PSG COLLEGE OF TECHNOLOGY

(Autonomous and an ISO 9001 certified

Institution)
COIMBATORE – 641 004

DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL VISIT AND TECHNICAL

SEMINAR

Submitted by
Names : 1) SOUNDAR RAJAN (12MD34)
2) SWAMYNATHAN (12MD35)
3) BHEEMAPPA (12MD81)

Branch : M.E, ENGINEERING DESIGN

 INDEX

1. INTRODUCTION
2. LIST OF DIVISIONS
3. DIVISIONS VISITED
Introduction:

Rotating Machine Division

The Rotating Machine Division of PSG College of Technology is involved in the production /
manufacturing of centrifugal, Open well submergible and Submergible Pumps of various
capacities. This Division involved in the following activities connected to
manufacture/Production of Pumps.

1) Machining of Pump Parts

2) Machining of Motor Parts
3) Assembly of Pumps
4) Winding of Motors
5) Balancing of rotor
6) Testing of Motors
7) Painting
8) Inspection
9) Despatch

The following Products are done

here

 Domestic Pumps
 Centrifugal Monoblock
 Submersible Monoblock
 Submersible Pumps
 Electric motors
 Industrial Motors
 Booster and Non-Clog Self Priming
 Compressors

DEFINITION
A pump is a device that raises or transfers fluids. Pumps are selected for processes not only to
raise and transfer fluids, but also to meet some other criteria. This other criteria may be
constant flow rate or constant pressure.

Pumps are used for a variety applications. Here is a list of a few applications:

 Drainage - Used to control the level of water in a protected area.

 Sewage - Used in the collection and treatment of sewage.
 Irrigation - Used to make dry lands agriculturally productive.
 Chemical Industry - Used to transport fluids to and from various sites in
the chemical plant.
 Petroleum Industry - Used in every phase of petroleum production,
transportation, and refining.
 Medical Field - Used to pump fluids in and out of the body.
 Steel Mills - Used to transport cooling water.

Classification of Pumps

Pumps are in general classified as Centrifugal Pumps (or Roto-dynamic pumps) and
Positive Displacement Pumps.

Centrifugal pumps can further be classified as

 End suction pumps

 In-line pumps

 Double suction pumps

 Vertical multistage pumps

 Horizontal multistage pumps

 Submersible pumps

 Self-priming pumps
  Axial-flow pumps

 Regenerative pumps

Positive Displacement Pumps

Positive Displacement Pumps has an expanding cavity on the suction side and a decreasing
cavity on the discharge side. Liquid flows into the pumps as the cavity on the suction side
expands and the liquid flows out of the discharge as the cavity collapses. The volume is
constant given each cycle of operation.

The pos***itive displacement pumps can be divided in two main classes

 Reciprocating

 Rotary

The positive displacement principle applies applies whether the pump is a

 Rotary lobe pump

 Progressing cavity pump

 rotary gear pump

 piston pump

 Diaphragm pump

 Screw pump

 Gear pump

 Vane pump

 Regenerative (peripheral) pump

  Peristaltic

SUBMERCIBLE PUMP

A submersible pump (or electric submersible pump (ESP)) is a

device which has a hermetically sealed motor close-coupled to
the pump body. The whole assembly is submerged in the fluid
to be pumped. The main advantage of this type of pump is that
it prevents pump cavitation, a problem associated with a high
elevation difference between pump and the fluid surface.
Submersible pumps push fluid to the surface as opposed to jet
pumps having to pull fluids. Submersibles are more efficient
than jet pumps.

Working Principle :

The submersible pumps used in ESP installations are multistage centrifugal pumps operating
in a vertical position. Although their constructional and operational features underwent a
continuous evolution over the years, their basic operational principle remained the same.
Produced liquids, after being subjected to great centrifugal forces caused by the high
rotational speed of the impeller, lose their kinetic energy in the diffuser where a conversion of
kinetic to pressure energy takes place. This is the main operational mechanism of radial and
mixed flow pumps.

The pump shaft is connected to the gas separator or the protector by a mechanical coupling at
the bottom of the pump. Well fluids enter the pump through an intake screen and are lifted by
the pump stages. Other parts include the radial bearings (bushings) distributed along the
length of the shaft providing radial support to the pump shaft turning at high rotational
speeds. An optional thrust bearing takes up part of the axial forces arising in the pump but
most of those forces are absorbed by the protector’s thrust bearing.

