HMT Ajmer, Summer Training Report

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A Report on
“VOCATIONAL PRACTICAL TRAINING”
From 16th
May 2017 to 15th
July 2017
Taken at
HMT MACHINE TOOLS LTD., AJMER
(ISO-9001-2008 Unit)
Academic Session 2014-2018
SUBMITTED TO: SUBMITTED BY:
Mr. Rahul Srivastava Upendra Singh Medtiya
H.O.D.(Mech. Dept.) B.Tech-4th Year /VIIth Sem.(Mech.)
Govt. Engineering College Govt. Engineering College
Bharatpur Bharatpur

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INDEX
Contents Page No.
1. Acknowledgment 3
2. Certificate -
3. Preface 4
4. History 5
5. Product’s Range 7
6. Pattern Shop 8
7. Foundry Shop 11
8. Assembly Shop 19
8.1 Crankshaft grinding machine 20
8.2 Double side grinding machine 22
8.3 K-130 (Cylindrical grinding machine) 24
8.4 Center less grinding machine 26
9. Tool Room 28
9.1 Studer-30 RHV 650 / 125 C 30
10. Round Section 31
10.1 Center Lathe 32
10.2 Pre-Selector Turret L 22 33
11. Medium Machining Shop 34
11.1 Knee type milling machine 34
11.2 CNC trainmaster machine center VMC 200 T PC 36
11.3 Milling Machine FNR 37
11.4 Vertical Machine Center VMC 200 T PC 38
12. Heavy Parts 40
13. Inspection 43
14. Reference 44

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ACKNOWLEDGEMENT
We would like to thanks them all those who have contributed in Vocational Training directly or
indirectly.
Most humbly and respectfully we want to express our deep sense of gratitude to Mr. SATISH GOYAL
(A.G.M. TRAINING OFFICER HMT MACHINE TOOLS LTD., Ajmer) for giving us the
opportunity to work as “TRAINEE” in this prestigious concern.
We want to extend our heartiest thanks to Mr. P.K. SINGH (Training Officer) and all those who are
associated and have contributed in this project.
Thanking You,

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PREFACE
The industrial revolution in the 18-century brought about the upliftment of science & Technology. The
revival of learning showed a new way of life the world in various spheres. Since then industries have
made a lot of progress.
The industries have made a history in the world and since then they are progressing with leaps and
bounds.
In India, industries during that time were small ones. The British were afraid that in case the India come
to know “The Know How” of various industries then the British Companies, would have lessened there
by bringing about the decline of the British Empire in India.
After independence India has made such a remarkable progress in the industries that it necessary to
mention that the India intelligence has proved its worth and the labors has also contributed a lot towards
the progress. The India Industries can now complete in the world.
The industries have helped India to have good trade with the other countries and have earned a good
amount of foreign exchange there by raising the economic standards and making way of India to become
self sufficient and self reliant.

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HISTORY
Hindustan Machine Tool is a public sector undertaking it was setup in Bangalore and registered in Feb
1953.
It is one of ten largest manufactures of machine tools in the world.
After that many manufacturing unit are opened in India:-
•Bangalore
•Ajmer
•Pinjore
•Hyderabad
•Ernakulum
 SALIENT FEATURES OF HMT MACHINE TOOLS LTD., AJMER
HMT Ajmer is a member of nation’s prestious company. The HMT LIMITED, Bangalore offering widest
range of machine tools in the world with its factories soared all over India. Other products with significant
market presence are Industrial machinery, Watches & tractors. HMT Ajmer Unit manufactures mainly
range of grinding machines and Training machines. It also has entered in the areas, such as,
Reconditioning & Retrofitting of old machines, job Order /Customer
Components manufacture, Hydraulic Groups manufacture and supply of castings.
HMT AJMER AT A GLANCE
1. Date of registration 11-01-1967
2. Commencement of production 1970-91
3. Land area 178 Acres
4. Township area 118 Acres
5. Covered area (plant) 31848 sq. m.
6. No. of Quarters 136
7. No. of Machines 168

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 VARIOUS TYPES OF GRINDING MACHINES WHICH ARE
MANUFACTURED BY HMT AJMER
•GCS (CRANCKSHAFT GRINDING MACHINE)
•GCP (CYLINDRICAL PURSUING GRINDING MACHINE)
•GRC (ROLLER CAMBER GRINDING MACHINE)
•GDS (DOUBLE SURFACE GRINDING MACHINE)
•K130 (CYLINDRICAL GRINDING MACHINE)
•GCL (CENTERLESS GRINDING MACHINE)
 OTHER SERVICE OFFERED BY HMT AJMER:-
• Manufacture of Jigs, Fixture, Tooling,
• Manufacture of Hydraulic group for Defence.Hydraulic Assembly for Tractors.
• Manufacture of high Precision & critical items, assemblies.
• Reconditioning & retrofitting of old machines.
• Supply of Castings.
• Training to outsiders/customers.
• Chemical, mechanical & Metrological Tests, Checking & Calibration.
COLLABORATION / TECHNICAL TIEUPS
Grinding
Year Collaborator Country Product
19970-71 Skodaexport Czechoslovakia Tool & cutter grinder
Vertical surface Grinder
1972-73 WMW GDR (East Company) Internal Grinder
Awards Of Excellence
1986-87 National Productivity award
1990 DSIR National Award for best R & D efforts in
Mechanical Engineering Sector 1990
1993 National Award for excellence in indigenization
of Defence Stores
1998 PMTCMTI Trust Award for Best Innovative
design at IMTEX 98 for CNC GDS 22

