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A
VOCATIONAL TRAINING REPORT
ON
“SIMPLEX CASTING LIMITED”
UNIT-3
Submitted to
CHHATTISHGARH SWAMI VIVEKANAND TECHNICAL UNIVERSITY, BHILAI
in the partial fulfillment of the requirements for the award of Degree
of
Bachelor of Engineering
In
Mechanical Engineering
By
SURENDRA KUMAR
Roll no. 3433714028
Department of Mechanical Engineering
Bharti college of Engineering and Technology
Pulgaon Chowk Durg, C.G.
Pin: 491001
Session - 2016-2017
TRAINING CERTIFICATE
2
PREFACE
I have made this vocational training report file on the topic manufacturing
process in short , CNC Machine in detail and fabrication welding process;I
have tried my best to elucidate all the relevant detail to the topic to be included
in the report. While in the beginning I have tried to give a general view about
this topic.
My efforts and wholehearted co-corporation of each and everyone has ended on
a successfulnote. I express my sincere gratitude to …………..who assisting me
throughout the preparation of this topic. I thank him for providing me the
reinforcement, confidence and most importantly the track for the topic
whenever I needed it.
3
ACKNOWLEDEMENT
We take an opportunity to express our sincer gratitude to the peoples who have
been helpful in the successfulofour industrial training and this project. We
would like to show our greatest apparition to highly esteemed and developed
technical staff of the SIMPLLEX CASTING LIMITED UNIT-3. We are highly
indebted to them for their tremendous support and help during the collection of
our training and project.
4
CONTENS
 Inroduction of componyprofile………………………
 Manufacturing process………………………………
 Machine shop…………………………………………
 Machining process…………………………………
 C.N.C machine shop…………………………………
 C.N.C. MACHINE………………………………….
 Meaning of CNC………………………………….
 Part of CNC………………………………………..
 CNC machine- input, process, output………………
 Advantages and disadvantages of CNC……………
 Industial flow chart…………………………………
 Fabrication shop ……………………………………
 Welding process………………………………………
 Types of welding………………………………………
 Arc welding ………………………………………….
 Gas welding……………………………………………
 Gas cutting ………………………………………..
 Weld joint……………………………………………..
 Types of weld joint…………………………………
 Branzing and soldering……………………………..
 Heavy fabrication shop……………………………..
 Conclusion ………………………………………….
 Referance……………………………………………
5
INTRODUCTION
Company Profile:
Simplex Castings Limited (SCL) started as a Partnership firm in the year 1970 as a small
Grey Iron Foundry. Subsequently, it was converted into a Private Limited Company
registered under the Indian Companies Act, with its registered office at Mumbai India, on 30
Jan 1980. The Company went Public in 1993. It's Shares are listed in Mumbai Stock
Exchange. SCL is a well managed dividend paying company making profit since it's
inception.
SCL has two Units in the state of Chhattisgarh (mineral rich State of India). One unit
is situated at 5 Industrial Estate, Bhilai and the other at Urla Industrial Estate, Raipur. The
company is engaged in manufacturing of Heavy Engineering Castings in various grades (in
cast, machined & assembled condition) for all industrial sectors (both from Domestic &
International markets) like Steel Plants, Power Plants (Thermal, Hydro, Wind), Railways,
Mines, Cement, Chemical, Oil, Defence, Sugar, Earth Moving, Machine Tools, Heavy valves
and pumps castings, ship building etc.
The company believes in developing new products in line with changing technology
and requirements of customers. Monitoring the international market in the present scenario of
changing economic condition is a continual process adopted by the company. Customer's
satisfaction is embedded into the corporate culture. Each employee is committed for quality
adherence.
Fig – simplex casting limited-3 fabrication work holl
6
Manufacturing process
There are large number of process available for manufacture to engineers. Thise process can
be classid into four categories.
1.Ca sting processes
2.Formimg processes
3.Fabrication processes
4.Metal removing processes (machining processes)
1. Casting process : There are the only processes where liquid metal is used casting is also
one of the oldest known is manufacturing process. molten metal is poured into this refractory
mould cavity and it allowed to solidify. The object ofer solidification is removed from the
mould. Casting processes are universally used for manufacture of a wide variety of products.
Fig – casting proces
2. Forming processes : These are solid state manufacturing process involving minimum
amaunt of material wastage and faster production. In a forming process, metal may b heated
to a temperature, which is slightly below the solidus tempreture and then a large force is
applied such that the material flows and takes a desired shape. The desired shape is controlled
by means a set set of tools called dies, which may be completely closed or partially closed
during manufacture.
Fig – Formimg process
Mold
cavity
chaplet
Mold
cavity
chaplet
7
3. fabrication processes : There secondary manufacturing processes where the starting raw
materials are processed by any of the previous manufacturing process described. It essentially
involves joining pieces either parnanently or temporarily, so that they would perform the
necessary function. The joining can be achieved by either or both of heat and pressure and or
a joining materal. Many of the steel structure constructions we see are first rolled and them
joined together by a fabrication process.
Fig – Fabrication process
4. Material removal processes : These also secondry manufacturing processes, where the
additional unwanted material is removed in the form of chips from the blant material by a
harder tool, so as abtain the final desired shap. Mmaterial removes is normally the most
expensive manufacturing process because more energy is consumed and also, a lot of waste
material is generated in the process. Still thise is widly used because it deliveres very good
dimensional accuracy and good surface finish. It is also called machining processes.
Fig – material removal process
8
MACHINE SHOP
SCL-1 has a large Machine Shop equipped with more than 100 Machine Tools including
CNC Machines especially Automatic Floor Type Travelling Column Milling Centre with
Heidenhain CNC Control, having Longitudinal Traverse "X" axis - 10000 mm, Vertical
Traverse "Y" axis - 2800 mm and Cross Traverse "Z" axis - 1800 mm, for finish machining
of jobs complicated with close accuracy at a high speed, precision and zero tolerance.
Machining Process
Machining is any of various processes in which a piece of raw material is cut into a desired
final shape and size by a controlled material-removal process. The processes that have this
common theme, controlled material removal, are today collectively known as subtractive
manufacturing, in distinction from processes of controlled material addition, which are
known as additive manufacturing. Exactly what the "controlled" part of the definition implies
can vary, but it almost always implies the use of machine tools (in addition to just power
tools and hand tools).
Machining is a part of the manufacture of many metal products, but it can also be used on
materials such as wood, plastic, ceramic, and composites. A person who specializes in
machining is called amachinist. A room, building, or company where machining is done is
called a machine shop. Machining can be a business, a hobby, or both. Much of modern day
machining is carried out by computer numerical control (CNC), in which computers are used
to control the movement and operation of the mills, lathes, and other cutting machines.
