Report on Industrial Training at HMT Machine Tools, Kalamassery

REPORT ON INDUSTRIAL TRAINING AT

HMT MACHINE TOOLS LTD, KALAMASSERY

Submitted by VEDANT PRUSTY Reg. No.: 120929210

DEPT.OF MECHATRONICS ENGINEERING

MANIPAL INSTITUTE OF TECHNOLOGY (A constituent institution of Manipal University)

January 2015

Report on Industrial Training at HMT Machine Tools, Kalamassery

2 Vedant Prusty

January 2015

Dept. of Mechatronics Engineering, MIT Manipal


January 2015

CONTENTS

Chapter Page No. ________________________________________________________________________

i. Training Certificate…………………………………………………………02 ii. Contents……………………………………………………………………. 03 iii. Acknowledgement..…………………………………………………………04 1. Introduction…………………………………………………………………05 2. Objectives…………………………………………………………………...13 3. Plant Services Department………………………………………………….14 4. Foundry and Pattern Shop…………………………………………………..17 5. Planning Department………………………………………………………..22 6. NH Assembly……………………………………………………………….27 7. CNC Assembly……………………………………………………………...30 8. Quality Control……………………………………………………………...33 9. Heat Treatment………………………………………………...…………....37 10. High Technology Center………………………………………………...….41 11. Printing Machines Division…………………………………………………44 12. Heavy Parts………………………………………………………………….46 13. Conclusion ……………...…………………………………………………...49 iv. References………………….………………………………………………..51 Industrial Training Schedule………………………………………………...52

______________________________________________________

3 Vedant Prusty



January 2015

ACKNOWLEDGEMENT

"...the beauty of the destination is half veiled and the fragrance of success half dull until the traces of all those enlightening the path are left to fly with the wind, spreading word of thankfulness..."

I am grateful to my guide, Mr. K. Ramachandran Nair, Deputy Chief Engineer (TS) for leading the path and encouraging me to widen my horizons. Thank You Sir for letting me dig deep into and exploring the concepts and practices of machine tool manufacturing, and production planning.

My gratitude to Mr. Gopi Mohan of the Training Center at HMT MTK for helping me identify, select and decide over the subject and scope of this training. Despite his busy schedule, he took out time to patiently guide and nurture us, making sure we had the best all-round exposure to the industrial practices.

Without the companionship of Mr. Sarthak Prakash and Ms. Sruthy J. Kunnel, HMT and Kalamassery would not have happened! Thanks to Sarthak, we made it! Thanks to Sruthy, we tried to make the fullest of our time here!

I run out of words while expressing my heartfelt gratitude and salutations to the kind couple, Mr. and Mrs. T.G. Job of Peruva, Kottayam District. Their foster parenthood, care and love added to the joy of learning and experiencing through this month.

This project would not have seen the light of day without the constant support of my family – my parents and my sister.

Special thanks to Mr. B. Sarkar at HVF, Dr. Chandrasekhar Bhat and everyone at the Dept. of Mechatronics Engineering, MIT Manipal for their help and support in realizing this training.

4 Vedant Prusty



January 2015

1. INTRODUCTION The machine tool industry constitutes the backbone of the industrial sector and is vital for the growth of the Indian Economy. Even though the Indian machine tool industry is a small segment of the engineering industry, it plays a very important role in the development and technology upgradation of the engineering industry. The quality and cost of engineering products depends on the quality of mother machine tools and their automation level. The development of the machine tool industry is therefore of paramount importance for a competitive and self-reliant industrial structure. This report discusses the 1 month Industrial Training at HMT’s Machine Tool Division at Kalamassery, Kerala. The training was completed in December-January 2015.

1.1 Company Profile By end of the Second World War, the government of India confronted by a big problem of disposing the colossal war waste. Ultimately, a committee was constituted to inquire into the possibilities. The committee report of 1948 proposed the establishment of a government owned machine tool industry. This was expected to fulfill two aspects. The first was being utilization of the Rs.4000 million worth of metallic waste. The second was the incorporation of a state owned infrastructure – manufacturing facility. The result was the birth of THE HINDUSTAN MACHINE TOOLS LIMITED, which diversified in due course of time to the present stature of the multi core, multi-location, and multi-unit, multiproduct industrial giant HMT Ltd. The HMT Ltd was started as a single factory to produce Tool Room Lathe at Bangalore in collaboration with M/s Oerlikon of Switzerland in 1953, with capacity to manufacture around 400 machines per year. Since then different collaborations, continued in house R&D and tremendous marketing efforts brought HMT, to present status. The growth of HMT Ltd. was characterized by the forward and backward integration of technology and product diversification. Thus the company that started with manufacturing and selling lathes expanded its machine tools products range to evolve as the ultimate solution in metal cutting. The product diversification efforts took the company to the business of watches in 1962, tractor in 1971, die-casting on plastic machinery in 1971, printing machinery in 1972, presses in 1972, lamps & lamp making machinery in 1976,

5 Vedant Prusty



January 2015

food processing machinery in 1980, CNC systems in 1986, ball screws in 1986 and reconditioning in 1990. The multi product activities made HMT Ltd. change its identity as Hindustan Machine Tools Limited. Today HMT Ltd has 16 manufacturing units with 22 products divisions spread through the length and breadth of India. A subsidiary viz., HMT (international) Ltd undertakes the exports of the company. They are also export agents for general other Indian companies.