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PRODUCTS RANGE
TURNING
CNC Trainer Lathe CNC T100
(S)
MACHINING CENTERS
Training Machining
Center
VMC 200T
(S)
GRINDING
Cylindrical – CNC SMART 125/175 CGM 225
CNC
HCG 840 CNC
Cylindrical –
NONCNC
G17 ANUBHAV
130
APURVA 175
Surface-CNC CNC GVS 30/40/60 CNC PSG
200
Surface-NONCNC GVS 30/40 PSG 200
Centerless-NONCNC GCL 60/100/140
Centerless Twin
Grip CNC
GCL 140 FGH TG /
GCL
200
Internal – CNC SMART IG 150 GI 100 CNC
Double Disc – CNC CNC GDS 15 CNC GDS 22
Crankshaft CNC CSG 500/500*800
CNC
Crankshaft-
NonCNC
GCS 500
Tool & cutter CTC 28 TM
Roll Camber GRC 55
Grinding Center GC 175/225
SPECIAL PURPOSE GRINDERS
REFUSING & RETROFITTING
Centerless
Grinder (MIKROSA)
Centerless
Grinder (HMT)
Roll Camber
Grinder (Johnson)
Centerless
Grinder (Cincinnati)
Cylindrical
Grinder(WMW)
/ Kellenberger
Cylindrical
Grinder(HMT)
Double Disc
Grinder(SIM)
Surface
Grinder (HMT)
Profile Grinder
SPECIAL APPLICATION COMPONENTS / JIGS / FIXTURES
Defence Valve Device Oil Priming
Pump
Cock
/ Distribution
Hydraullic Unit
T70 Tank
Agriculture /
General
Engineering
Wiping Cylinder
for
Printing Machine
Hydraulic Lift
Mechanism
For tractors
Jigs / fixture/
Assembled
Units

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PATTERN SHOP
A skilled pattern maker builds a pattern of the object to be produced, using wood, metal, or a plastic
such as expanded polystyrene.
In Pattern shop before making patter we make a pattern drawing by which we can know that pattern
is in one piece or multiple. In HMT we use solid work software for making pattern drawing or manual.
IN HMT AJMER we use wooden (sagwan) & thermacole for making pattern.
Sagwan wooden is mostly used in pattern shop due to its followings importance:-
• Long life
• Light weight
• Durable
• Termite resistant
• Moisture free
• Pure
 Mostly Machines which are used in Pattern Shop which are follows:-
• Bend saw
• Thickness Planner
• Surface Planner
• Miller
• Grinder
• Bobbing sander
• Disc sander
 After making pattern we paint them with three types of colors. These colorshave
their specific purpose.
• Red color- No machining only filing
• Yellow color- For machining
• Black color- Core print
• Silver color- For stopping sand wash

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 Allowances:-
To compensate for any dimensional and structural changes which will happen during the casting or
patterning process, allowances are usually made in the pattern.
1. Contraction allowances / Shrinkage allowance
The pattern needs to incorporate suitable allowances for shrinkage; these are called contraction
allowances, and their exact values depend on the alloy being cast and the exact sand casting method
being used. Some alloys will have overall linear shrinkage of up to 2.5%, whereas other alloys may
actually experience no shrinkage or a slight "positive" shrinkage or increase in size in the casting process
(notably type metal and certain cast irons). The shrinkage amount is also dependent on the sand casting
process employed, for example clay-bonded sand, chemical bonded sands, or other bonding materials
used within the sand. This was traditionally accounted for using a shrink rule, which is an oversized rule.
Shrinkage can again be classified into Liquid shrinkage and solid shrinkage. Liquid shrinkage is the
reduction in volume during the process of solidification, and Solid shrinkage is the reduction in volume
during the cooling of the cast metal.
Generally during shrinkage, all dimensions are going to be altered uniformly, unless there is a restriction.
2. Draft allowance
When the pattern is to be removed from the sand mold, there is a possibility that any leading edges may
break off, or get damaged in the process. To avoid this, a taper is provided on the pattern, so as to facilitate
easy removal of the pattern from the mold, and hence reduce damage to edges. The taper angle provided
is called the Draft angle. The value of the draft angle depends upon the complexity of the pattern, the
type of molding (hand molding or machine molding), height of the surface, etc. Draft provided on the
casting 1 to 3 degrees on external surface ( 5 to 8 internal castings)
3. Finishing or Machining allowance
The surface finish obtained in sand castings is generally poor (dimensionally inaccurate), and hence in
many cases, the cast product is subjected to machining processes like turning or grinding in order to
improve the surface finish. During machining processes, some metal is removed from the piece. To
compensate for this, a machining allowance should be given in the casting.

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4. Shake allowance
Usually during removal of the pattern from the mold cavity, the pattern is rapped all around the faces, in
order to facilitate easy removal. In this process, the final cavity is enlarged. To compensate for this, the
pattern dimensions need to be reduced. There are no standard values for this allowance, as it is heavily
dependent on the personnel. This allowance is a negative allowance, and a common way of going around
this allowance is to increase the draft allowance.
5. Distortion allowance
During cooling of the mold, stresses developed in the solid metal may induce distortions in the cast. This
is more evident when the mold is thinner in width as compared to its length. This can be eliminated by
initially distorting the pattern in the opposite direction.

