This report summarizes the industrial training completed by Siddharth Shiyani at Jyoti CNC Automation Ltd., a leading CNC machine manufacturing company in Rajkot, India. It describes the various production processes at the company, including the foundry shop (pattern making, molding, casting), sheet metal shop (cutting, bending, welding, grinding), paint shop, machine shop, and assembly. Key steps and machinery used at each stage are outlined, along with quality checks and various tests conducted. The training provided practical experience of CNC machine manufacturing and helped gain a better understanding of implementing theoretical concepts in industry.

1. REPORT ON
JYOTI CNC AUTOMATION LTD.
G-506&2839, Lodhika, G.I.D.C.
Village, Metoda, Rajkot
SUBMITTED BY
Siddharth Shiyani
siddharthpatel9864@gmail.com
STUDENT OF
PANDIT DEENDAYAL PETROLEUM UNIVERSITY
GANDHINAGAR (22nd to 30th June)

2. ACKNOWLEDGEMENT
I am very grateful to respected H.O.D. Mr. M.B.Kiran and all the
staff members of the department of Industrial engineering for their
constant encouragement and all those who helped me directly or
indirectly in my endeavour.
I am also very thankful to Mr. Nawaz Ghodi for granting my
industrial training in Jyoti CNC Automation Ltd. and supporting me
throughout my training.
Last but not the least I am very thankful to the company and the
entire department Heads for their constant guidance. I felt very
proud for getting my training in this company.

3. Abstract
The industrial training is very essential element, as it plays
important role in an engineer’s life. As we know all that the industrial
training is the right way for understanding the theoretical concept
more effectively. Sometimes it happens that the simple theory
becomes big complication when they are applied practically.
Hence, it is necessary for engineer to undergo through in-plant
training as it gives practical knowledge about the implemented
theory. As today, the experience of an engineer is considering more
valuable than his education degree. The industrial training helps a
lot.
As we are finally exposed to an industrial environment, the engineer
gains the maximum knowledge regarding the technology and
management system possessed by the company, through which
one can improve its working ability. Clearing all the doubts, he has a
better image of the industrial field, which greatly influences his
future carrier.
I fill very lucky to take an industrial training in ‘Jyoti CNC Automation
Ltd.’ at Rajkot, a Leading CNC Machine Manufacturing Company.
So, I am glade to present this in plant training report which contains
the contents regarding the concepts of practical training through
which I passed.

4. Index
Chapter 1: Introduction
Chapter 2: Foundry shop
2.1 Pattern shop
2.2 Foundry section
Chapter 3: sheet metal shop
3.1 Metal cutting
3.2 Sheet bending
3.3 Welding
3.4 Grinding and Finishing
Chapter 4: Paint shop
Chapter 5 : Machine shop
Chapter 6: Assembly
Chapter 7: conclusion

5. Chapter 1: Introduction
Some times ago we use convectional machining process like
drilling, milling, turning, grinding and etc. All these processes done
by manually and it takes more times or time consuming processes.
In manual operate process causes many defects and errors. In
recent times we use non-convectional machine like computer
numerical controller (CNC). In CNC machines takes less times to
perform and chances of errors is to less, and also get high finishing
products. Jyoti CNC is the first company of manufacturing of CNC
machines in Gujarat. Basically Jyoti CNC manufacturing 2-axis, 3-
axis, 4-axis, 5-axis machines. The company has wide products like
CNC turning, CNC milling, CNC horizontal machining, CNC vertical
machining. In campus there are total five machine unit and two
grinding unit.
1. Foundry shop
2. Sheet metal
3. Paint shop
4. Machine shop
5. Assembly shop

6. Chapter 2: Foundry shop
In foundry there are two sections:
1. Pattern section
2. Foundry section
There are Four types of pattern:
1. Wooden pattern
2. Aluminum pattern
3. POP pattern
4. Thermocol pattern
But generally wooden pattern are used.
Designing the pattern as per CNC part required.
Design a core component.
Making the core.
Making the pattern.
Painting the core and pattern.

7. In Jyoti CNC casting parts are made in foundry shop. Those parts
can’t be manufactured by machining process it is manufactured by
castings.
!

