools Limited. 2. Versatile lathe equally adaptable to precision tools room work and high speed production turning. 3. Direct multiple V belt drive to spindle ensures smooth torsional vibration. 4. Free high turning speeds. 5. Five inter. 6. Changeable tool holders with quic. 7. Change tool post, interlocked feed levers, full overload. 8. Protection foot brake and many other feature facilitiate fatigue. 9. Free, easy operation of the machine. MAIN DATA Centre height mm 170 Distance between centres mm 700 or 1000 Spindle nos/bore mm Americal type L 1/42 Main motor KW 7.5 Pre-selector turret lathe L 22 1. Pre selection of speeds and feeds 2. Precision indexing of turret head with solid 'V clamp locking 35
  36. 36. 3. Single lever for unclamping turret and withdrawing indexing pin extra sturdy to take overload stresses 4. Dropworm mechanism avoids overloading-hardened guideways. MAIN DATA Centre Height mm 237 Spindle nose/bore mm A2-6/65 Bore in turret mm 54 Main motor KW 9.3 2.1.3 Tool room 1. In HMT special jigs and fixtures are made in order to reduce the production time. 2. These jigs and fixtures are made in tool room. 3. Initially, tools were made in tool room but to expensiveness now it is purchased. 4. Now, parts, which are required to be highly super finished accurate are prepared in tool room. 5. For this purpose following machines are used in tool room :- 1. GEI (external & internal grinding machine). 2. SHM (super honning machine). 3. SGM (surface grinding machine). 4. RAD (radial arm drilling machine). GEI (external & internal grinding machine) 1. Used for external and internal grinding. 2. Hydraulic operated. 3. 200 mm maximum swing diameter. SHM (super honning machine) 1. Used for super finishing and accurate work. 2. Consumers less time. 3. Electrically operated. 36
  37. 37. 4. Desired diameter can be operated. 5. Job is manually hold. SGM (surface grinding machine) 1. Used for surface grinding. 2. Hydraulic operated. 3. Electromagnetic table is used for clamping job. RAD (radial arm drilling machine) 1. Used for drilling holes. 2. Electrically operated. 3. Nine different speeds can be obtained. 4. Different attachment can be made. JIGS & FIXTURES 1. The requirements of mass production and interchangeable assembly in industry, demand that the components be machined to identical form & size. 2. For this purpose, devices known as jigs & fixtures are used for holding, locating the work & guiding the tools while machining. 3. The use of jigs and fixtures makes possible rapid as well as accurate manufacturing at the same time, reducing the production cost. 4. A jig is a device, which holds and supports the work and also guides the path of the cutting tool, as the operation is performed. 5. Jigs are used extensively for operations such as drilling, reaming, tapping and counter-boring. 6. The jig need not be secured to the machine. 7. A fixture is a device which locates and holds the work securely in a definite position. 8. It is usually secured to the table of the machine and it does not guide the cutting tool. 37
  38. 38. 9. The cutting tool is either moved into position for the operation or the table is moved under the cutting tool. 10. Fixtures are used while performing milling, turning, honing, broaching, grinding and welding operations. 2.1.4 Tractor hydraulic 1. It is a part of manufacturing department where hydraulic lifting system of tractor is manufactured. 2. Hydraulic lifting system is used in tractor or lifting. 3. Hydraulic lifting system is a system which is used to lift the weight (Trolleys & Ploughs) by using the pressurized hydraulic oil. 4. The important components of the system are as follows :- 1. Housing. 2. Distributor. 3. Cylinder piston & connecting rod. 4. Main shaft. 5. Torsion shaft. 6. Lever with cam. 7. I. C. & O. C. levers. 8. Draft tube etc. 1. Hydraulic lifting system is assembled with 20 parts. DISTRIBUTOR 1. It is the heart of hydraulic lift system as it controls fluid flow direction. 2. It consists of integrated lines and also consists with I. C., O. C. and D. V. Bush. 3. It has one inlet out let opening. 38
  39. 39. 4. It received pressurized oil form pump and send it to the cylinder by U-connection. WORKING OF TRACTOR HYDRAULIC LIFTING SYSTEM 1. When pressurized oil enters cylinder it displace the piston in forward direction piston connected to the lever with connecting rod. 2. So when piston moves in forward direction leaver rotate. 3. Leaver connected to the main shaft by splint system so it rotate the main shaft. 4. Arms connected to the main shaft so it lift the arms and weight connected with arms so arms lifting the weight. HYDRAULIC LIFT TESTING 1. Hydraulic lift testing is done by hydraulic lift testing machine. 2. There is some standard parameter tested on testing machine which are as follows :- Setting parameter 1. Pressure – 120 kg s/cm2 2. Discharge – 20 Lt. /min. Testing parameter 1. Lifting time – 2 - 2.25 sec. at 20 Lt/min. 2. Lifting position 80 from top lift position. 3. Lifting and down movement – Should be jerk free, regular, no dropping sinking. PROBLEMS 1. Not lifting the weight. 2. Not coming down. 3. Sinking. 4. Jerking. 39
