BHEL BAP (RANIPET) internship report

1
A STUDY OF STANDARD TOOLS USED IN VARIOUS MACHINES
INTERNSHIP REPORT
A report submitted in partial fulfillment of the requirements for the award of
Degree of
BACHELOR OF ENGINEERING
In
MECHANICAL ENGINEERING
Submitted by
N.ARUNKUMAR (REG.NO: 11179D008)
J.THEERAJ RAGAVENDAR (REG.NO: 11179D134)
Under the Supervision of
Mr. D.VANCHINATHAN
(Senior Engineer, BHEL BAP, Ranipet)
(Duration: 16th
December, 2019 to 13th
January, 2020)
DEPARTMENT OF MECHANICAL ENGINEERING
Sri Chandrasekharendra Saraswathi Viswa Mahavidyalaya University
(Deemed to be university u/s 3 of act 1956) Accredited with ‘A’ grade by Naac
Enathur, Kanchipuram, Tamil Nadu 631561

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DEPARTMENT OF MECHANICAL ENGINEERING
Sri Chandrasekharendra Saraswathi Viswa Mahavidyalaya University
(Deemed to be university u/s 3 of act 1956)
Kanchipuram
CERTIFICATE
This is to certify that the following students of B.E in MECHANICAL from Sri
Chandrasekharendra Saraswathi Viswa Mahavidyalaya University, Kanchipuram
completed an Internship in BHEL, RANIPET during the period from 16/12/2019 to
13/01/2020 and the internship work done by them was found satisfactory .
1. N.ARUNKUMAR (REG.NO: 11179D008)
2. J.THEERAJ RAGAVENDAR (REG.NO: 11179D134)
( DEPARTMENT HOD )
Dr.T.Rajmohan ,
Head of Department,
Department of Mechanical Engineering,
SCSVMV UNIVERSITY,
Enathur,
Kanchipuram-631561.

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Acknowledgement
We would like to take this opportunity for thanking the
almighty for inspiring us with this internship and for allowing us to
complete it successfully.
We thankful to our HOD Dr. T. RAJMOHAN whose constant
enthusiasm engaged us on to achieve better.
Our Department Internship Coordinator Dr. K.PALANI is
most deserving of our gratitude as he constantly encouraged and
supported us. He guided us well in the internship both with his
knowledge and his words of encouragement.
We would like to thank MR.M.KANAGARAJ (DEPUTY
MANAGER/HR) for providing us opportunity to do Internship
successfully.
We are thankful to the company internship guide
Mr.D.VANCHINATHAN (SENIOR ENGINEER/TOOL ENGG) for helping to
carry out our internship successfully.
We would like to thank BHEL Management and
Department Staffs for their friendliness and helping nature, who
helped us in successful completion of this internship and clearing our
doubts.
We would like to thank our beloved Parents for their immense
support.

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ABSTRACT
The aim of our internship training in BHEL-BAP is about A STUDY
OF STANDARD TOOLS USED IN VARIOUS MACHINES.
In this field we learnt different types of tool inserts used in
manufacturing the products.
BHEL is the largest engineering and manufacturing enterprise in
India in the energy related infrastructure sector today and one of the
MAHARATNA company .It provides its customer a wide range of
suitable products, systems, services efficiently and at competitive
prices. Products of BHEL such as boiler, GAS generator, hydro
generator, steam turbines, transformers, hydro turbines, wind mill,
electrostatic precipitator etc.
We came to know about the types of tool inserts used for
manufacturing unit. It gives us clear idea practically where we studied
theoretically. Through this training we visualized the process
undergone in a manufacturing company, which is very helpful for our
further studies.

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TABLE OF CONTENTS
S.NO: TITLE PAGE NO:
1 INTRODUCTION 7
1.1 BHEL-OVERVIEW 7
1.2 OPERATIONS 9
1.3 ENGINEERING & MANUFACTURING
COMPANY
10
1.4 BHEL LOCATION MAP 11
1.5 BHEL PRODUCTS 13
1.6 BHEL SHARE 14
1.7 GOVERNMENT OF INDIA AWARDS 17
2 BHEL - BOILER AUXILIARIES PLANT(BAP) 18
2.1 COMPANY PROFILE 18
2.2 PRODUCTS OF BHEL BAP 19
2.3 VARIOUS DEPARTMENT IN BHEL BAP 20
3 CUSTOMERS AND COMPETITORS 24
4 BHEL SWOT ANALYSIS 25
5 TOOL ENGINEERING 26
5.1 MACHINE NO: 1
GEMINIS CNC LATHE MACHINE
28
5.2 MACHINE N0:2
HORIZONTAL LATHE CNC TAACHE
31
5.3 MACHINE NO: 3
INNSE CNC LATHE
33
5.4 MACHINE NO: 4
HORIZONTAL BORING MACHINE
36
5.5 MACHINE NO: 5
VERTICAL TURNING LATHE
38

