This is summer training report on Hindustan Machine Tools Ltd, Ajmer under Foundry, manufacturing & Assembly Department.

1. A
SUMMER TRAINING REPORT
ON
FOUNDARY MANUFACTURING ASSEMBLY
OF
HMT MACHINE TOOLS LTD, AJMER (RAJ.)
GOVT. ENGINEERING COLLEGE, BHARATPUR
(AN AUTONOMOUS INSTITUTE OF GOVT. OF RAJASTHAN)
BACHELOR OF TECHNOLOGY
MACHANICAL ENGINEERING
2015-2016
Submitted By:- Submitted To:-
GULSHAN KUMAR Er. RAHUL SHRIVASTAV
12EELME023 HEAD OF DEPARTMENT
YEAR - 4th
Year (VII SEM.) MECHANICAL ENGINEERING
MECHANICAL ENGINEERING
MECHANICAL ENGINEERING DEPARTMENT
GOVERNMENT ENGINEERING COLLEGE, BHARATPUR
(AFFILIATED BY RAJASTHAN TECHNICAL UNIVERSITY)

2. GOVT. ENGINEERING COLLEGE BHARATPUR
(AN AUTONOMOUS INSTITUTION OF GOVT OF RAJASTHAN)
DEPARTMENT OF MECHANICAL ENGINEERING
SESSION: 2015-16
Certificate
This is to certify that _____GULSHAN KUMAR________ of B-Tech IV year
ROLL NO. ___12EELMEO23__ Branch Mechanical Engineering has
Successfully Submitted Summer training Report.
HEAD
MECHANICAL ENGINEERING
DEPARTMENT

3. ACKNOWLEDGEMENT
I would like to thank the entire HMT limited who has provided me
this nine weeks training. I am thankful to the HRD officer of training
centre who organized my training schedule and also the DGM’s and
AGM’s of various shop departments who have provided me the various
knowledge about their respective shops.
I also thanks to the workers of their respective departments, who
were always ready to clarify our doubts and helped us to increase our
knowledge by illustrating us to the finer points.
I wish to express my deep gratitude to all the concerned persons,
whose co-operation and co-ordination have given me the success to
complete my training in organization.
I hope that my report will reflect our technical knowledge and
innovativeness, which we gained at HMT MACHINE TOOL
LTD,Ajmer.
Gulshan Kumar
Mechanical Engineering
Roll No. 12EELME023

4. PREFACE
Industrial training is part and parcel of every technical course and
gives a face or form to all the theoretical knowledge we gain in our
classroom. We get to have a virtual experience of the processes,
methods, objects and phenomenon which used to be just an imaginary
picture in our minds. It also gives an exposure to the environment of the
industries and workshops which are virtual components of our
professional life. We too were provided with this opportunity this
summer.
We are thankful to our college administration that handed this
invaluable chance to us and at the same time we pay our regards to the
administration of HMT Ajmer (Machine Tools Division) that proved to
be a great supporting force for the fulfillment of the purpose. The
officials and the workers of the firm provided us with the best of their
attention and share ample of knowledge of their concerned field with us.
GULSHAN KUMAR
MECHANICAL ENGINEERING
12EELME023

5. Index
1. Chapter-1
1.1Introduction – Fulcrum of Indian Industrial Development
1.2 HMT at A Glance
1.3 HMT Machine Tools Division, Ajmer
2. Chapter-2
2.1 Different Department Of HMT
3. Chapter-3
3.1 Foundry Department
(A) Pattern Shop
3.1.1 Pattern Making
3.1.2 Sand Mould and Core Making
(B) Melting Department
3.1.3 Metal Melting
3.1.4 Casting and Separation
3.1.5 Removal of Runner and Riser
3.1.6 Finishing
3.1.7 Sand Recovery and Reclamation
4. Chapter-4
4.2 Manufacturing department
4.2.1 MMS (Medium Machine Shop)

6. 4.2.1.1 Milling Machine (H & V-milling)
4.2.1.2 Lathe Machine (Centre & Turret)
4.2.1.3 Boring Machine
4.2.1.4 Radial Drilling Machine
4.2.1.5 Surface and Cylindrical Machine
4.2.1.6 Honing Machine
4.2.1.7 Shaper Machine
4.2.2 ROUNDS SHOP
4.2.2.1 Internal Grinding Machine
4.2.2.2 Surface Grinding Machine
4.2.2.3 Rotary Grinding Machine
4.2.2.4 Cylindrical Grinding Machine
4.2.2.5 Slotter
4.2.2.6 Gearing
4.2.3 HDMS (HEAVY DUTIES MACHINE SHOP)
4.2.3.1 Planning
4.2.3.1.1 Double Housing Planer
4.2.3.1.2 Open Slide Planer
4.2.3.1.3 Plano Milling Machine
4.2.3.2 Boring
4.2.4 TOOLS ROOM
4.2.4.1Veriner Caliper
4.2.4.2 Micrometer