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FOUNDRY SHOP
A foundry is a factory that produces metal castings. Metals are cast into shapes by melting them into a
liquid, pouring the metal in a mold, and removing the mold material or casting after the metal has
solidified as it cools.
 Basic process
There are six steps in this process:-
1. pattern in sand to create a mold.
2. Incorporate the pattern and sand in a gating system.
3. Remove the pattern.
4. Fill the mold cavity with molten metal.
5. Allow the metal to cool.
6. Break away the sand mold and remove the casting
 COMPONENTS OF FOUNDRY SHOP:-
1. Pattern
2. Box
3. Cores
4. Runner
5. Riser
6. Chaplets
7. Gating system
8. Clamping devices
9. Ram

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Plants in foundry shop:-
 Sand plant
 Furnace plant
 SAND PLANT:-
 There are two types of sand plants used in HMT AJMER :-
o OMEGA PLANT
o AUTOMATIC MOULDING MACHINE PLANT
 OMEGA PLANT:-
Silent features about this machine:-
¤ This plant is used for mixing the sand with the binder.
¤ This mixed sand is than fulfilled in the boxes which contain the pattern so to make a mould
or cavity.
¤ After filling the boxes the workers need ram to remove the extra sand pressurizes the
sand so it occupies all the space in the box.
Material used in Omega plant:-
SAND:-
SILICA SAND
NEW SILICA
SAND
RETURN
SILICA SAND

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Silica (SiO2) sand is the sand found on a beach and is also the most commonly used sand. It is made by
either crushing sandstone or taken from natural occurring locations, such as beaches and river beds. The
fusion point of pure silica is 1,760 °C (3,200 °F), however the sands used have a lower melting point due
to impurities. For high melting point casting, such as steels, a minimum of 98% pure silica sand must be
used; however for lower melting point metals, such as cast iron and non-ferrous metals, a lower purity
sand can be used (between 94 and 98% pure).
Silica sand is the most commonly used sand because of its great abundance, and, thus, low cost (therein
being its greatest advantage). Its disadvantages are high thermal expansion, which can cause casting
defects with high melting point metals, and low thermal conductivity, which can lead to unsound casting.
It also cannot be used with certain basic metal because it will chemically interact with the metal forming
surface defect. Finally, it causes silicosis in foundry workers.
BINDERS:-
i. RESIN:-
Resin binders are natural or synthetic high melting point gums. The two common types used are urea
formaldehyde (UF) and phenol formaldehyde (PF) resins. PF resins have a higher heat resistance than
UF resins and cost less. There are also cold-set resins, which use a catalyst instead of a heat to cure the
binder. Resin binders are quite popular because different properties can be achieved by mixing with
various additives. Other advantages include good collapsibility, low gassing, and they leave a good
surface finish on the casting.
ii. CATHETIC BINDERS
 AUTOMATIC MOULDING MACHINE PLANT:-
Silent features about this machine:-
¤ This machine is used to mix the sand and the binders and the composition we get from
this is called GREEN SAND.
¤ This machine is fully automatic here workers do not need any ram to remove excess
sand.
¤ This contains vibrator and the pressurized ram which apply pressure on the sand and
vibrator helps in removing the excess sand.

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Composition used in this machine:-
Silica sand (SiO2), or chromite sand (FeCr2O), or zircon sand (ZrSiO4), 75 to 85%, or olivine, or
staurolite, or graphite.
Bentonite (clay), 5 to 11%
Water, 2 to 4%
Inert sludge 3 to 5%
Anthracite (0 to 1%)
 FURNACE PLANT:-
In HMT Ajmer the first furnace used was CRUCIBLE FURNACE than they used CUPOLA FURNACE
than they used ELECTRIC INDUCTION FURNACE.
ELECTRIC INDUCTION FURNACE :-
The electric induction furnace is a type of melting furnace that uses electric currents to melt metal.
Induction furnaces are ideal for melting and alloying a wide variety of metals with minimum melt losses,
however, little refining of the metal is possible.
PRINCIPLE OF INDUCTION FURNACE :-
The principle of induction furnace is the Induction heating .
INDUCTION HEATING:
Induction heating is a form of non-contact heating for conductive materials.
The principle of induction heating is mainly based on two well-known physical phenomena:
1. Electromagnetic induction