  40. 40. 1. Following machines are used in tractor hydraulic section :- 1. CNC turning lathe (PUSHKAR 160). 2. CNC internal grinding (GI 100). 3. Universal milling machine. 4. Horizontal milling machine. 5. Vertical milling machine. 6. Centre lathe. CNC TURNING LATHE (PUSHKAR 160) 1. These machines yield excellent results in high speed turning and material removing processes. 2. The multi tool holding turret and variable and self adjusting spindle (RPM) gives superior surface finish. 3. Also tool post is mounted on a slant carriage (30 deg with vertical) to make easy way for tapers and clearances. 4. Hard turning facility. 5. Programmable tail stock. 6. Various types of working and holding devices. Max. Turning Diameter 250 mm Max. Turning Length 350 mm Spindle Power 12kw (7.5kw) Full Power Speed Range 880 – 3500 rpm Position Accuracy 40
  41. 41. X – axis 0.008 / 100 mm Z – axis 0.015 / 300 mm Repeatability +/-0.003 mm Table no. (2.2) Main Data of CNC Turning Lathe Pushkar 160 CNC INTERNAL GRINDING (GI 100) 1. Head stock with 6500 rpm with belt drive and 10,000 rpm with integral spindle for high speed machining. 2. Touch probe for automatic tool offset. 3. Built in live center for tail stock. 4. Rear chip conveyor. 5. Programmable tail stock. 6. Various types of working and holding devices. Min. Grinding Bore Diameter 10 mm Max. Grinding Bore Diameter 100 mm Max. Grinding Bore Length 100 mm Size Tolerance 1 to 6 Repeatability +/-0.001 mm Table no. (2.3) Main Data of CNC Internal Grinding Machine GI 100 2.1.5 Heavy duty machine shop 41
  42. 42. 1. HDMS is a part of manufacturing department where heavy parts of machine are manufactured like machine bed, machine body, wheel head, work head, gear box body etc. 2. Following machines are used to manufacture heavy parts of machine in HDMS : 1. Planer machine. 2. Boring machine. 3. Radial Drilling machine. 4. Ram type CNC Plano Milling machine. 5. Universal Milling machine. 6. Plano Milling machine. 7. VMC 800 M. 8. HMC 760. 9. KTM 760 10. Cylindrical Grinding machine. RAM TYPE CNC PLANO MILLING MACHINE Work table 2000 x 5000 mm X-axis travel longitudinal 5200 mm Y-axis travel cross 4200 mm Z-axis travel vertical 1100 mm Min. dis. b/w spindle face & table 400 mm Max. dis. b/w spindle face & table 1350 mm 42
  43. 43. Max. Load on table 10000 kg Rapid X & Y axes 7000 mm per min. Rapid Z-axis 5000 mm per min. Feed X, Y & Z axes 5-400 mm per min. Spindle tapper BT-50 T-slot (100 mm pitch) 28 H7 (1 No.) 28 H12 (10 No.) Spindle speed range vertical head 30-3000 rpm Spindle speed range spl. Angle head 30-1000 rpm Max. power vertical head 28 kw Max. Power spl. Angle head 15 kw Positioning accuracy X & Y axes +/-0.012 mm Positioning accuracy Z-axis +/-0.011300 mm Repeat accuracy X & Y axes +/-0.008 mm Repeat accuracy z-axis +/-0.005 mm Loading height 300 mm Table no. (2.4) Main Data of CNC Plano Milling Machine ESSENTIAL EQUIPMENT (STANDARD FEATURES) 1. Auto centralized lubrication. 2. Hydraulic power pack with chiller unit. 3. Coolant equipment. 4. Machine light. 43
  44. 44. 5. Special angular milling head. 6. Isolation transformer. 7. Electric cabinet with panel AC. 8. Chip conveyor with trolley. 9. CNC system model (SIEMENS 840D with PCU50). 10. Manual plus generator. 11. Rapid tapping facility. 12. Spindle cooling. 13. Coolant through spindle. 14. Pendant control station. VMC 800M (VERTICAL MACHINING CENTRE) Made by HMT Pallet size 860 x 860 mm X-axis travel 760 mm Y-axis travel 500 mm z-axis travel 450 mm No. of tools stations 30 Positioning accuracy 0.005 mm Repeatability +/-0.003 mm Operations name Turning, milling, drill & boring etc. Table length 800 mm 44
  45. 45. CNC system SIEMENS Table no. (2.5) Main Data of VMC 800 M HMC 760 (HORIZONTAL MACHINE CENTRE) Made by HMT Pallet size 760 x 760 mm X-axis travel 1300 mm Y-axis travel 1000 mm Z-axis travel 1000 mm B-axis travel 360 degree No. of tools stations 40 Positioning accuracy 0.010 mm Repeatability +/-0.003 mm CNC system SIEMENS Table length 760 mm Operations name Turning, milling, drill & boring etc. Table no. (2.6) Main Data of HMC 760 KTM 760 (KERNIAR TRAKER MARVEY) Made by KTM England Pallet size 760 x 760 mm X-axis travel 1300 mm Y-axis travel 1000 mm 45
  46. 46. z-axis travel 1000 mm B-axis travel 360 degree No. of tools stations 40 Positioning accuracy 0.01 mm Repeatability +/-0.003 mm Operations name Turning, milling, drill & boring etc. Table length 760 mm CNC system SIEMENS Table no. (2. 7) Main Data of KTM 2.2 ASSEMBLY DEPARTMENT 1. It is a part of industries where whole parts of machine are assembled and final product is prepared. Assembly Range of HMT Ajmer Grinding Machines: 1. CNC Double Disc Grinding Machine -GDS-15/22 2. CNC Grinding Center 3. CNC Center Less Grinding Machine -GCL-60/100/140/200 4. CNC Cylindrical Grinding Machine -CGM-125/150/175/22 5. CNC Surface Grinding Machine -PSG- 200 6. CNC Internal Grinding Machine -IG-100/150 7. Universal Tool and Cutter Grinder -GC-175/225 - GTC 28 TM Turning Centers: 46