Applications :

Submersible pumps are found in many applications. Single stage pumps are used for
drainage, sewage pumping, general industrial pumping and slurry pumping. They are also
popular with aquarium filters. Multiple stage submersible pumps are typically lowered down
a borehole and used for water abstraction, water wells and in oil wells.
Special attention to the type of ESP is required when using certain types of liquids. ESP's
commonly used on board naval vessels cannot be used to dewater contaminated flooded
spaces. These use a 440 volt A/C motor that operates a small centrifugal pump. It can also be
used out of the water, taking suction with a 2-1/2 inch non-collapsible hose. The pumped
liquid is circulated around the motor for cooling purposes. There is a possibility that the
gasoline will leak into the pump causing a fire or destroying the pump, so hot water and
flammable liquids should be avoided.

Tool and Die Making Centre

Machines held:

 L& t injection moulding machine (model Detech 60/320)

 Craftsman surface grinding machine (model SG 3060)
 Makino vertical machining centre (model S 33)
 Mitsubishi EDM wire cut (model FA 10 S)
 Mitsubishi EDM (model EA 8)
 Carl Zeiss CMM contura G2(7/10/6)

Layout:
 CRAFTSMAN MITSUBISH CARL ZEISS MITSUBISHI
SURFACE EDM CMM EDM WIRE CUT
GRINDING

L&T INJECTION
MOULDING
CARL ZEISS CMM
MAKINO VERTICAL
M/C CENTRE
WORK CENTRES

MACHINE - DESIGN OFFICE

- DIE ASSEMBLY

- FITTING WORK
 MITSUBISHI WIRECUT EDM MITSUBISHI EDM (MODEL-EA 8)

MITSUBISHI EDM WIRE CUT (MODEL FA 10 S)

Specifications:

Sl.no Description specification

1 Max submerged workpiece dimensions 800*600*215 mm

2 Max submerged workpiece weight 250 kg

3 Table dimensions 590*510 mm

4 Machining Range X-Y 350*250 mm

5 Max Z-axis height 220mm

6 U-V Axis Travel 32mm

7 Table Rapid feed speed 1300mm/min

8 Wire diameter Possible 0.1~0.3mm

9 M/c system dimensions 1975*1667mm

10 Power reqiurements 200-230V

11 Compressed air reqiurement 6 bar

12 M/c installed height 2036 mm

13 M/c system weight 2580 kg

14 Filters/Type 2/paper
 15 Minimum start hole diameter 25mm

16 Wide angle taper 45deg

17 Minimum drive unit /resoultion 0.0001/0.05micron

Working :

 Electrical Discharge Machining (EDM) is a process of metal machining in which a

tool discharges thousands of sparks to a metal workpiece.
 A non-conventional process, EDM works on parts resistant to conventional machining
processes, but only if these parts are electrically conductive; usually, they are non-
ferrous, and include steel, titanium, super alloys, brass, and many other metals.
 The wire-cut EDM is a discharge machine that uses CNC movement to produce the
desired contour or shape. It does not require a special shaped electrode, instead it uses
a continuous-traveling vertical wire under tension as the electrode. The electrode in
wire-cut EDM is about as thick as a small diameter needle whose path is controlled by
the machine computer to produce the shape required.
 Used for making Press tool.
 Accuracy achieved 5 micron.
 Wire diameter 0.25 mm.
 Copper+zinc bronze material for wire.

CONVENTIONAL EDM MITSUBISHI EDM (MODEL EA 8)

Specifications:

Sl.no Description Specifications

1 M/cing Range( X*Y*Z) 300*250*250 mm

2 Work tank internal dimensions (W*D*H) 70*500*250 mm

3 Max. workpiece dimensions 740*470*150mm

4 Max workpiece weight 550 kg

5 Table Dimensions (W*D) 500*300 mm

6 Max. electrode weight 25kg

7 Distnce between table surface & electrode weight 200~450 mm

8 Rapid travel Speed 2000mm/min

 9 M/c system Dimensions (W*D) 1625*17*9

10 M/c system height 2000 mm

11 M/c System weight 200kg

12 Filter tank capacity 196 L

Working :

 In the EDM process an electric spark is used to cut the workpiece, which takes the
shape opposite to that of the cutting tool or electrode. The electrode and the workpiece
are both 2 submerged in a dielectric fluid, which is generally light lubricating oil.
 A servomechanism maintains a space of about the thickness of a human hair between
the electrode and the work, preventing them from contacting each other.
 In EDM ram or sinker machining, a relatively soft graphite or metallic electrode can
be used to cut hardened steel, or even carbide. The EDM process produces a cavity
slightly larger than the electrode because of the overcut.

