An Internship Report on

DESCOM

Heavy Industries Taxila (HIT)

Submitted by:

Muhammad Shoaib

September 7th, 2018

Department of Mechanical Engineering

Capital University of Science & Technology,

Islamabad

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 Contents
1. INTRODUCTION ...............................................................................................................................4

2. OBJECTIVES ....................................................................................................................................4

3. ADMINISTRATION ............................................................................................................................4

4. SUB-FACTORIES ..............................................................................................................................4

5. DESCOM......................................................................................................................................4

6. FOUNDRY SHOP ..............................................................................................................................5

 CASTING .........................................................................................................................................5

 MOLDING .......................................................................................................................................5

 BAKING ..........................................................................................................................................6

 SAND .............................................................................................................................................6

 SAND MULLER .................................................................................................................................6

 CASTING TECHNIQUES .......................................................................................................................6

 SAND CASTING ................................................................................................................................6

 CENTRIFUGAL CASTING .....................................................................................................................6

 INVESTMENT CASTING.......................................................................................................................7

6.1. FURNACES ..................................................................................................................................7

 CUPOLA ..........................................................................................................................................7

 INDUCTION .....................................................................................................................................7

 PIT FURNACE ...................................................................................................................................7

 COPPER COIL ...................................................................................................................................8

7. HEAT-TREATMENT ..........................................................................................................................8

 CASE HARDENING .............................................................................................................................9

CASE HARDENING IS SPECIFIED BY HARDNESS AND CASE DEPTH. THE CASE DEPTH CAN BE SPECIFIED IN TWO WAYS ..9

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 TOTAL CASE DEPTH .........................................................................................................................10

 EFFECTIVE CASE DEPTH ....................................................................................................................10

 IMPRESSION-DIE DROP-HAMMER FORGING .......................................................................................12

 PRESS FORGING .............................................................................................................................12

 UPSET FORGING .............................................................................................................................12

9. MACHINE SHOP ............................................................................................................................13

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 1. Introduction

Heavy Industries Taxila commonly abbreviated as HIT is a substantial resistance gear generation
industry of Pakistan. It is presumed for the most part since it is a primary one and only tank fabricating
industry of Pakistan.

2. Objectives

 Manufacture, Rebuild, Upgrade & Develop Tanks, Tank Guns & APCs.
 Utilize surplus capacity of factories to meet requirements of civil sector and friendly countries

3. Administration

The whole production is carried out by co-ordination of number of sub factories along with
budget, Administration and technical directorate.

4. Sub-Factories

 DESCOM
 HRF-T
 HRF-M
 AARDIC
 APC
 Tank Factory
 Gun Factory
*Our Internship was in DESCOM.
Internship Duration: July 30th, 2018 – September 07th, 2018

5. DESCOM

DESCOM is an abbreviation of Development Engineering Support & Component Manufacturing.

This production facility has been established to provide engineering support to all factories of HIT.
Equipped with CNC machines it undertake manufacture of components, assemblies, tools, dies, gauges

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and arranges development of spare parts through the vendor industry. It also provides repair/maintenance
support to machinery/equipment installed in HIT.
Machining covers a few procedures. DESCOM undertakes manufacture of components, assemblies,
tools, dies, gauges and arranges development of spare parts there are no. of shops which are additionally
outfitted with CNC s and talented labour. This industrial facility is furnished with EM branch and in
addition Quality Control branch. Primary items it gives our nation are tanks, APC, ARV and Guns.

Below is the brief knowledge of shops present in DESCOM

6. Foundry Shop

Foundry Shop is dedicated for the casting of equipment parts that are joined together. Foundry is a
backbone of HIT and is solely located in DESCOM. It is equipped with modernized equipment’s to
maximize the production with minimization of time and labor.