HMT Ltd was restructured in 1992 to facilitate better administration of the multi product business activities. Accordingly, the following business groups were established:  Machine tools business group, to concentrate on metal cutting machines  Industrial machinery business group to deal with printing machines, die-casting and plastic injection molding machines food processing machines and metal forming machines  Agricultural business group to concentrate on tractor  Engineering components business group to deal with casting and ball screws  Consumer product business group, to deal with watches and lamps

In addition to these business groups, the company owns three subsidiaries as follows:  HMT (international) Ltd. which undertakes

overseas

project

&

exports  PRAGA

Tools

Ltd.

which

manufacturers machine tools  HMT

bearing

Ltd

which

Fig. No. 1: The NH 22 High Speed Precision Lathe is still the primary product of HMT

manufacture precision bearing in collaboration with M/S Kozo Japan

As per the revival plan of this public sector industry a turnaround plan has introduced in early days of this millennium and re-organized as HMT Ltd holding company including tractor division and presently comprises of the following subsidiaries:

6 Vedant Prusty



January 2015

1. HMT Machine Tools Limited. 2. HMT Watches Limited 3. HMT Chinar Watches Limited 4. HMT Bearing Limited 5. HMT International Limited 6. PRAGA Tools Limited

1.1.1 HMT Machine Tools Limited The HMT Machine Tools Limited is engaged in the manufacture and marketing of general purpose machine tools, special purpose machine tools, computer numerically controlled machine tools, precision machinery system, printing machines, metal forming passes, dies casting and plastic injection molding machines, ferrous and non-ferrous casting.

The product range of HMT Machine Tools:BANGALORE:  Heavy duty lathes  Single and multi-spindle automates  Radial drilling machines  Multi spindle drills  Cylindrical & surface grinders Fig. No. 2: ECONO CNC 26 Flat Bed Lathe

 Laser cutting machines  CNC turn mill centers  CNC wire cut EDM

PINJORE: FMS & FMC  Horizontal machining centers  Vertical machining centers  Milling machines  Broaching machines

KALAMASSERY:  CNC turning center  Turn mill center

7 Vedant Prusty



January 2015

 Flexible turning cell  Copying lathes  Center lathes  Offset printing machines  Paper cutting machines

HYDERABAD:  Special purpose machines  Horizontal machining center  FMS  CNC horizontal boring machines  Bed type & floor types boring machines

AJMER:  Grinding machines  SPM grinders  CNC grinders

Facilities available in different machine tool units:  CNC ram type Plano miller  Horizontal machining centers  Vertical machining centers  Vertical machining centers  Horizontal jog boring machines  CNC turning centers  Turn mill centers  Slide way grinders  Cylindrical grinders  Internal grinders  Precision gear shapers  Precision gear hobbers

Fig. No. 3: STALLION 100S series Slat Bed Lathes

 Gear grinders  Induction hardening machines  3D co-ordinate measuring machines

8 Vedant Prusty



January 2015

1.1.2. HMT Watches Limited HMT Watch Limited manufactures and markets watches including hand wound / automatic & quartz.

1.1.3. HMT Chinar Watches HMT Chinar Watches limited is also one of the subsidiaries engaged in the manufacture of chinar model watches located in Srinagar, Kashmir state.

1.1.4. HMT Bearing Limited HMT Bearing Limited is one of the subsidiaries engaged in the manufacture of different types of industrial bearing situated in Hyderabad.

1.1.5. HMT International Limited HMT International is engaged in the export of HMT’s range of product worldwide HMT (I) also market and backed up by a good sales & services network. It also under takes Turkey project & technical services for developing countries.

1.1.6. Praga Tools Limited Praga Tools Ltd is also a subsidiary of HMT Limited engaged in the manufacture of machine tools located in Hyderabad.

1.2 The Kalamassery complex of HMT Limited Kalamassery The Kalamassery unit, the 4th machine tools unit was established in 1963 and started production in 1964. The unit originally manufactured only two types of center lathes viz. H & LB, but later added special purpose lathes like copying and turret lathes. Model L. T20 was the first product to be indigenously developed by the unit (1968) and the development of this product was a landmark in the history of the unit. The production of this was later licensed to M/S Qetcos, Kerala, Matools, Philippines Ceylon Steel Corporation Sri Lanka. The original center lathes H&LB were then replaced by a new family of unified series of lathes, which was designed and developed by the unit, incorporating the concepts of typification, standardization & unification.

9 Vedant Prusty



January 2015

Diversification of Kalamassery Unit and Birth of Printing Machine Division During

the

Kalamassery

period unit

product range to machinery

division

1972-73,

diversified

its

include printing (PMK).

The

commercial entry of PMK was with two types of letter presses viz. RTE & RTAF under collaboration with M/S Nebiolo of Italy. Autoplaten, an indigenous development came up Fig. No. 4: SB CNC30

subsequently.

During the ensuing

years, the printing machinery division came up with offset press viz. OMIR in collaboration with M/S Nebiolo later indigenous offset press viz. SOM 136 was introduced to the market. The first two-color machine from HMT was OMIR in collaboration with M/S Korning & Baver of Germany. The latest development of PMK is the paper-cutting guillotine PG 92D3, in collaboration with M/S Divano Blinders of Italy.

THE CURRENT PRODUCT RANGE

Product Model Offset printing machines SOM436 SOM425 (four colour) SOM236 SOM231 SOM225 (double colour) SOM136 SOM131 SOM125g (single colour) Paper cutting machine PG-92D3 Fig. No. 5: VMC 1200M

The Kalamassery units of HMT are famous for development activities. Their product have always fetched award and prized at different trade fair & competitions. To name a few are the prizes bagged in different IMTEX fairs by FC-25, SBC & SBCNC machines. The CNC lathe model STC has won the VASVIK Industrial research award 1987 instituted by the

10 Vedant Prusty



January 2015

Vindhalaxi Audyogik Samsadhan Vikas Kendra, (VASVIK) for outstanding advancement of science and technology.

The machine tool products of this unit have been certified by RWTUV-(Reinisch West Falischer Techniseruber Wachungs Verein) an international certification agency of high repute as confirming to total quality management system. Both the division have been awarded ISO 9001 certification by IROS. The manufacturing shop at MTK is supported by various infrastructural facilities like high technology CNC machine centers, testing facilities, foundry, heat treatment, computer system, CAD systems etc. Around 600 well experienced personnel form the human resources of the unit keeping in line with the current corporate trends.

