training report

1. AASHIT DHARIYAPARMAR (11BME010)
KETAN GOJIYA(11BME013)
MAYUR KACHA (11BME020)
BHAUTIK VADHER (12BME163)
JYOTI CNC AUTOMATION LTD.
Industrial Training at

2. Company overview
Foundry shop
Sheet metal shop
Paint shop
Machining shop
Assembly shop

3. Location
 G - 506, Lodhika GIDC, Village Metoda, Rajkot – 360 021,
Gujarat, India.
Company overview
37 other countries
share in domestic metal cutting segment in FY 2012
• India +
• 12.7 %
• 24 products in 81 variants
• Their Indian operations
• 5 units : 3 in Rajkot, India and 2 in Strasbourg, France.
are ISO 9001:2008 certified
machines p.a. in India and 150 machines
Company acquired Huron Graffenstaden
• manufacture 2,500
p.a. in France.
• In November 2007,

4. Products
Entry Level Machines
5 types of Turning
Machines
1 Milling Machine
3 types of 3- Axis
Vertical Machining Centers
High End Machines
•4 types of Turning
Machines
•3 types of 3-AxisVertical
Machining centers
•1 Horizontal Machining
Center
•6 types of 5-Axis Vertical
Machining centres

5. SHEET METAL SHOP

7. 1. LASER cutting machine
Trumpf machine of Germany having Laser cutting technology.
 It is semiautomatic type and only loading and unloading of sheet
all done by machine itself according
is done,
to program
other operations are
given to it.
2. Bending machine
True band 5050
Trumpf CNC press brake machine
3. Robotic welding machines
4. Grinding equipments

8.  First sheet is cut by Laser cutting CNC machine which cuts
the sheet to the required size.
 Then sheet is bent to the required shape in bending
machine.
spot welding is done to attach number of
 After
sheets
bending
together.
 Before dispatching the sheet to the assembly unit grinding
of sheet is done.

9. PAINT SHOP

10. Surface Coating

11. process followed by Cathodic Electro Deposited
and conveyor zed baking with powder coating
 7 tank pre-treatment
(CED) primer coating
booths.
 4 powder coating booths for different colours.
 satisfy the aesthetic & protective requirements of customers.
Pre-treatment Plant:
per hour.
 It has capacity of
 Each basket with of the substrate to be treated.
 Basket size is 3000
 Maximum weight per
2 baskets
50 sq mtr
× 2500
basket
× 2300 mm.
is 2500 kg.
coating booths, one baking oven and overhead
Powder coating plant
 It consists of 4 powder

12. Process Duration(min) Temperature( °C)
Degrease 5-15 65-70
Rinse 1 Ambient
Rinse 1 Ambient
Derust-1 5-15 Ambient
Derust-2 30-45 Ambient
Rinse 1 Ambient
Rinse 1 Ambient
Activation 1 Ambient
Phosphate 5-15 50-55
Rinse 1 Ambient
D.I. Rinse 1 Ambient
Bake 15 160
Different surface coating processes are as follows:

13. FOUNDRY SHOP

14. FOUNDRY
Casting process body parts of CNC
machine like CNC bed, tail stroke,
is used to make the main
turn-table, saddle, etc.
Basic process for casting is described below :
Sand Mixing
• First of all, It all
preparation of sand.
sand
starts with the
They use
and 15%
85% of recycled
of fresh sand.
• it is prepared by mixing of
viz. Resin
special kind of additives
and Catalyst at particular
temperature.
• Special
automatic
OMEGA company
sand mixer is used in

15. • A sand mold is formed by packing sand into each half of
The sand is packed around the pattern, which is a
the mold.
replica of the external shape of the casting.
• When the pattern is removed, the cavity that will form the
casting remains.
• Any internal features of the casting that cannot be
the pattern are formed by separate cores which are made
formed by
of
sand prior to the formation of the mold.
• It takes 45 minutes to get completely mixed and set over the
pattern. In a mould box a pattern is kept over which the
prepared sand up.
• Now that box
is filled
is carried to the roll over machine
manufactured by OMEGA manufacturers.
• This machine turns the mould box upside down and separates
the mould with the pattern.
Mould Making

16. • After separation, mould is further carried away to the
painting or coating machine and the separated pattern
returns to be used again for the preparation of similar
kinds of moulds.
• A roller
the coating
is provided which takes mould from roll over to
machine.
• Coating is carried out either by machine or manually. If
to be coated is less, it is okay to go with
the portion
the manual coating and if the portion to be coated is
to go for machine coating.
more,
• This
one has
water based graphite coating helps in easy
separation after the molten metal is being poured.
• The next comes to the path is drying of the
thing
for which it is kept in the oven.
• drying upper and lower part is being assembled
mould
After
which is known as cope and drag assesmbly.

