Pattern material : wood and thermocol
Pattern handling is done using pillar crane.
Lacquer coating is done on pattern for easy
Fresh : used = 3 : 2
Yellow sand coating is used for core, brown
sand coating for mould.
The molds of size from 1000*800 mm to 3500*2500 mm are
prepared by the machines available
Use of Fast loop molding techniques supplied by OMEGA, U.K.
The fresh and used sand in proportion of 1 : 3.
During winter and monsoon heating of mold is done to reduce setting
Mixture of sand and resin is used.
Resin : GHA FUR 909. Imported from GARGI Foundry chemicals,
Pouring process for these graded materials is accomplished
on mechanized pouring and cooling lines equipped with 91
The cores are placed in mould cavity with the help of core
prints and supporting chaplets.
The molten metal is taken to the mould by using overhead
crane at higher temperature around 1700° C.
Then poured metal is allowed to cool for certain period of
For melting, Jyoti has installed 3 tonnes capacity Induction
This furnace is supported by 10 tonne induction holding
Graded castings are produced as per IS210 standard of
different grades-FG260, FG300, SG400/50, SG600/3, etc.
All batches of molten metal are tested for their chemical
Mould is taken to the Mould Breaker (Maxtech).
Knock-off process is done with pneumatically operated
vibrator and the wasted sand is re-cycled through sand
Remaining sand is separated by labours from casting.
CASTING PROCESS CONT.
Heat treatment and Shot Blasting
Casted components thus produced are relieved of stresses ensuring life time
accuracy of CNC machines in a gas fired furnace which has a capacity to process
castings of 20MT in a single batch.
After that cast product is taken to Shot Blasting unit for components weighing less
than 2 tonnes.
Finally the castings are protected with superior primer coating and chemicals.
Component is tested first
Visual testing and Ultrasonic testing
machining is done using hand grinders
Sand storage area is situated at backside of the foundry unit.
Sand testing, raw material testing and scrap testing is done
Sand testing consists of three tests:
SIEVE testing machine
indicates mesh number of sand particles.
facing sand is in between 45-55
backing sand this range is 65-75
Clay content - clay washer
Acid Demand Value
Acid and resin content in sand sample
For raw material and scrap testing, microscopic analysis is
done using spectrometer.
•900MT per month to 1,500 MT per month and for that addition of 2
melting furnace of 5MT capacity.
•A sand mixer : capacity of 45 ton/hour for large castings up to 20 tons.
•Rs.196.23 million for expansion of foundry Rs.90.75 million for the civil
works Rs.105.48 million for purchasing machines.
Machining shop of Jyoti CNC Automation pvt. Ltd. Is located at unit-3 of
Machining unit majorly consists of:
Raw material inlet & dispatch area
A quality control and measurement laboratory.
•Jyoti has developed sophisticated design, manufacturing and assembly
capabilities, to meet the needs of today’s industries.
•The components made from casting process, are machined to give them accurate
size and shapes.
•For that CNC machines are used. Following operations are carried out on raw
parts to give them desired finish and accuracy:
PARTS TO BE MACHINED
Following parts are machined at machining unit:
•Jigs& fixture parts
•Main spindle shaft
•Bed of CNC machines
Raw parts are imported either from the company foundry (a major portion of
needed parts for CNC machines is cast in the foundry located in company
itself) or purchased by order from outside means.
Main attractions of machine shops at Jyoti:
•Jyoti has five phase CNC machining centre which contributes to the
excellence towards the quality & productivity through head changer and multi
•The finest Horizontal Machining Center in mother machineries assets are
capable of producing accurate components with high productivity through
double pallet system.
•One of the best Horizontal Machining centers in our range of mother
machineries, is the one having pallet system with 60 tools Automatic Tool
•Almost all the machines use programming controller manufactured by
‘Siemens pt. Ltd.’
MACHINE COMPANIES AND
MODELSAlthough a significant amount of mother machinery at machining unit is from foreign
companies, many of the machines are manufactured by Jyoti itself.
Some other manufacturing companies of mother machines are:
Huron pvt. Ltd. – Germany
Here are some model no. of machines used at machining shop:
• VMC -640
MULTI TASKING TURN-MILL
Various possibilities of configuration with
spindles and turrets is developed to equip the
•Main advantage :
Simultaneous machining of several parts and
various operations in order to obtain significant
This types of machines are basically
4-axis Horizontal Machining Centers
with Rotary Table (TRIM) with APC.
It contains machines of HMC series.
•Jyoti CNC machining department also consists of two grinding shops.
•All the critical parts are finished using various grinding CNC machines.