7. 4.2.4.3 Dial Indicator
5. Chapter-5
5.3 Assembly Department
5.3.1 GPM Section
5.3.2 CNC Section
5.3.2.1 Assembly
5.3.2.2 Machine Description
5.3.2.2.1 Bed Type Machine Configuration
5.3.2.2.2 Linear Motion with Guide Ways
5.3.2.2.3 Open Package Design
5.3.2.2.4 Long Nose Quill Type Spindle
5.3.2.2.5 Spindle Cooling
5.3.2.2.6 Step-less AC Spindle Motor
5.3.2.2.7 Electronic Orientation
5.3.2.2.8 AC Servomotor
5.3.2.2.9 Lubrication
5.3.2.2.10 Automatic Chip Collection
5.3.2.2.11 Guide Protection
5.3.2.2.12 Automatic Tool Changer
5.3.2.2.13 Numerical Head Counter Balance
5.3.2.2.14 Machining Features
6. Chapter-6
6.1 Bibliography

8. Chapter-1
INTRODUTION
Fulcrum of Indian Industrial Development:
When India achieved independence in 1947, there was hardly any
industrial base in the country. Right form the prior H.M.T. has played an
important role in providing the much needed industrial base as well as a
launching pad for the growth & development of the country.
HMT was conceived by the Government of India in 1949, and was
incorporated in 1953, with the objective of producing a limited range of
machine tools, required for building an industrial edifice for the country.
HMT Limited was established in 1953 in technical collaboration with
M/s Orleikon of Switzerland. Over the years, new products have been
added to its manufacturing range. It has technical collaboration with
over 30 leading International Engineering Companies for manufacture of
various products HMT’s diversified product range includes Machine
Tools, Watches, Tractors, Printing Machine Press, Di-Casting and
Plastic Injection, Moulding Machines, Food Processing Machinery,
CNC Systems, Bal Screws etc.
This Unit was established as Machine Tool Corporation of India limited
in January 1964 keeping in view the Government Policy of differing
new industries in under developed areas of the country and achieving
self reliance in production of Grinding Machine Tools which were
imported.
This Unit was started 1970-71 with a production of Rs. 8.64 Lack faces
with difficulty in procurement of quality Machine Tool Casings a
captive Foundry Plant was installed in 193 with a capital of about Rs.2
Crore.

9. This Unit was subsequently merged with HMT Ltd. On 1st April 1975
as sixth Machine Tool Plant with this merger; the Unit got backup
support of HMT. The basic plant was established with the collaboration
of the Czechoslovakian firms, M/s Skoda Export, Praha and German
firm WMW, then in East Germany.
HMT’s commitment to the development of the machine tools
technology is clearly reflected in the fact that HMT has as many as
seven exclusive machine tool units, spread across the country. Each
superbly equipped to meet the most challenging demand for machine
tools. These units are in Ajmer, Banglore, Pinjore, Kalamassery, and
Hyderabad are all ISO 9000 certified.
Today HMT is well positioned at the fore front of the precision
engineering field. Its manufacturing plants employ highly skilled
workforces strongly supported by R&D. Today over 780000 machine
tools manufactured by HMT are in used in India and elsewhere.
In tune with changing business environment, HMT limited
restructured into holding company tractors as its core business and the
following subsidiaries:
 HMT Machine Tools Limited,
 HMT Watch Limited,
 HMT Bearings Limited,
 HMT Chinar Watches Limited,
 HMT (International) Limited,
 Praga Machine Tools Limited.

10. 1.1 HMT AT A GLANCE
Date of Registration 11-01-1967
Commencement of Production 1970-71
Merger with HMT 1-04-1975
Capital Employed (as on 1.4.2007) 201 Lacs.
Land Area –Total 178 Acres
Plant Foundry 62 Acres
Township 116 Acres
Covered Area (Plant) 31848 Sq. Mtrs.
No. of Quarters 136
Power Required 4.00 Lacs Units/Month
No. of Employees (as on 01.04.2011) 381
No. of Machines 250
ISO-9001 Certified 1994
factory campus 166 acres : for township 136 quarters : for housing its
employees]
Cost of Machines working in the unit 6 Lacs up to 1 CR.60 Lacs
No. Of machine shops 180
Working shifts 4 [‘A’ shift - (6.00am to
2.00pm) ‘B’ shift - (2.00pm to 10.00pm) ‘C’ shift - (10.00pm to
8.00am)

11. HMT, MACHINE TOOLS DIVISION, AJMER
Profile of the Unit
Name of the Company HMT MACHINE TOOLS LIMITED
Name of the Unit Machine Tools Division
Location Ajmer, Rajasthan
Major Products:
Wide range of CNC Conventional, General Purpose & Special Purpose
Grinding Machines (Cylindrical, Centreless, Internal, Crankshaft,
Double Disc, Duplex, Horizontal & Vertical, Tool & Cutter) CNC
Turning Centres PUSHKAR CNC Training Lathes & Machining
Centres Reconditioning & Refurbishing
Major Manufacturing Facilities:
Machine Shop equipped with Machining Centres, CNC Turning
Centres, Jig Boring Machine, Honing Machine, Superfinishing
Machines Measuring Centre Materials Testing Laboratory CAD Centre
Foundry.
Working Hours (General Shift) : 0830 Hrs. to 1630 Hrs.
Weekly Holiday: Sunday