17. Fast loop moulding technique

18. Once the mold has
molten metal to be
been made,
poured.
is first lubricated to
it must be prepared for the
facilitate
• The surface of the mold cavity
the removal of the casting.
• Then, the cores are positioned and the mold halves are
closed and securely clamped together.
halves remain securely closed
• It is essential that the
to prevent the loss of
mold
any material.
Clamping

19. • Induction
metal.
• Pig Iron, steel scrap, runners and
risers are used as a row material for
melting.
• Generally the temperature of molten
metal
• Jyoti
goes upto 1430
has two 3
̊C.
tons capacity
induction melting furnace and
tons capacity induction furnace
one 10
for
holding the molten
• According to %
metal.
ratios of carbon,
silicon and magnesium pig iron, steel
scrap is used in melting.
• Special also used to
achieve
additives are
particular property.
Melting of Metal
furnace is used to melt the

20. • The molten
set temperature in a
metal is maintained at a
furnace.
• After the mold has been clamped, the
molten metal can be ladled from its
furnace and
holding container in the
poured into the mold.
• The pouring can be performed manually
or by an automated machine.
• Enough molten metal must be poured
channels
to fill the entire cavity and all
in the mold.
• The filling time is very short in order
to prevent early solidification of any one
part of the metal.
• Inoculate is added at the time of
Pouring

21. molten metal poured into the mold will begin to
• The
cool
that
and solidify once
is
it enters
• When the is filled
the cavity.
and
entire cavity
final shape of the casting
solidifies, the
• It is allowed 24-48 hours of cooling.
• The mold can not be opened until
the molten metal
is formed.
the cooling time has
elapsed. The desired cooling time can be estimated based
upon the wall thickness of the casting and the temperature
of the metal.
of the possible defects occur are a result of
some
that can
of the molten metal cools
• Most
the solidification process. If
too quickly, the part may exhibit shrinkage, cracks, or
incomplete sections.
Cooling

22. • After
time
the predetermined solidification
has passed, the sand mold can
simply be broken, and the casting
removed.
• This step, sometimes called shakeout,
is typically performed by a vibrating
the sand and
machine that shakes
casting out of the flask.
• Then runner and risers are removed
by hammering.
• In Jyoti, there
above knock off
is a dust collector
machine.
Removal of casting

23. • After removal of casting
chamber, in which steel balls of
it goes into shoot blasting
very small diameter
is imparted on the casting.
• Shot blasting removes the any remaining sand,
especially from internal surfaces, and reduce
surface roughness.
the
• In Jyoti, there blasting furnace, one is
are 2 shoot
automatic and one is manual.
Fettling

25. • During cooling, the material from the channels in
the mold solidifies attached to the part.
trimmed
• This excess material must be
casting either manually via
from the
cutting or sawing, or
using a grinding and trimming process.
time required to the excess material can
• The
be estimated from
envelope. A larger
size of
will require a
the casting's
longer
grinding and trimming
trim
the
casting
time.
• The scrap material that results from this trimming is
either discarded or reused in the sand casting
process. However, the scrap material may need to
be reconditioned to the proper chemical composition
before it can be combined with non-recycled metal
and reused.
Grinding and Trimming

26. • Heat treatment
increase hardness of casting
process is used to
or
stress relieving.
casting
for
• In this process,
at particular temperature
particular time and then
is heated
for
it is
cooled down.
• Temperature, and cooling
time
the properties of
rate decide
casting.
Heat treatment process

27. • Patterns
the requirements.
general wooden pattern
are made up of many different materials
over here
as per
which
• In
is cheap in coast as well
is being used
as long lasting.
• For the complicated parts aluminium metal is being used.
• Thermocole is preferred if the pattern is going to be used
for only once.
Pattern making

28. Inspection tests
mold
• Strength of sand
• Tensile strength of casting
• Metallurgy of casting
• Chemical compositions of scrap.
Different
• Ultimate
• Polishing
tools for inspection
tensile strength machine
machine
• Impact testing machine
• spectrometer
Inspection Lab

29. ASSEMBLY SHOP

30. ASSEMBLY LINES & TYPE OF LAYOUT
Assembly unit is mainly divided into three lines:
line
line
line including ATMs
1)HM
C
2)TMC
3)VM
C
Fixed
position layout to assemble
different CNCs. In this,
is used
after fixation of leveling
points, all the other mountings are done at
same position.
The sub-assembly required in the machinery is
carried out in different department.

31. Assembly of DX-150 AND DX-250
Head-stock :
It supports
mechanism.
chuck and its
It has
system which
de-clamps of
clamps
work-
and
piece.

32. Tail-stock:
It contains the supporting
supporting elements i.e.
i.e. quill
Turret assembly: It is the
part of machine which has
tools to work on job.
Generally it has ten to twelve
tools.

33. Ball-screw: Ball-screw has bolt-nut which converts its
rotating motion to linear motion.

34. Electrical panel : It contains lots of electrical and
electronic devices which leads it to automatic.
automatic.

35. Motors :
There are four different motors.
1) One for revolving of chuck (induction motor)
2) another two for ball-screw (servo motor) (motion in X
(motion in X and Z axis)
3) One motor for revolving of turret. (servo motor)
motor)

36. Pumps : There are two pumps in DX-250 and DX-150. One is for
hydraulic oil transmission and the other is for coolant circulation.
coolant circulation.
Outer sheet metal body : It provide safety to user and gives good
looks.
Coolant circulation system : This system circulates coolant which
aims to cool down the working area and also directs th removal of

37. Hydraulic pressurized oil system : There is oil sump which
contain pressurized oil and one pump for circulation. One
circulation. One most important component for hydraulic
hydraulic system is solenoid valve. There are two valves
two valves require for it. Each solenoid valve is electrically
is electrically controlled for oil circulation.