  47. 47. 1. CNC Turning Center -STC 25/Pushkar 200 2. CNC Train Master Lathe -T 70 PC/100CNC 3. CNC Train Master Machining Center -VMC 200 TPC Other products: 1. CNC Syringe Needle Sharpening Machine 2. CNC Engine Value OD Grinding Machine 3. CNC Engine Value Seat Grinding 4. Keystone Grinding Machine for Piston Rings 5. Lens Grinding and Polishing Machine 6. Textile Cot Grinding Machine 7. All these products are also available with conventional hydraulic control. 1. A detailed description of some of these machines specification is given in the following pages. CRANK SHAFT GRINDER (GCS- 500) 47
  48. 48. Fig. no. (2.4) Crank Shaft Grinder Technical description of machine 1. Swing diameter -540 mm 2. Distance between centers -1800 mm 3. Max eccentricity of crank pins -130 mm 4. Max weight of crank shaft that may be loaded -120 kg. 5. Distance between chucks -1600 mm 6. Grinding wheel (dia X width X bore) -900x32x305mm 7. Max width of grinding wheel -50 mm 8. Min width of grinding wheel -25 9. Speed of wheel spindle -650, 780 rpm 10. Speed of work spindle -32,48,68,96 rpm 11. Length of table per one revolution 12. Weight of machine with standard accessories -16 mm Standard Accessories 1. Grinding wheel 48 -7000 kg
  49. 49. 2. Grinding wheel clamping flange 3. Puller of grinding wheel flange 4. Balancing arbor 5. Change pulley to be used. 6. Dial indicator for grinding wheel 7. Wheel dressing device (without diamond) 8. Two jaw marrow rest 9. Stand for rough setting of crank pins 10. Measuring plate for table and bed 11. Sit of weight for counter bad crank shaft 12. Plate for leveling of bed 13. Set spanners Technical description & principle of machine 1. The machine is intended for use in repair work shape. It mainly serves to regrind the crankshaft and journals of crank shaft. It can however be also used for normal grinding of shafts. The crank shafts are loaded in chucks. Name of machine parts 1. Wheel head 2. Work head 3. Tail stock 4. Clamping and counter balancing equipment 5. Table 6. Control board 7. Machining space of grinder 49
  50. 50. HYDRAULIC CYLINDRICAL GRINDER (K–130) Fig. no. (2.5) Hydraulic Cylindrical Grinder Technical description of machine 1. Height of centers -130 mm 2. Swing over tables -250 mm 3. Max. grinding length 4. Distance between centers -340 mm 5. With external tail stock -590 mm 6. Max. collet diameter -340 mm -30 mm Wheel 1. Grinding wheel : Max. & Min. dia. -340 & 240 mm 2. Std. & Max. width 3. Speeds 4. Rapid approach 5. Manual movement -40 mm 6. Automatic in feed at reversals -60 towards work-head -40 & 50 mm -1910 & 2120 rpm -45 mm -45 towards tail stock 50
  51. 51. Table 1. Max. travel -310 mm 2. Min. travel (automatic) -2 mm 3. Max swivel on either side -10 4. Speed infinitely variable -0.05 to 6 m/min 5. Dwell of reversal -0 to 0 sec. General 1. Motor wheel head -4 kw Oil pump -1.1kw Coolant pump -0.25 kw Work head -0.37 / 0.75 kw 2. Nett weight (approx) -1900 kg. 3. Shipping dimensions -2.18 x 1.6 x 1.34 m Salient features 1. It available in universal, production and plunge grinding models. 2. Variable table traverse with automatic infeed at table reversals the universal models are equipped with swiveling wheel head an built in provision for internal grinding 8 speed work head a single lever during production runs, controls table traverse work rotation, coolant flow and rapid approach of wheel head. 3. The production and plunge cut models are higher powered for high rates of stock removal with devices for batch production with infinite limits of tolerance. 4. Larger capacity coolant tank and hydraulic aggregate are separate from the m/c, minimizing the thermal effects on the structure. 51
  52. 52. Working principle of the hydraulic system 1. The pressurized oil is delivered by pump at a service pressure of 12 kg./cm2 and is governed by a high pressure relief value. Which is set by us before the machine leaves our works. 2. From the high pressure relief value the oil is taken to the distribution pipes in the m/c where the oil devides and the pressurized oil passes through appropriate control values to hydraulically operated tail-stock. 3. The circuit oil returns line pressure is also utilized for lubricating the table and wheel head guide ways. A pressure gauge is provided on the hydraulic power pack to indicate the pressure in the system. CNC Double Disc Grinding Machine – GDS–15/22 1. This machine performs the tasks of grinding the flat faces of components that are parallel and flat. 2. It’s an ideal system for plants requiring mass production at high rate of production. 3. Machines up to 4-axes CNC controls. 4. User- friendly grinding cycle by customized screen. 5. Preloaded antifriction guide ways for precise positioning and accuracy. 6. Super precision anti friction bearings for grinding spindles. 7. Direct driven ball screws with AC digital servo motor for linear axis. 8. Input resolution 0.0001 mm. Model GW size Power CNC GDS-15 455/500 mm 11/15 kw 52