Fig. No. 6: PG 29 Guillotine

Training Centre The manufacturing shops at MTK are supported by various infrastructure facilities like, high technology CNC machining center, testing facilities foundry, heat treatment, computer system CAD system etc. around 800 well experienced personal form the human resources of the unit keeping in line with the current corporate trends. This unit views HRD as one of the primary concerns as a measure to increase productivity and enhance social stranding. The company has a well-established training system by personnel of high technical and management skills.

11 Vedant Prusty



January 2015

1.3 The Marketing Network of HMT Ltd The machine tools marketing divisions with its headquarters at Bangalore and having wide network of regional and divisional offices spread throughout India caters to the marketing needs of this unit at the primary level. To co-ordinate the marketing activities at unit level and co offer technical support to machine tool marketing, a strong sales and services team is constituted at unit level. HMT’s major customer includes defense, railways, automobile and other engineering industries in various sectors.

Fig. No. 7: HMC 1000 series

1.4 Quality policy HMT MLT is committed to total customer satisfaction by the supply of quality products and services through:  Continuous improvement of technology of product and processes.  Innovation and creativity.  Effective implementation of quality management system.  Monitoring the effective realization of quality objectives and periodical review of its suitability.

This report is structured according to various divisions of the factory at HMT MTK. The functions, scope, and work done at each division is described briefly under these headings.

12 Vedant Prusty



January 2015

2. OBJECTIVES The Objectives of this training were as follows:  To study the planning, organization and setup of the Machine Tools Industry at HMT Kalamassery.  To understand in detail the overall production mechanism and products of HMT MTK.  To specifically study life cycle of products from casting, forging, machining, assembly to final testing, inspection and shipping.  To spot possible areas of reduced efficiency in the production cycle and identify their reasons.  To explore manufacturing and working of CNC, VMC and HMC, their electronics, control and mechanics, along with use of G- Codes.

13 Vedant Prusty



January 2015

3. PLANT SERVICES DEPARTMENT Plant services department is responsible for maintaining the machines and equipment of the unit in optimum condition of performance so as to make them available for production. The plat services department is responsible for the erection and commissioning of the machines in the plant. The department is also responsible for the electrical power distribution of the entire factory complex. The department looks after the internal transport functions and housekeeping activities inside the factory.

3.1 Scope  Erection, commissioning, repair, maintenance, reconditioning, retrofitting and preventive maintenance of all the machines and equipment used for production in the MTD and PMD plants and training center.  Maintenance of the cranes, jib cranes, air compressors and a/c units in the MTD and PMD plants.  Upkeep of R&M stores and spare parts planning.  Housekeeping activities in the shop floors.  Materials movement in the shop floors and maintenance of internal transport vehicles and equipment.  Maintenance of power supply to the entire factory complex.  Maintenance of 66 kV sub-station, switchgear, power transformers, and the entire distribution system.  Maintenance of supply distribution in colony, pump house.  Maintenance of internal telephone exchange and the communication system.  To arrange and co-ordinate contract works in connection with any of the above activities.

3.2 Objectives To maintain the plant, machines and equipment in optimum conditions of performance ensuring availability for production. The plant services department sets its measurable quality objectives for every year. These objectives ensure that the machines and equipment are well maintained to meet the requirements of the customers. The quality objectives are

14 Vedant Prusty



January 2015

communicated to all the employees in the department by displaying them in the key areas of the factory.

Chart No. 1: Process for Breakdown Maintenance

15 Vedant Prusty



January 2015

Chart No. 2: Process for Preventive Maintenance

Prepare preventive maintenance schedule

Intimate schedule to chief of manufacturing

Get monthly plan for preventive maintenance

Ensure availability of machine

NO Review and Reschedule Plan

YES Perform P.M as per check list Record Deviations, If any After completion of PM, Hand over machine to production

Update P.M Schedule

Review in the fortnightly maintenance meeting for process improvement and effectiveness

16 Vedant Prusty



January 2015

4. FOUNDRY AND PATTERN SHOP The foundry & pattern shop attached to the machine tool division, HMT, Kalamassery and part of engineering components business group is geared to manufacture all cast iron & spherical graphical iron required for machine tools and printing machinery division and can also undertake job orders. Established in 1968 with polish design, it is a semi mechanized foundry producing heavy duty gray & SG iron casting for machine tools and printing machines using mains frequency induction furnaces for melting and resin bonded sand for molding and core making.

4.1 Pattern Shop A pattern is defined as anything used for forming an impression called mould in the sand. Mould when filled with molten material on solidifying, forms a reproduction of the pattern and is known as mould. It is slightly larger in size than casting. As the first stage in preparing the casting, the pattern of the castings is prepared. Pattern of casting is prepared at pattern shop with either of the materials given below:  Wood: - Wood is the most commonly used pattern material as it is cheap, easily available and also easy to join and fabricate. But it has a large rate of moisture absorption and also warping and wearing is high.  Metals: - Metals have the advantage that they do not warp, are very accurate and have high strength. But shaping is slightly difficult and it is also subjected to rusting and the costs are also high.  Plastics: - They are mostly thermosetting plastics. They are light in weight, have very good surface, do not react with water or air and are not subjected to warping, but cannot withstand high temperatures.  Plasters: - The most common example is gypsum cement. Repairs can’t be easily done and it does not need skilled labor.  Wax: - Wax has very good surface finish, can be easily altered to any shape and is very accurate. But it cannot withstand high temperatures.  Wood with metallic coating  Thermocol: single use patterns are made using thermocol

17 Vedant Prusty



January 2015

In the process of 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. The pattern needs to incorporate suitable shrinkage allowances depending on material flow and heat transfer considerations. Pattern making is a skilled technique that was highly valued in the different cultures practicing casting through the centuries.

In sand casting, the pattern is usually of wood, whereas it may be metal or other materials in pressure or centrifugal casting. The patternmaker also decides where the sprues and risers (inlet and outlet for molten material) will be placed with respect to the pattern. Parts of the object which have holes or depressions are handled by inserting cores defining volumes that the material will not flow into. Sometimes patterns may also accommodate chills, solid pieces of the final material, to enable rapid cooling, resulting in martensitic hardening in the neighborhood of the chill.