8. 2. Foundry section
Wooden pattern are made in pattern shop after bring it to foundry
section. In foundry section making mold of pattern. And mold is
generally made of sand. Cope and drag pattern are used and if
parts are hollow then use core. Resin and catalyst is put into crop
and drag through hopper. Catalyst is used for hardness and resin is
used for binder. Hardness of mold is tested in chemical lab. After
making mold cope and drag pattern is removed. And painting mold
to avoid the moisture. To provide strength and hardness mold is
passing through baking process. There are three furnaces. Two
furnace are electric furnace and each capacity is three ton and
another one is holding furnace and it’s capacity is ten ton. Total
capacity is sixteen ton if we made large parts then we use holding
furnace to store molten metal. And it’s temperature is 1450oC.
After making molten metal it is pouring into mold. During pouring
process outer surface of mold is burn because of exhaust gas
removed and can’t create problems. After 2 to 3 days of the
pouring, mold sand will be removed by heavy vibrations. And this
process is called knock out process. And it’s sand is reused and it’s
ratio is 85:15. And other powder particles is collect by dust collector.
In dust collector blower are there and it such powder particles and
store in down way.
After heat treatment process is doing and it takes 8 to 9 hours. And
generally it is stress relieving process. It is not doing for all parts
when it’s require it is use.

9. Next step is shot blasting process. In Jyoti CNC two types of shot
blasting process one is room type shot blasting process and other
one is hanger type shot blasting and is fully automatic and it is used
for small parts. In room type, it is used for large parts and it takes
more time than hanger type. Basically in these process job is
hanging on hydraulic base and balls through on jobs and remove
sand particles.
After completing shot blasting parts is going on grinding and
finishing. In these department if any unnecessary material are there
then remove it by grinding process.
And paint the product to provide resistance against the moisture.
There are two labs.
1. Mechanical labs
2. Chemical labs.
In chemical labs check molten metal content if any material is less
than report in foundry shop.
In mechanical labs check impact test on job. And also finishing are
there.

10. Chapter 3: Sheet Metal Shop
In sheet metal shop four operation is perform:
1. Metal cutting
2. Sheet bending
3. Welding
4. Grinding
3.1 metal cutting :-
In metal cutting there are two types :
1. Laser cutting
2. Plasma cutting
In laser cutting machine is using to cut thin sheet and it’s size is 1
mm to 20 mm. spark gap maintain between sheet and tool is 0.5
mm to 0.8 mm. four types of material is used to cut. When the one
operation done in sheet pallet will be change and it’s happens
manually and automatically, so it reduce loading unloading time and
helps to increase production. Generally four types of material is
used to cut:
1. Aluminium
2. Stainless steel
3. Mild steel
4. CRC (cold roll coil)
Al and SS cut upto 8 mm and MS and CRC cut upto 20 mm. O2 is
used in CRC and MS and N2 is used for Al and SS.

11. In sheet metal shop there are two laser cutting machine one is fully
automatically we need to give just program. And in other one pallet
change by hydraulically and it’s manually.
3.2 sheet bending
In sheet bending there are seven types of bending machine each
machine is used for different purpose. There are various types of
bending machine like truebend 5130, truebend 5650, VLVD, EHP.
Once parts is bend then check is by used standard design and if
any defects are there then correct it by manually by using hammer.
3.3 Welding
Once laser cutting operation and bending operation is done then
parts are going to welding section. In welding section there are
different types of welding process is used.
1. MIG
2. TIG
3. Spot welding
4. Stud welding
In MIG welding, electrode is consumable. Copper wire electrode is
fed continuously with the help of welding gun.
In TIG welding, electrode is non consumable, and arc is generated
by tungsten.
Spot welding is done by electric current. And pressure is applied
from both side.
Stud welding, in these process stud is mounted on the sheet and
pressure is applied.
Drilling process, if we need small holes than we use it.

12. Robo welding is also used. When we need welding at any
complicated part at that time we use robo welding and also used for
heavy parts.
3.4 Grinding and Finishing
Any welding burrs are on parts and it’s removed by grinding
process. Grinding operation is doing for finishing purpose.
!

