Chapter 1

1.0 Introduction

1.1 About Jinasena (PVT) Ltd

Figure 1.1: Jinasena (PVT) Ltd

Jinasena is a diversified organization manufacturing and trading a range of products. These products are
escorted with unmatchable services to the customer, ensuring comprehensive customer satisfaction.
Jinasena deals with five product lines and provides presales and after-sales services for these products.
Jinasena Limited was founded in 1905 as a bicycle-repair shop but soon moved into machinery repairs. It
is founded by C.Jinasena, was a man of vision. He was a chartered engineer by profession and was educated
in the UK.Sri Lanka at that time was known as Ceylon and was under colonial rule. Engineering like many
areas of enterprise was the sole preserve of the British. When Jinasena Limited moved from servicing and
repairing machinery used extensively in the tea and rubber industries into manufacturing these very same
machines, it was like David going up against Goliath.Jinasena Limited was the first Ceylonese owned
engineering company and by 1932, it was rated among the five leading engineering companies in the island.
In 1950, the son of the founder T. S. Jinasena designed and manufactured the first Jinasena Centric Water
Pump. After years of servicing and repairing foreign water pumps, and gaining first-hand knowledge of
their shortcomings local conditions, the Jinasena Centric Water Pump was designed to overcome these

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problems and provide users with trouble-free performance. The original water pump was fitted with a
Hoover motor; but in 1967, a foundry was set up – and in 1973, a factory dedicated to manufacturing electric
motors was established. Jinasena Electrical Motors benefits from its technical agreements with German
firm, Messrs. E. Blum Gmbh, as a result of which it has access to the latest developments in designing and
manufacturing electric motors and a virtual guarantee of meeting the highest international standards. Its
factory comprises machine, winding and assembly shops, and state of-the-art testing facilities. Jinasena
Group also has interests in diverse fields, including hotel operations, generators, pneumatic rubber tires,
garments and agricultural machinery. It is agricultural machinery centers around a mission to design and
manufacture mechanized farming equipment that is suited to farming conditions in Sri Lanka in particular,
the relatively small paddy fields in rural areas. The range of tractors, threshers, reapers, choppers and
weeders really began to make their presence felt when the brand quickly gained the trust of the rural Sri
Lankan farmer, who is traditionally extremely skeptical about the mechanization of time -tried methods.

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 1.1.1 Organization structure

Chairmen

Deputy Chairmen

Managing Director

General Manager General Manager human

Production resource

Sectional managers Assistant HR

Senior Engineers
manager

Engineers Engineers Executive HR

officer

Assistant Engineers Assistant Engineers

HR Assistant

Technical officers Supervisors

Skilled workers

Workers

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1.1.2 Nature of business
Jinasena is synonymous with the manufacture of water pumps and has been in the forefront of this field for the past
five decades. Their “Centric” range of water pumps now meets every conceivable demand.

1.1.3 Their Vision

The leading domestic, agricultural & industrial water pump manufacture & will achieve 95% local market
share at 2025
1.1.4 Their Mission
To be recognized as one of the finest global companies that provides products, services and a management style
that would improve the quality of life of individuals, both internal and external to the company

1.2 Management practices

1.2.1 ETF

Employees’ Trust Fund (ETF) is where the employer merely provides his contribution of 3% of monthly
salary of an employee. ETF can be claimed at any time when employee needs to quite own career. There
is a separate board with a chairman, board of directors and managers who are responsible for maintaining
the fund properly.

1.2.2 EPF

The Employees Provident Fund (EPF) was established under the Act No. 15 of 1958 and is currently the
largest Social Security Scheme in Sri Lanka. The aim of the EPF is to assure financial stability to the
employee in the winter of life and to reward the employee for his or her role in the economic growth of the
country. Each and every employee has an EPF account which is maintained from the day he starts his career.
Although in many organizations, the contribution from employee is 8% and from employer 12% of
employee’s monthly salary.

1.2.3 Recruitment Procedures

Doing the exams and doing interviews which each post.

1.3 Safety practices

It has been observe that a lot of accidents while doing work occur because of lack of safety awareness.
There are the results of unsafe acts the reason for these being that there had not been complete instruction
on safe practice. Further accidents also occur due to unsafe condition of operation. We have to understand
that safety is a practice of good management; the safety efforts help in improving production costs and
quality Compensation and medical payment, damage equipment and products, and production delay

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resulting from accidents all subtract directly from profit. Safe environment increases employee morale and
willingness to work. Ultimately it increases the productivity and efficiency.

