NAME : - Ankit S. Patel

COURSE : - B.Tech. (Mechanical Engineering)

SUBJECT: - Training Report on

“Construction of CNC Machine”

COLLEGE: - Chandubhai S. Patel Inst. Of Technology

Changa (Anand)

PURPOSE: - Training In JYOTI CNC AUTOMATION LTD, METODA GIDC, RAJKOT

CONTACT: - +91 9510045111

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CERTIFICATE

This is to certify that the project report of training in Jyoti cnc automation pvt. Ltd. is

Submitted by,

NAME : - Ankit Patel

SUBJECT: - “Construction of CNC Machine “

COURSE:-B.Tech (Mechanical)

COLLEGE: - CSPIT (Changa)

Is completed his training by faithfully under our supervision and guidance. The matter learn by this training is by his hard work.

By,

Mr. Vincent Dabhi

Training Centre,

(Jyoti CNC Automation LTD,

Metoda GIDC, Rajkot)

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ACKNOWLEDGMENT

Any task cannot be successfully carried out without the co-ordination and co-operation of several individuals. Like, in this work also there are several individuals who directly or indirectly are involved, who shaped up our work to a great extent, so we must wish sincere thanks to them.

First & foremost, I express our deep regards and gratitude towards a visionary staff and jyoti industry, for giving me to take training in this industry. I am heartily thankful to them.

Its give me great pleasure to learn my sincere thanks to my guide. Jyoti industry’s worker who help me to learn new things and also thanks to Mr. Vincent Dhabhi who give me permission to take training in this industry and give me proper guidance.

I dedicate the success of my training to my parents and families and goodwill & grace of god for nourishing me with their blessings and support which helped me out of any kind of injuries.

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INDEX

SR NO. NAME OF TOPIC PAGE NO.

1 History 5

2 Company Profile 6

3Construction of

CNC machine7

3-a Foundry 8

3-b Paint shop 13

3-cSheet metal shop

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3-dAssembly shop

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3-eR&D Section

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HISTORY

Jyoti pvt. ltd. was initiated by Mr. P.G. Jadeja and Mr. S.L.Jadeja in 1989.

Driven by a vision to build the company into a temple of technology through team work, the organization has grown manifold from manufacturing gear boxes for machines to developing precision all-geared head lathe machines and later on sophisticated CNC Machines. Continuous process improvement and fast adoption of State-of-the-art technology has led Jyoti in becoming a leader in innovating manufacturing techniques.

Jyoti is respected as “A Temple of Technology” by the staff and its esteemed clientele, who welcome and worship the new technology.

Further to transform the technology-savvy attitude into reality, Jyoti started designing and manufacturing the wonder babies like CNC Turn Mill Centres, CNC Oval Turning Machines (the first in India), fastest Vertical Machining Centre of India, etc.

Jyoti is proud of the fact that its transition through technology-orientation was destined towards effectively revolutionizing the Indian Industry. This aspect has always been reflected through the company motto.

“Propelling Technology, Prospering Life”.

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COMPANY PROFILE

Jyoti is the brainchild of legendary Mr. P.G. Jadeja and Mr. S.L. Jadeja, established in 1989. Driven by a vision to build the company “A Temple of Technology” through teamwork, the company has grown manifold from manufacturing gear boxes for machines to developing precision all-geared head lathe machines. Later on Jyoti has rightly identified Shift from conventional machines to highly sophisticated CNC machines in the presence of manufacturers.

Jyoti was the first company to manufacture CNC machines in Gujarat. It was not an end, there are many firsts attached with Jyoti since then. Jyoti, driven by technology and innovation keeps including new firepower in its arsenal by introducing machines like CNC Turning Centres, Vertical Machining Centres, Oval Turning Centre I-SECT and first Indian machines like VMC 40/70 Linear with innovative linear technology.