MACHINING PROCESS:
The three principal machining processes are classified
as turning, drilling and milling. Other operations falling
into miscellaneous categories include shaping, planing,
boring, broaching and sawing.
 Turning operations are operations that rotate the
workpiece as the primary method of moving metal
against the cutting tool. Lathes are the principal
machine tool used in turning.
 Milling operations are operations in which the
cutting tool rotates to bring cutting edges to bear
against the workpiece. Milling machines are the principal machine tool used in milling.
9
 PROCESS: An unfinished workpiece requiring machining will need to have some
material cut away to create a finished product. A finished product would be a workpiece
that meets the specifications set out for that workpiece by engineering
drawings or blueprints. For example, a workpiece may be required to have a specific
outside diameter. A lathe is a machine tool that can be used to create that diameter by
rotating a metal workpiece, so that a cutting tool can cut metal away, creating a smooth,
round surface matching the required diameter and surface finish. A drill can be used to
remove metal in the shape of a cylindrical hole. Other tools that may be used for various
types of metal removal are milling machines, saws, and grinding machines. Many of
these same techniques are used in woodworking.
More recent, advanced machining techniques include electrical discharge machining (EDM),
electro-chemical erosion, laser cutting, or water jet cutting to shape metal workpieces.
As a commercial venture, machining is generally performed in a machine shop, which
consists of one or more workrooms containing major machine tools. Although a machine
shop can be a stand-alone operation, many businesses maintain internal machine shops which
support specialized needs of the business.
Machining requires attention to many details for a workpiece to meet the specifications set
out in the engineering drawings or blueprints. Beside the obvious problems related to correct
dimensions, there is the problem of achieving the correct finish or surface smoothness on the
workpiece. The inferior finish found on the machined surface of a workpiece may be caused
by incorrect clamping, a dull tool, or inappropriate presentation of a tool. Frequently, this
poor surface finish, known as chatter, is evident by an undulating or irregular finish, and the
appearance of waves on the machined surfaces of the workpiece.
Fig – machining process
10
CNC Machine Shop :
In CNC machine the program is stored in the memory of the computer. The programmer can
easily write the codes, and edit the programs as per the requirements. These programs can be
used for different parts, and they don’t have to be repeated again and again.
Compared to the NC machine, the CNC machine offers greater additional flexibility and
computational capability. New systems can be incorporated into the CNC controller simply
by reprogramming the unit. Because of its capacity and the flexibility the CNC machines are
called as “soft-wired” NC.
How the CNC Machine Works? The CNC machine comprises of the computer in which the
program is fed for cutting of the metal of the job as per the requirements. All the cutting
processes that are to be carried out and all the final dimensions are fed into the computer via
the program. The computer thus knows what exactly is to be done and carries out all the
cutting processes. CNC machine works like the Robot, which has to be fed with the program
and it follows all your instructions. Milling machines, Drilling Machine etc. The main
purpose of these machines is to remove some of the metal so as to give it proper shape such
as round, rectangular, etc. In the traditional methods these machines are operated by the
operators who are experts in the operation of these machines. Most of the jobs need to be
machined accurately, and the operator should be expert enough to make the precision jobs. In
the CNC machines the role of the operators is minimized. The operator has to merely feed the
program of instructions in the computer, load the required tools in the machine, and rest of
the work is done by the computer automatically. The computer directs the machine tool to
perform various machining operations as per the program of instructions fed by the operator.
Some of the common machine tools that can run on the CNC are: Lathe, You don’t have to
worry about the accuracy of the job; all the CNC machines are designed to meet very close
accuracies. In fact, these days for most of the precision jobs CNC machine is compulsory.
When your job is finished, you don’t even have to remove it, the machine does that for you
and it picks up the next job on its own. This way the need of much monitoring, of course you
will have to feed it with the program initially and supply the required raw material.
Fig - C.N.C. Machine
11
C.N.C. MACHINE
INTRODUCTION:
In Industry it is not efficient or profitable to make everyday products by hand. On a CNC
machine it is possible to make hundreds or even thousands of the same items in a day. First a
design is drawn using design software, and then it is processed by the computer and
manufactured using the CNC machine. This is a small CNC machine and can be used to
machine woods, plastics and aluminum. In industry, CNC machines can be extremely
Fig – CNC machine
MEANING OF “C.N.C.”:
CNC means Computer Numerical Control. This means a computer converts the design into
numbers which the computer uses to control the cutting and shaping of the material .
12
USE OF TYPICAL CNC MACHINE
1.The design is loaded into the computer which is attached to the CNC machine. The
computer changes the design into a special code (numerical) that controls the way the CNC
cuts and shapes the material. Show fig (a).
2. The material to be shaped is taped on to a block with double sided tape. This must be done
carefully so that it does not come off the block during machining. Show in fig (b).
3.The block is then placed in the vice, inside the CNC. It must be tightened up carefully. If it
is not secure when the machine starts to cut the material it can come away from the vice.
When the machine starts working, the vice moves up, down, right and left according to the
design. Show in fig (c).
4.The guard is placed in position. It protects the machine operator in case the material is
pulled out of the vice by the power of the cutter. For safety reasons, if the guard is not in
position the motor will not start. Show in fig (d).
5.The CNC is turned on and the shape is cut from the material. When the cutter has stopped
the shaped material can be removed from the vice. Show in fig (e).
Fig (a) fig (b) fig (c)
Fig (d) Fig (e)
13
PARTS OF CNC MACHINE
VICE: This holds the material to be cut or shaped. Material must be held securely otherwise
it may 'fly' out of the vice when the CNC begins to machine. Normally the vice will be like a
clamp that holds the material in the correct position.
GUARD: The guard protects the person using the CNC. When the CNC is machining the
material small pieces can be 'shoot' off the material at high speed. This could be dangerous if
a piece hit the person operating the machine. The guard completely encloses the dangerous
areas of the CNC.
CHUCK: This holds the material that is to be shaped. The material must be placed in it very
carefully so that when the CNC is working the material is not thrown out at high speed.
Fig – C.N.C. MACHINE
MOTOR: The motor is enclosed inside the machine. This is the part that rotates the chuck at
high speed.
LATHE BED: The base of the machine. Usually a CNC is bolted down so that it cannot
move through the vibration of the machine when it is working.
CUTTING TOOL: This is usually made from high quality steel and it is the part that
actually cuts the material to be shaped.