1.3.1 Normal Safety Equipment’s

Employees should be required to wear all the necessary safety equipment for their specific tasks. Everyone
should wear steel-toe boots in a workshop. Provide safety goggles, safety masks, gloves, hard hats and other
safety equipment items in the workshop for employees to use as needed.

1.3.2 Safety equipment

Throughout the operation in workshop, there is possibility of occurring sudden accidents. To reduce such
accidents technicians and other workshop staff should follow safety instructions and wear safety equipment.
Some of them are,
➢ Protective clothes.

➢ Gloves.

➢ Goggles.

➢ Hand Shield.

➢ Ear muffs.

Figure 1.2: Safety equipment

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Chapter 2
2.0 Training Experience

2.1 Introduction about training locations

It is a great pleasure to have my industrial training module 1 at JINASENA (PVT) LTD. I got a golden
opportunity to improve my practical skills in mechanical as well as some amount of electrical field.

This training period of three and half months which started from 12th February 2017 to 16th June
2017,traning is a really helped me to have a general idea about mechanical, electrical engineering and
maintenance and, it guides me to put a foundation to my future career.

It is pleasure to say that I was able to work with different kinds of employees, from top management to
labor. They also satisfied that helping us to improve our knowledge in every possible time during their
working hours.

This training report contains all my experience I had at my training as an industrial trainee. I have included
all those things which I learnt. I have presented this report best of my knowledge and fullest effort.
In order to have my training I was provided with a training schedule by jinasena (PVT) Ltd. According to that
Schedule my training period was completed as shown in table 2.1

Division Duration Date of start Date of End

Casting Division 2 weeks 13/02/2017 24/02/2017

Central Machining
Division 2 weeks 27/02/2017 10/03/2017

CNC Division 2 weeks 13/03/2017 24/03/2017

Winding Division 1 weeks 27/03/2017 31/03/2017

Motor Assembly
Division 1 weeks 03/04/2017 7/04/2017

Pumps Division 1 weeks 17/04/2017 21/04/2017

Plastic Division 1 weeks 08/05/2017 12/05/2017

Die and Mold
Division 2 weeks 15/05/2017 26/05/2017

JAM Division 1 weeks 29/05/2017 02/06/2017

Project Division 2 weeks 05/06/2017 16/06/2017

Table 2.1 Training Schedule

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2.2 Casting Division

2.2.1 What is casting

Casting is a process which basically involves pouring of molten metal into a mold cavity where, upon
cooling down & solidification, it takes the shape of the cavity

2.2.2 Where Cast products are used

All the pump body parts are made at Jinasena casting Limited.

Figure 2.1: casting pump bodies

2.2.3 Why Casting is so important?

❖ Intricate of shapes
❖ May be cast in a single operation
❖ Some metals can only be cast to shape
❖ Resistance to working stress
❖ Construction may be simplified, no assembly.
❖ Mass production at high production rates.
❖ Very large, heavy metal objects may be cast
❖ Good engineering properties

2.2.4 Types of materials used in Casting Division

❖ Ferrous metals: Cast iron
❖ Non-ferrous metals: Copper alloys, Aluminum alloys

2.2.5 Basic requirements of casting process

❖ Mold Cavity
❖ Melting Process
❖ Pouring Techniques
❖ Solidification Process
❖ Mold Removal
❖ Cleaning, Finishing & Inspection

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2.2.6 Types of Molds
❖ Expandable Molds
❖ Permanent molds
❖ Composite molds

2.2.6.1 Expendable Molds

❖ Usually made of sand, plaster, ceramics & mixed with various binders or bonding agents.
❖ After the casting has solidified, the mold is broken up to remove the casting
❖ Preferred for production of smaller quantities

❖ Types of Expendable Molds

Expendable mold with re-usable pattern
Expendable mold with disposable pattern

In JCL most of the casting parts are made from this type of mold. Because of low cost and can be recycling.