4.2 Sand Mould Making Procedure The procedure of making a typical sand moulding starts by placing a bottom board first either on the moulding platform or on the floor, making the surface even. The drag mounding flask is kept upside down on the bottom board along with the drag part of the pattern at the center of the flask on the board. There should be enough clearance between the pattern and the walls of the flask Rest of the drag flask is completely filled with the backup sand and uniformly rammed to compact the sand. The ramming of sand should be done properly so as not to compact it too hard, which makes the escape of gases difficult, nor too loose so that mould would not have enough strength. After the ramming is over, the excess sand in the flask is completely scraped using a flat bar to the level of the flask edge. The finished drag flask is now rolled over to the bottom board exposing the pattern. Using a stick, the edges of the sand around the pattern is repaired and cope half of the pattern is placed over the drag pattern, aligning it with the help of dowel pins. The cope flask on top of the drag is located aligning again with the help of the pins. The dry parting sand is sprinkled all over the drag and on the pattern.

A sprue pin for making the sprue passage is located at a small distance of from the pattern. Also a riser pin if required is kept at an appropriate place and freshly prepared moulding sand similar to that of the drag along with the backing sand is sprinkled. The sand is thoroughly rammed, excess sand scraped and vent holes are made all over in the cope as in

18 Vedant Prusty



January 2015

the drag. The sprue pin and the riser pin are carefully withdrawn from the flask. Later the pouring basin is cut near the top of the sprue. The cope is separated from the drag and any loose sand one the cope and drag interface of the drag is blown off with the help of bellows. Now the cope and the drag pattern halves are withdrawn by using the draw spikes and rapping the pattern all around to slightly enlarge the mould cavity so that the mould wall are not spoiled by the withdrawing pattern. The runner and the gates are cut in the mould carefully without spoiling the mould. Any excess or loose sand found in the runners and mould cavity is blown any using bellows. Now the facing sand in the form of a paste is applied all over the mould cavity and the runners which would give the finishing casting a good surface finish. A dry sand core is prepared using a core box. After suitable baking, it is placed in the mould cavity. The cope is replaced on the drag taking care of the alignment of the two by means of pins. The mould is now ready to pouring.

4.3 Moulding Procedure The pig iron, MS scrap, Carbon, manganese and other constituent materials are melted in the electric furnace. The molten metal is drawn into a ladder and transported using an overhead crane. The molten metal is poured to the mould trough the cavity designed for the same.

4.4 Forging Forging is the operation where the metal is heated and then a force is applied to manipulate the metal in such a way that the required final shape is obtained. This is the oldest of the metal working processes known to mankind since the copper age. Forging is generally a hot working operation through cold forging is used sometimes.

4.5 Fettling The complete process of the cleaning of casting, called fettling, involves the removal of the cores, gates and risers, cleaning of the casting surface and chipping of any of the unnecessary projections on the surface. The dry sand cores can be removed simply by knocking off with an iron bar, by means of a core vibrator, or by means of hydro blasting. The method depends on the size, complexity and the core material used. The gates and risers can be removed by hammering, chipping, hack sawing, abrasive cutoff or by flame or cutting. Removal of gates and risers can be simplified by providing a reduced metal sections at the casting joint, for brittle materials such as grey cast iron, the gates cab easily

19 Vedant Prusty



January 2015

be broken by hitting with a hammer. For steel and other similar materials sawing with any metal cutting saw like hack saw or band saw would be more convenient. For large size gates and risers we use flame or arc cutting to remove them. Similarly, abrasive cut off may also be used for removal of gates. Most of the abrasive cut off can be carried out by portable grinding machines with an angled grinding head. For cleaning the sand particles sticking to the casting surface, sand blasting is normally used. The casting is kept in a closed box and a jet of compressed air with a blast of sand grains or steel grits is directed against the casting surface, which thoroughly cleans the casting surface. T The shots used are either chilled cast iron grit or steel grit. Chilled iron is less expensive but is likely to be lost quickly by fragmentation. In the operation, the operator should be properly protected.

20 Vedant Prusty



January 2015

Chart No. 3: Foundry Process

21 Vedant Prusty



January 2015

5. PLANNING DEPARTMENT

The Production planning department is the most vital link between product design and production department. This department provide necessary facilities and technical knowhow for the manufacture of the product. Production requires optimum utilization of natural resources, men, money, material and machines. But before starting the work of actual production, Production planning has to be done in order to anticipate possible difficulties and decide in advance how the production should be carried out in the best and economic way. The principle of Production planning lies in the statement “First plan your work, and then work for your plan”.

5.1 Objectives In any business organization, production activities must be related to market demands as indicated by the continuous stream of the customer’s orders. For maximum effectiveness this must be done in such a way that customer’s demand is satisfied. But at the same time, production should be carried out in an economic manner. The process of developing this kind of relationship between market demand and production capability is the function of production planning and control.

5.2 Role of Planning Department The role of Production planning department comprises of: 

Production Pre Planning (PPP) and Planning Estimation (PPE)



Production Planning Ordering (PPO) & Finished Part Section (FPS)

5.3 Functions and Responsibilities 1. PRODUCTION PRE PLANNING  Processing design documents  Identification of house manufacturing item, outside manufacturing item and brought

out parts

 Preparation of preparation layouts

22 Vedant Prusty



January 2015

 Identifying and intending actions for all special tooling  Implementation of design alterations  Manufacturing special tool data  Attending shop problems  Coordinating activities related to alteration requests  Preparation of documents related to assembly of products  All data entry in computer related to PPP  Verification and approval of materials warrant  Maintain all data and records related to the products  Arranging and ensuring all quality formats

2. PRODUCTION PLANNING ESTIMATION  Estimation of standard time for manufacturing and assembly operations  Preparation and implementation of alterations  Data entry of activities related to PPE function in the computer  Attending shop complaints regarding standard time  Authorization of special time in job cars  Arranging time study

3. PERFORMANCE MONITORING WING  Analyze the organization requirement  Design the structure report  Create appropriate database  Develop software for report  Prepare making list and dispatch of statements

4. COSTING SECTION  Arranging the data related standard labour, material and assembly cost  Assessment of rectification or rework expenses  Coordination of activities related to annual product costing

5. TIME RECORD  Monitoring and ensuring the regular flow of job card  Entering ticket numbers and actual hours on each job

23 Vedant Prusty



January 2015

 Calculating the total standard hours for a job  Obtaining signature on job cards and idle cards  Acting as a link between PPD and shop floor.