14
CNC MACHINE - INPUT, PROCESS, OUTPUT
A CNC production facility needs three pieces of equipment:
A Computer:
The computer is used to draw the design. However, the design is only a picture and the CNC
machine cannot use this to manufacture the product. The computer software must also
convert the drawing into numbers (coordinates) that the CNC machine can use when it starts
to cut and shape the material.
An Interface:
A computer cannot be directly connected to a CNC machine. The computer is connected to
an interface. This converts the signals from the computer to a form that the CNC machine
understands. The signals are in the form of digital signals when they are sent to the CNC
machine.
CNC (Computer NumericalControl) Machine:
The signals from the interface control the motors on the CNC machine. The signals
determine the way the vice moves. The vice moves in three directions X, Y and Z.
(Horizontally, vertically and depth). The signals also control the speed of the cutting tool.
15
CNC ROUTER - THE IMPORTANT PARTS
16
ADVANTAGES AND DISADVANTAGES OF CNC MACHINES
CNC (Computer Numerical Control machines) are widely used in manufacturing industry.
Traditional machines such as vertical millers, centre lathes, shaping machines, routers etc.
operated by a trained engineer have, in many cases, been replaced by computer control
machines.
ADVANTAGES :
1. CNC machines can be used continuously 24 hours a day, 365 days a year and only need to
be switched off for occasional maintenance.
2. CNC machines are programmed with a design which can then be manufactured hundreds
or even thousands of times. Each manufactured product will be exactly the same.
3. Less skilled/trained people can operate CNC’s unlike manual lathes / milling machines
etc... Which need skilled engineers?
4. CNC machines can be updated by improving the software used to drive the machines
5. Training in the use of CNC’s is available through the use of ‘virtual software’. This is
software that allows the operator to practice using the CNC machine on the screen of a
computer. The software is similar to a computer game.
6. CNC machines can be programmed by advanced design software such as
Pro/DESKTOP®, enabling the manufacture of products that cannot be made by manual
machines, even those used by skilled designers / engineers.
7. Modern design software allows the designer to simulate the manufacture of his/her idea.
There is no need to make a prototype or a model. This saves time and money.
8. One person can supervise many CNC machines as once they are programmed they can
usually be left to work by themselves. Sometimes only the cutting tools need replacing
occasionally.
9. A skilled engineer can make the same component many times. However, if each
component is carefully studied, each one will vary slightly. A CNC machine will
manufacture each component as an exact match
DISADVANTAGES :
1.CNC machines are more expensive than manually operated machines, although costs are
slowly coming down.
2. The CNC machine operator only needs basic training and skills, enough to supervise
several machines. In years gone by, engineers needed years of training to operate centre
lathes, milling machines and other manually operated machines. This means many of the old
skills are been lost.
3. Less workers are required to operate CNC machines compared to manually operated
machines. Investment in CNC machines can lead to unemployment.
4. Many countries no longer teach pupils / students how to use manually operated lathes /
milling machines etc... Pupils / students no longer develop the detailed skills required by
engineers of the past. These include mathematical and engineering skills.
17
INDUSTRIAL PRODUCTION FLOWCHART
18
FABRICATION SHOP
SCL has a large Fabrication shop having approx. 3500 Sq. Mtr. Area with annual fabrication
capacity of 4000 T to carry out technological fabrication works. It is equipped with latest
Plate Bending Machines, Welding Machines, TIG, MIG, Plasma Cutting Machine(Model:
MESSER Omni Mat-T), Semiautomatic Submerged Arc Welding Machines, Welding Booms
and Manipulators, , EOT cranes to handle single piece weighing upto 50 tons, etc.
Fig- Fabrication shop
19
WELDING PROCES
WELDING-Welding is a materials joining process which produces coalescence of
materials by heating them to suitable temperatures with or without the application of
pressure or by the application of pressure alone, and with or without the use of filler
material.
Welding is used for making permanent joints. It is used in the manufacture of
automobile bodies, aircraft frames, railway wagons, machine frames, structural works,
tanks, furniture, boilers, general repair work and ship building.
TYPES OF WELDING-
 Plastic Welding or Pressure Welding
The piece of metal to be joined are heated to a plastic state and forced together by
external pressure
(Ex) Resistance welding
 Fusion Welding or Non-Pressure Welding
The material at the joint is heated to a molten state and allowed to solidify
(Ex) Gas welding, Arc welding
Classification of welding processes:
(i). Arc welding
1. Carbon arc
2. Metal arc
3. Metal inert gas
4. Tungsten inert gas
5. Plasma arc
6. Submerged arc
7. Electro-slag
(ii). Gas Welding
1. Oxy-acetylene
2. Air-acetylene
3. Oxy-hydrogen
20
(iii). Resistance Welding
1. Butt
2. Spot
3. Seam
4. Projection
5. Percussion
(iv) Thermit Welding
(v) Solid State Welding
1. Friction
2. Ultrasonic
3. Diffusion
4. Explosive
(vi) Newer Welding
1. Electron-beam
2. Laser
(vii) RelatedProcess
1. Oxy-acetylene cutting
2. Arc cutting
3. Hard facing
4. Brazing
5. Soldering
Arc welding methods
1. Metalarc welding
It is a process of joining two metal pieces by melting the edges by an electric arc. The
electric arc is produced between two conductors. The electrode is one conductor and the work
piece is another conductor. The electrode and the work piece are brought nearer with small
air gap. (3mm app.)
When current is passed an electric arc is produced between the electrode and the work
piece. The work piece and the electrode are melted by the arc. Both molten piece of metal
become one. Temperature of arc is about 4000°c Electrodes used in arc welding are coated
with a flux. This flux produces a gaseous shield around the molten metal. It prevents the
reaction of the molten metal with oxygen and nitrogen in the atmosphere. The flux removes
21
the impurities from the molten metal and form a slag. This slag gets deposited over the weld
metal. This protects the weld seam from rapid cooling. Fig.1 shows arc welding process.
Equipments:
 A welding generator (D.C.) or Transformer (A.C.)
 Two cables- one for work and one for electrode
 Electrode holder
 Electrode
 Protective shield
 Gloves
 Wire brush
 Chipping hammer
 Goggles
Fig - Electric Arc Welding Equipments
22
Fig. 1 Arc Welding
Advantages
 Most efficient way to join metals
 Lowest-cost joining method
 Affords lighter weight through better utilization of materials
 Joins all commercial metals
 Provides design flexibility
Limitations
1. Manually applied, therefore high labor cost.
2. Need high energy causing danger
3. Not convenient for disassembly.
4. Defects are hard to detect at joints.
23
GAS WELDING
Oxy-Acetylene welding
In gas welding, a gas flame is used to melt the edges of metals to be joined. The flame
is produced at the tip of welding torch. Oxygen and Acetylene are the gases used to
produce the welding flame. The flame will only melt the metal. A flux is used during
welting to prevent oxidations and to remove impurities. Metals 2mm to 50mm thick are
welded by gas welding. The temperature of oxyacetylene flame is about 3200°c. Fig 3
shows Gas welding equipments.