•One more feather in cap is the unique machine – the ultimate solution in
cylindrical grinding. It gives finest accuracy finishes to the machine parts that
is in perfect tune with mission of the company.
•Grinding Shops consists of:
• Cylindrical grinding CNC m/c
• Rotary horizontal-spindle surface grinding
• Rotory vertical-spindle surface grinding CNC m/c.
QUALITY CONTROL &
MEASUREMENT LAB•Machining department of Jyoti is innovatively facilitated with modern accurate testing
and measurement laboratory.
•Jyoti believes in the quote “Quality is avoidance of financial loss to society after the
product is shipped.”
•Before leaving the plant, the Jyoti CNC machine is passed through a series of quality
•Jyoti has established a system of quality in line with the ISO 9001:2000.
•Jyoti has enhanced quality testing and measuring capabilities that incorporate
sophisticated measuring equipments like
• Co-ordinate measuring machine (CMM)
• Roundness testing machine
• Profile projector
• Various gauges and test charts
MACHINE•3D Coordinate measuring machine which is
compatible for providing increased accuracy and
measuring speed that helps to increase the
quality of processes and products. CMM is also
used for Reverser Engineering.
MACHINEJyoti uses the state of art roundness
testing to check Cylindricity, Circularity,
roundness, concentricity and perform
piston analysis of machine parts.
•Quality testing instrument for checking the
flatness, straightness, angle and squareness
of machine parts through Precision electro-
optical measurement programs in
conjunction with a DA series autocollimator
& reflector having an interface with the
computer. Its dual axis digital systems are
capable of measuring accuracy in terms of
fraction of micro.
ASSEMBLY LINES & TYPE OF
Assembly unit is mainly divided into three lines:
3)VMC line including ATMs
Fixed position layout is used to assemble different CNCs. In this, after
fixation of leveling points, all the other mountings are done at same position.
The sub-assembly required in the machinery is
carried out in different department. The requirements
of customers are written on the notes stick to the
machine. After completion of mounting, the machine
is carried to dispatch unit.
Head-stock: It supports chuck
and its mechanism. It posses
system which clamps and de-
clamps of work-piece.
Tail-stock: It possesses the supporting elements.
Bolt-screw : Bolt-screw always posses bolt-nut which converts its
rotating motion to linear motion
Turret assembly : It holds tools to work on job. Generally it
has ten to twelve tools.
Electrical panel : It contains lots of electrical and electronic devices
which leads it to automatic.
Motors : There are four different motors. One for revolving of chuck,
another two for bolt-screw and last motor for revolving of turret.
Pumps : There are two pumps in DX-250 and DX-150. One is for
hydraulic oil transmission and the other is for coolant circulation.
Coolant circulation system : This system circulates coolant which
aims to cool down the working area and also directs the removal of
Hydraulic pressurized oil system : There is oil sump which contain
pressurized oil and one pump for circulation. One most important
component for hydraulic system is solenoid valve. There are two
valves require for it. Each solenoid valve is electrically controlled for
Lubrication system : This system is require to reduce friction and
3 Point leveling system : It require for leveling of machine to the
floor which maintain minimum vibration.
Outer sheet metal body : It provide safety to user and gives good
Operating numeric control system with screen : It operates
automatic system and also provide connection to PC for data
STEPS OF ASSEMBLY
First step of assembly is to do 3
point leveling by spirit level and then
tight the other 3 points.
•Second step is scrapping to remove the paint from guide-
ways for fitting alum. Then worker clean the surface by
diesel and air cleaner.
•Then fit the alum and it is supported by eccentric head
bolts. For this process worker is use keys and “Mac Master”
which is torque controlling equipment with minimum effort.
•Then worker uses spray-cleaner to remove dust from it and
mount blocks on it. Then worker does “Auto-collimator Test”
for measuring allowances.
• This is very important test as saddle is mounted on it. So,
it must be perfect.
•Same process carried out for alum of saddle and then bolt-
screw is mounted on saddle with two bearing and its run-
out testing is carried out and then again top and side of
bolt-screw is maintained in tolerance limit with help of dial-
•Dial gauge indicator is most important testing device for
which minimum reading is 2 µm and 10 µm for different
•After that saddle is mounted on CNC bed with the help of
hoists available in assembly unit. Then bolt-screw is
mounted on CNC bed for z-axis. Than the same process is
carried out as it is carried out for bolt-screw of saddle. Then
lock-nut is mounted on it.
•After that, worker fixes the alum on tail-stock’s guide-ways. Then
cleaning process is carried out and preparing alum with paint for
mounting of surface plate on it.
•As surface plate is not accurately machined, scrapping is carried out
till it slides thoroughly on alum.