Table No. 1: Process Model of Production Planning

24 Vedant Prusty



January 2015

Chart No. 4: Planning Process Flow Chart

25 Vedant Prusty



January 2015

Chart No. 5: Planning Process Flow Chart contd.

26 Vedant Prusty



January 2015

6. NH ASSEMBLY The machine tool assembly department at Kalamassery assembles various components of conventional lathe and CNC lathes. For convenience, the assembly department is subdivided into NH assembly and CNC assembly. (NH Lathe stands for New Heavy Lathe). NH assembly section assembles conventional lathe and CNC assembly section assembles computer numerically controlled lathes. The most of the electrical components are ‘brought out’ items and is assembled by electrical assembly section.

Procedure followed in NH Assembly  Scrapping -

High points are removed for better contact. Blue paint is rubbed over

parts to find uneven surfaces. Scrapping is done for good quality contact in saddle, keepers, cross slide, Legs, Apron- Split nut, Tail Stock Base, Compound Slide, Accessories.  Saddle Assembly-This section includes the grooving for oil passage, installation of distributor assembly and oil assembly and cross feed assembly.  Feed Base Assembly- Six shaft preassembles with gear core first taken here. This is followed by friction cone assembly and shifter block assembly.  The machine is run for up to 3 hours to check for noise/friction defects. Assembly of gears is oiled using a cam mechanism in running lathe.  Apron assembly -this include the pre assembly, the group assembly, the split nut lead screw engagement, the reciprocating pump and lubrication. Also transmission of feed drive to cross slide and the longitudinal movement on thread are implemented there.  Hydraulics - lathe uses hydraulics to engage certain gears and also for braking and gear shifting lapping and pump assembly, pipe bending, value body assembly, distributor assembly and piping to machines.

27 Vedant Prusty



January 2015

 Trail stock assembly- this includes sleeve clamping, roller assembly, top and bottom clamping, hand wheel assembly, tail stock group assembly. Needle bearing is used in roller assembly. The ABPO-464 balancing machine is used to check uniform weight.  Swivel is assembled next  Headstock assembly- this involves head stock pre assembly , spindle balancing and pulley balancing, brake assembly, clutch assembly and hydraulic checking , lubrication distributor piping and assembly, dial assembly, head stock control assemblies and headstock group assembly.  Headstock inspection+ noise level is checked. Main spindle run out and headstock lubrication are also checked as per ISO quality standards. Machines may be returned to replace component if needed.  Final assembly- this takes 65 hours for complete assembly. It can be divided into front work and top work.  Front work on bed includes saddle assembly, feed box assembly, lead screw, bearing assembly, support assembly and rack assembly.  Top work involves head stock assembly, tail stock assembly and centrereading of cross slide assembly and swivel assembly.  Quadrant box assembly- Gears with different gear ratios are fitted at quadrant for feeds as per requirement, AI key is used to shear if high loads occur.  Motor mounting- Depending on requirement pulley A -type, B type for A2-6 and L/S AL-8 is used.  Machines- For maintaining accuracy of product as per quality standard.  Surface grinder, taper grinding, turning lathe and milling machine. -

Variants include

28 Vedant Prusty



January 2015

 Bed length wise  Gap bed /Straight bed  Hardness  Centre height (NH-22, 26, 32)  Headstock  Motor speed  Protection assembly - this includes installing front covers, name plates, chip tray, splash guard, wipers, side cover and hydraulic tank assembly.

29 Vedant Prusty



January 2015

7. CNC ASSEMBLY The increasing demands the need for high accuracy, scrap reduction etc. have pulled for development in the field of machining and manufacture. All these have led to the invention and improvement of CNC machines which can undoubtedly be termed as one of milestones of century.

HMT is famous for its world class CNC turning centres. It was in late 80's that HMT Kalamassery started the production of CNC turning centres. The earlier models of machines used Sinumerik and Hinumerik control systems and MCU whereas new generation CNC idea Fanuc/Siemens control systems.

Assembly can be divided into: Group assembly  Pre final assembly  Final assembly

Group assembly Place where assembly of headstock, tailstock, turret indexing unit, power rack, turcite fixing etc. Is done. After the assembly of each part they are set to an extensive test and it is passed on to pre final assembly only after inspection department certifies it. Units includes STC-15, STC-20, STC -25/SBCNC-30, SBCNC-40/60/80, SHELL TURN, STALL 10 AND ECOCNC.

Pre-final assembly It is the section where the assemblies of various components of CNC lathes like headstock take place to the lathe bed. It is here that the alignment of ball screw is done. The assemblies of saddle, cross slide etc. to the bed also take place here. Once the various parts are put together, lathe is taken to final assembly.

Final assembly As the lathe is brought from the pre assembly, the various electrical components required are installed.