12. Chapter-2
DIFFERENT DEPARTMENTS OF HMT, AJMER
 Foundry
 Manufacturing
 Assembly
 Maintenance
 Inspection
MMS
ROUNDS
HDMS
TOOLS ROOM
K130
GCL
GDS
GTC
ELECTRICAL ASSEMBLY

13. Chapter-3
3.1. Foundry Department
Headed by AGM Foundry. This department is administratively
under HMT Ajmer, but functionally under executive director.
HMT’s foundry shop comprises of two units:
 One is the captive foundry, meant for the small production of
casting having weight upto 4 tonnes. The capacity of this foundry
is 1000 MT per annum.
 And the other is meant for mass production of comparatively
smaller tractor and machine components. The capacity of this
foundry is 2000 MT per annum.

14. (A) PATTERN SHOP
3.1.1 Pattern making
In casting, a pattern is a replica of the object to be cast, used to
prepare the cavity into which molten material will be poured during the
casting process.
Patterns used in sand casting may be made of wood, metal, plastics or
other materials. Patterns are made to exacting standards of construction,
so that they can last for a reasonable length of time, according to the
quality grade of the pattern being built, and so that they will repeatably
provide a dimensionally acceptable casting.
Patterns provide the exterior (mould) or interior (core)shape of the
finished casting and are produced in wood,metal or resin for use in sand
mould and core making. Patterns are usually made in two halves.
Fig. Pattern of motorcycle-yolk

15. 3.1.2. Sand mould and core making
In HMT due to complex structure of components (such as gear
box) are produced with the help of master pattern. Here core is first
made with the help of master pattern after which the core is allowed to
be baked.
Sand casting is the most common production technique, especially for
ferrous castings. Sand is mixed with clay and water or with chemical
binders and then packed or rammed around the pattern to form a mould
half. The two halves are joined together to make the mould - a rigid
cavity that provides the required shape for the casting.
The core is made with the help of sand such as
 Rigid coated sand in shell core machining.
 Air setting sand or no bake sand.
 Green sand.
Here the gear box is made with no bake/air setting sand which is
prepared by mixing different constituents.
Here the prepared core (made from master pattern) is allowed to
solidify.
Smaller core is baked with the help of shell core machine, which
has a box containing rigid coated sand. When allowed to operate the
front assembly rotates and the box moves upward from which the
sand falls in the die (die used according to shape of core required)
here die can be changed.
Now the core is put in cope, drag and the molten metal is poured
after which pattern can be easily obtained.

16. Fettling:
Fettling is the process by which the pattern obtained is given the desired
finish by various processes. Before fettling, the casting obtained is
subjected to removal of projections, chips, core, runner, riser etc. by the
following processes:
 Decoring
 Chipping
 Shot blasting (for heavy pattern)
 Wheel abrasion (for small pattern)
Decoring:
Decoring is the process of removing the fused sand.
Chipping:
Chipping is the process of removing the runner, riser etc.
Shot Blasting & Wheel Abrasion:
Shot blasting or wheel abrasion is used for removing the sand particles
by the usage of air.
After this fettling is done by the following process:
 Pneumatic gun- to remove corner sand.
 Angle grinder- to give corner finish.
 Die grinder- to give finish to inner portion.
 Pedestal grinder-to give surface finish.
While making casting for gears, surface finish is not required because
gear has to be cut on it with the help of milling machine after which it is
grinded.
Priming & Painting:
After clean and fettling, the casting is subjected to priming and painting
to prevent corrosion.

17. (B) Melting Department
3.1.3 Metal melting
The process of melting in HMT is carried out in induction furnaces at a
temperature of about 1400°-1450° C.
Process:
At first the induction furnaces are coated with fine cement clay. Now
metal scrap is inserted in the furnace and slag coagulant is added to it.
The requisite amount of coke is added to it. The current is supplied to
copper coils provided in the furnace which induce current in the metal
scrap and the scrap gets heated up, when the melting temperature is
reached the molten metal is collected in ladles and taken to the pouring
zone. When this process is being carried out the copper coils are
regularly cooled with coolant (water) so that the coils do’not melt due to
the high temperature generated in the coils.
The foundary of HMT has three furnaces, two, each having capacity
of 3MT and one of 1.5MT. The two types of induction furnaces are:-
 Main frequency Induction Furnace(50Hz)
 Medium frequency Induction Furnace(250Hz)
Melting of metal ion medium frequency furnaces are faster than the
main frequency furnaces. Molten metal is prepared in a variety of
furnaces, the choice of which is determined by the quality, quantity and
throughput required.
Electric induction furnaces are the most common type used for batch
melting of ferrous, copper and super alloys. This method involves the
use of an electrical current surrounding a crucible that holds the metal
charge. Furnace sizes range from < 100 kg up to 15 tonnes. For

18. production of super alloys and titanium, melting may be undertaken in a
vacuum chamber to prevent oxidation .
Fig. Electrical furnace
3.1.4 Casting and separation
Molten metal is poured into moulds using various types of ladles, or in
high volume production, automated pouring furnaces. Metal is poured
into the “runner” (a channel into the mould cavity) until the runner bush
is full. The “riser” provides an additional reservoir of feed metal to
counteract the shrinkage that occurs as the casting begins to cool.
When the metal has cooled sufficiently for the casting to hold its shape,
it is separated from the mould by mechanical or manual methods. Where
sand moulds are used, the process is often referred to as shakeout or
knockout, and large amounts of dust may be generated.