  53. 53. CNC GDS-22 585/660/760 mm 18.5/22/37 kw Table no. (2.8) Main Data of CNC Double Disc Grinder Special executions 1. Variable speed drivers for grinding wheels suitable for different areas on opposite surfaces. 2. Machine can be equipped with rotary feeder, rotary magnetic plate through feeder, reciprocating feeder, swivel arm feeder, oscillating feeder as per the requirement. 3. Diamond wheels. 4. Post process guage. 5. Wheel positioner for grinding wheel. Fig. no. (2.6) CNC Double Surface Grinder CNC Grinding Center (GC 175/225) 1. This machine is a state of the art grinding solution for multipurpose grinding with single chucking. 2. It is capable of delivering ground finish to the job’s internal, external and flat surfaces. 53
  54. 54. 3. The machine has been designed to provide optimum grinding performance at lowest operating cost. 4. Lower cost with faster through put, reduced part handling and in process inventory. 5. Ideal for flexible production 6. User friendly grinding cycle by customized screen. 7. Significant reduction of non-productive time due to single loading unloading cycle. 8. Higher quality due to onetime clamping 9. Preloaded anti friction guide ways for precise positioning and accuracy of in feed slide. 10. Ultra precision GAMET taper roller bearing for work head to ensure circularity of 0.001 mm. 11. Auto dressing of all the wheels by single dresser. Specifications 1. Center height 175/225 mm 1. ABC 250/450/750 mm 2. G W power 5.5/7.5/11kw 3. Cutting speed 45/60 m/s 4. Work spindle 10-1000 rpm 5. Rapid traverse 15 m/min 6. Input resolution 0.0001mm Special executions 54
  55. 55. 1. H F internal grinding spindles. 2. MARPOSS inprocess gauging 3. Dynamic wheel balancer. 4. Air gap and crash controller 5. Linker scale for axes. Center Less Grinding Machine (GCL CNC) 55
  56. 56. Fig. no. (2.7) Function of GCL 1. This machine specially designed for grinding of cylindrical rods with accuracy of the order of 0.001 mm. 2. The main feature is the non requirement of holding the job between two centers. 3. The job is held between periphery of two cylinders with cylinder supporting the job and the other one grinding its surface. 4. Thus a lot of time is earned by deleting the need of clamping and centering of individual job pieces, as the loading/ unloading is also automatic. 5. Machine up to 8-axes CNC controls. 6. User friendly grinding cycle by customized screen. 7. Anti friction as well as hydrodynamic bearing for GW spindle. 1. Cantilever spindle as well as twin grip spindle for various wheel sizes. 2. Preloaded anti-friction guide ways for precise positioning. 3. Dynamic wheel balancer. Model GW size Power (kw) Job dia (mm) GCL60 350*100 mm 7.5 1.5-60 GCL100 500*200 mm 22 3-100(140) GCL140FGH 500*250 mm 22(30) 3-140 GCL 140 TG 610*305 mm 22(30) 3-140(225) GCL 200 TG 610*500 mm 37 10-200(250) Table no. (2.9) Main Data of Centre Less Grinder 56
  57. 57. Special Executions 1. Fully automatic loading and unloading system/ transfer line 2. Oblique dresser for OD and grinding simultaneously. 3. Diamond roller form dresser 4. Machine for grinding rear axle of heavy vehicles. 5. Motorized long bar grinding up to 6000 mm. CYLINDRICAL GRINDING MACHINE (CGM CNC) 1. This machine solve the need of high precision cylindrical grinding and proves useful for medium to large scale production centers. 2. The machine is centered type with variants designed accordingly. 3. Also an important function of the machine is angular head grinding general and defense engineering. 4. Machines up to 6-axes CNC controls. 5. User friendly grinding cycle by customized screen. 6. Anti friction as well as hydrodynamic bearing for GQ spindles. 7. Direct driven ball screws with AC digital servo motor for linear axis. 8. Input resolution 0.0001 mm Center Height 125/150/175/225 mm Admit between centers 300/500/800 mm GW size 400/500/630 mm Power 5.5/7.5/11 kw Table No. (2.10) Main Data of CGM Special executions 57
  58. 58. 1. 3-axes CNC Camshaft grinder with SINUMERIK 840d CNC system. 2. 4-axes / 6-axes CNC Crankshaft journal machine with complete automatic cycle. 3. 4-axes Syringe Needle Grinding machine. 4. Grinding of hard chrome plated component. Internal Cylindrical Grinding Machine ( 1G-100/150) Fig. no. (2.8) Internal Cylindrical Grinding Machine 1. Providing high cutting speeds up to 60 m/sec, it completely solves the need of grinding o tapered bores of bushes, gears, con rods etc. 2. Preloaded anti friction needle roller guide ways for both the axes. 3. Word head roller spindle is supported on precision GAMET taper roller bearing for high running accuracies and rigidly. 4. Infinitely variable speed for the work head. 5. Hydraulically operated swing type grinding wheel dresser. Bore Grinding Range 4-150 mm Max. Grinding Depth 150 mm 58