6
5.6 MACHINE NO: 6
SKIQ 12 CNC LATHE
40
5.7 MACHINE NO: 7
ECONO CNC 26
42
5.8 MACHINE NO: 8
VERTICAL MILLING MACHINE
45
5.9 MACHINE NO: 9
GBM 14 CNC LATHE MACHINE
46
5.10 MACHINE NO: 10
STC 25 CNC MACHINE
47
5.11 MACHINE NO: 11
5M 4G LATHE MACHINE
50
5.12 MACHINE NO: 12
OOD 200 CNC LATHE MACHINE
55
5.13 MACHINE NO: 13
SB CNC LATHE: SLANTING BED
TURNING CENTER LATHE
57
5.14 MACHINE NO: 14
CNC DRILLING MACHINE
61
5.15 MACHINE NO: 15
SORALECE CNC LATHE MACHINE
62
5.16 MACHINE NO: 16
SU80 LATHE MACHINE
65
5.17 MACHINE NO: 17
SNC CNC LATHE
67
5.18 MACHINE NO: 18
L77 CNC
70
5.19 MACHINE 19:
CNC HORIZONTAL DRILLING
MACHINE
72

7
5.20 MACHINE NO: 20
L57 8M CENTRE LATHE
74
5.21 MACHINE NO: 21
HORIZONTAL BORING MACHINE
76
5.22 MACHINE NO: 22
GG TURNING CNC LATHE MACHINE
78
5.23 MACHINE NO: 23
DOUBLE COLUMN 2000 CNC
MACHINE CENTER
80
5.24 MACHINE NO: 24
HEAVY DUTY CNC LATHE
82
5.25 MACHINE NO: 25
RM 65 RADIAL MILLING MACHINE
85
5.26 MACHINE NO: 26
SV 63 LATHE MACHINE
87
5.27 MACHINE NO: 27
SAFOP CNC LATHE HEAVY DUTY IN
HORIZONTAL
89
5.28 MACHINE NO: 28
REM 62 CNC VERTICAL TURNING
LATHE
91
5.29 MACHINE NO: 29
AZ11 HORIZONTAL MILLING
MACHINE
93
6 CONCLUSION 94
7 REFERENCES 95

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1. INTRODUCTION
1.1 BHEL-OVERVIEW
Bharat Heavy Electricals Limited (BHEL) owned and
founded by the Government of India, is an engineering and
manufacturing company based in New Delhi, India. Established
in 1964, BHEL is India's largest power generation equipment
manufacturer.
BHEL was established in 1964 ushering in the
indigenous Heavy Electrical Equipment industry in India. Heavy
Electricals (India) Limited was merged with BHEL in 1974.
In 1991, BHEL was converted into a public limited company.
Over time, it developed the capability to produce a variety of
electrical, electronic and mechanical equipment for all sectors,
including transmission, transportation, oil and gas and other
allied industries .However, the bulk of the revenue of the
company is derived from sale of equipment for power
generation such as turbines, boilers, etc. As of 2017, BHEL
supplied equipment contributed to about 55% of the total
installed power generation capacity of India. The company has
also supplied thousands of Electric Locomotives to Indian
Railway, as well as defence equipment such as the Super Rapid
Gun Mount (SRGM) naval guns manufactured in partnership
with the Indian Ordnance Factories and Defence Simulators to
the Indian Armed Forces.

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1.2 OPERATIONS
BHEL is engaged in the design, engineering,
manufacturing, construction, testing, commissioning and
servicing of a wide range of products, systems and services for
the core sectors of the economy, viz. power, transmission,
industry, transportation, renewable energy, oil & gas, and
defence.
It has a network of 17 manufacturing units, 2 repair
units, 4 regional offices, 8 service centres, 8 overseas offices, 15
regional centres, 7 joint ventures, and infrastructure allowing it
to execute more than 150 projects at sites across India and
abroad.
The company has established the capability to
deliver 20,000 MW p.a. of power equipment to address the
growing demand for power generation equipment.

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1.3 Engineering & Manufacturing Company

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1.6 BHEL SHARE
One of the Seven “Maharatna”
YEARLY TURNOVER

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Building Indigenous Technology
• Started with technology support from Global OEMs and
developed indigenous capabilities
• Capability to design product to customer specs
• Better understanding of Indian coals
• Offering coal based sets of ratings upto 1000 MW
• IGBT based technology in Transportation segment
• Nuclear sets of ratings upto 700 MWe
• UHVAC Transformer and Reactors
• GIS substations
• Emission control equipment – NOx, SOx and particulates
control
• Developed regenerative braking system for electric
locomotives-first time in the country
• Currently developing India's first coal fired Advanced Ultra
Supercritical (AUSC) power plant technology with IGCAR &
NTPC
• Developing coal-to-methanol technology for industrial scale
methanol production
• Propulsion systems for electric vehicles

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BHEL Make Electric Utilities Installations Across India
References in 83 countries across the world

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1.7 Government of India Awards

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2 BHEL - BOILER AUXILIARIES PLANT(BAP)
2.1COMPANY PROFILE:
. BOILER AUXILIARIES PLANT (BAP), the 13th
manufacturing unit of BHEL was set up at Ranipet in
1980.
. BAP at Ranipet was set up as a byproduct plant for the
manufacture of boiler auxiliaries.
. The total capacity of BAP is 57000 tons/year.
. The main products are ESP(Electrostatic precipitator),
APH(Air Pre-heater), FANS and DAMPERS & GATES.
. The unit also manufactures fuel tank for ISRO.
. BAP is the first unit of its whole corporation to upgrade
to ISO 9001:2015 quality management system.