Gas Welding Equipment
1. Gas Cylinders
Pressure
Oxygen – 125 kg/cm2
Acetylene – 16 kg/cm2
2. Regulators
Working pressure of oxygen 1 kg/cm2
Working pressure of acetylene 0.15 kg/cm2
Working pressure varies depends upon the thickness of the work pieces welded.
3. Pressure Gauges
4. Hoses
5. Welding torch
6. Check valve
7. Non return valve
24
Fig- Gas Welding Equipment
TYPES OF FLAMES
• When acetylene is burned in air, it produces a yellow sooty flame, which is not
enough for welding applications
• Oxygen is turned on, flame immediately changes into a long white inner area
(Feather) surrounded by a transparent blue envelope is called Carburizing flame
(30000c)
25
• This flames are used for hardening the surfaces
• Addition of little more oxygen give a bright whitish cone surrounded by the
transparent blue envelope is called Neutral flame (It has a balance of fuel gas and
oxygen)
• Most commonly used flame because it has temperature about 32000c
• Used for welding steels, aluminium, copper and cast iron
• If more oxygen is added, the cone becomes darker and more pointed, while the
envelope becomes shorter and more fierce is called Oxidizing flame
• Has the highest temperature about 34000c
• Used for welding brass and brazing operation
Fig 4 shows the types of flames.
Fig Types of Gas Flames
26
Advantages
1. Equipment has versatile
2. Same equipment can be used for oxy acetylene cutting and brazing by varying the
torch size
3. Heat can controlled easily
Disadvantages
1. Slower process
2. Risk is involved in handling gas cylinders
GAS CUTTING
• Ferrous metal is heated in to red hot condition and a jet of pure oxygen is projected
onto the surface, which rapidly oxidizes
• Oxides having lower melting point than the metal, melt and are blown away by the
force of the jet, to make a cut
• Fast and efficient method of cutting steel to a high degree of accuracy
• Torch is different from welding
• Cutting torch has preheat orifice and one central orifice for oxygen jet
• PIERCING and GOUGING are two important operations
• Piercing, used to cut a hole at the centre of the plate or away from the edge of the
plate
• Gouging, to cut a groove into the steel surface
Fig Automatic Gas Cutting
27
Fig Manual Gas Cutting
Weld joint
There are 5 basic joint types in welding
• Butt joint: Two materials are in the same plane, joined from the edges.
• Corner joint:The corners of two materials form a right angle and joined.
• Lap joint: Two parts overlaps.
• Tee joint: One part is perpendicular to the other, making a T shape.
• Edge joint: Edges of the two materials joined.
Types of weld
1. Fillet weld: Used in T joints,corner joints, lap joints.
2. Groove weld:Used in butt joints.
3. Plug weld: Used in lap joints.
4. Slot weld: Used in lap joints.
5. Spot weld: Used in lap joints.
6. Seam weld: Used in lap joints.
7. Flange weld:Used in edge joints.
8. Surfacing weld:Not a joining process, it is used to increase the thickness of the plate,
or provide a protective coating on the surface.
28
Fig Types of Weld Joints
Weldability is the ease of a material or a combination of materials to be welded under
fabrication conditions into a specific, suitably designed structure, and to perform
satisfactorily in the intended service
Brazing and Soldering
Brazing
It is a low temperature joining process. It is performed at temperatures above
840º F and it generally affords strengths comparable to those of the metal which it joins. It is
low temperature in that it is done below the melting point of the base metal. It is achieved by
diffusion without fusion (melting) of the base
29
Depending upon the method of heating, brazing can be classified as
1. Torch brazing
2. Dip brazing
3. Furnace brazing
4. Induction brazing
Fig BrazinG
Advantages
 Dissimilar metals which canot be welded can be joined by brazing
 Very thin metals can be joined
 Metals with different thickness can be joined easily
 In brazing thermal stresses are not produced in the work piece. Hence there is
no distortion
 Using this process, carbides tips are brazed on the steel tool holders
Disadvantages
 Brazed joints have lesser strength compared to welding
 Joint preparation cost is more
 Can be used for thin sheet metal sections
Soldering –
It is a low temperature joining process. It is performed at temperatures below 840ºF for
joining.
30
Soldering is used for,
• Sealing, as in automotive radiators or tin cans
• Electrical Connections
• Joining thermally sensitive components
• Joining dissimilar metals
Fig Soldering
31
HEAVY FABRICATION SHOP
Simplex Castings Limited is a Quality Metal fabricator of Heavy Engineering Spares &
Technological Equipment upto 70 MT as a Single Piece. This plant has all testing facilities,
large stress Relieving furnace and Big CNC Boring Machines. Quality Accredited with API
& ASME for U-Stamping.
Sturctural & Fabrication Facilities
Capabilities:
 Equipment Fabrication Capacity - 500T per
month
 Structural Fabrication Capacity - 300 T Per
Month
Press, Bending & Forming:
 Folding: 8mm to 10mm
 Plate Bending Machine: upto 63mm, 3mtr.
wide
 Pipe Bending: upto Dia 60mm
 Hydraulic Press: 400 Tons
 Punching
Material Handling: Upto 70 Tons (Crane
Facility)
Painting Booth: Covered 19 Mtr. x 8 Mtr. x 6
Mtr.
 CNC Horizontal & Boring Machines
 Drilling
 Assembly & Testing Lines
Plate Cutting & Profile Facilities:
 CNC Plasma & OXY - Acetylene
Cutting Machine
 Pug Cutting Machine
Welding Facilities:
 Manual Welding, SAW, TIG, MIG,
STUD Welding
 Separate enclosure for SS Welding
Heat Treatment Facility:
 Oil Fired Stress Relieving Furnace 50
Tons
 7.2 Mtr. x 6 Mtr. x 4.5 Mtr.
Finishing:
 Grit Blasting - 6 x 6 x12 Mtr.
 Sand Blasting
Fig- heavy fabrication shop machine
fig- fabrication shop (welding)
32
Conclusion
CNC:
• Cnc mean computer numerical control machine it’s a form of programmable automation
drill drawings on wood use g coding consist of 3 motors and their drivers and pic with its
basic circuit and body made of wood hold on motors and drill and the wood we want to draw
on it
• We tried to make cheap fast safety cnc machine that drill on wood piece according to any
drawing we draw to it.