  59. 59. Max. Swing In Chuck 350 mm Input Resolution 0.0001 mm Max Cutting Speed 60 m/sec Work Spindle Speed 10-1000 rpm Table no. (2.11) Main Data of Internal Grinder Special executions 1. Shoe center less grinding facility for bore and track grinding of bearing races. 2. Air gap eliminator and crash controller. 3. Automatic loading and unloading. 1. Some other machine which are also assembled by HMT Ajmer are as under: 1. GTC 28 ( Tool Cutter Grinder ) 2. CSG 500 CNC ( Crank Shaft Grinder ) 3. GCP (Cylindrical Grinder For Production ) 4. GRC ( Roller Camber Grinder ) 5. GSF 140 ( Surface and Face Grinder ) 2.3 HEAT TREATMENT 1. Heat treatment may be defined as an operation of heating of metals in the solid state to induce certain desired properties into them. It is generally employed :- 2. To improve machinability. 3. To refine grain size. 4. To relieve the stress of the metal induced during cold or hot working. 5. To improve electric & magnetic properties. 59
  60. 60. 6. To increase resistance to wear, heat & corrosion. 7. To produce a hard surface on a ductile interior. HARDENING OR TOUGHENING OPERATION PROCEDURE:1. Study the drawing and process sheet and take work instruction whenever required from supervision. 2. Set the temperature of furnace as per requirement of the component vise. 3. Ensure the components are dry. 4. Ensure the components are properly wired as per work instruction. 5. Ensure that the component is preheated as per component vise. 6. Component should be put slowly in salt bath furnace and ensure that the component are not touching electrode of the furnace. 7. Ensure proper quenching media and temp as per component. 8. Do not put component in water from quenching bath directly. 9. Check first piece for hardness, distortion and soft porting before carrying out bath. STABLISING OPERTION PROCEDURE:1. Wire the component as per instruction. 2. Use bucket/fixture as per requirement of component. 3. Load the component in the furnace taking care that they do not strike with furnace. 4. Ensure that the components are fully dipped in oil. 5. Set the temp between 130 to 170 deg. C and put ‘on’ the furnace. 6. Hold on temp for 4-6 hours depending on the section of component. 7. Put ‘off’ the furnace after completion of soaking time. 8. Cool furnace air to room temp. 9. Cut wire/remove from bucket or fixture and clean. STRESS RELIEVING OPERTION PROCEDURE:60
  61. 61. 1. Ensure that the temp of furnace <200 deg. C 2. Load the component taking care that they do not strike each other as well as furnace refectory and heating elements. 3. Set the temperature of furnace as given below :1. Steel 550-560 deg. C 2. Grey Iron 540-564 deg. C 3. SG Iron 565-600 deg. C 4. All Copper Base Casting 250-330 deg. C 5. Put ‘ON’ the furnace 4. Soak for one hour plus one hour for every additional 25mm cross section at temp. 5. Put ‘OFF’ heating and cool in furnace. 6. Remove Component. NITRIDING OPERATION PROCEDURE:1. Preparation for nit riding :- 1. De greases the component by cleaning the surface with thinner. 2. Etching:- 3. Prepare 10% HCL solution in water dip the component in solution for 15 to 20 min clean the component thoroughly with running water wipe off water by clean cloth. Hang to the fixture. 4. Loading:- 5. Loading the fixture along with tool piece in nitriding furnace tighten the lid of furnace to make leak proof checking the leakage with PH paper. 6. Nit riding :- 7. Allow ammonia gas to flow in line after 156 min. Switch on the furnace and set the temp to 510+5 deg. c maintain the % of ammonia dissociation to 25-30%. 8. Switch off the furnace after 72 hours. Remain charge then temp comes to 100-120 degree centigrade 61
  62. 62. ANNEALING OPERTION PROCEDURE:1. Ensure that the furnace temp < 200 deg. C. 2. Load the component taking care that they do not strike with each other as well as furnace refectory and heating elements. 3. Set the furnace temp as given- for steel having carbon % up to 0.8. 4. Put ‘ON’ the furnace 5. Soak for one hour plus one hour for every additional 25mm.cross section at temp. 6. Put ‘OFF’ heating and cool in furnace. 7. Remove Component. BLACKENING OPERATION PROCEDURE:1. Degrease the component. 2. Ensure that the components are rust/paint free. 3. Prepare blacking batch 1. Water =50% by weight 2. Black = 15 salt 48% by weight 3. Black D= 2% by weight 4. PRECAUTION: - Always add salt to water and not water to salt while pouring bath. 4. Heat liquid to boiling. 5. Hang component free from all of the pot and each other. 6. Check for blackening result it components are getting iron and water. 7. Remove the components. 8. Oil the components. 2.4 METROLOGY DEPARTMENT 62
  63. 63. 1. One of the most important part of production process is measuring and inspection. 2. All the components produced on machines are impacted after each step using sophisticated techniques of measurement. 3. The accuracy is maintained at the level of microns. 4. To keep up such level of quality control metrology section becomes quite important part of the unit. 5. It consists of very sophisticated and accurate machine that can measure at the level of one micrometer and even less. 6. The temperature of measuring and standards room is set constant used in this section are:- CO-ORDINATE MESURING MACHINE Make :Carl/is Lena company Germany. Range of measurement :100mm * 200 mm. Least count :1 micron. System : Optical. Applications : measuring threads profiles, taper indexing. UNIVERSAL MESURING MACHINE (MUL 1000) Make :Sockets Genevieve (Swiss). Range of measurement :100 mm. Least count :0.5 micron. System :Optical. Applications :measuring data of internal and external threads length of precision components. 63