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2.2 PRODUCTS OF BHEL BAP
1) Air Pre-heater:
Air pre-heater transfer heat from flue gases to cold
primary and/ or secondary air by means of rotating
heating surface elements. Beneath this regenerative type
air pre-heaters, there exists a steam coil air pre-heater.
These are located in the secondary pass of the furnace
at a height of around '16' M level. Each 200 MW unit is
provided with two such air pre-heaters.

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Electrostatic precipitator :
These are generally two plate type located between boiler
and the chimney. The precipitator is arranged for
horizontal gas flow and is constructed with welded steel
castings.

21
GATES AND DAMPER:
A Gates and Damper is a valve or plate that stops or
regulates the flow of air inside a duct, chimney, VAV box,
air handler, or other air-handling equipment. A damper
may be used to cut off central air conditioning (heating
or cooling) to an unused room, or to regulate it for room-
by-room temperature and climate control.

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Fans:
Axial reaction fans of single stage and double stage type
for clean air application. Axial impulse fans for clean air
and flue gas applications. Single and double suction type
radial fans for clean air dust laden hot gas applications
upto 400° C
P.A. Fan: The primary air fans (2 per unit - 50% capacity
each) are designed for handling atmospheric air upto a
temperature of 50 deg C. These fans are located at *0'M
level near the boiler. near the PA Fan.
ID Fans: There are two induced Draft fans per boiler
located between the Electrostatic precipitator and the
chimney. These fans are used for sucking flue gas from
furnace.
FD Fan: These fans, again two per boiler, are used to
supply air for cooling and combustion of air fuel mixture.

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2.3 VARIOUS DEPARTMENT IN BHEL BAP

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3 CUSTOMERS AND COMPETITORS
CUSTOMERS:
. The major customers are National Thermal Power
Corporation Limited (NTPC) and STATE ELECTRICITY
BOARD
. Some private customers are TATA, Adhani, jinthal
steels, Reliance etc.
COMPETITORS:
. Larsen & Toubro Limited (L&T)
. Doosan
. Mitsubishi
. IJT

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5 TOOL ENGINEERING
OBJECTIVE:
To provide right tools, jigs and fixtures and
facilities in time to enable BHEL unit to achieve its
production target and striving to bring in excellance in
manufacturing technology through continuous technology
upgradation .
Tool engineering is a vital area of production
engineering. It includes metal cutting, pressing, and various
work holding devices. Metal cutting is the operation in which
thinlayer of metal is removed by wedge shaped tool. Metal
cutting is commonly associated with industries like
automotive, aerospace, home appliance, etc. The machining
of metal and alloys play a crucial role in the range of
manufacturing activities including ultraprecision machining
of extremely delicate components.
To provide various facilities required for shop like
pneumatic tools, permanent magnetic lifters, aluminum
platforms & ladders and fabricated items.

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Tool engineer function is to design the
jigs, fixtures, templates, mandrels, punches and dies
for press tools and non-standard drills, counterbores
to suit shops requirements.
The function of standard tools is to cater
the daily tool requirements of all the bays in BHEL.
All the tools readily available with all supplier are
categorised as standard tools. These tools are
procured and distributed through tool cribs. These
tools ranges from hand tools like screw drivers,
hammers upto high end insert type cutters for CNC
machines. Measuring instruments and gauges also
come under this category.

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5.1 MACHINE NO: 1
GEMINIS CNC LATHE MACHINE (HEMISPHERE
COMPONENT):
SPECIFICATIONS:
Swing over bed :Ø 620 mm, Control; FAGOR 8055 ,Swing over cross
slide: 370 mm, Distance between centre 2000 mm, Spindle bore:
105 mm, Spindle speeds / ranges :1600 Rpm, Bed width :430 mm,
Power:15Kw, DIMENSIONS :Length 4600 mm, Width 2400 mm,
Height 2000mm.
I. In this machine we can able to perform profile machining.
II. In this machine the lower part of hemisphere component of
satellite fuel tank for ISRO is in process.
III. insert tool used is TITANIUM.
IV. Tip material is of carbide.

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INSERT TOOLS USED:
1)CNMG19 06 12:
C-shape, N-clearance angle, M-tolerance on size, G-insert type,
19-cutting edge length, 06-thickness, 12-nose radius
2)DNMG15 06 08:
D-shape, N-clearance angle, M-tolerance on size, G-insert type, 15 -
cutting edge length, 06-thickness, 04- nose radius
3)VBMT16 04 08:
V-shape, B-clearance angle, M-insert type, T-tolerance on
size, 16-cutting edge length, 04-thickness, 08-nose radius.