After the opening up of the Indian Economy, there were great challenges present for Indian companies but Jyoti converted all challenges into great opportunities. Jyoti has even decided to compete at the global level and has taken concrete steps by exporting CNC machines. It has also established distribution networks in various continents around the globe.

Jyoti is passing through the trajectory of rapid growth by achieving over 100% growth rate since its inception. Export penetration and inclination has helped Jyoti to establish goodwill among the foreign buyers and distributors.

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CONSTRUCTION OF CNC MACHINE

For the construction of CNC machine different department is use.jyoti has following department,

A) Foundry

B) Sheet metal Shop

C) Paint Shop

D) Assembly and Sub-assembly shop

E) R&D Centre

F) Machine Shop

Jyoti CNC offers vide range of CNC Turning Centre, CNC Machining Centre (3-4-5 Axes), CNC Horizontal Machining Centre, Vertical Line CNC Machines, VTL’s etc. These machines are designed in the State of Art in-house Computerized Design Department equipped with the latest Designing Soft-wares. The Machine Tool is manufactured in-house with the latest Machines right from preparing casting in foundry till final dispatch. Even many bought-out components used are outsourced from the best available in the world.

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A) Foundry

Main base, saddle, turning bed, and other main parts are casted in Foundry. Jyoti has a CAPTY type Foundry. Foundry has also different different parts. Namely,

1) pattern making shop2) metal melting furnace 3) moulding loop line4) core making shop5) floor area6) shot blasting & heat treatment7) fettling8) Mechanical and Chemical laboratories

1) Pattern making shop:

For the casting of any part, patter is necessary .pattern is mostly 3 types. Namely, Aluminium pattern, wooden pattern, thermocol pattern. Aluminium pattern is made for rapid use and is useful for no. Of uses. Wooden pattern is easy to make and useful for few casting. While thermocol pattern is used when design is very complicated and instant use for saving time. It used only one time. Due to the contraption allowances, pattern is made 1% larger than main cast. Part line is designed such as more material takes place in bottom part and less material takes place in top part. Most of cores are mounted in bottom part. Intake gate, riser, sprue, ceramic neck is not make in pattern. In moulding all of above is made. Runner is also not in design but it is

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necessary as a part of process. Riser is used to check either metal is filled or not and refilling after few time because of contraption. Design engineer gives design of models model material. From their, pattern is made in pattern making shop. Production inspector concentrates on workers and process. After pattern made, quality inspector checks all dimensions and finishing Pattern has mostly 3 parts,

a) main partb) core partc) loose piece

Loose parts are fitted by screw or bolt or v groove.

Draw tapper (1%) is given for easily remove pattern from mould.

Primer is is used for better surface finish and long life of carting.

2) moulding loop line: First of all, sand mixer (capacity=40 tons per hour) mix the fresh sand and reclaim sand. Ratio is 80% fresh and 20% reclaim sand. Than 1.7% of sand, RESIN and 28% of resin, CATALYST is mixed.

Following sequence is proceed,

a) Sand filling with the help of hopper and screw conveyor system.b) Cleaning of main pattern.c) Fitting of loose part.d) Sand filling and reinforcement of sand.e) Removing the pattern from mould by roll-over machine revolving

180 degree. It totally operated by hydraulic system.f) Joining of small damage parts.g) Painting of mould.

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h) Heating of mould into oven for removing moisture within 10-15 min.

i) Core assembling.j) Joining of top part and bottom parts.k) Close looping of whole mould.l) Pouring of molten metal.

m) Around 2 days allowed for solidify the metal.n) Casting is removed from mould by vibrator machine.

3) Metal melting furnace: Furnace type: induction type furnace No. Of Furnace: 2 Capacity: 3 tons per 1:30 hour for each. Power: 1500kw Voltage: 2500V Frequency: 400-500 Hz Maximum production: 45tonns per day. Temperature: 1450 C (loop area) 1430 C (floor area) Metals: Pig iron, Mild steel, scrap, Si, Mn, Cu, Mg Temperature measuring instrument: Contact type thermocouple Carbon-silicon analyser and spectrometer is used to analysis of metal mixture. Crusil+Sodium silicate is used to lapping of furnace. In our foundry, one temperature maintaining furnace. It is used when mould is greater than 6 ton. First metal is pouring in ladder for its heating. And then metal is reheated in furnace so. Metal does not solidify by the low temp. Of ladder.