30 Vedant Prusty



January 2015

 Bed- most of CNC turning centres are of slant bed type.  Headstock- CNC do not have shift gear incorporated. Main spindle is mounted on angular contact bearings which could take both axial and radial loads.  Drives - It contain 3 servo motors- one for main spindle, one for saddle traverse over the bed and the third one for cross slide/turret movement across the saddle.  Saddle- saddle is the portion which carries the turret and slides over the load. The saddle is actually fixed to a ball nut.  Turret is that part which holds various tools and would position the required tool to perform the cutting. Sequence is as follows Unclamping- the turret make part unclamped from the curvic coupling. This is actuated by piston cylinder arrangement enclosed with turret housing.  Rotation- It is actuated by means of a direction control valve- Solenoid valve. This rotation is fed back to the controller by another encoder.  Creep - As the turret reaches desired angle, an opposite flow is given to motor so as to reduce the speed.  Clamping- once the desired pain is attained the turret clamps back in to the coupling and is ready for machining. For operations such as drilling, milling a special C- axis motor is required and is fitted on consumer request.  Tailstock- Instead of a rotating, a rotation center is used to reduce heat generation.  Hydraulic systems- Many of the critical operations include full proof set ups are hydraulic systems (owing to their flexibility and controllability)  Headstock- workpiece is clamped by means of piston cylinder arrangement.  Turret- turret clamping, indexing, creeping are controlled hydraulically.  Tailstock- it is controlled by Solenoid controlled valve. The plunger is hydraulically controlled.

31 Vedant Prusty



January 2015

 Gear box- It is actuated by hydraulic systems. Levels are shifted when piston inside a cylinder pushes them.  Lubrication- ensuring sufficient lubrication to maintain smooth running for the machine as well as to reduce vibrations, heat generation and errors. Other systems include  Chip conveyor  Cabinet cooling  Oil refrigeration  Power supply  Axis alignment- it is done by giving the tool pre-defined test feed and then comparing with actual position.

32 Vedant Prusty



January 2015

8. QUALITY CONTROL

Quality control in its simplest term refers to control of quality during the manufacture. Both quality control and inspection are envisaged to assure the quality in entire area of production process. Inspection is a function of determining the quality. When quality becomes effective, the need for inspection decreases. Hence, the quality control determines the cause of variation in the characteristics of products and gives solutions by which these variations can be controlled. It is economical in its purpose, objective in its procedure, dynamic in its operation and helpful in its treatment.

8.1 SCOPE

Objectives The total quality management department sets its measurable quality objectives for every year. These objectives ensure that requirements of the products are not only identified and met with, but also constantly reviewed and improved. The quality objectives are communicated to all the employees in the department by displaying it in the key areas. The measurable objectives are set taking into consideration of the following:  Reduce internal losses due to scrap rejection and rework.  Reduce external losses due to service cost.  Maximize the customer satisfaction

33 Vedant Prusty



January 2015

Purpose  To ensure the conformance of the incoming items or raw materials being used for the production with the specified standards.  To ensure that the casting produced in the foundry department meet the design standards.  To ensure documentation of the quality of the components and assembled units by inspecting or testing.  To ensure the testing of end products for its conformation with the specification. This is carried out by inspecting the performance of the end machine in a systematic manner as specified in the working instruction manual.  To ensure the documentation of all inspection report.  To ensure the procurement of modern testing instruments and periodic calibration of the existing testing facilities.  To ensure the quality of the manufacturing process of the major components in the unit.  To ensure the systematic analysis of the feed backs on performance and reliability reports of the products from inspection.  To ensure the systematic analysis of customer complaints for continual improvement of the product quality  To ensure total customer satisfaction.

8.2 Measurement of Total Quality Management Effectiveness

Inspection The effectiveness of the inspection process is measured through four parameters taken from internal and customer feedback. An average expected value per annum will be fixed by evaluating previous year’s records and strategic measures will be planned to bring down it to a lower value than the expected. The measurement parameters are: No. of NCR in assembly due to the manufacturing components  No of NCR in assembly due to brought out parts  Warranty cost due to failure of BOP items during the month in Rupees  Warranty cost due to failure of manufacturing items during the month in Rupees

34 Vedant Prusty



January 2015

Quality Control The effectiveness of the quality control is measured with five parameters. The average expected value per annum will be fixed by evaluating previous year’s record and strategic measures will be planned to bring down it to a lower value than expected. These parameters will be analyzed monthly in UQC meeting for necessary correction and preventive measures are taken to ensure its effectiveness.

The measuring parameters are: Percentage loss of standard hours  Loss in rupees  Percentage loss in foundry product  Average warranty cost per machine  Average breakdown days per machine

8.3 Quality Policy HMT MTL is committed to:  Maintain QUALITY LEADERSHIP in all products and services.  TOTAL CUSTOMER SATISFACTION through quality goods and services.  Commitment of management of CONTINUALLY IMPROVE the quality system.  To create a CULTURE among all employees towards TOTAL QUALITY CONCEPT.  Total quality through PERFORMANCE LEADERSHIP.

Quality Objectives The objectives of the quality management at HMT MTL at Kalamassery are: Total production for the year 2010-11 - 78 cores  Total sales for the year 2010-11 - 78 cores  Operational profit (PBDIT) - 250 lakhs  Internal losses (% of standard hours) - 0.6%  Total foundry rejection - 2.4%  Average warranty cost per month - Rs.900/-

8.4 ISO 9001 Accreditation

35 Vedant Prusty



January 2015

The HMT Ltd is accredited with ISO 9001 certification in 2001. Quality assurance offers more scope for reducing costs, rework. Extra handling, rejections etc. and enhancing competitiveness and profitability than other management techniques there by considerably reducing warranty claims and premium pricing. Effective quality management system in a company will help the company to acquire and maintain desired quality and optimum costs through planned and efficient utilization of the technological and material resources available to the company.

Chart No. 6: Quality Department Structure

36 Vedant Prusty



January 2015

9. HEAT TREATMENT

Heat Treatment is the controlled heating and cooling of metals to alter their physical and mechanical properties without changing the product shape. Heat treatment is sometimes done inadvertently due to manufacturing processes that either heat or cool the metal such as welding or forming.

Heat Treatment is often associated with increasing the strength of material, but it can also be used to alter certain manufacturability objectives such as improve machining, improve formability, and restore ductility after a cold working operation. Thus it is a very enabling manufacturing process that can not only help other manufacturing process, but can also improve product performance by increasing strength or other desirable characteristics.