CRAFTSMAN SURFACE GRINDING MACHINE-MODEL SG 3060

Specifications

Sl.no Description Specifications

1 Table size 305 x 610 mm
 2 Max.Grinding Length x Width 610 x 305 mm
3 Max.Dist from table surface to spindle 630 mm
center
4 Standard magnetic chuck size 300 x 600 mm
5 Longitudinal travel - Hydraulic 650 mm
6 Longitudinal travel speed - Hydraulic 5~25 m/min
7 Longitudinal Automatic transverse 1~25 mm
increment
8 Rapid travel approx 2.9 m/mm
9 Max automatic transverse travel 360 mm
10 Maximum manual transverse travel 370 mm
11 Cross slide Hand wheel /revolution 4 mm
12 Cross slide Hand wheel /graduation 0.02 mm
13 Cross slide Micro Feed /revolution 0.1 mm
14 Cross slide Micro Feed / graduation 0.002 mm
15 Wheel head Automatic infeed 0.002-0.004 mm
16 Wheel head Hand wheel /revolution 2 mm
17 Wheel head Hand wheel / graduation 0.01 mm
18 Wheel head Rapid travel.approx 300 mm
19 Wheel head Micro feed/revolution 0.2 mm
20 Wheel head Micro feed/ graduation 0.002 mm
21 Grinding spindle drive speed 1450 rpm
22 Grinding wheel Power rating 5 hp
23 Grinding wheel Diameter x Width x Bore 350 x 50 x 127 mm
24 Hydraulic pump motor 2 hp
25 Hydraulic tank Capacity 160 liters
26 Net Weight approx 2500 kg
27 Rated Power,approx 7.4 kw

 Surface Grinding is used to produce a smooth finish on flat surfaces. It is a widely

used abrasive machining process in which a spinning wheel covered in rough particles
grinding wheel cuts chips of metallic or nonmetallic substance from a work piece,
making a face of it flat or smooth.
 The surface grinder is composed of an abrasive wheel, a work holding device known
as a chuck and a reciprocating or rotary table. The chuck holds the material in place
while it is being worked on. It can do this one of two ways: ferromagnetic pieces are
held in place by a magnetic chuck, while non-ferromagnetic and nonmetallic pieces
are held in place by vacuum or mechanical means. A machine vice (made from
ferromagnetic steel or cast iron) placed on the magnetic chuck can be used to hold
non-ferromagnetic work pieces if only a magnetic chuck is available.
 PLATIC INJECTION MOULDING MACHINE L&T DETECH 60/320 LUCS

Specifications:

Sl.no Description Specifications

1 Clamping Force 600 kn
2 Locking Force 660 Kn
3 Mould Opening Stroke 310 mm
4 Mould Height(Min/Max) 180/410 mm
5 Max.Daylight between Platens 720 mm
6 Overall Size of Platens 480 x 480 mm
7 Distance between Tiebars 320x320 mm
8 Total Mould carrying capacity 420 kg
9 Max.mould.wt.in moving platen 280 Kg
10 Hydraulic Ejector stroke 100 mm
11 Ejection Force/Retraction Force 28/13 Kn
12 Oil Tank Capacity 180 L
13 Net Weight (Without oil) 3200 Kg
14 Dimensions of machines (L x B x H) 5000x1400x2000 mm
15 Cooling water requirement 40 lpm

Injection molding is a manufacturing

process for producing parts from both thermoplastic and thermosetting plastic or other
materials including metals, glasses, elastomers and confections. Material is fed into a heated
barrel, mixed, and forced into a mold cavity where it cools and hardens to the configuration
of the cavity. After a product is designed, usually by an industrial designer or an engineer,
molds are made by a mould maker from metal, usually either steel or aluminium and
precision-machined to form the features of the desired part. Injection molding is widely used
for manufacturing a variety of parts, from the smallest component to entire body panels of
cars.

MAKINO VERTICAL MACHINING CENTRE MODEL S33

Specifications:

Sl.no Description Specification

1 Axes Travel X,Y,Z 650X500X450 mm
2 Table Top to Spindle Face 150-600 mm
3 Rapid Transverse XYZ 40 m/min
4 Axis Feed Rate 1-40000 mm/min
5 Size of the Table 850X500 mm
6 Table Load Capacity 650kg
7 Max. Work size on table 850X500X450 mm
8 Spindle Speed Range 200-20000 rpm
9 Spindle Power(30min/ Cont) 15/11 kw
10 Max. Torque(5min/ Cont) 32/19 Nm
11 Tool Clamp Force 8800+/-5%N
12 No. of Tools 23/30(OPTION)
13 Tool Change Time(Tool To Tool) 1.3 sec
14 Max Tool Diameter 114/76.2(ATC20/ATC30)min
15 Max. Tool Dia with alternative pocket empty 130 mm
16 Max .Tool Weight 8 kg
17 Min. Pneumatic Pressure 5 kg/cm^2
18 Pneumatic Consumption 0.4 m^3/m
19 ATC Magazine Power 0.5 kw
20 Machine Weight 7500 kg
21 Spindle Nose DIN 69871-A40
22 Spindle Oil Cooling System CORE COOLING
23 Power Supply 40 KVA
24 T Slot Size 18H8
25 Accuracy 0.003 Micron
 26 Repeatability 0.002 Micron