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2. The Joule effect
1) ELECTROMAGNETIC INDUCTION:-
The energy transfer to the object to be heated occurs by means of electromagnetic induction. Any
electrically conductive material placed in a variable magnetic field is the site of induced electric currents,
called eddy currents, which will eventually lead to joule heating.
2) JOULE HEATING:-
Joule heating, also known as ohmic heating and resistive heating, is the process by which the passage
of an electric current through a conductor releases heat.
The heat produced is proportional to the square of the current multiplied by the electrical resistance of
the wire.
→Induction heating relies on the unique characteristics of radio frequency (RF) energy - that portion
of the electromagnetic spectrum below infrared and microwave energy. Since heat is transferred to the
product via electromagnetic waves, the part never comes into direct contact with any flame, the inductor
itself does not get hot and there is no product contamination.
→Induction heating is a rapid, clean, non-polluting heating.
→The induction coil is cool to the touch; the heat that builds up in the coil is constantly cooled with
circulating water.
FEATURES OF INDUCTION FURNACE:-
→ An electric induction furnace requires an electric coil to produce the charge. This heating coil is
eventually replaced.
→ The crucible in which the metal is placed is made of stronger materials that can resist the required
heat, and the electric coil itself cooled by a water system so that it does not overheat or melt.
→ The induction furnace can range in size, from a small furnace used for very precise alloys only
about a kilogram in weight to a much larger furnaces made to mass produce clean metal for many
different applications.
→ The advantage of the induction furnace is a clean, energy-efficient and well-controllable melting
process compared to most other means of metal melting.
→ Foundries use this type of furnace and now also more iron foundries are replacing cupolas with
induction furnaces to melt cast iron, as the former emit lots of dust and other pollutants.
→ Induction furnace capacities range from less than one kilogram to one hundred tones capacity,
and are used to melt iron and steel, copper, aluminum, and precious metals.

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→ The one major drawback to induction furnace usage in a foundry is the lack of refining capacity;
charge materials must be clean of oxidation products and of a known composition, and some alloying
elements may be lost due to oxidation (and must be re-added to the melt).
CONSTRUCTION OF INDUCTION FURNACE :-
→ There are many different designs for the electric induction furnace, but they all center around a
basic idea.
→ The electrical coil is placed around or inside of the crucible, which holds the metal to be melted.
Often this crucible is divided into two different parts. The lower section holds the melt in its purest form,
the metal as the manufacturers desire it, while the higher section is used to remove the slag, or the
contaminants that rise to the surface of the melt.
→ Crucibles may also be equipped with strong lids to lessen how much air has access to the melting
metal until it is poured out, making a purer melt.
TYPES OF INDUCTION FURNACE:-
There are two main types of induction furnace: coreless and channel.
1. Coreless induction furnaces
→ The heart of the coreless induction furnace is the coil, which consists of a hollow section of
heavy duty, high conductivity copper tubing which is wound into a helical coil.
→ Coil shape is contained within a steel shell.
→ To protect it from overheating, the coil is water-cooled, the water being recirculated and cooled
in a cooling tower.
→ The crucible is formed by ramming a granular refractory between the coil and a hollow internal.

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→ The coreless induction furnace is commonly used to melt all grades of steels and irons as well as
many non-ferrous alloys. The furnace is ideal for remelting and alloying because of the high degree of
control over temperature and chemistry while the induction current provides good circulation of the melt.
2. Channel induction furnaces
→ The channel induction furnace consists of a refractory lined steel shell which contains the
molten metal. Attached to the steel shell and connected by a throat is an induction unit which forms the
melting component of the furnace.
→ The induction unit consists of an iron core in the form of a ring around which a primary induction
coil is wound.
→ This assembly forms a simple transformer in which the molten metal loops comprises the
secondary component.
→ The heat generated within the loop causes the metal to circulate into the main well of the furnace.
→ The circulation of the molten metal effects a useful stirring action in the melt.
→ Channel induction furnaces are commonly used for melting low melting point alloys and or as a
holding and superheating unit for higher melting point alloys such as cast iron.
ADVANTAGES OF INDUCTION FURNACE:
Induction furnaces offer certain advantages over other furnace systems. They include:
i. Higher Yield. The absence of combustion sources reduces oxidation losses that can be significant
in production economics.
ii. Faster Startup. Full power from the power supply is available, instantaneously, thus reducing
the time to reach working temperature. Cold charge-to-tap times of one to two hours are common.
iii. Flexibility. No molten metal is necessary to start medium frequency coreless induction melting
equipment. This facilitates repeated cold starting and frequent alloy changes.
iv. Natural Stirring. Medium frequency units can give a strong stirring action resulting in a
homogeneous melt.
v. Cleaner Melting. No by-products of combustion means a cleaner melting environment and no
associated products of combustion pollution control systems.
vi. Compact Installation. High melting rates can be obtained from small furnaces.
vii. Reduced Refractory. The compact size in relation to melting rate means induction furnaces
require much less refractory than fuel-fired units
viii. Better Working Environment. Induction furnaces are much quieter than gas furnaces, arc
furnaces, or cupolas. No combustion gas is present and waste heat is minimized.

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ix. Energy Conservation. Overall energy efficiency in induction melting ranges from 55 to 75
percent, and is significantly better than combustion processes.
DISADVANTAGES OF INDUCTION FURNACE :-
o Refining in Induction Furnace is not as intensive or effective as in Electric Arc Furnace (EAF).
o Life of Refractory lining is low as compared to EAF.
o Removal of S & P is limited, so selection of charges with less impurity is required.
BASIC PROCESS IN MAKING CAST IN FOUNDARY SHOP WHICH ARE AS FOLLOWS:-
» Firstly fill the sand in the box which has patterns carefully.
» wait for some time than remove the pattern from the box carefully so that sand mould does not
break.
In case if the mould or cavity are broken dawn than we can fix that broken part by the help of
BENTONITE .
» Than paint the cavity with the WHITE ZIRCON then GRAPHITE then THINNER PAINT.
» After that burn the cavity for some time so that mould become hard and the sand does not wash.
» If we require the internal cavity in the casting than we use core.
These cores can be fixed inside the mould by the help of chaplets.
» Put the bentonite threads between the top box and bottom box so that both the boxes tightly fixed.
» Than set the top box and bottom box by the help of clamping devices(C -Clamp) or nut bolt or
by putting heavy weights on the top box as per requirement.
» Than set the riser box and runner box on the top box and provide the proper gating system for the
flow of molten metal.
» Than pour the molten metal which comes from the furnace plant.
» Than kept the box for minimum 24 hours for cooling.
» After that box is put on the vibrator so that cast can easily leave the box and cast is taken out from
the box.
» Than that metal cast is send to the machining shop for finishing.
Here foundry shop completes…………………………………….