19. 3.1.5 Removal of runners and risers
A riser, also known as a feeder, is a reservoir built into a metal
casting mold to prevent cavities due to shrinkage. Most metals are less
dense as a liquid than as a solid so castings shrink upon cooling, which
can leave a void at the last point to solidify.
Risers prevent this by providing molten metal to the casting as it
solidifies, so that the cavity forms in the riser and not the casting. Risers
are not effective on materials that have a large freezing range, because
directional solidification is not possible.
They are also not needed for casting processes that utilized pressure to
fill the mold cavity. A feeder operated by a treadle is called an
underfeeder.
After casting, these extraneous pieces of metal are rem oved and often
collected for re- melting. In ferrous castings and larger non-ferrous
castings, they may be removed by knocking off, sawing or cutting using
an arc air or oxy-propane torch. In die-castings, they are often snapped
off manually.

20. 3.1.6 Finishing
A range of finishing processes is usually undertaken. These include:
♦ cleaning to remove residual sand, oxides and surface scale, often by
shot or tumble blasting;
♦ heat treatment, including annealing, tempering, normalising and
quenching (in water or oil) to enhance mechanical properties;
♦ removal of excess metal or surface blemishes, (e.g., flash resulting
from incomplete mould closure or burrs left from riser cut-off), by
grinding, sawing or arc air (oxy-propane cutting);
♦ rectification of defects by welding;
♦ machining;
♦ non destructive testing to check for defects;
♦ priming, painting or application of a rust preventative coating.
3.1.7 Sand recovery and reclamation
The industry recycles a large proportion of mould and core making sand
internally for re-use. This involves processing to remove tramp metal
and returns the sand to a condition that enables it to beused again for
mould or core production .

21. Chapter-4
4.2. Manufacturing Department
Headed by AGM (manufacturing). HMT Ajmer’s manufacturing
environment is highly advanced; this department also looks after
utilizing only the latest production techniques in all phases of
manufacturing maintenance.
MACHINE FEATURES
 Bed made of high tensile strength cast iron, heavily ribbed for
better vibration damping and shock absorption.
 Precision, widely placed V & flat guideways for table with
continuous automatic lubrication. Turcite lining for G17.
 Grinding wheel head spindle runs in a high precision
hydrodynamic bearing.
 Higher powered wheel head for production model for high rate of
stock removal.
 Spindle is nitrided and super finished for reliability and life.
 Precision, V & Flat guideways with turcite for infeed slide for
better damping & higher repeatability.
 Automatic infeed at table reversal for traverse grinding operation.
 Auto plunge grinding cycle consisting of rapid approach, coarse
feed, fine feed, spark out and rapid retraction.
 Single piece robust construction with long guided sleeve for better
rigidity of tailstock.
 Independent drive for internal grinding attachment.
 Single push button control cycle.

22. 4.2.1 MMS (Medium Machine Shop)
In HMT, Ajmer; It is the medium machine shop which gives the shape
to the castings which come from the foundry after being painted rough.
In this section various operations are performed for making small parts
of machines by the help of lathe (V-Turret & Centre lathe), milling,
drilling, boring and surface grinding machines. In it first of all the jobs
are marked, checked so that machining time is saved if the casting size is
oversized.
There are many types of machines are available for performing
operation like as cutting, drilling, milling, grinding etc. Each machine is
used for different operation purpose.
The main machines in shop are:
 Milling (H & V-milling) Machine
 Lathe (Centre & V-Turret) Machine
 Vertical Boring Machine
 Radial Drilling Machine
 Surface & Cylindrical Grinding Machine
 Honing Machine
 Shaper Machine

23. 4.2.1.1 Milling Machine (H & V-milling)
Milling is the machining process of using rotary cutters to remove
material from a workpiece advancing (or feeding) in a direction at an
angle with the axis of the tool.
It covers a wide variety of different operations and machines, on scales
from small individual parts to large, heavy-duty gang milling operations.
It is one of the most commonly used processes in industry and
machine shops today for machining parts to precise sizes and shapes.
V-Milling Machine
Fig. V-milling Machine
Vertical milling machine. 1: milling cutter 2: spindle 3: top slide or
overarm 4: column 5: table 6: Y-axis slide 7: knee 8: base

24. In the vertical mill the spindle axis is vertically oriented. Milling
cutters are held in the spindle and rotate on its axis. The spindle can
generally be extended (or the table can be raised/lowered, giving the
same effect), allowing plunge cuts and drilling.
H-Milling Machine
A horizontal mill has the same sort but the cutters are mounted
on a horizontal arbor ( Arbor milling) across the table.
Many horizontal mills also feature a built-in rotary table that allows
milling at various angles; this feature is called a universal table.
4.2.1.2 Lathe Machine (Centre & V-Turret)
A lathe is a machine that shapes pieces of material. Usually the
material being molded is wood or metal, and is referred to as the "work."
The most common lathes are centre lathe.
The sits between two parts of the lathe called the headsock and the
tailsock. The two parts hold the work in place and spin it quickly. When
using centre lathes the pieces are shaped by tools with a single point
cutting tools, while lathes that shape other materials, such as metal, have
tool attached to an adjustable carriage that holds the cutting tools in
contact with the spinning metal.