 Mission:
 To cast components for Tank, APC’S, ASV, 125mm Gun Barrel.
 To Produce Casting required for tooling items.
 To Cast Machinery Spares for all Projects of HIT

The main process which is carried out in foundry is casting process

 Casting

In casting processes, a solid material is first melted, heated to proper temperature, and sometimes treated
to modify its chemical composition. The molten material, generally metal, is then poured into a cavity or
mold that contains it in the desired shape during solidification. Thus, in a single step, simple or complex
shapes can be made from any material that can be melted. Casting is one of the most important of the
manufacturing processes.

 Molding

Pattern i.e. replica of thing to be casted is used to make mold. Pattern is either made up of wood known
as master pattern or maybe made up of metal.

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Mold is made in two parts lower part that is known as drag and upper part or cope.

 Baking

Baking is carried out in pit furnace by heating at 400 degree Celsius for sufficient time.

 Sand

Granular particle of sand are used to make mold which is either dry or green sand. Sand is mixed
with molasses to enhance binding ability.

 Sand Muller

Sand Muller is used to mix and restore ready to use texture of molding sand

 Casting Techniques

Following are the casting techniques,

1. Investment Casting
2. Sand Casting
3. Pressure Die Casting
4. Centrifugal Casting
5. Vacuum Casting

 Sand Casting

The sand grains are blended with little measures of different materials, for example, clay and water, to
enhance pliability and firm quality, and are then stuffed around a sample that has the shape of the
coveted casting. Since the grains will pack into thin segments and can be utilized financially in large
amounts, items crossing an extensive variety of sizes and detail can be made by this technique.

 Centrifugal Casting

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Centrifugal casting is used as a means of casting small, detailed parts or jewelry. An articulated arm is free
to spin around a vertical axle, which is driven by an electric motor or a spring. The entire mechanism is
enclosed in a tub or drum to contain hot metal should the mold break or an excess of metal be used. Single
use molds are prepared using the lost wax method. A small amount of metal in a crucible (a sort of ceramic
pan) next to the mold is heated. When the metal is molten the arm is released, forcing (by centrifugal force)
the metal into the mold. The high forces imposed on the metal overcome the viscosity, resulting in a finely
detailed work piece.

 Investment Casting

Investment casting is carried out by using paraffin wax and urea cores to make internal shape of casting.
Urea is used to make cores because when casting is placed in water urea dissolve in water leaving behind
a core print.

It is carried out when dimensional accuracy and higher surface finish is required.

6.1. Furnaces

Following Furnaces are available in Foundry

1- Cupola
2- Induction
3- Pit Furnace

 Cupola

It is used on Foundry for melting of cast iron and is a vertical cylindrical furnace.

 Induction

DESCOM foundry is equipped with two induction furnaces of 15 ton melting capacity. They are used to
melt iron, steel, Aluminum or precious metal by heat applied on basis of induction heating of metal i.e.
by resistance of electron movement within a metal.

 Pit Furnace
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 Descom Foundry is equipped with 1 Pit furnace.

 Copper Coil

It is an equipment which is used to melt metal the metal by induction of current in a copper coil
that generate heat and melt metal

7. Heat-Treatment

 Mission
 Heat Treatment of newly made parts required for Re Build of Tanks, ARV, APC, T-
80UD, Gun Barrel 125 mm.
 Heat Treatment of tools and Dies
 Heat Treatment of Components required for repairing of Machinery

Organizational Profile

 Hardening Section
 Salt bath Hardening Section
 Inspection Section
 Spring Manufacturing Section
 Scale Removing & Straightening Section
 P & C Maintenance Section

Shop 8 is dedicated for heat treatment of different metallic parts in order to enhance their working
capability and making them friendly for certain task.

 Objective

The main objective of heat treatment is to alter physical and sometime chemical properties of metal
by heating or chilling of metal usually at extremely high temperature. There are two mechanisms that may
change an alloy's properties during heat treatment: the formation of martensitic causes the crystals
to deform intrinsically, and the diffusion mechanism causes changes in the homogeneity of alloy.

 Effect of heat treatment on steel

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 1. Increase the hardness
2. Improve the toughness
3. Increase the ductility
4. Improve the machinability
5. Refine the grain structure
6. Remove the residual stresses
7. Improve the wear resistance

 Hardening
Steels can be heat treated to high values of hardness and strength levels.