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CRANKSHAFT GRINDING MACHINE
(CSG)
SILENT FEATURES:-
»This machine is used to grind the crankshaft of the automobile.
»This machine is mainly divided into three parts:-
1. Work Head
2. Tail stock
3. Wheel Head
1. Work Head:-
» In this part job is clamped or mounted or hold by another equipment (Chuck etc.)
» Here job rotates by the help of shaft that is connected by the motor.
2. Tail Stock:-
» This is a device which is also used for holding the devices (Center to center)
3. Wheel Head:-
» Here grinding wheel is mounted on it.
» This is rotated with the help of the motors (Pulley and belt mechanism)

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Materials required for the making CSG machine body:-
» On the guide ways we use a turkide plastic because it provides the friction less motion and it has
l long life.
» this turkide plastic is fixed with the help of gum called Ardalite.
» This turkide plastic is replicable whenever it is required to remove.
Layout:-
USES:- Grinding the crankshaft, mendle, cylindrical rod.

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DOUBLE DISC GRINDING MACHINE
(GDS)
SILENT FEATURES:-
• This machine is used to grind the job on the both side at the same time.
• In this machine there are two grinding wheels are used.
• Here job is fixed between the two grinding wheel.
• Ideal grinder for mass production of components having two flat and opposite parallel surfaces with
higher geometrical accuracies.
• Machine up to 4-axes CNC control.
• User-friendly grinding cycles by customized screen.
• Preloaded antifriction guide ways for precise positioning and rigidity.
• Super precision antifriction bearing spindles.
• Hydraulic swing arm dresser.
• Automatic centralized system.
• Free standing electrical panel and hydraulic power pack.
• Pendent type operator panel.
• Built in safety interlocks.
• Input resolution 0.0001mm.
SPECIFICATION:-
• Variable speed drives for grinding wheels suitable for different areas on opposite surfaces.
• Machine can be equipped with rotary feeder, through feeder, rotary magnetic plate through feeder,
reciprocating feeder, swivel arm feeder, oscillating feeder as per requirement.
•Diamond wheels.
•Post process gauge.

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CNC GDS 15 CNC GDS 22
Grinding wheel
size(OD*W)
mm 400/450/500*65 585/660/762*70/80
Peripheriral/cutting
speed
m/sec 30 30
Dressing distance mm 80 200
Grinding Wheel motor kw 11/15 18.5/22/37
Spindle speed of both
wheels
rpm 1000 900
Dressing distance
between wheels
mm 80 200
Rotary feeder capacity-
job dia.
mm 10-50 20-80
Rotary feeder capacity-
Thickness
mm 3-30 3-40
Through feeder- job
outer dia
mm 20-70 35-220
Through feeder-job
thickness
mm 3-25 3-40
Control system Siemens/Fanuc Siemens/Fanuc
LAYOUT:-
Uses:-
This machine is used for grinding the Piston ring which requires grinding on both sides.

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K-130
SILENT FEATURE:-
•K130 is the cylindrical grinding machine which is used for grinding the cylindrical job.
•Here K130 is the specific name of the machine.
•This machine is available in the market with the different diameter as follows:-
» K130-300
» K130-500
» K130-800
» K130-1000
Here 300, 500, 800, and 1000 is the diameter. According the diameter of the job this machine is used.
•CNC cylindrical grinding machine with angular wheel head/straight wheel head facility.
•high rapid transverse for slides.
•Rigid structure.
•Well ribbed cast iron bed.
•Wheel spindle supported on multilobbed hydrodynamic bearings.
•Turkite pasted table guide ways.
•Preloaded antifriction guide ways for X-axis to have high positioning accuracy.
•Work head spindle mounted on preloaded ball bushing for axial movement of the spindle through
electromechanical drive.
•CNC dresser driven by DC servomotors.
•Moving weight type inside balancing equipment.
•Air blast oil cooler/refrigerating type to maintain temperature of lubrication oil.
•Automatic wheel slide retraction facility during power failure.
•3 axes CNC system sinumerik 810/hinumerik 3G.
OPTIONAL FEATURE:-
•Refrigeration type oil cooler to control the temperature of lubrication oil, with reference to ambient.
•Automatic center depth composition facility.
•In process gauging unit for controlling component diameter.
•AC servo motors in place of DC servo motors.
•DC motor for work head/wheel.
Paper band cum magnetic separator for fine filtration of coolant.

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•Match grinding equipment.
•Cam grinding.