WELDING:
Welding process a very good process for joining a metal and dissimilar metal to required a
varias purpose
33
REFERANCE
www.studymafia.com
www.google.com
www.wikipedia.com

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VOCATIONAL TRAINING REPORT OF SIMPLE CASTING LIMITED

  • 1. A VOCATIONAL TRAINING REPORT ON “SIMPLEX CASTING LIMITED” UNIT-3 Submitted to CHHATTISHGARH SWAMI VIVEKANAND TECHNICAL UNIVERSITY, BHILAI in the partial fulfillment of the requirements for the award of Degree of Bachelor of Engineering In Mechanical Engineering By SURENDRA KUMAR Roll no. 3433714028 Department of Mechanical Engineering Bharti college of Engineering and Technology Pulgaon Chowk Durg, C.G. Pin: 491001 Session - 2016-2017 TRAINING CERTIFICATE
  • 2. 2 PREFACE I have made this vocational training report file on the topic manufacturing process in short , CNC Machine in detail and fabrication welding process;I have tried my best to elucidate all the relevant detail to the topic to be included in the report. While in the beginning I have tried to give a general view about this topic. My efforts and wholehearted co-corporation of each and everyone has ended on a successfulnote. I express my sincere gratitude to …………..who assisting me throughout the preparation of this topic. I thank him for providing me the reinforcement, confidence and most importantly the track for the topic whenever I needed it.
  • 3. 3 ACKNOWLEDEMENT We take an opportunity to express our sincer gratitude to the peoples who have been helpful in the successfulofour industrial training and this project. We would like to show our greatest apparition to highly esteemed and developed technical staff of the SIMPLLEX CASTING LIMITED UNIT-3. We are highly indebted to them for their tremendous support and help during the collection of our training and project.
  • 4. 4 CONTENS  Inroduction of componyprofile………………………  Manufacturing process………………………………  Machine shop…………………………………………  Machining process…………………………………  C.N.C machine shop…………………………………  C.N.C. MACHINE………………………………….  Meaning of CNC………………………………….  Part of CNC………………………………………..  CNC machine- input, process, output………………  Advantages and disadvantages of CNC……………  Industial flow chart…………………………………  Fabrication shop ……………………………………  Welding process………………………………………  Types of welding………………………………………  Arc welding ………………………………………….  Gas welding……………………………………………  Gas cutting ………………………………………..  Weld joint……………………………………………..  Types of weld joint…………………………………  Branzing and soldering……………………………..  Heavy fabrication shop……………………………..  Conclusion ………………………………………….  Referance……………………………………………
  • 5. 5 INTRODUCTION Company Profile: Simplex Castings Limited (SCL) started as a Partnership firm in the year 1970 as a small Grey Iron Foundry. Subsequently, it was converted into a Private Limited Company registered under the Indian Companies Act, with its registered office at Mumbai India, on 30 Jan 1980. The Company went Public in 1993. It's Shares are listed in Mumbai Stock Exchange. SCL is a well managed dividend paying company making profit since it's inception. SCL has two Units in the state of Chhattisgarh (mineral rich State of India). One unit is situated at 5 Industrial Estate, Bhilai and the other at Urla Industrial Estate, Raipur. The company is engaged in manufacturing of Heavy Engineering Castings in various grades (in cast, machined & assembled condition) for all industrial sectors (both from Domestic & International markets) like Steel Plants, Power Plants (Thermal, Hydro, Wind), Railways, Mines, Cement, Chemical, Oil, Defence, Sugar, Earth Moving, Machine Tools, Heavy valves and pumps castings, ship building etc. The company believes in developing new products in line with changing technology and requirements of customers. Monitoring the international market in the present scenario of changing economic condition is a continual process adopted by the company. Customer's satisfaction is embedded into the corporate culture. Each employee is committed for quality adherence. Fig – simplex casting limited-3 fabrication work holl
  • 6. 6 Manufacturing process There are large number of process available for manufacture to engineers. Thise process can be classid into four categories. 1.Ca sting processes 2.Formimg processes 3.Fabrication processes 4.Metal removing processes (machining processes) 1. Casting process : There are the only processes where liquid metal is used casting is also one of the oldest known is manufacturing process. molten metal is poured into this refractory mould cavity and it allowed to solidify. The object ofer solidification is removed from the mould. Casting processes are universally used for manufacture of a wide variety of products. Fig – casting proces 2. Forming processes : These are solid state manufacturing process involving minimum amaunt of material wastage and faster production. In a forming process, metal may b heated to a temperature, which is slightly below the solidus tempreture and then a large force is applied such that the material flows and takes a desired shape. The desired shape is controlled by means a set set of tools called dies, which may be completely closed or partially closed during manufacture. Fig – Formimg process Mold cavity chaplet Mold cavity chaplet
  • 7. 7 3. fabrication processes : There secondary manufacturing processes where the starting raw materials are processed by any of the previous manufacturing process described. It essentially involves joining pieces either parnanently or temporarily, so that they would perform the necessary function. The joining can be achieved by either or both of heat and pressure and or a joining materal. Many of the steel structure constructions we see are first rolled and them joined together by a fabrication process. Fig – Fabrication process 4. Material removal processes : These also secondry manufacturing processes, where the additional unwanted material is removed in the form of chips from the blant material by a harder tool, so as abtain the final desired shap. Mmaterial removes is normally the most expensive manufacturing process because more energy is consumed and also, a lot of waste material is generated in the process. Still thise is widly used because it deliveres very good dimensional accuracy and good surface finish. It is also called machining processes. Fig – material removal process
  • 8. 8 MACHINE SHOP SCL-1 has a large Machine Shop equipped with more than 100 Machine Tools including CNC Machines especially Automatic Floor Type Travelling Column Milling Centre with Heidenhain CNC Control, having Longitudinal Traverse "X" axis - 10000 mm, Vertical Traverse "Y" axis - 2800 mm and Cross Traverse "Z" axis - 1800 mm, for finish machining of jobs complicated with close accuracy at a high speed, precision and zero tolerance. Machining Process Machining is any of various processes in which a piece of raw material is cut into a desired final shape and size by a controlled material-removal process. The processes that have this common theme, controlled material removal, are today collectively known as subtractive manufacturing, in distinction from processes of controlled material addition, which are known as additive manufacturing. Exactly what the "controlled" part of the definition implies can vary, but it almost always implies the use of machine tools (in addition to just power tools and hand tools). Machining is a part of the manufacture of many metal products, but it can also be used on materials such as wood, plastic, ceramic, and composites. A person who specializes in machining is called amachinist. A room, building, or company where machining is done is called a machine shop. Machining can be a business, a hobby, or both. Much of modern day machining is carried out by computer numerical control (CNC), in which computers are used to control the movement and operation of the mills, lathes, and other cutting machines. MACHINING PROCESS: The three principal machining processes are classified as turning, drilling and milling. Other operations falling into miscellaneous categories include shaping, planing, boring, broaching and sawing.  Turning operations are operations that rotate the workpiece as the primary method of moving metal against the cutting tool. Lathes are the principal machine tool used in turning.  Milling operations are operations in which the cutting tool rotates to bring cutting edges to bear against the workpiece. Milling machines are the principal machine tool used in milling.