Structural components subjected to high operating stress need the high strength of a hardened structure.

E.g. tools such as dies, knives, cutting devices, and forming devices need a hardened structure to resist
wear and deformation

 Tempering

 As-quenched hardened steels are so brittle that even slight impacts may cause fracture.
 Tempering is a heat treatment that reduces the brittleness (increase the ductility of a steel
without significantly lowering its hardness and strength).
 All hardened steels must be tempered before use.
 Annealing

Annealing is a technique used to recover cold work and relax stresses within a metal. Annealing typically
results in a soft, ductile metal. When an annealed part is allowed to cool in the furnace, it is called a "full
anneal" heat treatment. When an annealed part is removed from the furnace and allowed to cool in air, it
is called a "normalizing" heat treatment. During annealing, small grains recrystallize to form larger grains.
In precipitation hardening alloys, precipitates dissolve into the matrix, "solutionizing" the alloy.

 Case hardening

Case hardening is specified by hardness and case depth. The case depth can be specified in two ways

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  Total case depth
 Effective case depth

Available Capabilities:
1) Annealing/Normalizing:
 Full annealing/normalizing
 Stress relief annealing
 Isothermal annealing
 Process annealing
2) Hardening:
 Free hardening
 Press hardening
 Deep well hardening
3) Tempering:
 Low tempering
 High tempering
4) Salt bath treatment:
 Low temperature salt bath treatment
 Medium temperature salt bath treatment
 High temperature salt bath treatment
 Nitrate temperature salt bath treatment
5) Case hardening
 Bright carburizing
 Gas carburizing
 Gas carbon nitriding
 Induction hardening
Manufacturing of springs:
Following are the processes by which springs are manufactured;
1) Wounding of wire on mandrel of an engine lathe.
2) Diameter is then tempered up to 300~350 centigrade.
3) Cutting of wire

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 4) Grinding
5) Rectification
 Straightness
 Pitch variation
 Length
6) Again tempering
7) Inspection
8. FORGING SHOP
 Mission
 Forging of the components of Al Zarrar, Al Khalid, T-59, T-69, and T-80 UD.
 Forging of tooling items including Die fixtures for manufacturing of tank parts.

Forging is the term for shaping metal by using localized compressive forces. Hot forging is done at a
high temperature, which makes metal easier to shape and less likely to fracture.

 Process:
Forging changes the size and shape, but not the volume, of a part. The change is made by force
applied to the material so that it stretches beyond the yield point. The force must be strong
enough to make the material deform. It must not be so strong, however, that it destroys the
material. The yield point is reached when the material will reform into a new shape. The point
at which the material would be destroyed is called the fracture point.

Most metals are hot forged; for example, steel is forged at temperatures between 2,100oF and 2,300oF
(1,150oC to 1,260oC).

 Open-die drop-hammer forging

Open-die forging is also known as smith forging. In open-die forging a hammer comes down
and deforms the work piece, which is placed on a stationary anvil. Open-die forging gets its name from
the fact that the dies (the working surfaces of the forge that contact the work piece) do not enclose the
work piece, allowing it to flow except where contacted by the dies. Therefore the operator needs to
orient and position the work piece to get the desired shape.

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  Impression-Die Drop-Hammer Forging

Impression-die forging is also called closed-die forging. In impression-die work metal is placed in a die
resembling a mold, which is attached to the anvil. Usually the hammer die is shaped as well. The
hammer is then dropped on the work piece, causing the metal to flow and fill the die cavities. The
hammer is generally in contact with the work piece on the scale of milliseconds. Depending on the size
and complexity of the part the hammer may be dropped multiple times in quick succession. Excess
metal is squeezed out of the die cavities; this is called flash. The flash cools more rapidly than the rest
of the material; this cool metal is stronger than the metal in the die so it helps prevent more flash from
forming. This also forces the metal to completely fill the die cavity. After forging the flash is trimmed
off.