38. Lubrication system :
This system is require to reduce friction and increase efficiency.
increase efficiency.
Lubrication is provided in two X and Z axis ball-screw and L.M.
screw and L.M. through metering cartridge.
Lubrication is also provided in tailstock sleeve.

39. STEPS OF ASSEMBLY
 Base assembly
set the bad on level pad
3 point leveling system by spirit level
 Attach the L.M. guide ways on base with nut and bolts

40. using AUTO-
by means of straight
Set the guide ways linearly
COLLIMETER
check the parallelism of it
edge(linear dial)
This is very important test as saddle is mounted
on it. So, it must be perfect.
Z-axis ball screw assembly mounting
X-axis saddle and ball screw mounting
After that saddle is mounted on CNC bed with
the help of hoists
Tail stock assembly
L.M. guide is fixed
available in assembly unit.
and same process is carried
out as saddle ball screw assembly

41. Head stock assembly
fixed by hoist and alignment is done by dial gauge
gauge
squareness test is carried out for x-axis bolt-screw.

42. hydraulic oil system is fitted with its all mountings like oil
sump with nitrogen gas accumulator, solenoid valves, pipe.

43.  THERE ARE SEVERAL TESTS USED IN ASSEMBLY,
AS DESCRIBED BELOW.
 GEOMETRICAL TEST
 SQUARENESS TEST
 LASER TEST
 BALL BAR TEST
 PRACTICAL TEST
 COOLANT TRIAL
 ELECTRICAL FINAL TEST
 FINAL INSPECTION
 PRE DISPATCHED INSPECTION

44. MACHINE SHOP

45. Shop and sub-section
 Machining shop is located at Unit-1 of company
premises.
 Total 7 Sub
Machining
Machining
Machining
Sections :
shop-1
shop-2
shop-3
Grinding
Grinding
shop-1
shop-2
A quality control and
Raw material inlet & dispatch area
measurement laboratory.

46. PROCESSES
 The components made from
to give them accurate size and
casting process,
shapes.
parts
are machined
to give
Following operations are carried out on raw
them desired finish and accuracy:
Turning
Facing
Milling
Grinding
Drilling
Boring etc.

47. Parts being machined
 Following parts are machined at the machining unit:
• Bearing covers
parts
shaft
• Tool
• Jigs&
• Main
• Work
• Bed
sockets
fixture
spindle
table
of CNC
 Some of the
machines
parts are imported from the outside vendors

48. Machining shops features
Main attractions of machine shops at
 5 phase CNC machining
 Head positioning changer
Jyoti:
centre
and multi tool ATC.
the best Machining center having
 One of
APC with 60 tools
Horizontal
ATC.
Controller by ‘Siemens pt. Ltd.’ or ‘Fanuc’
 Programming
 Higher quality & productivity machines

49. Unique Features
 Due to
difficult to locate m/c
uneven mass its
on
3
 4
points
point location is tedious
and requires patience
 Easy to locate
moreover leads
on 3 point
to no
stress or twisting

50. Unique Features
 TRIM :
 Use of high torque integral
servo motor
 Replacements of complex
mechanical components like
worm and worm wheel
 Torque transmission is direct
to motor hence perfect

51. Machine companies and models
unit is
of mother machinery at machining
of the machines are manufactured by Jyoti
 Although a significant amount
from foreign companies, many
itself.
 Some other manufacturing companies of mother machines are:
 Huron pvt. Ltd.
 Nicola correa
 DMC ltd.
 SNK machines
 Here are
• VMC
some model no. of machines used at machining shop:
-640
• DX-250
• ATM-160
• VMC-430

52. Machining shop overview

53. Horizontal turning CNC m/c centers

54. Grinding shops
 All the critical parts are finished using various CNC grinding machines.
 It gives finest accuracy finishes to the machine parts that is in perfect tune with
mission of the company.
 Grinding Shops consists of:
Cylindrical grinding CNC m/c
Rotary horizontal-spindle surface grinding
Rotory vertical-spindle surface grinding CNC m/c.

55. Grinding CNC centers at Jyoti

56. References
1. http://www.jyoti.co.in/company_profile.aspx?pg=abt&sub=comp
2. http://www.jyoti.co.in/category.aspx
3. http://www.jyoti.co.in/foundry.aspx?pg=str&sub=fdry
4. http://www.jyoti.co.in/mfg_excellence.aspx?pg=str&sub=mfg
5. http://www.jyoti.co.in/sheet_metal_shop.aspx?pg=str&sub=sms
6. http://www.jyoti.co.in/paint_shop.aspx?pg=str&sub=paint
7. http://www.jyoti.co.in/research_dev.aspx?pg=str&sub=rd
8. http://www.jyoti.co.in/training.aspx?pg=str&sub=training
9. http://www.jyoti.co.in/qlty_assurance.aspx?pg=str&sub=qlty