13. Chapter 4: Paint shop
There are many process which is done on sheet metal and it is
given below :
Paint shop plant in two sections:
1. Pretreatment
2. Powder coating plant
In pretreatment process desined for 2 baskets/hrs. each basket 50
sq mtr. Of the substrate to be treated and sub sequently coated.
Max. basket size is 300 mm. weight capacity of basket is 2500 kg.
In powder coating, powder is baking in oven.
SR.NO PROCESS DURATION TEMP.
1 Degrease 5-15 65-70 ºc
2 Rinse 65-70 ºc
3 Rinse 65-70 ºc
4 Derust-1 65-70 ºc
5 Derust-2 65-70 ºc
6 Rinse 65-70 ºc
7 Rinse 65-70 ºc
8 Activation 65-70 ºc
9 Phosphate 50-55 ºc
10 Rinse Ambient
11 Bake 160 ºc

14. There are many defects during paint :
Water spotting
Blistering
Pinholes
Poor adhesion
Poor opacity
!

15. Chapter 5: Machine shop
There are total seven section, five are machine shop and two are
grinding shop. Each machine shop doing different different
operation. In machine shop 5, heavy machine are there, also there
are hard hardening machine if we increase any parts hardness then
we use it. Machine shop 3 &4 only heavy machine are there. And
machining only on large parts like bed, column and etc. In turning
machine there are turret for tool changer and other machines ATC
used. There are two types of ATC one is drum type and second is
chain type. With the help of ATC we can reduce tool changing time
and increase production rate. There are many different range of
ATC. Maximum ATC is 160 tool and minimum is 20 tool. During
machining process if any operation are left perform or rework then
we done it manually because it’s loading and unloading time more
and program setting time is more so that left operation done by
manually. Many jobs are small and saddle table is large so using
fixtures and clamping devices fix it on saddle table. Machine shop
1,2 & 5 are also perform small types of jobs. When the parts are
small and require to change in every so it takes more time so that
we use automatic pallet changer so that reduce loading and
unloading time. There are total six pallet changer machine. There
are many types of machines like 2-axis, 3-axis, 4-axis, 5-axis
machine. If we need machining at any angle at that time we use 5-
axis machine, in this machine 4th axis is workpiece rotating table
and 5th axis is tool at any angle. During machining process tool
wear and tool breakage chances is more so that we use coolant
system. Water and cutting fluid mixture are used as coolant. And its
change once in a year.

16. Grinding shop
Grinding operation is used for finishing purpose. Grinding shop 1 &2
are many types of grinding machines like vertical,
horizontal ,angle ,chamfer, hollow grinding.
Machines in grinding shop 1 is like these: ELS, keil bergor, centre
grinding, studder machine, Homart-150.
Machines in grinding shop 2 is HMT, LBG, 400 VG, soloco,
CINCINATTI MILACRON.
Grinding wheel is used abrasive particles. There are two types one
is simple grinding and another is angle grinding.

17. CHAPTER 6: ASSEMBLY DEPARTMENT
In assembly department, all the parts are assemble there. Casting
base are bring from foundry department and assemble other parts
on it. Alignment of guide ways to fit LM and if any problem to slide
LM on guide ways then check surface of guide ways by collimator.
Headstock and tailstock fitted on base. And apron are fitted on
guide ways and ball screw’s variation is not more than 10 microns.
After assemble all parts casing on it. And controller fitted. Generally
two types of controller used one is siemens and another is fanuc
controller. There are two department inside one is small scale
machines and another is heavy duty machine. There are many
series like DX, PX, VMC, HSX, NX and many more. After assemble
all parts of CNC than testing on it.
Squareness test, in this test checking saddle alignment.
Geometry test. In this test checking all dimensions of machines like
saddle, ballscrew, tailstock, headstock.
Laser calibration, in this test only one can be calibrated.
Ball bar test, checking all axis and dimensions checking of x and z
axis.
Then after doing practical test and inspect the job.
In jyoti CNC has no any inventory he makes machine as per
customer requirement.

18. Assembly step of VMC:
1. Base assembly
2. Z axis LM headstock and spindle mounting
3. Saddle assembly
4. Squareness testing and Y-axis ball screw mounting
5. Column alignment
6. CRC guarding
7. Lubrication interfacing
8. Electrical interfacing
9. ATC mounting
10.Power and commissioning
11. stroke setting
12. Geometric testing
13.SS guarding
14. laser lubrication and ball bar testing

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

20. CHAPTER 7: CONCLUSION
At the end of the training I learned the way of conducting each
manufacturing steps in industry and the co-operation between
superiors and workers, i also got brief idea on hierarchy of the
company, and hence it was very exciting experience to be a part
of that company for a while.