  64. 64. TOOL MAKERS MICROSCOPE 1. The working of this machine is like that of universal measuring machine except that:- Least count :10 microns. System : mechanical. ROUNDNESS TESTING MACHINE (FORMTESTER MMR4) 1. The machine consists of a very accurate round table and a senor printer attached that gives a quantitative idea about the machines plot profile of the cylindrical. Least count :10 microns. System : mechanical. Applications :to check the roundness cylindrical parts after grinding etc. SURFACE ROUGHNESS TESTING MACHINE (PERTHOMETER) Make :Perthen Germany. Least count : 0.5 micron. System :Pneumatic & CNC. 1. An important feature of above two machines is that the macro errors on the surface can be filtered automatically. 2. Along with these highly technical accurate machines some other simple best equally important machines and apparatus are also used in the metrology for example:- 1. Dial gauges (make mistook Japan). 2. Slip gauges (set M 112). 64
  65. 65. 3. Height gauges (make mistook Japan). 4. surface plates cast iron and graphite. 2.5 MAINTENANCE DEPARTMENT 1. It is a part of industry that provides lubrication and coolant to the machine components and maintains all machines of industry. 2. The maintenance of machine is following three types 1. Break Down Maintenance 2. Preventive Maintenance 3. Reconditioning Maintenance Break Down Maintenance 1. Break down maintenance is done when the machine stop suddenly due to sudden breakdown during the operation. 2. In this type of maintenance only those parts are replaced which during the operation. 3. This type of maintenance takes less time. Preventive Maintenance 1. This type of maintenance is done to prevent the machine from breakdown maintenance. 2. In this maintenance every machine is tested and repaired after a fixed period either it faults or not. 3. Lubrication of machine is done at every part. Reconditioning Maintenance 65
  66. 66. 1. Only old machines are taken in field of reconditioning complete machine is dissembled and different faults are repaired. 2. The old parts are changed by new parts and those parts. 3. This can be repaired by some operations they are repaired on the machines and then fixed at right place. 4. Lubrication of machine is also done. 5. After all these process machine is assembled and tested. Important of Maintenance 1. To maintain the accuracy of machine 2. To prevent the danger which come in account by sudden breakdown of any parts 3. For the safety of operator. 4. To maintain the efficiency of machine 5. To keep running the machine continuously without only broke- down etc. Sequence of Maintenance 1. Disassembly 2. Washing 3. Fault finding 4. Assembly Disassembly 1. In every type disassembly is maintenance is little change. Disassembly of the machine depends upon the type of maintenance. 2. Break down maintenance – In this maintenance only those part are disassembled which are damaged and other part are not touched 3. Preventive maintenance – In this type of maintenance all parts of machine is disassembled after a fine time either those are damaged or not. 66
  67. 67. 4. Reconditioning maintenance – This type of maintenance dissemble of machine is same as preventive maintenance but it’s done anytime. This maintenance is done only with old machine. Washing 1. After the process of disassemble washing process in done for washing purpose kerosene oil is used every disassembled part is washed. Fault Finding 1. After washing the disassembled part fault is finding and try to remove it if it is not possible to remove it then those part is changed. Assembly 1. After all these process every part is assembled at right place. LUBRICATION 1. Lubrication is very important process of maintenance. 2. For every work other lubricant is used. 3. Some lubricants which are used for lubrications is follows:- (a) Spin - 5 Viscosity – 5 Used In – Grinding Machines, Wheel Head, Work Head. (b) Spin - 12 Viscosity – 12 Used In – Spindle on high speed when clearance is 10 microns. (c) Spin - 32 Used In – Hydraulic Machines, Column, Gear box, Milling machine, Cutter lubrication. 67
  68. 68. (d) Spin - 68 Used In – Lubrication of Grinding Machine, Hydraulic Tank, Lathe Machine. (e) Ser. Way 68 Used In – Guideways of Grinding Machine and mostly used for K-130 (f) S. Way 220 Used In – Guideway (g) S-Mesh 320 Used In – Planner Pockets (h) Servo System H.L.P. - 68 Used In – Hydraulic Tank of Air Compressor. (i) S-Cut 345 Used In – Cutting Oil, Gear Hobbing coolant. (j) Flushing Oil Used In – When the machine parts are cleaned then its all oil is taken out and flushing oil is filled for oil level for 2 to 3 days. By this process all corners are cleaned. (k) E.P.90 Used In – Distributor (l) S.A.E. - 40 Used In – Hydraulic Tank Lifting Machine (m) Kerosene Used In – As a direct cutting oil in super finishing machine. (n) Grease 68