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4) Shot blasting and heat treatment furnace: After get a casting form vibrator, it is heated in heat treatment furnace for best grain structure and surface hardening of casting. Shot blasting is a process of cleaning of made casting.In shot blasting, casting is placed in a closed chamber and small metal balls are fired on it with high velocity. Firing of metal balls is done by guns. Which is worked based on air pressure. Metal balls can be reuse. Types of chamber: 1) hinged type and 2) room type For less than 3 tons or small size casting, hinged type shot blasting furnace is used and for large size of casting, room or platform type furnace is used. In hinged type chamber, no need of labour inside the chamber. Metal balls are fired by 4 rotating guns. Whereas, in room type chamber, one worker have to inside the furnace for controlling pressure.

5) Fettling : For the removing of extra metal from casting, and finishing purpose, fettling is necessary. Fettling has,

1) grinding area2) chip removing area3) gas cutting area4) pneumatic area5) rejection6) rework area7) primer coating area8) finished goods

Extra materials on outer surfaces and some of inner surfaces are grinded by hand motor grinder machine. This type of grinding is mostly

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use to remove riser, runner bar etc. Where motor grinder does not reach, hand grinders and portable grinders are used. It is mostly use for sharpen edge round halls and inner surface finishing which cannot be cleaned by shot blasting. In chip removing area, mould sand which does not remove in shot blasting and vibrating machine is removed with high pressure air compressor. In gas cutting area, metal is removed by gas arc flame. Inner surfaces and small halls are cleaned in pneumatic area. In rework area, some casting which is not accurate enough is worked. Defected castings are rejected and placed in rejected area. Finished products are prime coated and then dimension and hardness checked in finished goods part.

6) Mechanical and Chemical Laboratory:

For the testing of metal and sand used in mould is being tested in mechanical and chemical laboratories. Silica sand is also tested.AFS no. , clay contain is sand and acid domain value is checked before use.After the mixing of resin and catalyst, strength of mould sand is measured on universal strength machine. Hardness of mould is tested by mould tester and scratch hardness is also checked. AFS no. Is found out by sand analyser. And for foundry purpose it must be between 45 to 55. For the reclaim sand alloy loss of ignition is checked. Weight analyser is used to cross check reading of carbon-silicon analyser. Micro-spectro lab Contains high profile electron microscope and spectrometer. Microscope is use for domain and grain structure checking and spectro meter is used for all metal % in sample.

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B) PAINT-SHOP

In this shop job is coming for foundry for painting. In this shop there are two types of painting oil painting and powder coating. After painting job is going for different type of machining and after that job is coming here for finish painting and that dispatch for assembly.

C) SHEET-METAL

In this shop work done on various type of metal sheet like bending, cutting, welding etc.

There is robotics arm by which we can do more accuracy welding. There is laser cutting we save our time and done more precision work which manual can’t be achieve. This shop there are outer body is made.

D) ASSEMBLY AND SUB-ASSEMBLY This section is most important in industry. Because all the parts made in different section are attached here. And make useful machines. Here not only assemble parts but also test that part is perfectly attached or not. This section most of work done manually. And most important machine is crane cause by this heavy part put on one another. In our industry, assembly is parted into 5 lines. Line A and B is for turning CNC machine like DX-100,150,200,250 etc. Line C and D is for VMC machines like VMC-850,1050,SX4,SX6,PX10,PX20,PX30,PX40 etc. And line D is for special and huge machines like DX-500,NX serias,HMC-560 etc.