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CENTERLESS GRINDING MACHINE
(GCL)
SILENT FEATURE;-
» This machine is used for center less grinding means those jobs which do not have center they can easily
grinded by this GCL machine.
»This machine consist two wheels:
¤ Grinding Wheel
¤ Rotating Wheel
»In this machine both the wheels are attached with the two different motors.
Grinding wheel motor run at constant rpm
Rotating wheel motor run at different rpm according to the job requirement.
»Bed made of high tensile strength cast iron ,heavily ribbed for better vibration damping and shock
absorption.
» Grinding wheel spindle mounted on special tilting pad type hydrodynamic bearings.
» regulating wheel spindle on super precision antifriction bearing for higher rigidity.
» Faster and easy wheel change due to cantilever design spindle.
»Automatic separate lubrication system for grinding wheel head spindle.
»outboard support provided for better rigidity in GCL 140.
»Electrically operated Micronics impulse feed for size correction and rapid movement of in feed slide
for faster setting (except GCL60).
» GCL-60 a compact machine suitable for batch &mass production.

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SPECIFICATION:-
GCL60 GCL100 GCL140
•Center height…………………………mm 975 1100 1160
•Grinding dia-min/max………….mm 1.5/63 3/100 3/140
•Max.length through feed……….mm 220 320 370
Grinding without feeding equipment...mm
•Max. Length in feed grinding….mm 95 195 245
•Grinding wheel size (OD x W)…mm 350x100 500x200 500x250
•Grinding wheel motor………….kw 7.5 22 22
•Grinding wheel speed…………..rpm 20-350 20-200 20-120
LAYOUT:-

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TOOL ROOM
Various small parts having a great accuracy are manufacture and tool room department. Also tool room
use to manufacture various tooling for different materials and due to this region and this section is called
tool room .the department is pitted with different critical machine imported when the industry was set
taped .the department are also manufactures jigs and fixtures for the machine tool projects. Three critical
machines are given below with their detail:-
COORDINATE JIG BORING MACHINE WKV-100
The machine is called as coordinate jig –boring machine because the machine operates on three
coordinates axis named as x-axis ,y-axis and z-axies.the x –axis is the vertical heads across movement
the y-axis movement is longitudinal movement of the table holding the zone. The z-axis movement is the
up and down movement of the horizontal head the machine is provided with the microscopic indicator
for ease reading the measurement the machine was initially used to make jigs.
General specification:-
I. Hydraulic table movement
II. Max. And main products jigs and fixtures.
III. At present rectified jigs and highly accurate components.
IV. Three coordinates axis motion control
V. Two spindles heads namely horizontal and vertical.
VI. Control temperature 20°C to 2°C.
Technical specification:-
Machine accuracy =0.001 mm
Vertical head
a) Min rpm = 12.5
b) Max. rpm = 2000
c) Spindle movement = right and left
d) Spindle working length = 300 mm
e) Spindle check diameter =135 mm
1. Horizontal head:-
a) Min rpm = 20

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b) Max. rpm = 1000
c) Spindle movement = up and down
d) Spindle working length = 300 mm
e) Spindle check diameter =135 mm
f) Spindle sleeve taper= 100 : 15
2. Size of machine table:-
a) Working length= 1400mm
b) Table width = 1000mm
3. Two accesoceries:-
a) Universal indexing head
b) Rotary table

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STUDER S-30 RHV 650/125 C
(PRECISION CYLINDRICAL GRINDING MACHINE)
Machine specification heading:-
1) Max. swing diameter 250mm
2) Distance between center 700mm
a) Achievable accuracyCirculatory on live spindle 0.5 micron
b) Cylindricity 2 micron
General specification:-
1) The studer S-3 machine was imported to make precision components with greater accuracy at the
time of HMT Machine Tools unit, Ajmer setup.
2) The machine is equipped with a magnetic chuck with a great holding capacity, dressing head
internal grinding head, and external grinding head.
3) The machine is capable of both internal grinding and an external grinding. Generally external
grinding is done by using this machine. There is one attachment is provided for the internal
grinding and the external grinding heads set to be ideal.
4) The machine was initially used to ground various gauges specially. Various gauges comprise
plain gauges and taper gauges.
5) Presently it is being used to ground precision components requiring microns level accuracy.
6) The components being ground comprises gear blanks, hollow shafts, sleeves and spindle etc.

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ROUND SECTION
Here small rounded components are manufacture. Following m/c are used to manufacture the round parts.
Name of M/C No. off types
1. Capstan Lathe 1
2. Drum Turret Lathe 1 RTV50
3. Turret Lathe 2
4. Centre lathe 6
5. Drilling M/c 1
6. Radial Drilling m/c 1
7. In growing m/c 2
8. Centre less grinding
m/c
1 GCL60
9. Cylindrical grinding
m/c
1 KI30U
10. BUA31 grinding m/c 1
11. Circular Dividing m/c 1
12. Linear dividing m/c 1
13. K-130 Grinding m/c 1
14. Horizontal Milling m/c 1
15. Vertical milling m/c 1
16. Slotler m/c 1 CH-25

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CENTRE LATHE LB
Manufactured by Chamundi Machine Tools Limited
Versatile lathe equally adaptable to precision tools room work and high speed production turning.
• Direct multiple V-belt drive to spindle ensure smooth torsion vibration.
• Free high turning speed
• Five inter
• Changeable tool holders with quick.
• Change tool post, interlocked feed levers, and full overload
• Portion foot brake and many other features facilitate fatigue
• Free, easy operation of the machine
MAIN DATA
CENTRE HEIGHT MM 170
DISTANCE BETWEEN
CENTRES
MM 700 OR 1000
SPINDLE NOSE/BORE MM AMERICAL TYPE L 1/42
MAIN MOTOR KW 7.5

