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INDUSTRIAL TOUR

KTDMC and AMANTECH

Name: ADIL IQBAL (P)


Time/Date: 9.30 AM 2.00 PM, 30th Sept 2014
Place: (1) KTDMC
(2) AMANTECH
Total Words: 1456

Observations
KTDMC
As part of our Engineering Material coursework, our instructor arranged an industrial
tour to Karachi Tools, Dies and Molds Center (KTDMC). KTDMC provides, in addition
to design and manufacturing services, training and consultancy in different sections.
These sections include: CAD/CAM/CAE, Sheet Metal Dies, Injection Molds and others.
A presentation on the different processes of die manufacturing was followed by a
physical visit to the facilities where one could see the actual processes taking place. The
presentation covered almost all major engineering topics ranging from general molds and
dies to machine names and brands. The tour to the main facility was comprehensive and
well-coordinated.

Reverse Engineering Reverse Engineering is a complex method whereby a 3D


virtual model or meshwork of an existing part is created for use in CAD, CAM or
CAE software. Of the many types of reverse engineering like CMMs, laser scanners
and Industrial CT scanning, two types were illustrated. By one process (3D scanner),
images of the part product was taken from different angles and a meshwork was
created in CAD or CAM software. The meshwork or virtual model was then
analyzed. The other type of reverse engineering process (Coordinate-measuring
machine) featured probing process; whereby, the foreign product part was analyzed
by applying a probe to each section of the part and then a virtual model of the product
part was created. The product part that was analyzed was that of an engine mold.
CAE-CAM analysis After the product part was created into a meshwork in reverse
engineering process, the CAD analysis was then transferred to the next section. This
next section is responsible for machining and engineering the 3D meshwork and
transferring it to CNC machine. CAE software (like CATIA and PTC Creo) applied
stress analysis, thermal and fluid flow analysis and finite element analysis on the 3D
meshwork. CAM concerns high speed machining and 5-axis machining.
Dies and Molds Development The engineered 3D model was coordinated with
CAM software and the model was sent to the CNC machine. Stainless Steel (SS) was
used in the CNC machine to produce the required mold or die. For rapid cooling of
the product and machine, cooling oil was being used. Electric discharge machining
was also shown to us where the desired shape is obtained by application of electrical
sparks. The desired shape can also be obtained by wire cut.

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Other machinery On the facility we were also introduced to other machineries like
lathe and milling machines. Some products were also observed, including engine
parts, mechanical parts and others. Presses were also seen at the facility where mold
shapes were casted and pressed into sheet metal.
Heat Treatment To change the properties of a metal sheet or mold, heat treatment is
utilized whereby a vacuum hardening furnace is used to heat the mold to a specific
temperature. The furnace at KTDMC has a load capacity of 800 kg and nitriding,
hardening and tempering is processed. Annealing and quenching processes were also
discussed. The process and design of the furnace was explained to us by the presenter.

AMANTECH
The tour to AMANTECH was made as part of our Engineering Materials course.
AMANTECH is the technical limb of AMAN Foundation which is a not-for-profit trust
and aims to dignify the lives of the underserved by focusing on their basic issues (health,
education etc.).
We were divided into two groups upon entering the technical area, each group led by a
presenter. The facility at AMANTECH was very clean and spacious and the site was
designed in a very colorful manner. The instructors and support staff were professional
but polite enough to answer our questions. In addition, we also saw the routine of the
students present there. During our interaction with the students there, we noticed how
skillful and well poised they were.
We were led to the different parts of the facility ranging from plumbing and woodwork to
Automotive. The observations on the different sections are made below:

Refrigeration The facility at AMANTECH houses a refrigeration and AC section


with all the necessary equipment and troubleshooting specimens. Different specimens
of AC and refrigeration cycles were provided for the students technical education.
The projects of the students were also shown to us by the presenter.
Plumbing AMANTECH also provides a plumbing section for its students. All
necessary piping, drain fitting and valve assemblies were shown to us and the
presenter also stressed upon the importance of plumbing as a job. A project of a
student was highlighted which was based on sewage system.
Automotive The Automotive section of AMANTECH is very comprehensive and
user-friendly. Simulators, car steering systems and a Toyota Corolla engine automated
specimen was present; the AC system of a Lexus was also present.

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Carpentry In addition to other services and facilities, there was a carpentry section.
The section was spacious and fully equipped with carpenter equipment; the section
could house around 15 students in one go. The projects shown to us were very
innovative and inspiring.
Welding The welding section was maybe the largest section at AMANTECH and
contained almost all relevant welding machines and types. The welding machines at
AMANTECH ranged from Gas Metal Arc welding to Tungsten Inert Gas welding. An
Electroslag welding machine was present too. The application of the different
welding machines was shown to us as the metal tables at the facility were welded by
the students of AMANTECH.
Other amenities Apart from the technical education imparted to the students, we
were also introduced to the grooming resources present at the site. A separate
classroom was designated especially for the prepping of the students. The room
contained practice suits and ties for interviews. Eating, speaking and walking
manners, among others, are taught in that section.

Learning Objectives
KTDMC

This tour was the perfect example of application based learning and provided a relief
from our general routine.
For most of us, this tour was our first encounter with professional and office
environment and we learned comprehensively.
We learned about the importance of different processes that would help later in our
studies and projects.
The importance of dies and mold industry was stressed upon and we were provided
with a comprehensive knowledge of dies and mold manufacturing.
We observed the day to day operations of the industry and the role of a mechanical
engineer in an industry.

AMANTECH

The application of the different skills i.e. plumbing, carpentry etc. was explained
comprehensively to us and we learned many new things.
The importance of this tour would show its true colors when our final year projects
are due and the skills and machines shown would be used extensively.

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We learned the importance of obtaining knowledge and Allahs blessings that has
been showered upon us. The underprivileged people of our country have equal
technical expertise if their energies are channeled in the right way.
Due to the presenters expertise in communicating information to us, we also learned
how to effectively communicate in a professional environment.
We learned about the managerial side of a mechanical engineer in contrast to the
general technical aspect.

Learning Outcomes
KTDMC The tour to KTDMC linked our Engineering Materials course as well as
thermodynamics.
Engineering Materials: The strength, resilience and other properties of the mold material
is of much importance to the industry. The changing of properties through heat treatment
is a part of our Engineering Materials course.
Thermodynamics: The processes inside the CNC (cooling etc.) and Heat Treatment plant
(annealing, quenching etc.) form a part of our thermodynamics course and provided a
detailed application on our obtained knowledge.
AMANTECH The tour to AMANTECH provided a deeper knowledge of
Thermodynamics.
Thermodynamics: The refrigeration section at AMANTECH provided us a chance of
visually observing the refrigeration and heat cycles. This helped us to understand the
applications and working of the cycles more closely.

Future Visit
I would appreciate if a visit to Pakistan Steel Mills, KANUPP, HinoPak or Atlas Honda is
arranged.

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Conclusion
KTDMC The tour to KTDMC was a refreshing part of our studies and the knowledge
obtained would be utilized when the projects come by. Overall, the tour was very wellcoordinated and well prepped. The visit was very informative and helped us visualize the
application of knowledge.
AMANTECH The tour to AMANTECH was maybe the best tour of our college years
to date. Apart from the technical and educational preferences of AMANTECH, the social
development side of the industry is a noteworthy aspect. AMANTECH is maybe the only
trust that relieves the underserved people of Pakistan of their problems be it health,
education or residence. The work there is very inspiring, well-organized and expertly
done.

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