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TOOL HOLDERS USED:
1) PCLNL2525:
2) PDJNL2525:
3) SUVBL16:
ISSUE: NIL

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5.2 MACHINE N0:2
HORIZONTAL LATHE CNC TAACHE:
I. In this machine, we can perform turning, facing, boring, thread
cutting, and grinding.
II. We can able to machine our work piece up to 8mm
III. Swing over diameter:1200mm
IV. In this machine, crank shaft is used for the process
INSERT TOOLS USED:
1) CNMG19 06 12:

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2) DNMG 15 06 08:
TOOL HOLDERS USED:
1) PCLNL2525:
2) PDJNL2525:
ISSUE: NIL

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5.3 MACHINE NO: 3
INNSE CNC LATHE
Specifications:
Center Height 1,500 mm
Maximum Swing Over Bed 2,800 mm
Maximum Swing Over Carriage 2,200 mm
Face Plate Diameter 1,750 mm
Chucking Diameter 300 - 1,320 mm
Turning Length 11,000 mm
Work Load Capacity Between Centers 125 Ton
Main Spindle Drive Power 176 kW
Spindle Speed - 3 Ranges 0.8 - 160 RPM

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Headstock Torque 118 KNM
Cutting Force 200 KNM
Z Axis Feed Rate 6,000 mm/min
X Axis Feed Rate 2,500 mm/min
Bed Width 2,800 mm
Approximate Machine Weight 227,000 kg
Machine Dimensions
19,456 x 5,842 x 2,590
mm
FUNCTIONS:
I. In this machine we can able to perform profile machining.
II. Mainly in this machine the inner ring of hemisphere satellite
fuel tank is being processed.
III. Both inner diameter and outer diameter of inner ring we can
able to perform.
INSERT TOOLS USED:
1) CNMG19 06 12:

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2) DNMG 15 06 08:
TOOL HOLDERS USED:
1) PCLNL2525:
2) PDJNL:
ISSUE: NIL

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5.4 MACHINE NO: 4
HORIZONTAL BORING MACHINE:
SPECIFICATIONS:
 Boring spindle diameter 100 mm
 Max spindle travel 900mm
 Head stock vertical travel (Y-axis) 1120 mm
 Moving column type design
 Highly rigid construction
 Automatic clamping/unclamping of ISO-60 tooling facility
 Circulating lubrication system for H/S & Feed gear box.
FUNCTIONS:
I. In this machine we can able to perform boring operation.
II. A horizontal boring machine or horizontal boring mill is a
machine tool which bores holes in a horizontal direction
III. . There are three main types — table, planer and floor.
IV. The table type is the most common and, as it is the most
versatile, it is also known as the universal type.

37
INSERT TOOLS USED:
1) CCMT12 04 08:
C-shape, C-clearance angle, M-insert type, T-tolerance on size,
2) TCMT 16T308:
T-shape, C-clearance angle, M-insert type, T-tolerance on size,
16-cutting edge length, T3-thickness,
08-nose radius
ISSUE: NIL

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5.5 MACHINE NO: 5
VERTICAL TURNING LATHE:
SPECIFICATIONS:
A. Maximum diameter:3200 mm
B. Maximum job diameter:3450mm
C. Maximum job height:2500mm
D. Maximum job weight:50MT
E. MAKE:CKDBLANSKO
F. CNC SYSTEM: SINUMERIK 840D
FUNCTION:
In this machine we can able to perform turning as well as grinding
operation.

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INSERT TOOLS USED:
1) CNMG19 06 12:
2) DNMG 15 06 08:
TOOL HOLDERS USED:
1) PCLNL2525:
2) PDJNL 2525:
ISSUE: NIL

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5.6 MACHINE NO: 6
SKIQ 12 CNC LATHE:
SPECIFICATIONS:
Max. TURNING diameter: Ø1500 mm
Table: Ø1250 mm
Control: Siemens 840 D
Stroke ram left: 750 mm
Speeds / ranges; 250 Rpm
Power: 40 kW
DIMENSIONS:
Length: 5000 mm
Width: 5800 mm
Height: 5570 mm
FUNCTION:
1) In this machine mainly grinding operation is being in process.
2) We can able to machine 15 tools.
3) In this machine ATC is there (AUTOMATIC TOOL CHANGER)

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4) Currently primary fan fabrication work is being processed
through grinding.
INSERT TOOLS USED:
1) CNMG19 06 12:
2) DNMG 15 06 08:
TOOL HOLDERS USED:
1) PCLNL2525:
2) PDJNL 2525:
ISSUE: NIL

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5.7 MACHINE NO: 7
ECONO CNC 26
SPECIFICATIONS :
Height of centers mm 260
Swing over bed mm 575
Swing over cross slide mm 340
Distance between
centers
mm 1000 (optional 1500/2000)
Bar passage/Spindle
bore
mm 53 (optional 80)
Spindle power
(100%)
kW 11
Speed range rpm
16 from 40-2040 forward 8 from
60-2375 reverse
Rapid traverse mm/min 5000
No. of tool stations
(turret)
8
Tailstock travel mm 200
Control system Siemens / Fanuc

43
MAINLY THIS MACHINE IS USED TO PERFORM TURNING
OPERATION.
INSERT TOOLS USED:
1) CNMG19 06 12:
2) DNMG 15 06 08:
D-shape, N-clearance angle, M-tolerance on size, G-insert type, 15
-cutting edge length, 06-thickness, 04- nose radius
3) VBMT16 04 08:
V-shape, B-clearance angle, M-insert type, T-tolerance on size, 16-
cutting edge length, 04-thickness, 08-nose radius