  69. 69. Used In – Bearings (o) Sherol - h Used as – Coolant Oil Colour – White Formula – (Water + Oil) 40 : 1 2.6 FOUNDARY DEPARTMENT 1. In faundry department castings of different parts of grinding machine like bed, body, work head & wheel head are prepared by using moulding box, pattern & moulding materials. FOUNDRY TOOLS AND EQUIPMENTS 1. There are large number of tools and equipments used in foundry shop for carrying out different operations such as sand preparation, molding, melting, pouring and casting. 2. They can be broadly classified as hand tools, sand conditioning tool, flasks, power operated equipments, metal melting equipments and fettling and finishing equipments. 3. Different kinds of hand tools are used by molder in mold making operations. 4. Sand conditioning tools are basically used for preparing the various types of molding sands and core sand. 5. Flasks are commonly used for preparing sand moulds and keeping molten metal and also for handling the same from place to place. 6. Power operated equipments are used for mechanizing processes in foundries. 7. They include various types of molding machines, power riddles, sand mixers and conveyors, grinders etc. 69
  70. 70. 8. Metal melting equipment includes various types of melting furnaces such as cupola, pit furnace, crucible furnaces etc. 9. Fettling and finishing equipments are also used in foundry work for cleaning and finishing the casting. 10. General tools and equipment are used in foundry are discussed as under. HAND TOOLS USED IN FOUNDRY DEPARTMENT 1. The hand tools used in foundry department are given below:- 1. Hand riddle. 2. Shovel. 3. Rammers (Hand, Peen, Floor & Pneumatic Rammers.). 4. Sprue pin. 5. Strike off bar. 6. Mallet. 7. Draw spike. 8. Vent rod. 9. Lifters. 10. Trowels. 11. Slicks. 12. Smoothers. 13. Swab. 14. Spirit level. 15. Gate cutter. 70
  71. 71. 16. Gaggers. 17. Spray-gun. 18. Nails & wire pieces. 19. Bellows. 20. Clamps, cotters & wedges. FLASKS 1. The common flasks are also called as containers which are used in foundry department as mold boxes, crucibles and ladles. MOULDING BOXES 1. Moulding boxes are used in sand maulding following two types:- 1. Open moulding boxes. 2. Closed moulding boxes. CRUCIBLE 1. Crucibles are made from graphite or steel shell lined with suitable refractory material like fire clay. 2. They are commonly named as metal melting pots. 3. The raw material or charge is broken into small pieces and placed in them. 4. They are then placed in pit furnaces which are coke-fired. 5. In oil- fired tilting furnaces, they form an integral part of the furnace itself and the charge is put into them while they are in position. 6. After melting of metals in crucibles, they are taken out and received in crucible handle. 71
  72. 72. 7. Pouring of molten is generally done directly by them instead of transferring the molten metal to ladles. 8. But in the case of an oilfired furnace, the molten metal is first received in a ladle and then poured into the molds. LADDLE 1. It is similar in shape to the crucible which is also made from graphite or steel shell lined with suitable refractory material like fire clay. 2. It is commonly used to receive molten metal from the melting furnace and pour the same into the mold cavity. 3. Its size is designated by its capacity. 4. Small hand shank ladles are used by a single foundry personal and are provided with only one handle. 5. It may be available in different capacities up to 20 kg. 6. Medium and large size ladles are provided with handles on both sides to be handled by two foundry personals. 7. They are available in various sizes with their capacity varying from 30 kg to 150 kg. 8. Extremely large sizes, with capacities ranging from 250 kg to 1000 kg, are found in crane ladles. 9. Geared crane ladles can hold even more than 1000 kg of molten metal. 10. The handling of ladles can be mechanized for good pouring control and ensuring better safety for foundry personals workers. 11. All the ladles consist of an outer casing made of steel or plate bent in proper shape and then welded. 12. Inside this casing, a refractory lining is provided. 13. At its top, the casing is shaped to have a controlled and well directed flow of molten metal. 14. They are commonly used to transport molten metal from furnace to mold. POWER OPERATED EQUIPMENTS 1. Power operated equipments used in foundary department are given below:72
  73. 73. 1. Moulding Machines. 2. Sand Slingers. 3. Core making & core baking equipments. 4. Power riddles. 5. Mechanical conveyors. 6. Sand Mixers. 7. Material Handling Equipments. INDUCTION FURNANCE 1. Induction Furnace is used for melting the metal. 2. There is tilting head in furnace for pour out the melting metal. 3. To get more special properties following metal is added. 1. Ferro Manganese. 2. Ferro Silicon. 3. Ferro chromium. 4. Carbon (as required). 5. To remove slag from the melting metal silica sand is mixed in the furnace. 6. To get more fluidity of metal elino cline mixed in the melted metal. 73