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PRE-SELECTOR TURRET LATHE L 22
• Pre selection of speed and feeds
• Precision indexing of turret head with solid V-clamp locking
• Single lever for unclamping turret and withdrawing indexing pin extra sturdy to take overload
stress
• Dropdown mechanism avoids overloading-hardened guide ways.
MAIN DATA
CENTRE HEIGHT MM 237
DISTANCE
BETWEEN
SPINDLE
NOSE AND
TURRET
CASE
MIN. MM 390
MAX. MM 1120
Spindle nose/bore MM A2-6/65mm
Bore in turret MM 54
Main motor MM 9.3

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MEDIUM MACHINE SHOP
(M.M.S.)
KNEE TYPE MILLING MACHINE
Salient Features:-
» production milling machine
» Wide range of speeds and feeds
» Longitudinal automatic program cycle
» Rapid traverse to minimize idle time
» separate motors for spindle and feed drives
» Centralized push button controls for ease of operation
» Main spindle runs on precision taper roller bearings
Scale Horizontal Universal vertical
Table size(length &
width) 1070x230
Mm 1070x230 1070x230
Powered operated
longitudinal traverse
Mm 560 560 560
Cross traverse
(manual)
Mm 275 275 275
Vertical traverse
(manual)
Mm 375 300 375
Main motor Kw 2.2 2.2 2.2
Salient feature: -
» Streamlined construction, rugged and vibration free.
» 7.5/515 kw motor for heavy stock removal.
» Power operated feeds and rapid traverse in all direction.
» Independent main drive and feed drive motors.
» Wide range of spindle speeds and feeds.
» Instantaneous braking of spindle and table drives through electromagnetic clutches.
» High rate of rapid traverses.

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» Light fingertip push button controls.
» Inching push button for speed and feed drives.
SPECIFICATION:-
FN3/FN3E
(H & V)
FN3/FN3E
(U)
FN2/FN2E
(H,U,V)
SCALE
Overall
dimensions
(Lxw)
2050x355 2060x300 1520x310 mm
Clamping area
(Lxw)
1600x355 1600x300 1350x310 mm
POWER OPERATED TABLE TRANSVERSE
Longitudinal Mm 1200 950 800
Cross Mm 320 320 256
Vertical Mm 425 375 400
Max. safe
weight on table
Kg 600 400 350(H&V)
250(U)
Number of
speeds
18 18 18
Speed range rpm 25.5-1800 35.5-1800 35.5-1800
Main motor Kw/rpm 7.5/1500 7.5/1500 5.5/1500
Feed motor Kw/rpm 3.7/3000 3.7/3000 1.5/1500
Space required
(LxwxH)
Mm 386x253x214
(H)
345x253x209 255x250x207(H)
255x196x197
(V)
386x206x217
(W)
255x313x201
(U)
Packing case
(LxWxH)
Cm 260x245x230 260x245x230 230x195x210
Weight-
Net/Gross
Kg 3600/4500
(H)
3700/4600 2400/3200
(H)
3700/4600
(V)
2500/3300
(V&U)

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CNC TRAINMASTER MACHINING CENTER VMC 200T PC
Salient Feature:-
» An economical and user and friendly pc based system to meet training requirement of all
training centers, Technical and educational institute in CNC machine tools operation &
programming.
» Provides a comprehensive range of CNC functions for both vertical and many more advanced
features.
» Compact table top model, most ideal for training institutes.
» Step less DC drive with RPM and load indication for spindle.
» Hardened and ground spindle runs in precision antifriction bearings.
» Economical CNC system best suited to educational institutions.
» Recalculating ball screw and nut arrangement for all axis.
SPECIFICATION:-
Table size mm 420x125
Max. job weight kg 20
x-Axes (long. slide) mm 200
Y-Axes
(cross slide)
mm 125
Z-Axes
(vertical slide)
Mm 200
Type of drive Stepper drive
Resolution mm 0.01
Rapid transverse rate Mm/min 700
Feed rate Mm/min 2-550
Spindle taper ISO-30
Type of drive DC servo motor
Speed range(stepless) rpm 200-2000
Power kw 0.44
CNC system 3-axis continuous path
Pc based CNC system
Tool change Manual with CNC
prompting
No. of tools Nos. 8

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MILLING MACHINE FNR
Salient Feature:-
» Streamlined construction, rugged and vibration free
» 5.5 kw motor heavy stock removal
» Power operated feeds and rapid transverses in all direction
» Independent feed drive motor
» Wide range of spindle speeds and feed
» Speeds up to 1800 rpm and feeds up to 800 mm/min.
» All operations controlled with effortless ease by push buttons
» ‘Inching’ push button for speed and feed drives
MAIN DATA:-
Table size clamping
area(length & width)
scale Horizontal Vertical
Mm 135x310 1350x310
Powered operated(table
transverse)
Mm 800 800
Longitudinal transverse Mm
Cross mm 265 265
Vertical mm 400 400
Main motor Kw 5.5 5.5
This section consists of basically CNCoperated machine. There are three machines in this section capable
of doing several operations in one complete cycle. Two of the machine is HMC (horizontal machine
centre) and one is VMC (vertical machining centre).
The centre is so called as machine centre as the spindle
Centre remains same for various operations irrespective of function.
Each tool with its collect chuck gets attached to spindle before operation.
VMC- Vertical M/C centre at Pinjore unit.
HMC- Horizontal M/C centre
1. In KTM, London
2. In HMT,copied of KTM in Hyderabad unit