 Press forging

Press forging is variation of drop-hammer forging. Unlike drop-hammer forging, press forges
work slowly by applying continuous pressure or force

The main advantage of press forging, as compared to drop-hammer forging, is its ability to deform the
complete work piece.

 Upset forging

Upset forging increases the diameter of the work piece by compressing its length. Based on
number of pieces produced this is the most widely used forging process. A few examples of common
parts produced using the upset forging process are engine valves, couplings, bolts, screws, and other
fastener

Materials:
Common materials are used for forging of components are as under; 38 Crsi.A3, Steel-10, steel-

40, steel-35, steel-41, steel-15, 20Cr2Ni4A, 18Cr2Ni4A.

 Machines used in forging shop

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  Pneumatic hammer:
It is used for medium and heavy forging.
1. Maximum weight forged on 250kg hammer=9kg
2. Maximum weight forged on 750kg hammer=40~45kg
3. Maximum diameter forged on 750kg hammer=1000mm
4. Maximum diameter forged on 250kg hammer=345mm
5. Maximum weight forged on 250kg hammer=1kg
6. Maximum weight forged on 750kg hammer=8kg

 Press:

7. Double disc friction screw press used for forging of small and large components.
8. Open type inclined able press is used for trimming of forged components.
 Heating:
Heating of steel is very important and main operation in forging practice. If a piece of steel is heated, it becomes
softer and its tensile strength is reduced and at the same time its plasticity and malleability is increased. The
structural transformations which occur in metals on heating their mechanical and physical properties also
change.
 Safety measurements:
i. Keep shop clean
ii. Metal scraps should be placed in scrap box
iii. Never use compress air to clean the machine of chips
iv. Keep hand tools in good condition
 Pre-heated temperature of forging dies:
v. 250~300 centigrade

9. Machine Shop

 Mission
 To manufacture components for Tank T-59, T-69, T-85, AK-1, AK-2, 125 mm Gun, APC and
ARV etc.

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  To Manufacture Components for ADDL Modification of Tanks like T-59, T-69, T-85, AK-1,
AK-2, etc.
 To Manufacture Components for 520HP, 580HP, 730HP, and 6TD-I Engines with in AVAL
Capacity.
 MANUFACTURING AND MACHINING PROCESS

Machining is the broad term used to describe removal of material from a work piece; it covers several
processes, which we usually divide into the following categories:

 Cutting, generally involving single-point or multipoint cutting tools, each with a clearly defined
geometry.
 Abrasive processes, such as grinding.
 Nontraditional machining processes, utilizing electrical, chemical, and optimal sources of energy.

Lathe

A lathe is a machine tool which spins a block of material to perform various operations such as
cutting, sanding, knurling, drilling, or deformation with tools that are applied to the work piece to create an
object which has symmetry about an axis of rotation. Metal is removed from the work piece using a hardened
cutting tool, which is usually fixed to a solid moveable mounting, either a tool post or a turret. The work
piece may be supported between a pair of points called centers, or it may be bolted to a faceplate or held in
a chuck. A chuck has movable jaws that can grip the work piece securely.

All lathes have a bed, which is (almost always) a horizontal beam. At one end of the bed (almost always the
left, as the operator faces the lathe) is a headstock. The headstock contains high-precision spinning bearings.
Rotating within the bearings is a horizontal axle, with an axis parallel to the bed, called the spindle. The
counterpoint to the headstock is the tailstock, sometimes referred to as the loose head, as it can be positioned
at any convenient point on the bed, by undoing a locking nut, sliding it to the required area, and then relocking
it. Metalworking lathes have a carriage (comprising a saddle and apron) topped with a cross-slide, which is
a flat piece that sits crosswise on the bed, and can be cranked at right angles to the bed. Sitting atop the cross
slide is a tool post, which holds a cutting tool which removes material from the work piece.