44
TOOL HOLDERS USED:
1) PCLNL2525:
2) PDJNL2525:
3) SUVBL 16:
ISSUE: STAINLESS STEEL CURRENTLY USING SOMETIMES
WEAR
SOLUTION: IT IS BETTER TO USE STAINLESS STEEL WITH
HIGH GRADE

45
5.8 MACHINE NO: 8
VERTICAL MILLING MACHINE
SPECIFICATIONS:
Simultaneously controllable axes: 3
No. of spindles: 1
Table size: 2240*750mm
Maximum drilling capacity: 70mm
Maximum load on table: 3000kgs
Positioning travel: 2050*310*750mm
FUNCTIONS :
1) This machine is used to take slot, face milling, drilling,
grooving, boring.
2) It is able to use 40 tools for the job.
TOOLS AND TOOL HOLDERS USED FOR RESPECTIVE
MACHINING PROCESSES:

46
TOOLS USED :
a)For drilling: Drill bit sleeve MT4 is most probably
used
.
b) For milling: End mill has been used.
DRILLING ADAPTER: FALCONI
ISSUE: NIL

47
5.9 MACHINE NO: 9
GBM 14 CNC LATHE MACHINE:
In this machine it is able to perform boring, drilling, end milling.
INSERT TOOLS USED:
1) APMT160438:
A-shape, P- clearance angle, M- tolerance on size, T- insert type,
16- cutting edge length, 04- thickness, 08- nose radius
Issue: In this machine DIAMETER OF 25mm insert is being
here to machining.
SOLUTION: It is better to use 28mm insert to make the job in
quick time as well as without wearing the radius of the tool.

48
5.10 MACHINE NO: 10
STC 25 CNC MACHINE:
SPECIFICATIONS:
Maximum turning dia. mm 250
Maximum turning length mm 600/1000/1500/2000
Bar passage/Spindle
bore
mm 80
Spindle power (100%) kW 15
Speed range rpm 35-3500
Rapid traverse m/min 12
Tailstock travel mm 110
Designed for high productivity and accuracy, with high traverse
rates and reduced non-cutting times
» 12-Station tool turret.
» Large precision couplings ensure accuracy of indexing and
rigidity.
» Optional C-axis and driven tool turret/servo turret.

49
» 700 Slant bed for easy chip flow and heat dissipation
» Separate pairs of hardened and ground rectangular SHAPE for
saddle and tailstock.
» Main spindle supported on super precision angular contact
bearings.
» Selection of pre-set dual chucking pressure / tape control FOR
dual chucking pressure
INSERT TOOLS USING CURRENTLY IN THIS MACHINE:
1) KNUX 160410L11:
K-shape, N-clearance angle, U-tolerance on size, X- INSERT type, 16-
cutting edge length, 04-thickness, L11-nose radius
2) CNMG 120408:
C-shape
N-clearance angle
M-tolerance on size
G-insert type
12-cutting edge length
04-thickness
08-nose radius

50
4) DNMG 15 06 08:
D-shape, N-clearance angle, M-tolerance on size, G-insert type, 15
-cutting edge length, 06-thickness, 04- nose radius
INSERT TOOLS MOST PROBABLY USING CURRENTLY IS CNMG AND
DNMG:
TOOL HOLDERS FOR CNMG PCLNL 2525M12:
TOOL HOLDER FOR DNMG PDJNL2525M12

51
1) The main issue of this machine is “the quality of the current
using insert tools made by this tip material sometimes makes
wear in the nose radius part of the tool”
2) It is better to use high graded advance because it is advanced
in making and it will be able to make the finishing of the
material in earlier.
3) From the operator side it is better to use advanced type of
inserts and tool holders for the job.
SOLUTION:
From our side, it is better to use insert tools and tool holders
which was in currently in the market in an advanced manner.

52
5.11 MACHINE NO: 11
5M 4G LATHE MACHINE
SPECIFICATIONS:
CNC control SIEMENS 802D
SL / FANUC 0i
Mate
Bed Type Slant bed 45
degree
Swing over Bed 275mm
Swing over Cross
slide
80mm
Swing over Way
covers
240mm
Maximum
turning
Diameter/Length
80mm /
180mm
FUNCTIONS:
1) In this machine we can able to do all kind of operations like
turning, facing, etc..,
2) This machine is one of the best kind IN CNC LATHE
OPERATIONS

53
INSERT TOOLS USED:
1) KNUX 160410L11:
K-shape
N-clearance angle
U-tolerance on size
X- Insert type
04-thickness
L11-nose radius
2) CNMG 120408:
C-shape
N-clearance angle
M-tolerance on size
G-insert type
04-thickness
08-nose radius
4) DNMG 150604:

54
D-shape, N-clearance angle, M-tolerance on size, G-insert type
15 -cutting edge length, 06-thickness, 04- nose radius
TOOL HOLDER FOR DNMG PDJNL2525M12:
ISSUE:
SCREW HOLDER TIP SOMETIMES WORN OUT.
SOLUTION:
IT IS BETTER TO USE SCREW HALON KEY WITH HARDNESS
BECAUSE IT WILL NOT MAKE ANY WORN OUT IN THE SCREW
HOLDER.