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VMC 200 T PC
VERTICAL MACHINING CENTRE
Specification:-
Table size mm 420x125
Max job weight kg 20
AXES TRAVELRANES:-
Longitudinal(table) mm 200
Cross (saddle) mm 125
Distance from spindle nose to table top mm 25-225
Throat, spindle centerline to mm 155
(horizontal) to table top mm 114-314
SPINDLE:-
Spindle nose 150 30
Spindle motor kw 0.44 DC
Speed range(infinitely
variable) RPM
200-2000
FEED RATES:-
Rapid transverse rate MM/min. 700
Feed rate MM/Min. 2-550
TOOLS:-
Tool change Manual with CNC prog.
No. of tools Nos. 8
CNC SYSTEM:-
Type PC based
No of axes 3
Axes drive Stepper Motor
Resolution 0.01 mm
Rapid transverse rate 750 MM/min.
Manual rate Incremental

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MAIN DATA:-
Table size clamping
area(length, width)
mm Horizontal
FN RH
Universal
FN RU
1350X310 1350X310
Power-operated table transverses:-
Longitudinal Mm 800 800
Cross Mm 265 265
Vertical Mm 400 400
Table swivel (On either side)
Universal Head swivel (On either side along the table as well as towards and away from the column face)
Main Motor KW 5.5 5.5
Universal Head motor KW 0.75 0.75

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HEAVY PARTS SECTION
Heavy Parts section Deals with the parts having greater dimensions. All the bed of different
castings are dealt here along with other heavy castings. The process plan here starts with the marking
three basic equipments are used viz. Tri-square, Height gauge & Surface plate. The marking is done to
pave the way of casting for other operations. After marking planning is done on a huge machine called
as Double Housing Plano- Milling Machine. The machine is capable of having four cuts in a single pass.
After planning drilling, boring etc. are done. Before marking the priming is done which gives two
advantages. First - The Consumption of paint will be less while painting. And second - The marking will
become visible.
Double housing Plano-Milling Machine
The double housing Plano Milling Machine, as its name implies, Does planning and milling. There are
two vertical heads, which travel on horizontal rails. Each head comprises of two head one Side head and
the other Cross head. So in a single pass four cuts are possible. The brief specifications of the machine
are as given below:
1. Length of Bed = 20 m
2. Width of Bed = 2 m
3. Table Width = 2 m
4. Table Length = 10 m
5. No. of Side Heads = 2
6. No. of Cross-Heads = 2
7. Height of Machine Housing = 3 m
8. Maximum Permissible Table Load = 40,000 kg.

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WD - 130 HORIZONTAL BORING MACHINE
Specifications:-
1. Capable of doing boring, Drilling and Milling operations.
2. Whole Machine travels on a Spring - Bed.
3. Rotary table.
4. Table Size
(a) Length = 2000mm
(b) Width = 2000 mm
5. Clamping Surface Area of table = 2000x2000mm2
6. Length of Bed = 3000mm
7. Width of ways on Bed = 1430mm
8. Height of table = 890 mm
9. Table travel on Bed = 1200 mm
10. Feed Motor = 4 KW
11. Motor RPM = 1720
12. Max Permissible Table Load = 20,000 kg
13. Rates of Rotary feed are applied to the 450 mm diameter of circular scale.
14. Hydraulic systems for the movement of the Machine & Table on Anti friction guide ways.

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CNC 3-Axes Planomilling Machine
Salient Features :
 Twin column machine with vertical ram.
 Ideal for medium & large size components.
 All five faces of a component can be machined with a right angle attachment.
 Siemens 840D control system.
 Auto attachment pick up and auto indexing of right angle head.
 60-Tool ATC.
 All sides fitted with LM guides.
 Universal milling attachment (optional)
Specifications:
Table mm 2000x5000
Width between columns mm 2600
Height of vertical spindle face from
table top – Min. / Max.
mm 400 / 1500
Horizontal spindle axis (ram) from table top
– Min. / Max
mm 150 / 1235
Max. load on table kg 10,000
Traverse – X / Y / Z min 5200 / 4200 / 1100
Rapid Traverse – X / Y / Z mm/min 7000 / 10000 / 5000
Spindle taper ISO 50
Spindle speed rpm 30-3000
Spindle power kW 22

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INSPECTION
It is department in which the job is inspected after every operation.
This inspection is done by the various measuring equipment.
There are some measuring instruments are as follows:-
1) Vernier caliper
2) Micrometer outside
3) Micrometer inside
4) Slip gauge
5) Height Gauge
6) Dial indicator

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REFERENCES
The main source of reference for us, during our training period have been the people here working for
the company started its production. They were the only source of information based on which we have
formulated the departments section and came to know about the lacunas existing in the company.
Through the presence of the company’s website cannot be ignored which acts as a good platform to
compare their products range with the other’s of the same category. The following are the source of
information.
1) www.hmtindia.com
2) www.wikipedia.com