Feed, Speed, and Depth of Cut

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 Cutting speed is defined as the speed at which the work moves with respect to the tool (usually
measured in feet per minute). Feed rate is defined as the distance the tool travels during one revolution of the
part. Cutting speed and feed determines the surface finish, power requirements, and material removal rate.
The primary factor in choosing feed and speed is the material to be cut. However, one should also consider
material of the tool, rigidity of the work piece, size and condition of the lathe, and depth of cut. To calculate
the proper spindle speed, divide the desired cutting speed by the circumference of the work. Experiment with
feed rates to achieve the desired finish. In considering depth of cut, it's important to remember that for each
thousandth depth of cut, the work diameter is reduced by two thousandths.

There are 3 Vertical lathes in this shop, which are commonly used for machining of sprocket.

Drilling machine

Drill can be defined as a rotary end cutting tool having one or more cutting lips, and having one or
more helical or straight flutes for the passage of chips and the admission of a cutting fluid

Gear manufacturing

Gear Basics

Gears are used to reverse rotational direction, increase or decrease speed of rotation, transfer rotation
to a different axis, or to synchronize rotation across two or more axis in a machine or engine. The basic gear
train is comprised of two gears, one large and one small. They rotate in opposite directions from one another,
with their teeth interlocking and driving the rotation. A gear in a train is referred to as a driver (the gear that
effects the rotation), a driven gear (the gear last in the train), or an idler (any gear between the first and last
gear). The power output or torque produced by a gear train is determined by the gear ratios and the by output
direction (which gear drives which).

Gear Types

 Spur Gear: characterized by their straight cogs, these gears are mounted on parallel shafts. You'll
find examples of spur gear trains in watches and clocks.

 Bevel Gear: characterized by cogs cut in a cone shape. The gear shafts are generally mounted at 90º
angles to each other.
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  Worm Gear and Wheel: a gear comprised of a wheel gear with inclined cogs that is rotated by a
screw thread (a single-cogged gear called a worm).

 Helical Gear: characterized by cogs that are cut at an angle to the face of the gear. Can be mounted
perpendicularly or parallel. Automobile transmissions make use of these gears.

Manufacturing

Hobbing

Hobbing is a machining process for making gears, splines, and sprockets on a hobbing machine,
which is a special type of milling machine. The teeth or splines are progressively cut into the work piece by
a series of cuts made by a cutting tool called a hob. Compared to other gear forming processes it is relatively
inexpensive but still quite accurate, thus it is used for a broad range of parts and quantities such as cylinder
of tank engine

Honing machine
Honing is a manufacturing process that produces a precision surface on a work piece by scrubbing
an abrasive stone against it along a controlled path. Honing is primarily used to improve the geometric form
of a surface, but may also improve surface texture. Honing is a relatively expensive manufacturing process.
The improved shape after honing may result in a quieter running or higher precision component.

Thread rolling machine

This type of cold-forming process is used because cylindrical parts (such as the remaining round part
of the bolt) can easily have thread applied by rolling the work billet through two dies. The thread rolling
process is usually chosen over machining because thread rolling provides higher production rates, more
effective material usage, stronger thread due to work hardening, and finally better fatigue resistance because
the work billet undergoes compressive stresses during the rolling process.

CNC LATHE MACHINE SHOP

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 The machine is controlled electronically via a computer menu style interface, the program may be
modified and displayed at the machine, along with a simulated view of the process.

Tool system

Revolve type tool turret with direct logic option with driven tool

Tooling fixture act to DIN 69880

Project

CREO Modelling

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Machining Operations

 Turning:
o A single point cutting tool removes material from a rotating work piece to generate a
cylindrical shape
o The tool is fed linearly in a direction parallel to the axis of rotation
o Performed on a machine tool called a lathe
o Variations of turning that are performed on a lathe:
 Facing
 Contour turning
 Chamfering
 Cutoff
 Threading
 Facing:
o Tool is fed radially inward to create a flat surface.
 Threading:
o Pointed form tool is fed linearly across surface of rotating work part parallel to axis of
rotation at a large feed rate, thus creating threads.

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