•During this process, the other worker mounts head-stock on its
•After that, chuck, pulley, motor and spindle is mounted on head-
stock. Then mandrel is mounted on chuck and its alignment test is
•Than, squareness test is carried out for x-axis bolt-screw.
•Center line of head-stock and tail-stock must be co-linear, If
not then it is carried out with the help of height-gauge.
•After that telescopic cover is mounted on saddle to cover
sliding mechanism from coolant.
•Subsequently, hydraulic oil system is fitted with its all
mountings like oil sump with nitrogen gas accumulator,
solenoid valves, pipe.
•After that sheet metal body(cabin) is fitted. For preventing
leakage of coolant, copper stripes is rigidly fitted with silicon
•Then electric panel board is fitted to machine and numeric
control operating system is mounted on it with colourful
screen and data transmission slot is given for data
transmission with PC.
•Thus, mounting of CNCs are done.
DIFFERENT TESTS AND
•First test is Auto-collimator which is performed for perfect alignment of L.M.
with base. In this process, Auto-collimator ,a light sensing device, is used.
For final fixing of L.M., they provide 5 µm for side and 10 µm for top
•Then alignment test for bolt-screw is carried out by dial gauge. In this
process tolerance must be less than 10 µm. With the use of mandrel ,
alignment test of head-stock with tolerances of 10 µm is carried out.
•For squareness test, sq. gauge is required for alignment test of saddle’s
bolt-screw after mounting of pulley and head-stock motor.
•For final inspection of whole assembly, laser testing and ball-bar
testing is carried out. These instruments are very costly and precise
in its function.
•In laser testing, they test the pitch of bolt-screw for different cycles
with different interval of space and compare graph of forward and
reverse half cycle.
•In ball-bar testing, different type of errors is tested and eliminated as
maximum as possible.
•After that trial operation like turning, facing, boring is carried out on
SHEET METAL OPERATION
1.LASER cutting machine
•Trumpf machine of Germany having Laser cutting
• It is semiautomatic type and only loading and
unloading of sheet is done, all other operations are
done by machine itself according to program given to
SEQUENCE OF OPERATION
•First sheet is cut by Laser cutting CNC machine which cuts the
sheet to the required size.
•Then sheet is bent to the required shape in bending machine.
•After bending spot welding is done to attach number of sheets
•Before dispatching the sheet to the assembly unit grinding of
sheet is done.
It is mainly divided into two parts:
1) Pre treatment + CED coating
2) Powder coating plan
1)Pre treatment + CED coating
- It consists of 7 tanks pre-treatment process followed by CED
- The process of pretreatment coating is tabulated below:
Powder coating plant
- This unit consists of a powder coating oven.
- There are 4 powder coating booth in line of different colors.
Paint shop delivers sheet metal materials duly powder
coated or painted with CED primary coating and
casting are delivered with CED primary coating and
followed by baking.
RESEARCH & DEVELOPMENT
•Jyoti has developed a well versed and a versatile R & D
centre to keep up the company with the international trends
towards the automation and manufacturing excellence.
•The exclusive R & D centre is been established to design and
develop technologically advanced world class machines for
the better quality, reliability & productivity to cater to
sophisticated Aerospace, Automobile and Defence
applications where high level of accuracies and reliabilities
•The Active R & D team of Jyoti has achieved outstanding
success by developing TPM (Total Productive Maintenance)
friendly machines, CNC Machines with Linear Technology of
higher dynamics and productivity, in house developed
software like “POTS” etc.
•R & D activities here are conducted through a young team of
87 technocrat professionals facilitated by latest softwares, &
assembly/testing and calibration equipments from world
•The R & D Centre of Jyoti is been Dedicated to an ancient
design genius Leonardo Da’ Vinci who designed the First
Lathe machine in early of 16th Century.
•Training and Development holds a special attention and place
at Jyoti. Even CNC Operators are equivalent to Service
Engineers after undergoing few years of Training and
Development activities that they provide. Each new employee
is brought up speedily so that he can be productive as quickly
•They are arranging various training programs which can help
them to learn and practice their field work in depth.
All the new employs are trained in their respective fields. Few are mentioned
2. Machine Shop
3. Designing and Development
4. Electrical Department
5. Quality Control
6. Workers/Supervisors Development Program
7.Industrial Safety & Use of Fire Fighting Tools
8. Seminar on "Energy Conservation“
9. Re-Information of ISO-9000/2001 & SAP
They firmly believe in old saying
"Give m an a fish; yo u fe e d him fo r a day,
Te ach him ho w to fish; yo u fe e d him fo r a
life tim e . "