Fig. No. 8: Heat Treatment

37 Vedant Prusty



January 2015

The various components used for the manufacture of parts for machine tools and printing machines are shown in Table 2 below.

Table No. 2: Components used for Machine Manufacturing Sl. No.

Material

Analysis by ERC weight

1.

Cast Iron

70%

2.

Steel

20%

3.

Non-ferrous alloys

5%

4.

Non-metallics (Plastic, rubber, etc.)

5%

____________________________________________________________________

Cast Iron is comparatively low in cost and has the following properties:  Castablility  Machinability  Wear Resistance  Damping Characteristics  Dimensional Stability  Pressure tightness

38 Vedant Prusty



January 2015

Table No. 3: Process of Heat Treatment

BATH/FURNACE

1. Carburising Bath

APPROX CONTENTS Sodium Cyanide 8 – 10% Sodium Chloride, Barium Chloride Temp 910 degrees C+-20

2. Hardening Bath

NaCl, Barium Chloride, Working Temp 850 degrees C +- 20

3. Annealing Bath

Same as hardening bath Working Temp 650 degrees C +-20

4. Quenching Bath

Sodium Nitrite, Sodium Nitrate Working Temp 180 degrees C +-20

Electroplating Section

BATH/FURNACE

1. Chromium Plating Bath

APPROX CONTENTS

Chromium acid 200gm/liter, 300gm/liter H2SO4, Temp 45-50 degrees C

2. Blackening Bath

NaOH, Sodium Nitrite, Sodium Nitrate, Temp 145 degrees C +- 10

39 Vedant Prusty



January 2015

Chart No. 7: Hardening Process

Prepare Job for Hardening

Pre-heat at 450 degree C +-20

Heat treat at 650 degree C +-20 for 30 mins

Heat at 780/820/850 degree C for 30 mins

Quench in Quenching bath at 180 degree C +-20

Cool at room temp by quenching in water

NO Is hardness as per requirement? YES Temper at 180 +-20 degree C in quenching bath

Cool to room temp by quenching in water

Wash and dispatch job

40 Vedant Prusty



January 2015

10. HIGH TECHNOLOGY CENTER

A machine tool is a power driven machine which can be used for the manufacture of components of other machines. HMT Kalamassery unit is a machine tool factory. In the High Technology Center there are 5 CNC machines.  VMC  HMC  HM4  VTC  VTC2

All these machines are working with the help of CNC control. Controlling a machine tool by means of a prepared programme which consists of blocks or series of numbers is known as Numeric control. It contain machine control unit and machine tool itself.

VMC 400 It can do drilling and milling operation. It can hold 12 tools in the magazine. The work table movement in X and Y axis are 400 mm and z axis is 420 mm. System 802- Auto tool change- pneumatic control.

HMC (Horizontal milling machine) Spindle works horizontally. It table length of X axis 630mm, Y axis 560mm and Z axis 500mm. It can hold 60 tool. It has 4 axis X, Y, Z and B.

HM4 - its table capacity is x axis 1600 y axis 1200 and B axis 360 degrees. It can hold 60 tools in the magazine.

VTC 1 AND 2 Vertical Machining Centre with automatic tool changer. Its capacity is X axis 1150mm, Y axis is 640mm and z axis is 500 mm. It can hold 30 tools.

41 Vedant Prusty



January 2015

10.1 Applications of CNCs It includes both for machine tools as well as non-machine tools. CNC is widely used for lathe, drill press, milling machine grinding unit, laser, sheet metal press, tube bending machine.

Elements of a CNC  Part program  Machine control unit  Machine tool

Part program is a detailed set of commands to be followed by the machine tool. Each

Fig. No. 9: HINUMERIC 2100M CNC Control System

command specifies a position in the Cartesian coordinate system. Programmers should be well versed with machine tools machining process.

Machine Control Unit (MCU) is a microcomputer that store the program and executes the command into actions by the machine tool.

It consists of two main units the date processing unit (DPU) and control loop unit (CLU). DPU software includes control system software, calculations algorithm, translation software that converts path program into usable further, interpolation algorithm to achieve smooth motion of cutter, editing of part program. CLU consists of the circuits for position and velocity control loops, deceleration and backlash take up, function controls such as spindle on/off.

Point to Point systems That move the tools or the workpiece from one point to another and then the tool programs the required task.

Continuous path systems It provides continuous path such that the tool can perform while the tools are moving, enabling the system to generate angular surfaces, two dimensions or three dimensional contours. Velocity error is significant in affecting the position of the cutter.

42 Vedant Prusty



January 2015

Interpolator The input speed of 1in/sec in example 2 is converted into the velocity components by an interpolator called the linear interpolator whose function is to provide the velocity signals to X and Y directions.

Incremental and absolute systems In incremental, sister distance is measured from one point to the next. An absolute system is one which all the morning commands are referred from a reference point.

Open loop control There is no feedback and uses motors for driving the lead screw. A motor is a device whose output shaft rotates through a fixed angle in response to an input pulse.

Closed loop control There is a force resisting the movement of the tool/work piece. Milling and turning are typical examples. Servo motors and feedback devices are used to ensure that the desired position is achieved.

Manual part programming It first prepares the program manuscript in a standard format .Manuscripts are typed with a device known as flexo writer. The punch type of prepared on the flexo writer. Computer aided programming Complex shaped component require calculation to produce the component done by programming software contained in the computer. Program communicates through system language which is based on words. Programming languages are: APT, ADAPT, AUTOSPOT, COMPAT – 2, CLROMANCE, SPLIT.

43 Vedant Prusty



January 2015

11. PRINTING MACHINES DIVISION The printing machine department of HMT Kalamassery is a leading manufacturer of offset printing machines in India. PMK department is functioning very similar to that of MTK manufacturing. The major components are cast with the help of foundry department. The cast components are manufactured into printing machine components at PMK manufacturing department.