25. Main operation perform on Lathe machine are:
 Turning
 Taper turning
 Threading (External & Internal)
 Boring
 Grooving
 Drilling
 Facing
 Knurling
 Taping (internal thread cutting) etc.
Turret Lathe
It allow multiple cutting operations to be performed, each with a
different cutting tool in easy, rapid succession, with no need for the
operator to perform setup tasks in between, such as installing or
uninstalling tools, nor to control the toolpath. The latter is due to the
toolpath's being controlled by the machine, either in jig-like fashion, via
the mechanical limits placed on it by the turret's slide and stops, or via
electronically-directed servomechanisms for computer numerical control
lathes.

26. 4.2.1.3 Boring Machine
Boring is the operation of enlarging an already drilled hole. The
holes are pre-drilled as in casting only.
Machining time in boring:-
Machining time is the time required to complete the work place in
a request period of time.
Time required = Length of cut/(RPM × feed per meter)
Machines installed
 Horizontal Boring Machine
 Vertical Boring Machine
 Jig Boring Machine
Horizontal Boring Machine
In the horizontal boring machine, operations are performed on
those large components which cannot be rotated. The spindle and the
boring bar are horizontal.
It has mechanical system and fixture is attached with table. The
work table can be transverse along and across the machine bed.
Vertical Boring Machine
The spindle is vertical and bores vertical holes in the spindle. The
size of the machine is determined by maximum length of the job which
can be machined on it. The machine can also be used as a drilling
machine.

27. Jig Boring Machine
Jig boring machine is used to accurately enlarge existing holes and
make their diameters highly accurate. Jig boring can also maintain high
accuracy between multiple holes and surfaces.
Tolerances can be held readily within ±0.002mm. The machine can also
do accurate milling, reaming, drilling and facing,
In general, the vertical jig boring machine employs a precision
vertical tools spindle and coordinate work table with a great accuracy.
The position measuring system consists of accurate lead screw with
micrometer and an optical scale along with a vernier.
The machine are of rail type i.e. they are constructed with a cross
rail that is supported and adjusted vertically on two columns. The cross
rail serves to carry vertical spindle in its housing along the transverse
axis.
4.2.1.4 Radial Drilling Machine
A radial drilling machine or radial arm press is a geared drill head
that is mounted on an arm assembly that can be moved around to the
extent of its arm reach.
The most important components are the arm, column, and the drill
head. The drill head of the radial drilling machine can be moved,
adjusted in height, and rotated.
Aside from its compact design, the radial drill press is capable of
positioning its drill head to the work piece through this radial arm
mechanism.

28. Salient Features :
» Massive and rigid construction.
» Ergonomically grouped controls for operating convenience.
» Light centering of spindle.
» Precise depth release.
» Electrohydraulic clamping provided for drill head, arm & sleeve.
» Shock-free engagement of taps through clutch and spindle reverse for
withdrawals.
» Machine with drilling capacity 80 mm / 100 mm also available.
Fig. Radial Drilling Machine

29. Specifications :
RM 62 RM 63 RM
65
Drilling
Capacity
In Steel
In Cast Iron
mm
mm
50
60
50
60
50
60
dia 100
(At 60 rpm
with
0.5 mm/rev.
dia.125
(at 60 rpm
with 0.62
mm/rev)
Drilling depth Mm 325 325 325
Tapping In Steel
In Cast Iron
M56x2.5 or BSW 1-3/4
M70 or BSW 2-1/2"
dia. 80 dia.
100
Boring
In Steel
In Cast Iron
dia. 250 dia.
300
Spindle speeds Rpm 12:40-1800 32:10-1545
Spindle feeds no:mm/rev 6:0.125-1.25 18:0.075-4
Max. drilling
radius
Mm 1500 1790 2350
Main motor Kw 3.6 / 4.5 20

30. 4.2.1.5 Surface And Cylinder Grinding Machine
Grinding Machines are also regarded as machine tools. A distinguishing
feature of grinding machines is the rotating abrasive tool.
Grinding machine is employed to obtain high accuracy along with
very high class of surface finish on the workpiece.
However, advent of new generation of grinding wheelsand grinding
machines, characterised by their rigidity, power and speed enables one
to go for high efficiency deep grinding (often called as abrasive milling)
of not only hardened material but also ductile materials.
Conventional grinding machines can be broadly classified as:
(a) Surface grinding machine
(b) Cylindrical grinding machine
(c) Internal grinding machine
(d) Tool and cutter grinding machine
Fig. Cylindrical Grinding Machine