55
5.12 MACHINE NO: 12
OOD 200 CNC LATHE MACHINE
SPECIFICATION:
Capacity:
Max Turning Diameter: 13.78″
Max Turning Length: 15.75″
Max Bar Capacity: 2.56″
Swing Over Bed: 20.08″
X Axis Travel: 9.53″
Z Axis Travel: 17.32″
Rapid Traverse X Axis: 787 IPM
Rapid Traverse Z Axis: 1000 IPM
Spindle Nose: A2-6
Spindle Bore: 2.99″
Spindle Speed: 45 – 4500 RPM
Spindle Motor: 11/15 kW
Turret Capacity: 12 Stations
Turret Index Time: 0.5 Second
Tailstock Taper: MT-4
Tailstock Quill Dia.: 2.95″
Tailstock Quill Travel: 3.15″

56
General:
Power: 220v / 3-Phase
Overall Dimensions: 105″ x 64″ x 69″ High
Weight: 8800 lbs
FUNCTIONS:
1) Milling
2) Drilling
3) Boring
In this machine we can able to drill up to 70mm
INSERT TOOLS USED OF CARBIDE TIP:
1) SPKN 12 03 EDR:
2) TCMT 16T308:
08-nose radius
ISSUE: NIL

57
5.13 MACHINE NO: 13
SB CNC LATHE: SLANTING BED TURNING
CENTER LATHE:
MAIN OPERATION AND REASONS FOR THE USAGE OF THIS LATHE:
Designed for high speed turning of components, with high
rigidity and minimum TORSIONAL deflection.
» The single machine for multiple benefits.
» Optional Turn Mill Center with C-axis and driven tools.
» Optional Flexible Turning Cell with gantry job/tool
loading/unloading and post processor.
» 70° Inclined computer slant bed with large torque tube.
» Separate pairs of hardened and ground rectangular shape for
saddle and tailstock.
» Main spindle supported on preloaded taper roller bearings.
» Large precision curved couplings ensure accuracy of turret
indexing and high rigidity of turret.
SPECIFICATIONS :
Swing over bed mm 660
Maximum turning dia. mm 400
Maximum turning
length
mm 1000/1500/2000

58
Bar passage/Spindle
bore
mm 100
Spindle power (100%) kW 20
Speed range rpm 22-2750
Rapid traverse m/min 12
Tailstock quill travel mm 100
INSERT TOOLS USING CURRENTLY IN THIS MACHINE:
1)KNUX 160410L11:
K-shape
N-clearance angle
U-tolerance on size
X- insert type
04-thickness
L11-nose radius
2) CNMG 120408:
C-shape
N-clearance angle

59
M-tolerance on size
G-insert type
04-thickness
08-nose radius
3)CCMT 09T304:
C-shape, C-clearance angle, M-tolerance on size, T-insert type
09-cutting edge length, T3-thickness, 04-nose radius.
4) DNMG 150604:
INSERT TOOLS MOST PROBABLY USING CURRENTLY IS CNMG AND
DNMG:
TOOL HOLDERS FOR CNMG PCLNL 2525M1

60
ISSUE:
1) The main issue of this machine is “the quality of the current
using insert tools made by carbide tip sometimes makes wear
in the nose radius part of the tool”
2) It is better to use high graded tip because it is advanced in
making and it will be able to make the finishing of the material
in earlier.
3) From the operator side it is better to use advanced type of
inserts and tool holders for the job.
SOLUTION:
From our side, it is better to use insert tools and tool holders
which was in currently in the market in an advanced manner.

61
5.14 MACHINE NO: 14
CNC DRILLING MACHINE
FUNCTIONS:
In this machine we can able to do drilling and reaming
operation.
TOOL HOLDERS USED:
1) DRILL TIP OF HSS:
2) REAMER OF HSS:
ISSUE: NIL

62
5.15 MACHINE NO: 15
SORALECE CNC LATHE MACHINE:
SPECIFICATIONS:
Characteristics FMT 4000
Longitudinal traverse, “X” axis mm 4000
Vertical traverse, “Y” axis mm 1300/1500
Cross traverse, “Z” axis mm 1800
WORK PIECE diameter mm 2200
Working volume mm 4000 x 1500 x 1800
Fixed table mm
1240 x 4000 with embedded
turning table

63
Turning table diameter mm 1600
Turning table drive motor* kW 53
Turning table speed range* min-1 250
Maximum table capacity* Kg 8000
Heads Universal / Orthogonal
Spindle power kW 43
Spindle nose taper ISO-50 / HSK-100
Spindle speed range min-1 4000 / 5000
Rapid traverse mm/min
45000 (X axis / 35000 (Y axis, Z
axis )
CNC system** TNC 640 / Siemens 840 D SL
Coolant system
External coolant system over a
ring / Internal coolant system
up to 70 bar
Tool magazine No. tools 40 / 60 / 80 / 100 / 120
Machine weight Kg 32100
FUNCTIONS:
It is a universal machine contains universal head and it is a special
type