11.1 Sections in PMK manufacturing The PMK manufacturing is broadly divided into three sections, namely, small parts, heavy parts and high technology center.

Small parts The small parts are again sub-divided into rounds non rounds and CGR (cams, gears and rollers). The round or symmetrical objects are machined rounds. The irregular parts are machined in non-rounds cams, Gears and rollers require more accuracy, hence they are machined in separate special purpose machines (SPM) in CGR.

Heavy Parts As the name suggests, the heavy parts deals with machining of heavy parts like: 1. Weld metal base – The base is made by welding Fig. No. 10: SOM 536

together the beams in the

welding shop. 2. Side frame – Side frames are mechanized, drilled bored. 3. Cylinder Drums are machined, and grinded

44 Vedant Prusty



January 2015

High Technology Center In this section works which require high accuracy are done in certain special machines.

11.2 Machines Available at PMK Manufacturing 1) NH/CNC Lathes 2) Grinding Machines 3) Milling Machines 4) Drilling Machines 5) Rack cutting machine 6) Cam milling machine 7) Gear hobbing machines 8) Planning machines 9) Boring machine 10) Straight bevel conflux generator Fig. No. 11: SOM 436

11) Engraving machines

Each unit is of single colour. A four color machine will have 4 units, one for each color, ink first comes on to plate roller then transferred to blanket roller and then to impression roller on which paper is being fed. Thus, the image is formed on the paper. After sheet is passed through all the units, required image is formed.

45 Vedant Prusty



January 2015

12. HEAVY PARTS

This section is in charge of manufacturing heavy parts like:  Headstock  Tailstock  Bed/Guideways

Marking It is the first process in which dimensions are marked on the surface of the casted product, so that machining can be done on it. Many machining operations are carried out in heavy parts.

Planing Machine It is used to machine the guideways.

Profile Milling Machine Cutting tools are made in such a way that it is having the profile which is milled on the jobs surface. This machine has 8 cutting tips they are carbide and replaceable.

CNC Plano Milling This is a computer numerically controlled milling machine. It has 6 point Tools. Tool Movement and changing are controlled by the computer. It has 3 axes, that is x, y, z axes and a right angle unit that allow tool Movement in the perpendicular direction.

Groove Cutting Groove is made using an ‘L’ shaped cutting tool which pushes. At first, a circular slot is made using normal cutting tool. Then ‘L’ shaped tool is inserted and by push action, it is made to go forward.

46 Vedant Prusty



January 2015

Grinding Sideway

grinding,

surface

grinding, and internal grinding etc. are used in Heavy Parts. The grinding wheel is made of aluminum oxide and diamond is used to shape them. Grinding is mainly done on guideways and bed using surface grinding wheels. Fig. No. 12: PSG 200 Surface Grinding Machine

An Autocollimator is used to

check the convexity of the guideway.

Line Boring Machine In very long holes, ordinary boring is not done and it causes bending and taper. In such cases, a single point tool supported at many parts is inserted through workpiece.

Induction Hardening Machine Many parts require hardness only at selected region; so hardening operation are done only in those parts by principle of induction.

Other Functions At heavy parts coolants are rarely used as cast Iron is self-lubricating due to presence of carbon in it. In many machines, bore center, parallelism, etc. are obtained by use of dials. This is called “dialing”

All objects in this section are carried by cranes.

47 Vedant Prusty



January 2015

Chart No. 8: Objective Measurement Chart

48 Vedant Prusty



January 2015

13. CONCLUSION

HMT Machine Tools Kalamassery is one of the last few profit generating facilities in HMT’s core and original field – heavy machine tool manufacturing. Recently, HMT Machine Tools at Kalamassery has made a foray into defence manufacturing by producing directing gears, a ship-borne positioning mechanism, for sonars fitted on warships for tracking enemy submarines.

HMT Machine Tools completed the project around September 2014 in collaboration with the Naval Physical and Oceanographic Laboratory (NPOL), a DRDO lab that designs and develops sonars and underwater surveillance and communication systems for the Indian Navy, and Bharat Electronics Ltd (BEL), which manufactures the whole system. It has already received orders for several of these modules. The contract for this was valued at about Rs.16 crore. HMT MTK has not only re-entered the market, but has revitalized the heavy machine manufacturing industry in India this decade. While it may not be in its erstwhile glory days of thousands of employees, the facility is slowly but surely rising quickly.

Fig. No. 13: The Main Manufacturing Facility at HMT Kalamassery

49 Vedant Prusty



January 2015

Perhaps one point that is a big boost to this company is the tremendous respect it has for quality of service. From microscale precision right in the convexity of lathe beds, rigorous testing of all equipment, and secured delivery and training services, HMT MTK is now generating

clientele

in

the

public

as

well

as

private

sectors.

My experience has been one of thrill as well as intense learning. The on-site exposure to the traditional methods of manufacturing using lathes, cutting, drilling, milling and slotting machines, using collimators for measurement, as well as hands on experience with modern Computer Integrated Manufacturing using VMC and HMC lathes, multi-point cutting tools, multi tool turret systems, etc. The exposure to areas like Production and Operations management, Job Shop Scheduling, Aggregate Planning, etc. were a key aspect of the training period.

At the end of it, I have had quite a bit to take back from this place, and recognize the contribution it made in my understanding of the industry in engineering.

50 Vedant Prusty



January 2015

REFERENCES All content in this report are based solely on company reports and documentation at HMT. All procedures mentioned are HMT customized versions of standards available in open source. Any images of machines are taken from the website of Hindustan Machine Tools http://www.hmtmachinetools.com/. The company profile and product range is readily available for further perusal at http://www.hmtmachinetools.com/kalamassery-complex.htm.

Fig. No. 14: HMT Kalamassery

51 Vedant Prusty



52 Vedant Prusty

January 2015


Report on Industrial Training at HMT Machine Tools, Kalamassery

Recommend Documents