  74. 74. Fig. no. (2.9) Induction Furnace Melting Process of Cast Iron PARTS OF GRINDING MACHINE PREPARED IN FOUNDARY DEPARTMENT OF HMT AJMER 1. Following parts of grinding machine are prepared in foundary department of HMT Ajmer:- 2. Column. 3. Bed. 4. Drive Ring. 5. Clutch Cylinder. 74
  75. 75. Fig. no. (2.10) Column Fig. no. (2.11) Bed Fig. no. (2.12) Clutch Ring Fig. no. (2.13) Clutch Cylinder 75
  76. 76. Fig. no. (2.14) Production Flow Chart CHAPTER 3 CORPORATE PROFILE 3.1 SHAFETY MEASURES 76
  77. 77. 1. Do not wear loose garments they got caught leading to accidents. 2. Either roll up your uniform releases or bottom up the cuffs. 3. Always wear uniform and shoes they are for your safety. 4. Long and unruly hair is always dangerous particularly when working near rewbeing parts or machines or cutters. 5. Ring, bracelets and watches can get caught in the machinery. Do not wear them when on duty. 6. Be calm and patient while working. A disturbed mind will invite trouble and haste makes waste. 7. While walking watch your steps. 8. Be watchful of blind corners, you may be caught in the wrong way. 9. Do not ailment the attention of others or do not got yourself alleviated by other while working. 10. Don't carry to many tools/instruments. 11. Put the work area clean dry clip free and free of obstructions. 12. Watch out for jobs, brass, rods, etc. which protrude form for vice and machines it my hit you resulting in accident. 13. Use personal protective equipment and safety drives. 14. Do not touch/operate equipment unless you are authorized. 15. Do not leave on the machine. 16. Lubricate the Machine as is required. 17. Do not clean the machine parts with hearts, bars use cloth, cotton, wash brush. 18. Do not repair or try to adjust or repair any equipment when in motion. 19. Ensure all machine controls of the machine are accessible to you. 77
  78. 78. 20. Do not attempt to change the speed of the machine when in motion. 21. Don’t keep unwanted instruments/tools on the machine bed. 22. Use the right tools for the right join the right way. 23. Use the proper speed. 24. Use the proper feed. 25. Use the proper depth of cut 26. Do not use broke or blunt or damaged tools. 27. Do not walk or work under suspended loads. 28. Do not blow air from your mount to clean the components. 29. Keep yourself at a safe distance from the cutting tool in motion. 30. Don’t touch with pressure the job when it is hot or in motion. 31. Switch off machine immediately in anything goes wrong. 32. For any injury whether small or big got first aid first. 3.2 FUTURE VISION 1. Looking to the strategic role being played by the Ajmer & other HMT-MTL Units in infrastructure & industrial development of the country and contributing in Defence & other strategic sectors like Atomic Energy, Space, etc; Govt. is considering Revival Package for all HMT Units. 2. Plan envisages upgradation and addition of facilities in Shops, Information Technology, etc. Ajmer Unit is likely to get support of Rs.10-12 crore for new Plant & Machinery, reconditioning/upgradation of existing Plant & Machinery, Information Technology, Tooling/Productvity Aids, Measuring/Inspection facilities and Foundry Division. 78
  79. 79. 3.3 HMT CORPORATE VISION Fig. no. (3.1) HMT Corporate Vision 3.4 HMT CORPORATE MISSION 1. To establish ourselves as one of the world’s premier companies in the engineering field having strong international competitiveness. 2. To achieve market leadership in India through ensuring customer satisfaction by supplying internationally competitive products and services. 3. To achieve sustained growth in the earnings of the group on behalf of shareholders. 3.5 HMT CORPORATE OBJECTINES & GOALS 1. To encourage the modernisation of Indian Industry through the supply of engineering goods and services of world class excellence. 2. To maintain technological leadership through continuous efforts to update product technology and manufacturing methods. 79
  80. 80. 3. To globalise our operations by developing a mix of international markets and businesses. 4. To ensure a satisfactory return on capital employed, to meet the growth needs and the aspirations of our stakeholders. 5. To present an active, pleasant and productive working environment. 3.6 CONCLUSION 1. It was a wonderful experience for all of us having our first industrial exposure at HMT-Machine tools Ltd. 2. Realized the experience of team work. 3. Get the knowledge of a production company 4. Get the knowledge of working of machinery in the company. 5. Get the little knowledge of CNC machine working. 6. Good experience of the production of machine tools. 80
  81. 81. References [1] Catalogue of Hindustan Machine Tools Limited Ajmer. [2] Production Technology by R. K. Jain. [3] Introduction to Basic Manufacturing Process & Workshop Technology by Rajender Singh Professor, Department of Mechanical Engineering CRSCE, Murthal, Haryana. [4] www.hmtindia.com. [5] www.Wikipedia.com. [6] Catalogue on Grinding Wheel. 81
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