  • 9. 9  PROCESS: An unfinished workpiece requiring machining will need to have some material cut away to create a finished product. A finished product would be a workpiece that meets the specifications set out for that workpiece by engineering drawings or blueprints. For example, a workpiece may be required to have a specific outside diameter. A lathe is a machine tool that can be used to create that diameter by rotating a metal workpiece, so that a cutting tool can cut metal away, creating a smooth, round surface matching the required diameter and surface finish. A drill can be used to remove metal in the shape of a cylindrical hole. Other tools that may be used for various types of metal removal are milling machines, saws, and grinding machines. Many of these same techniques are used in woodworking. More recent, advanced machining techniques include electrical discharge machining (EDM), electro-chemical erosion, laser cutting, or water jet cutting to shape metal workpieces. As a commercial venture, machining is generally performed in a machine shop, which consists of one or more workrooms containing major machine tools. Although a machine shop can be a stand-alone operation, many businesses maintain internal machine shops which support specialized needs of the business. Machining requires attention to many details for a workpiece to meet the specifications set out in the engineering drawings or blueprints. Beside the obvious problems related to correct dimensions, there is the problem of achieving the correct finish or surface smoothness on the workpiece. The inferior finish found on the machined surface of a workpiece may be caused by incorrect clamping, a dull tool, or inappropriate presentation of a tool. Frequently, this poor surface finish, known as chatter, is evident by an undulating or irregular finish, and the appearance of waves on the machined surfaces of the workpiece. Fig – machining process
  • 10. 10 CNC Machine Shop : In CNC machine the program is stored in the memory of the computer. The programmer can easily write the codes, and edit the programs as per the requirements. These programs can be used for different parts, and they don’t have to be repeated again and again. Compared to the NC machine, the CNC machine offers greater additional flexibility and computational capability. New systems can be incorporated into the CNC controller simply by reprogramming the unit. Because of its capacity and the flexibility the CNC machines are called as “soft-wired” NC. How the CNC Machine Works? The CNC machine comprises of the computer in which the program is fed for cutting of the metal of the job as per the requirements. All the cutting processes that are to be carried out and all the final dimensions are fed into the computer via the program. The computer thus knows what exactly is to be done and carries out all the cutting processes. CNC machine works like the Robot, which has to be fed with the program and it follows all your instructions. Milling machines, Drilling Machine etc. The main purpose of these machines is to remove some of the metal so as to give it proper shape such as round, rectangular, etc. In the traditional methods these machines are operated by the operators who are experts in the operation of these machines. Most of the jobs need to be machined accurately, and the operator should be expert enough to make the precision jobs. In the CNC machines the role of the operators is minimized. The operator has to merely feed the program of instructions in the computer, load the required tools in the machine, and rest of the work is done by the computer automatically. The computer directs the machine tool to perform various machining operations as per the program of instructions fed by the operator. Some of the common machine tools that can run on the CNC are: Lathe, You don’t have to worry about the accuracy of the job; all the CNC machines are designed to meet very close accuracies. In fact, these days for most of the precision jobs CNC machine is compulsory. When your job is finished, you don’t even have to remove it, the machine does that for you and it picks up the next job on its own. This way the need of much monitoring, of course you will have to feed it with the program initially and supply the required raw material. Fig - C.N.C. Machine
  • 11. 11 C.N.C. MACHINE INTRODUCTION: In Industry it is not efficient or profitable to make everyday products by hand. On a CNC machine it is possible to make hundreds or even thousands of the same items in a day. First a design is drawn using design software, and then it is processed by the computer and manufactured using the CNC machine. This is a small CNC machine and can be used to machine woods, plastics and aluminum. In industry, CNC machines can be extremely Fig – CNC machine MEANING OF “C.N.C.”: CNC means Computer Numerical Control. This means a computer converts the design into numbers which the computer uses to control the cutting and shaping of the material .
  • 12. 12 USE OF TYPICAL CNC MACHINE 1.The design is loaded into the computer which is attached to the CNC machine. The computer changes the design into a special code (numerical) that controls the way the CNC cuts and shapes the material. Show fig (a). 2. The material to be shaped is taped on to a block with double sided tape. This must be done carefully so that it does not come off the block during machining. Show in fig (b). 3.The block is then placed in the vice, inside the CNC. It must be tightened up carefully. If it is not secure when the machine starts to cut the material it can come away from the vice. When the machine starts working, the vice moves up, down, right and left according to the design. Show in fig (c). 4.The guard is placed in position. It protects the machine operator in case the material is pulled out of the vice by the power of the cutter. For safety reasons, if the guard is not in position the motor will not start. Show in fig (d). 5.The CNC is turned on and the shape is cut from the material. When the cutter has stopped the shaped material can be removed from the vice. Show in fig (e). Fig (a) fig (b) fig (c) Fig (d) Fig (e)
  • 13. 13 PARTS OF CNC MACHINE VICE: This holds the material to be cut or shaped. Material must be held securely otherwise it may 'fly' out of the vice when the CNC begins to machine. Normally the vice will be like a clamp that holds the material in the correct position. GUARD: The guard protects the person using the CNC. When the CNC is machining the material small pieces can be 'shoot' off the material at high speed. This could be dangerous if a piece hit the person operating the machine. The guard completely encloses the dangerous areas of the CNC. CHUCK: This holds the material that is to be shaped. The material must be placed in it very carefully so that when the CNC is working the material is not thrown out at high speed. Fig – C.N.C. MACHINE MOTOR: The motor is enclosed inside the machine. This is the part that rotates the chuck at high speed. LATHE BED: The base of the machine. Usually a CNC is bolted down so that it cannot move through the vibration of the machine when it is working. CUTTING TOOL: This is usually made from high quality steel and it is the part that actually cuts the material to be shaped.