64
INSERT TOOLS USED:
1) XDHT 090308:
X- shape, D- clearance angle, H- tolerance on size, T- insert
type, 09- cutting edge length, 03- thickness, 08- nose radius
2) TPKN 2204PDR:
TOOL HOLDER USED:
ISO BT40:
ISSUE: FOR TOLERANCE MAINTENANCE 32 SIDE FULL
CUTTER TOOL NEEDED.
SOLUTION: To make 11mm or 12mm cutting it is better to use
32 SIDE FULL CUTTER TOOL

65
5.16 MACHINE NO: 16
SU80 LATHE MACHINE:
SPECIFICATIONS:
Model SU 80A/2750
Make TOS (Czech Republic)
Center Height 400 mm
Length of Job 2750 mm
Swing over Bed 800 mm
Swing over Cross
Slide
530 m
FUNCTIONS:
It is a manual processing machine we can use this machine for,
1) Turning
2) Facing
3) Step turning

66
INSERT TOOLS USED:
CNMG 120408:
C-shape
N-clearance angle
M-tolerance on size
G-insert type
04-thickness
08-nose radius
TOOL HOLDERS USED:
ISO 2
ISSUE: NIL

67
5.17 MACHINE NO: 17
SNC CNC LATHE:
SPECIFICATION:
Centre distance: 2.000 mm
Centre height: 350 mm
Control: Siemens 805T
Turning diameter: 700 mm over bed
425 mm over slide
Spindle speed: 0 - 2.000 Rpm
Spindle bore: 105 mm
Bed width: 450 mm
Feed on axis: 1 - 6.000 mm/rev.
Rapid traverse on axis: 6.500/8.000 mm/rev.
Work piece without steady: 3.000 kg
Work piece with 1 steady: 4.000 kg

68
Featured with: - 1 Steady
- Multi fix D1 Tool post
- Cooling unit
- User manuals
Country of origin: Italy
Engine power: 15 KW
Machine weight: 5.500 kg
Machine DIMENSIONS: 470 x 225 x 180 cm
FUNCTIONS:
1) Plain milling
2) Boring
3) Keyway
4) Drilling
5) Reaming
6) Circular parting
7) Thread cutting
INSERT TOOLS USED:
1) SPKN 12 03 EDR:

69
2) TPKN 2204 PDR:
3) TCMT 16T304:
08-nose radius
4) APMT 16 04 PDSR:
A-shape, P- clearance angle, M- tolerance on size, T- insert type,
16- cutting edge length, 04- thickness, 08- nose radius
ISSUE: NIL

70
5.18 MACHINE NO: 18
L77 CNC
FUNCTIONS:
1) OD turning
2) Facing, boring, step turning, threading.
3) Radius profile finishing
INSERT TOOLS USED:
1) CNMG 19 06 08:
C-shape
N-clearance angle
M-tolerance on size
G-insert type
04-thickness
08-nose radius

71
2) DNMG 15 06 08:
TOOL HOLDERS USED:
ISSUE: NIL

72
5.19 MACHINE 19:
CNC HORIZONTAL DRILLING MACHINE:
FUNCTIONS:
In this machine we can do horizontal milling, drilling, etc..,
INSERT TOOLS USED:
1) SPKN 12 03 EDR:

73
Tool holder used:
ISO 50
ISSUE: INSERT TIP USING CURRENTLY IS IN
ANCIENT MODEL
SOLUTION: IT IS BETTER TO USE ADVANCED
MODELS OF INSERTS

74
5.20 MACHINE NO: 20
L57 8m centre lathe:
FUNCTIONS:
1) Boring
2) Turning
3) Step turning
4) Taper machining
5) It contains double carriage
6) Fixed, closed steady
7) Open steady
INSERT TOOLS USED:
1) CNMG 19 06 08:
C-shape
N-clearance angle
M-tolerance on size
G-insert type

75
04-thickness
08-nose radius
2) DNMG 15 06 08:
TOOL HOLDERS USED:
ISSUE: CURRENTLY USING TIP SOMETIMES MAKES THE
TOOLS WEAR
SOLUTION: HIGH GRADED TIP CAN BE REPLACED TO MAKE
THE TOOL LIFE IN LONG TIME

76
5.21 MACHINE NO: 21
HORIZONTAL BORING MACHINE:
FUNCTIONS:
In this machine IMPELLAR hub is used.
INSERT TOOLS USED:
1) CCMT12 04 08:
C-shape, C-clearance angle, M-insert type, T-tolerance on size,
TOOL HOLDERS USED:
WOHL HAUPTER HSS:

77
ISSUE:
Using inserts sometimes make the time for a long
SOLUTION:
It is better to use SILITING saw cutter, it makes the
angle in a proper way what we need and it makes the
time period for job in a less way.

78
5.22 MACHINE NO: 22
GG TURNING CNC LATHE MACHINE:
SPECIFICATIONS:
HOLDING DIAMETER: 250mm
LENGTH: 6m
CYLINDRICAL: 840D
FUNCTIONS:
It is used to do rotor post to machine
INSERT TOOL USED:
DNMG 15 06 08:

79
TOOL HOLDERS USED:
ISSUE: NIL

80
5.23 MACHINE NO: 23
DOUBLE COLUMN 2000 CNC MACHINE CENTER:
FUNCTIONS:
1) Drilling
2) Threading
3) Tapping
INSERT TOOLS:
1) DRILL BIT M10:
ISSUE:
CURRENTLY IN THIS MACHINE TAPPER IS NOT IN
USE.