 This vertical machining centre is slightly different from our conventional milling
machine. because, here it is fully automated (i.e operations were controlled by CNC
programs)
 In this centre we can do machining even for complicated profiles.
 This centre can holds 40 different tools for performing different operations.
 The operations sequence ,tool change and spindle speeds were controlled by CNC
codings.
 With in 2 seconds, tool unloading and loading will takes place and this is one of the
great advantage in this centre.
 We can obtain greater accuracy, surface finish etc..

CARL ZEISS CMM CONTURA G2(7/10/6)

Specifications:

Sl.no Description specification

1 Measuring ranges in mm (in.) X axis 700 mm
2 Measuring ranges in mm (in.) Y axis 1000 mm
3 Measuring ranges in mm (in.) Z axis 600 mm
4 Width 1560 mm
5 Length 1840 mm
6 Height 2800 mm
7 Table height 850 mm
 8 Clearance under bridge 850 mm
9 Clearance under probe head 680 mm
10 Work table area X,Y 920 x 1340 mm
11 CMM Weight 1640 kg
12 Maximum workpiece weight 730 kg
13 Set up 0 to mm/sec
14 Measuring operation-axial max 250 mm/sec
15 Measuring operation-vertical max 425 mm/sec
16 Creep speed 0 to 5 mm/sec
17 Probe length max 500 mm
18 Measuring force during data acquisition variable 50 to 1000 mN
19 Styli tip diameter minimum 1 mm
20 Styli tip weight max 500 gm
21 Power supply 1000 va
22 Compressed air supply 6 to 8 Bar Pressure
23 Air Humidity 40 to 60 %
24 Permissible ambient Temperature 17 - 35 °C
25 Temperature Range 18 - 22 °C

 A coordinate measuring machine is a 3D device for measuring the physical

geometrical characteristics of an object.
 Measurements are defined by a probe attached to the third moving axis of this
machine.
 probes may be sensors.
 A machine which takes readings in six degrees of freedom and displays these readings
in mathematical form is known as a CMM.
 Coordinate-measuring machines include three main components:
 The main structure which include three axes of motion
 Probing system
 Data collection and reduction system - typically includes a machine controller,
desktop computer and application software.

 The typical 3 "bridge" CMM is composed of three axes, an X, Y and Z.

 These axes are orthogonal to each other in a typical three dimensional coordinate
system.
 Each axis has a scale system that indicates the location of that axis.
 The machine will read the input from the touch probe, as directed by the operator or
programmer.
 The machine then uses the X,Y,Z coordinates of each of these points to determine size
and position with micrometre precision typically.
 A coordinate measuring machine (CMM) is also a device used in manufacturing and
assembly processes to test a part or assembly against the design intent.
  By precisely recording the X, Y, and Z coordinates of the target, points are generated
which can then be analyzed via regression algorithms for the construction of features.
 These points are collected by using a probe that is positioned manually by an operator
or automatically via Direct Computer Control (DCC).
 DCC CMMs can be programmed to repeatedly measure identical parts, thus a CMM
is a specialized form of industrial robot. We can measure even critical physical
geometry.

Heavy Engineering Division

The main activities performed in this Division is Manufacturing and Assembly and
testing of PSG Lathes. The some of the components of lathe viz lathe bed, guide ways etc
will be getting from PSG Foundry Division and further operation will be carried on the
components using Boring Machines, Grinding Machines, Grinding Machines etc and final
assembly will be carried out. The list machines held in this Division are as follows.

Heavy Shop ‘A’

1. WMW Sloting machine

2. Renicker vertical milling machine
3. TOS63A boring and milling machine
4. CSPL drilling machine
5. TOS FA 5V vertical milling machine
6. Duplex Milling machine
7. PRVO MAJSKA shaper
8. Btliboi shaper

Heavy Shop ‘B’

1. HMT radial drilling machine

2. TOS FA 5U universal milling machine
3. Bombay lathe
4. Cooper planer
5. HMT cylindrical grinding machine

Heavy Shop ‘C’

1. WMW slideway grinding machine-open end

2. WMW guideway grinding machine double column
3. FSG honing machine
4. FSG line boring machine
5. WMW BF-80 boring and milling machine
6. UMA boring machine
7. SACEM boring machine
8. TOS H100A boring and milling machine
9. Inspection
10. HMT surface grinding machine
11. WOTAN internal grinding machine