  • 14. 14 CNC MACHINE - INPUT, PROCESS, OUTPUT A CNC production facility needs three pieces of equipment: A Computer: The computer is used to draw the design. However, the design is only a picture and the CNC machine cannot use this to manufacture the product. The computer software must also convert the drawing into numbers (coordinates) that the CNC machine can use when it starts to cut and shape the material. An Interface: A computer cannot be directly connected to a CNC machine. The computer is connected to an interface. This converts the signals from the computer to a form that the CNC machine understands. The signals are in the form of digital signals when they are sent to the CNC machine. CNC (Computer NumericalControl) Machine: The signals from the interface control the motors on the CNC machine. The signals determine the way the vice moves. The vice moves in three directions X, Y and Z. (Horizontally, vertically and depth). The signals also control the speed of the cutting tool.
  • 15. 15 CNC ROUTER - THE IMPORTANT PARTS
  • 16. 16 ADVANTAGES AND DISADVANTAGES OF CNC MACHINES CNC (Computer Numerical Control machines) are widely used in manufacturing industry. Traditional machines such as vertical millers, centre lathes, shaping machines, routers etc. operated by a trained engineer have, in many cases, been replaced by computer control machines. ADVANTAGES : 1. CNC machines can be used continuously 24 hours a day, 365 days a year and only need to be switched off for occasional maintenance. 2. CNC machines are programmed with a design which can then be manufactured hundreds or even thousands of times. Each manufactured product will be exactly the same. 3. Less skilled/trained people can operate CNC’s unlike manual lathes / milling machines etc... Which need skilled engineers? 4. CNC machines can be updated by improving the software used to drive the machines 5. Training in the use of CNC’s is available through the use of ‘virtual software’. This is software that allows the operator to practice using the CNC machine on the screen of a computer. The software is similar to a computer game. 6. CNC machines can be programmed by advanced design software such as Pro/DESKTOP®, enabling the manufacture of products that cannot be made by manual machines, even those used by skilled designers / engineers. 7. Modern design software allows the designer to simulate the manufacture of his/her idea. There is no need to make a prototype or a model. This saves time and money. 8. One person can supervise many CNC machines as once they are programmed they can usually be left to work by themselves. Sometimes only the cutting tools need replacing occasionally. 9. A skilled engineer can make the same component many times. However, if each component is carefully studied, each one will vary slightly. A CNC machine will manufacture each component as an exact match DISADVANTAGES : 1.CNC machines are more expensive than manually operated machines, although costs are slowly coming down. 2. The CNC machine operator only needs basic training and skills, enough to supervise several machines. In years gone by, engineers needed years of training to operate centre lathes, milling machines and other manually operated machines. This means many of the old skills are been lost. 3. Less workers are required to operate CNC machines compared to manually operated machines. Investment in CNC machines can lead to unemployment. 4. Many countries no longer teach pupils / students how to use manually operated lathes / milling machines etc... Pupils / students no longer develop the detailed skills required by engineers of the past. These include mathematical and engineering skills.
  • 18. 18 FABRICATION SHOP SCL has a large Fabrication shop having approx. 3500 Sq. Mtr. Area with annual fabrication capacity of 4000 T to carry out technological fabrication works. It is equipped with latest Plate Bending Machines, Welding Machines, TIG, MIG, Plasma Cutting Machine(Model: MESSER Omni Mat-T), Semiautomatic Submerged Arc Welding Machines, Welding Booms and Manipulators, , EOT cranes to handle single piece weighing upto 50 tons, etc. Fig- Fabrication shop
  • 19. 19 WELDING PROCES WELDING-Welding is a materials joining process which produces coalescence of materials by heating them to suitable temperatures with or without the application of pressure or by the application of pressure alone, and with or without the use of filler material. Welding is used for making permanent joints. It is used in the manufacture of automobile bodies, aircraft frames, railway wagons, machine frames, structural works, tanks, furniture, boilers, general repair work and ship building. TYPES OF WELDING-  Plastic Welding or Pressure Welding The piece of metal to be joined are heated to a plastic state and forced together by external pressure (Ex) Resistance welding  Fusion Welding or Non-Pressure Welding The material at the joint is heated to a molten state and allowed to solidify (Ex) Gas welding, Arc welding Classification of welding processes: (i). Arc welding 1. Carbon arc 2. Metal arc 3. Metal inert gas 4. Tungsten inert gas 5. Plasma arc 6. Submerged arc 7. Electro-slag (ii). Gas Welding 1. Oxy-acetylene 2. Air-acetylene 3. Oxy-hydrogen
  • 20. 20 (iii). Resistance Welding 1. Butt 2. Spot 3. Seam 4. Projection 5. Percussion (iv) Thermit Welding (v) Solid State Welding 1. Friction 2. Ultrasonic 3. Diffusion 4. Explosive (vi) Newer Welding 1. Electron-beam 2. Laser (vii) RelatedProcess 1. Oxy-acetylene cutting 2. Arc cutting 3. Hard facing 4. Brazing 5. Soldering Arc welding methods 1. Metalarc welding It is a process of joining two metal pieces by melting the edges by an electric arc. The electric arc is produced between two conductors. The electrode is one conductor and the work piece is another conductor. The electrode and the work piece are brought nearer with small air gap. (3mm app.) When current is passed an electric arc is produced between the electrode and the work piece. The work piece and the electrode are melted by the arc. Both molten piece of metal become one. Temperature of arc is about 4000°c Electrodes used in arc welding are coated with a flux. This flux produces a gaseous shield around the molten metal. It prevents the reaction of the molten metal with oxygen and nitrogen in the atmosphere. The flux removes
  • 21. 21 the impurities from the molten metal and form a slag. This slag gets deposited over the weld metal. This protects the weld seam from rapid cooling. Fig.1 shows arc welding process. Equipments:  A welding generator (D.C.) or Transformer (A.C.)  Two cables- one for work and one for electrode  Electrode holder  Electrode  Protective shield  Gloves  Wire brush  Chipping hammer  Goggles Fig - Electric Arc Welding Equipments
  • 22. 22 Fig. 1 Arc Welding Advantages  Most efficient way to join metals  Lowest-cost joining method  Affords lighter weight through better utilization of materials  Joins all commercial metals  Provides design flexibility Limitations 1. Manually applied, therefore high labor cost. 2. Need high energy causing danger 3. Not convenient for disassembly. 4. Defects are hard to detect at joints.