31. 4.2.1.6 Honing Machine
Honing is an abrasive machining process that produces a precision
surface on a metal workpiece by scrubbing an abrasive stone against it
along a controlled path.
Honing is primarily used to improve the geometric form of a surface,
but may also improve the surface texture.
Typical applications are the finishing of cylinders for internal
combustion engines, air bearing spindles and gears.
There are many types of hones but all consist of one or more abrasive
stones that are held under pressure against the surface they are
working on.
4.2.1.7 Shaper Machine
A shaping machine is used to machine surfaces. It can cut curves,
angles and many other shapes. It is a popular machine in a workshop
because its movement is very simple although it can produce a variety of
work.
The tool feed handle can be turned to slowly feed the cutting tool into
the material as the 'ram' moves forwards and backwards. The strong
machine vice holds the material securely.
A small vice would not be suitable as the work could quite easily be
pulled out of position and be damaged. The vice rests on a steel table
which can be adjusted so that it ca be moved up and down and then
locked in position. Pulling back on the clutch handle starts the 'ram'
moving forwards and backwards.

32. 4.2.2 ROUNDS SHOP
This section concerned with the round job construction and
working. The section involves operation like grinding, slotting, drilling
etc.
Following are the lists of machines and operations concerned with
them:-
4.2.2.1 Internal Grinding Machines
Concerned with grinding of inner surface of job.
4.2.2.2 Surface Grinding Machines
Concerned with outer surface of job. It uses magnetic chuck and
shows only horizontal motion of the table at the bed.
4.2.2.3 Rotary Grinding Machines
Concerned with horizontal as well as rotational movement of the
table. It also uses magnetic chuck.
4.2.2.4 Cylindrical Grinding Machine
This is used to grind cylindrical jobs with the motion of grinder
itself. This job is held in the jaw chuck.
4.2.2.5 Slotter
This machine is concerned with slot cutting. It uses carbide tip and
shows vertical motion of the tool for slot cutting.
The other machines concerned with this section are lathes, drilling
machines etc.

33. 4.2.2.6 Gearing
Gear is used for power transmission of different parts of machines.
This section is concerned with teeth cutting. Proper indexing is
maintained in the process with fixtures on the machines concerned.
There are four types of gears used in manufactured here:-
1. Spur gear
2. Worm gear
3. Helical gear
4. Bevel gear
The various machines involved are:-
Milling Machine
Generally used for manufacturing of spur gears. Cutters of
prescribed sizes are used.
Gear Hobbing Machines
Gear hobbing machine is used for manufacture of worm gear. It
uses hydraulic action.
Broaching Machine
Broaching machine is used to put splines in gear.
Gear Teeth Grinding Machines
It is used for grinding the teeth of the gears. In this machine gear teeth
are grinded by a worm type grinding wheel. Here the tooth profile are
checked with a machine called gear tooth profile tester.

34. 4.2.3 HDMS (HEAVY DUTIES MACHINE SHOP)
It is the shop which gives the shape to the largest castings which
come from the foundary after being painted rough. In this section
various operations are performed by the help of planers, boring and
planning-boring machines.
In this section, first of all the jobs are checked for the castings to
be over-size or undersize. If they are undersize, they are sent to scrap. If
they are oversize, they are marked and sent for machining.
Different types of operations are done by using different machines
including various measuring devices.
This section also includes in itself a high technology section in
which advanced machines are placed to machine crucial parts generally
guide ways etc. It accommodates a tool preset device which is used to
set the tool of all machines and CNC machines. It is used to measure the
length and diameter of the tool with the help of leases.
This section is generally divided into two sections:
 Planning
 Boring
4.2.3.1 Planning
This section consists essentially of planers mounted on one side of
the section. In this section the job planning is one of the basic operations
done for machining process. It is primarily intended for machining large
flat surfaces.
Machines Installed
 Double Housing Planer

35.  Open Side Planer
 Plano Milling Machining
 Horizontal Turning Centre
4.2.3.1.1 Double Housing Planer
This is the heavy type of planer and is used for heavy cuts by
double cutters. Its length is 3000mm. It consists of two columns, one on
each side of bed. The cross rail is fitted between the two housings which
can accommodate one or two heads, according to the specifications.
4.2.3.1.2 Open Side Planer
This type of planer consists of a single column situated vertically
on one side of the bed and other side is left open without any column.
The cross-rail is wholly supported on the single column. Only one
tool head can be located on it as there is only one column.
4.2.3.1.3 Plano Milling Machine
This is similar to a double housing planer but the tool can be
milling tool. One of the machines is TNC (three axis turning centre) in
which only one axis can be moved at a time. Thus round jobs cannot b
machined here.
Another machine is CNC in which two axis can be moved
simultaneously to machine round job. The length of the bed is 2800mm.
4.2.3.2 Boring
This is already discussing in MMS section.