81
SOLUTION:
IF WE USE TAPPER IT WILL REDUCE THE TIME
USAGE. BECAUSE FOR TAPPER WE HAVE TO USE
ANOTHER MACHINE, IF WE USE THIS MACHINE
ITSELF FOR TAPPING IT WILL MAKE THE JOB TIME
PERIOD IN EFFICIENT MANNER.

82
5.24 MACHINE NO: 24
HEAVY DUTY CNC LATHE:
SPECIFICATIONS:
SWING OVER CARRIAGE: 1600 mm
SWING OVER BED: 2000 mm
ADMIT b/n CENTRES: 10000mm
LOAD CARRYING CAPACITY: 25000kg
CNC SYSTEM: Siemens 840D
FUNCTIONS:
1) It produces 47 inch shaft assembly
2) It has turning process, facing and ID boring.

83
INSERT TOOLS USED:
1) CNMG 19 06 12:
2) DNMG15 06 08:
3) VBMT16 04 08:
V-shape, B-clearance angle, M-insert type, T-tolerance on
size, 16-cutting edge length, 04-thickness, 08-nose radius

84
TOOL HOLDERS USED:
1) PCLNL2525:
2) PDJNL2525:
4) SUVBL16:
ISSUE: IN THREADING TOOL STAR SCREW IS IN USE ,
BUT IT SOMETIMES MAKES THE TOOL TO BE WORN .
SOLUTION:
IT IS BETTER TO USE HEXAGON SCREW.

85
5.25 MACHINE NO: 25
RM 65 RADIAL MILLING MACHINE:
FUNCTIONS:
1) It can be able to drill 65mm drilling
2) Tapping
3) Counter bore
4) Spot facing

86
TOOLS USED:
1)DRILL BIT M24:
ISSUE: DRILL BIT ANGLE MAKES ERROR
SOLUTION: IT IS BETTER TO USE ADVANCED DRILL BIT ANGLE
MADE AUTOMATED DRILL BITS

87
5.26 MACHINE NO: 26
SV 63 LATHE MACHINE:
FUNCTIONS: MANUAL PROCESS
1) TURNING
2) FACING
INSERT TOOLS USED:
CNMG 120408:
C-shape
N-clearance angle
M-tolerance on size
G-insert type
04-thickness

88
08-nose radius
DNMG 150604:
ISSUE: NIL

89
5.27 MACHINE NO: 27
SAFOP CNC LATHE HEAVY DUTY IN
HORIZONTAL:
SPECIFICATIONS:
SWING OVER BED:
SWING OVER CARRIAGE:
ADMIT b/n CENTRES:
MAXIMUM WEIGHT:
MODEL:
CNC SYSTEM: SINUMERIC 840p
FUNCTIONS:
1) It is used for special purpose of making 47 sector
SHAFT
2) Central ring job of satellite fuel tank of ISRO is
currently in process
INSERT TOOLS:
1) DNMG 15 06 08:

90
2) CNMG 120408:
C-shape
N-clearance angle
M-tolerance on size
G-insert type
04-thickness
08-nose radius
ISSUE: WHEN UNCLAMPING IT IS IN STEADY REST TOO HARD TO
CLAMP
SOLUTION: IN BOTTOM BLACK OF STEADY REST WE CAN PLACE
M16 DRILL TAP IT IS HELPFUL FOR LIFTING

91
5.28 MACHINE NO: 28
REM 62 CNC VERTICAL TURNING LATHE
FUNCTIONS AND SPECIFICATIONS:
1) Turning
2) Vertical boring
3) Milling and drilling
4) Mainly the model is based on SC17CNC ISF1MSFP
INSERT TOOLS USED:
1) CNMG 120408:
C-shape
N-clearance angle
M-tolerance on size
G-insert type

92
04-thickness
08-nose radius
3) DNMG 15 06 08:
TOOL HOLDERS:
ISSUE: NIL

93
5.29 MACHINE NO: 29
AZ11 HORIZONTAL MILLING MACHINE
FUNCTIONS:
1) Drilling
2) Tapping
3) Step boring
INSERT TOOLS USED:
1) DRILL BIT M24:
2) TAPPER:
ISSUE: NIL

94
CONCLUSION:
We had undergone training in BHEL-BAP for 4 weeks under
the guidance of Engineers and other Staff members.
In this we learn about A STUDY OF STANDARD TOOLS USED
IN VARIOUS MACHINES in the company.
We got a practical experience that how tools and machines
are used using new technology .We came through different types of
machines tools, lathes and other parts used in cutting ,fitting
,welding etc. It gives us a clear view about working of machines in
the manufacturing unit.
Through this training we got good experience and practical
knowledge of tools used in machines.
Department Engineers and other staff members helped us
in clearing our doubts in timely manner and made our training
successful.
It gave us an opportunity to learn about various manufacturing
functions and different departments.

95
REFERENCE:
www.bhel.com
www.learningengineering.org
www.wikipedia.org

BHEL BAP (RANIPET) internship report

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