  • 23. 23 GAS WELDING Oxy-Acetylene welding In gas welding, a gas flame is used to melt the edges of metals to be joined. The flame is produced at the tip of welding torch. Oxygen and Acetylene are the gases used to produce the welding flame. The flame will only melt the metal. A flux is used during welting to prevent oxidations and to remove impurities. Metals 2mm to 50mm thick are welded by gas welding. The temperature of oxyacetylene flame is about 3200°c. Fig 3 shows Gas welding equipments. Gas Welding Equipment 1. Gas Cylinders Pressure Oxygen – 125 kg/cm2 Acetylene – 16 kg/cm2 2. Regulators Working pressure of oxygen 1 kg/cm2 Working pressure of acetylene 0.15 kg/cm2 Working pressure varies depends upon the thickness of the work pieces welded. 3. Pressure Gauges 4. Hoses 5. Welding torch 6. Check valve 7. Non return valve
  • 24. 24 Fig- Gas Welding Equipment TYPES OF FLAMES • When acetylene is burned in air, it produces a yellow sooty flame, which is not enough for welding applications • Oxygen is turned on, flame immediately changes into a long white inner area (Feather) surrounded by a transparent blue envelope is called Carburizing flame (30000c)
  • 25. 25 • This flames are used for hardening the surfaces • Addition of little more oxygen give a bright whitish cone surrounded by the transparent blue envelope is called Neutral flame (It has a balance of fuel gas and oxygen) • Most commonly used flame because it has temperature about 32000c • Used for welding steels, aluminium, copper and cast iron • If more oxygen is added, the cone becomes darker and more pointed, while the envelope becomes shorter and more fierce is called Oxidizing flame • Has the highest temperature about 34000c • Used for welding brass and brazing operation Fig 4 shows the types of flames. Fig Types of Gas Flames
  • 26. 26 Advantages 1. Equipment has versatile 2. Same equipment can be used for oxy acetylene cutting and brazing by varying the torch size 3. Heat can controlled easily Disadvantages 1. Slower process 2. Risk is involved in handling gas cylinders GAS CUTTING • Ferrous metal is heated in to red hot condition and a jet of pure oxygen is projected onto the surface, which rapidly oxidizes • Oxides having lower melting point than the metal, melt and are blown away by the force of the jet, to make a cut • Fast and efficient method of cutting steel to a high degree of accuracy • Torch is different from welding • Cutting torch has preheat orifice and one central orifice for oxygen jet • PIERCING and GOUGING are two important operations • Piercing, used to cut a hole at the centre of the plate or away from the edge of the plate • Gouging, to cut a groove into the steel surface Fig Automatic Gas Cutting
  • 27. 27 Fig Manual Gas Cutting Weld joint There are 5 basic joint types in welding • Butt joint: Two materials are in the same plane, joined from the edges. • Corner joint:The corners of two materials form a right angle and joined. • Lap joint: Two parts overlaps. • Tee joint: One part is perpendicular to the other, making a T shape. • Edge joint: Edges of the two materials joined. Types of weld 1. Fillet weld: Used in T joints,corner joints, lap joints. 2. Groove weld:Used in butt joints. 3. Plug weld: Used in lap joints. 4. Slot weld: Used in lap joints. 5. Spot weld: Used in lap joints. 6. Seam weld: Used in lap joints. 7. Flange weld:Used in edge joints. 8. Surfacing weld:Not a joining process, it is used to increase the thickness of the plate, or provide a protective coating on the surface.
  • 28. 28 Fig Types of Weld Joints Weldability is the ease of a material or a combination of materials to be welded under fabrication conditions into a specific, suitably designed structure, and to perform satisfactorily in the intended service Brazing and Soldering Brazing It is a low temperature joining process. It is performed at temperatures above 840º F and it generally affords strengths comparable to those of the metal which it joins. It is low temperature in that it is done below the melting point of the base metal. It is achieved by diffusion without fusion (melting) of the base
  • 29. 29 Depending upon the method of heating, brazing can be classified as 1. Torch brazing 2. Dip brazing 3. Furnace brazing 4. Induction brazing Fig BrazinG Advantages  Dissimilar metals which canot be welded can be joined by brazing  Very thin metals can be joined  Metals with different thickness can be joined easily  In brazing thermal stresses are not produced in the work piece. Hence there is no distortion  Using this process, carbides tips are brazed on the steel tool holders Disadvantages  Brazed joints have lesser strength compared to welding  Joint preparation cost is more  Can be used for thin sheet metal sections Soldering – It is a low temperature joining process. It is performed at temperatures below 840ºF for joining.
  • 30. 30 Soldering is used for, • Sealing, as in automotive radiators or tin cans • Electrical Connections • Joining thermally sensitive components • Joining dissimilar metals Fig Soldering
  • 31. 31 HEAVY FABRICATION SHOP Simplex Castings Limited is a Quality Metal fabricator of Heavy Engineering Spares & Technological Equipment upto 70 MT as a Single Piece. This plant has all testing facilities, large stress Relieving furnace and Big CNC Boring Machines. Quality Accredited with API & ASME for U-Stamping. Sturctural & Fabrication Facilities Capabilities:  Equipment Fabrication Capacity - 500T per month  Structural Fabrication Capacity - 300 T Per Month Press, Bending & Forming:  Folding: 8mm to 10mm  Plate Bending Machine: upto 63mm, 3mtr. wide  Pipe Bending: upto Dia 60mm  Hydraulic Press: 400 Tons  Punching Material Handling: Upto 70 Tons (Crane Facility) Painting Booth: Covered 19 Mtr. x 8 Mtr. x 6 Mtr.  CNC Horizontal & Boring Machines  Drilling  Assembly & Testing Lines Plate Cutting & Profile Facilities:  CNC Plasma & OXY - Acetylene Cutting Machine  Pug Cutting Machine Welding Facilities:  Manual Welding, SAW, TIG, MIG, STUD Welding  Separate enclosure for SS Welding Heat Treatment Facility:  Oil Fired Stress Relieving Furnace 50 Tons  7.2 Mtr. x 6 Mtr. x 4.5 Mtr. Finishing:  Grit Blasting - 6 x 6 x12 Mtr.  Sand Blasting Fig- heavy fabrication shop machine fig- fabrication shop (welding)
  • 32. 32 Conclusion CNC: • Cnc mean computer numerical control machine it’s a form of programmable automation drill drawings on wood use g coding consist of 3 motors and their drivers and pic with its basic circuit and body made of wood hold on motors and drill and the wood we want to draw on it • We tried to make cheap fast safety cnc machine that drill on wood piece according to any drawing we draw to it. WELDING: Welding process a very good process for joining a metal and dissimilar metal to required a varias purpose