36. 4.2.4 TOOLS ROOM
This department keeps various kinds of tools which are useful during
manufacturing of heavy pats. Most of the tools are measuring devices
such as vernier caliper, micrometer etc.
4.2.4.1 Vernier Caliper
A vernier caliper is a device used to measure the distance between
two symmetrically opposing sides.
The tips of the caliper are adjusted to fit across the points to be
measured, the caliper is then removed and the distance read by
measuring between the tops with a measuring tool, such as a ruler.
Vernier calipers can measure internal dimensions (using the uppermost
jaws in the picture), external dimensions using the pictured lowered jaws
and depending on the manufacturer, depth measurements by the use of a
probe that is attached to the movable head and slides along the center of
the body. This probe is slender and can get into deep grooves that may
prove difficult for other measuring tools.
The vernier scale may include both metric and inch measurements
on the upper and lower part of the scale.
Vernier calipers commonly used in industry to provide a precision
to a hundredth of a millimeter (10 micrometers), or one thousandth of an
inch.

37. Parts of Vernier caliper
 Outside Jaws: used to measure external diameter or width of an
object
 Inside Jaws: used to measure internal diameter of an object
 Depth Probe: used to measure depth of an object or an hole
 Main Scale: gives measurements of up to one decimal place (in
cm)
 Main Scale: gives measurements in fraction (in inch)
 Vernier gives measurements up to two decimal places (in cm)
 Vernier gives measurements in fraction (in inch)
 Retainer: Used to block movable part to allow the easy
transferring a measurement.
4.2.4.2 Micrometer
A micrometer sometimes known as a “Micrometer Screw Gauge”,
is a device used widely in mechanical engineering and machining as
well as most mechanical trades for precision measurement, along with
other metrological instruments such as dial calipers and vernier calipers.
Micrometers are often, but not always, in the form of calipers.
Types of Micrometer:
 Outside Micrometer (aka micrometer caliper), typically used to
measure wires, spheres, shafts and blocks.
 Inside Micrometer, used to measure the diameter of holes.
 Depth Micrometer, measures depths of slot and steps.
 Bore Micrometer, typically a three-anvil head on a micrometer
base used to accurately measure inside diameters.
 Tube Micrometer, used to measure the thickness of tubes.

38. 4.2.4.3 Dial Indicator
Dial indicators, also known as dial gauge and probe indicators, are
instruments used to accurately measure small linear distances, and are
frequently used in industrial and mechanical processes. They are named
as so because the measurement results are displayed in a magnified way
by means of a dial.
Dial Indicator may be used to check the variation in tolerance
during the inspection process of a machined part, measure the deflection
of a beam or ring under laboratory conditions, as well as many other
situations where a small measurement needs to be registered or
indicated. Dial indicators typically measure ranges from 0.25mm to
300mm (0.015in to 12.0in), with graduations of 0.001mm to 0.01mm
(metric) or 0.00005in to 0.001in (empirical).

39. Chapter-5
5.3. Assembly department
5.3.1 GPM Section
GPM stands for general purpose machines. These are generally
manually worked machines involving no computerized or numerical
control. These machines are semiautomatic in nature and some of its
operation like table movement, job movement, tool movement etc. can
be carried out either automatically or even manually.
These are operated by concerned operations only. The concept of
modern days machines originated from GPMs itself.
These are the simplest form of the metal working machines.
Main machine in this section are:
 K130
 GCL (Centre-less Grinding)
 GDS (Double Surface Grinding)
 GTC (Tool Cutter Grinding)

40. 5.3.2 CNC SECTION
Introduction
We know that GPMs are semi-automatic machines. They require an
operator for each work piece loaded on machine and in a limited period.
Mass production is not possible in these machines. Moreover complex
shaped jobs require high precision. They need for flexible automation
has always been felt. And this is an era of machine tool automation. So,
flexible automation is implemented in machine tools in the form of NC
and CNC (Computerized Numerical Control) technology . Today HMT
is producing a lot of CNC variants of conventional machine tools with
the specialized functions and mostly CNC products.
CNC machines are part of the field named mechatronics. This field is the
combination of electronics and mechanical engineering fields. When
they work in combination they are termed as above. A single CNC
machine can perform variety of machining operations in a sequential
order (based upon the programme). For example drilling , tapping ,
slotting, milling, etc. operator is used only for clamping and declamping
purpose ( after feeding the programme ). These machines ensure
repeatability of the dimensions (precision). Accuracy of these machines
is in microns.
A CNC machine may be of three dimensional coordinate system with
XYZ axis. Rest two are available on machines whose table can rotate
and tilt. These are 4th
and 5th
axis. The axis of the spindle is termed as Z
axis. The axis which crosses Z axis perpendicularly is X axis and the
other mutually perpendicular axis is Y axis. CNC machines differ in
orientation of the main spindle. If spindle is horizontal it is termed as
HMC (horizontal machining centre) and if the spindle is vertical it is
termed as VMC (vertical machining centre). Model number of machine
depends upon capacity of machine. Capacity means traverse length
along various axis or maximum size of the pallet. Thus a VTC 1000
designates a CNC machines whose spindle is vertical with pallet size or
traverse length of 1000mm.

41. 5.3.2.1 Assembly
Main parts of the CNC machine are:-
1. Bed
2. Column
3. Saddle
4. Table
5. Pallet chaner (optional)
6. Magazine
7. AC servo motors
8. Tool changer arm
9. Head
10. Main spindle
The different processes of assembly are:-
1. Procurement of various parts.
2. Bed is leveled.
3. Column is fixed on bed.
4. Ball screws and drive motors are installed.
5. Alignment of column w.r.t. bed.
6. Fixing table on saddle.
7. Installing ball screws and drive motor.
8. Alignment of saddle w.r.t. column.
9. Fixing table on saddle.