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In our company, assembly is product type layout. Main machining is done in unit 1-2.and stored in material storage. While ordered material are storage directly after checking at unit 1,2. In material storage, order wise rake created and these rakes are placed into assembly line.

TURNING MACHINES:-

DX 100,150,200,250,500 etc are the turning machine. This is mostly use for facing, turning, and chamfering, drilling, boring, counter taping etc. Purpose. DX-200 is commonly use in general industrial area.

Following is the assembly general process for turning machines. a) Main base assemblyb) Saddle and runner bar assemblyc) Head stock and spindle motor and encoder assemblyd) Tail stock preparatione) Z-axis base assemblyf) Tail stock final alignmentg) Lubrication & proximityh) Spindle motor and flange mountingi) SS guardingj) CRC guardingk) Turret mounting, axis motor mountingl) Hydraulic system and cylinder mountingm)Electrical interfacingn) Power on or commissioningo) Stroke setting and turret guardingp) Block bearing and turret coverq) Geometric testingr) Chuck mounting and coolant fitting

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s) Final inspectiont) Despatch preparationu) Pre-dispatch inspection

Main parts for DX turning machines:-a) Head stock assembly

Spindle Spindle belt Encoder belt Draw bar

b) Z-axis assembly L.M. rail Ball screw Coupling make Ball screw support bearing End bearing

c) X-axis assembly L.M. rail Ball screw Coupling Ball screw support

d) Tail stock assembly Live quill Dead centre Front bearing Rear bearing Revolving centre Cylinder Tail stock height dia.

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Lubrication unit turret AC/heat exchanger

e) Optional Cylinder Job clamping device(chuck & collate) Chip conveyor Bar feeder Steady rest Bar puller Measuring probe Gear box

After the finishing of assembly process, following test are necessary,

a) Geometrical testb) Squarnessc) Laser testd) Ball bar teste) Practical testf) Coolant trialg) electrical finalh) final inspection

DX means turning machine and suffix no. Indicates saddle stoke of their. E.g. DX-200 has 200 mm stoke of saddle.

Turning machine has mostly 2 axis, Z and X. DX-200 have 4000 r.p.m maximum spindle speed,3 servo motors for spindle rotation, saddle movement and turret rotation, accumulator for oil pressure and regulation. Hydraulic system is for quill and chuck regulation. Separate

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coolant tank and motor circulation pipes. Electrical panel is made in Germany by symense.

VMC MACHINES:-

For the vertical machining process this type of machines are introduced. For mass production and reduce time of tool changing and work peace changing Automatic tool changer is mounted. More than 100 tools can be mounted on it. VMC- 640,850,1050,1260 ,PX-10,20,30,40 , SX4,6 are VMC type machines.

General process for VMC machines-

base assembly S-axis, LM, & head stock ATC alignment Saddle assembly Squareness setting and y axis ball screw mounting Column alignment CRC guarding Conduflex and lubrication interfacing Electrical interfacing Axes motor mounting Power on or commissioning Stroke setting Geometric testing SS guarding Laser calibration and ball bar Cutting trail Cooling trail Final inspection Pre-dispatch inspection Despatch preparation

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Main parts of VMC machines:

Base, saddle, table Column Head stock Z-axis motor bracket Z-axis end bracket Y-axis motor bracket Y-axis end bracket X-axis nut housing Bearing housing Spindle motor mounting flange ATC universal bracket ATC middle bracket Unclamp cylinder mounting bracket

Optional parts:

Chiller for spindle cooling Lubrication unit Power pack unit AC/heat exchanger Rotary table / tilting table Chip conveyor/tray Tool coolant pump CTS pump Filter pump Gear box Measuring probe

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Spindle, turret and rotating base are pre assembled in sub assembling department. Electrical panel, wires and other parts are also assembled in sub assembly department.

R&D SECTION

Research and development section develop new machines and also design various pars and done analysis. Certain changes in current machines and new techniques are also carried by this section.

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