42. 10. Laser test:- In this test the laser beam is thrown on the pairs of
prism one attached to the table and other on the spindle of the machine
and reflected back through the same part and data is collected on the
computer and thus can be corrected.
11. Tool magazine is assembled and attached to the machine.
12. The oiling system is attached to the machine as separate apparatus
and solves the purpose of lubrication .
13. All electrical and electronics appliances are installed.
14. The body of the machine is and rest of the accessories are attached to
it.
15. Final inspection is done.
5.3.2.2 Machine Description
Salient features of CNC machines are as follows:-
5. 3.2.2.1 Bed type machine configuration
Bed type construction with longitudinal and cross movement to
work table and vertical movement to head , provides stable cutting
condition and maximum rigidity. Box type construction of bed and
column with properly ribbed reinforcement minimizes torsion and
flexural deflection.
5.3.2.2.2 Linear motion with guide ways
Preloaded anti - friction linear motion type. Guide ways in the entire
three provide clearance free guidance for slides during cutting. Their use
significantly reduces the coefficient of friction and eliminates stick slip
and thermal generation during high speed positioning. In addition they
offer high positioning and outstanding contouring capability.

43. 5.3.2.2.3 One package design
One package design i.e. integral mechanical- electrical construction
with CNC unit mounted on machine guarding, substantially cuts down
floor space requirements. This enhances productivity per unit area and
assures easy machine movement when production line is changed.
5.3.2.2.4 Long nose quill type spindle
Cylindrically shaped head end and prevents any interference with the
work complicated shape. This configuration also eliminates interference
even with large steep work. Machining of deep holes in the work are
also possible with full power and without compromising tool rigidity.
5.3.2.2.5 Spindle cooling( for machine with spindle speed of 6000
rpm)
Circulation of cooled oil through the oil jacket around the main
spindle bearing, maintains precision even in long and continuous runs.
5.3.2.2.6 Stepless AC spindle motor
AC spindle motor eliminates the troublesome brush inspections and
replacements required in case of DC motors. Another advantage of DC
motor is that it reduces electricaly consumption.
5.3.2.2.7 Electronic spindle orientation
The spindle motor has build in encoder for position feedback of the
spindle. Spindle orientation stops spindle in a particular position. This
helps in retracting bars without damaging bores in boring operations and
counter-boring/Facing. Automatic tool change is also achieved through
the features.

44. 5.3.2.2.8 AC servomotors
All the three axes are driven through AC servomotors. Their use
provides a higher rapid rate of revolution with minimum maintenance.
They also provide high acceleration and deceleration property and
subsequently increase the machining efficiency.
5.3.2.2.9 Lubrication
Automatic lubrication is provided for minimal operator attention.
Main spindle bearing and all axes drive bearing are fitted with synthetic
grease, requiring no attention for long periods . All axes ball screws and
linear re-circulating bearings are also lubricated.
5.3.2.2.10 Automatic chip collection
Flushing coolant with discharge of 100lpm is used for automatic
flushing of chips and is collected in tray at rear of machine. Wide
channels with sufficient scope are provided in both sides of bed for easy
disposal of chips at rear of machine.
5.3.2.2.11 Guide protection
Guide ways protection with telescopic cover protects guide ways
against external damages and chips.
5.3.2.2.12 Automatic Tool Changer(ATC)
Machine is equipped with a suitable number of tool station/pocket
(mainly12,30,60,120) . Using cam the automatic tool changer changes a
tool accurately and swiftly.
3.2.2.13 Numeric head counter balance
It offsets the natural weight of spindle head and guarantees consistent
cutting,high speed and highly accurate positioning. It eliminates head
falling.

45. 5.3.2.2.14 Machining Features
1. External coolant on spindle:- External coolant facilities the
machining of steel/aluminium. It also helps in taking away chips from
machining zone with its large flow.
2. Mist coolant:- Machining of light metals is faciliated with mist
coolant. Mist coolant takes away heat from work zone, with change of
state. It does not require any return path.
3. Chip conveyor:- It takes away large volume of chips produced
out of the machine continuously with its independent drive.
4. Refrigeration type of spindle coolant:- Coolant of cooled oil
with heat exchanger(refrigeration type), through spindle jacket provides
higher spindle stability which results in improved working accuracy.
5. Spindle mounted probe:- Spindle mounted probe with auto
measuring cycle and datum cycle makes fixture/job setting simple.
6. Higher speed spindle upto 8000 rpm :- It facilitates machining
of light metals with latest tool technology.
7. Pallet changer:- This part is concerned with handling of
additional table on which the next job can be mounted for machining
meanwhile machining of the current job is going on which considerably
reduces the mounting time.

46. Chapter-6
6.1 Bibliography
1. www.hmtmachinetools.com
2. www.hmtmachinetools.comAjmer-comlex
3. www.google.com
4. www.hi.wikipedia.org