Figure 2.2: Sand Mold

2.2.6.2 Permanent Molds

❖ Usually made of metals
❖ Used repeatedly
❖ Designed in such a way that the casting can be easily removed
❖ Generally restricted to large production

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 Figure 2.3: permanent mold & cores

2.2.6.3 Composite molds

❖ Made of two or more different materials, such as sand, graphite & metal
❖ Combined advantages of each material

❖ Advantages of Permanent Molds

Good surface finish
Good dimensional accuracy
High strength & thermal conductivity

2.2.7 Mold Cavity

❖ Should be of desired shape & size
❖ Ability to compensate shrinkage of the solidifying metal
❖ Must be able to reproduce the desired detail
❖ Must have refractory characteristics

Figure 2.4: mold cavity

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2.2.8 Casting Terminology

➢ Pattern
Approximate duplicate of the casting, when the pattern is withdrawn, its imprint provides the mold
cavity.
➢ Core
Placed into a mold cavity to form the interior surfaces or features of castings.
➢ Molding material
Readily formed aggregate material, which is packed around the pattern.
➢ Flask
Rigid wood or metal frame that hold the molding aggregate.
➢ Cope
Top half of the pattern, flask, mold or core of a two-part mold.
➢ Drag
Bottom half of any of the above features
➢ Mold cavity
Combination of mold material & core produce a shaped hole.
➢ Riser
An extra void created in the mold to hold molten metal, that acts as a reservoir of liquid that can
flow into the mold cavity to compensate for any shrinkage.
➢ Gating system
Network of connected channels used to deliver the molten metal to the cavity.
➢ Vent
Additional channels to provide an escape for the gasses that are originally present in the mold or
generated during the pour.
➢ Parting line
Interface that separates the cope & drag halves of mold, flask, core or pattern.
➢ Draft
Taper on a pattern or casting that permits it to be withdrawn from the mold.
➢ Core box
Mold or die used to produce cores.
➢ Sprue
Vertical portion of the gating system.
➢ Choke
Cavity in the mold at the base of the Sprue to allow the metal to flow smoothly.

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 ➢ Runners
Horizontal channels.
➢ Gate
Controlled entrance.

2.2.9 Sand Casting

• Most common & the most versatile among other casting processes.
• Sand casting consists of,

Figure 2.5: block diagram of sand casting

Figure 2.6: Mold making Machines

2.2.10 Sands used in sand casting

This is the green soil mixture used in jinasena casting limited.

❖ Silica sand - 55 kg
❖ Red sand - 3 kg
❖ Bentonite - 5.5 kg
❖ Carbon dust - 9kg
❖ Normal soil (can be found by recycling mold and core)-250 kg

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This ingredients were added to the automated soil mixing machine (Require water percentage were
automatically added in the machine)

Checking steps of green soil mixture ejects from the Machine

❖ 160g green soil sample were compressed (SHATTER INDEX TESTER);

❖ Equation { 160-x * 100} ;where x is filted fallen down soil sample after compressing.
160
❖ Moisture should be closely 3.06%
❖ Permeability should be 25%-30%

2.2.11 Patterns for Sand Casting

❖ Used to mold the sand mixture into the shape of the casting

2.2.11.1 Factors affecting selection of pattern material

❖ Size & shape of the casting

❖ Desired dimensional accuracy
❖ Quantity of castings required
❖ Molding process
2.2.11.2 Types of pattern material

❖ Wood
❖ Metal
❖ Plastic

Figure 2.7: Making Patterns

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2.2.12 Melting Furnaces
Selection of a furnace depends on,

❖ Economic consideration
❖ Composition & melting point of the alloy
❖ Capacity & control of the furnace atmosphere
❖ Environmental consideration
❖ Type of charge material used

2.2.13 Types of furnaces available are

❖ Cupolas
❖ Crucible furnaces
❖ Electric arc furnaces
❖ Induction furnaces
❖ Levitation melting
In the past cupola furnace was used in JCL. Now induction furnace is replaced for it due to environmental
pollution

2.2.13.1 Induction furnaces

Figure 2.8: Melting cast iron in induction furnace

How does it work?

Electromagnetic Induction
The energy transfer to the object to be heated occurs by means of electromagnetic induction. Any
electrically conductive material placed in a variable magnetic field is the site of induced electric currents,
called eddy currents, which will eventually lead to joule heating

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 Figure 2.9: induction furnace working principle

Features of Induction Furnace

❖ An electric induction furnace requires an electric coil to produce the charge. This heating coil is
eventually replaced.
❖ The crucible in which the metal is placed is made of stronger materials that can resist the required
heat, and the electric coil itself cooled by a water system so that it does not overheat or melt.
❖ The induction furnace can range in size, from a small furnace used for very precise alloys only about
a kilogram in weight to a much larger furnaces made to mass produce clean metal for many different
applications.
❖ The advantage of the induction furnace is a clean, energy-efficient and well-controllable melting
process compared to most other means of metal melting.
❖ Foundries use this type of furnace and now also more iron foundries are replacing cupolas with
induction furnaces to melt cast iron, as the former emit lots of dust and other pollutants.
❖ Induction furnace capacities range from less than one kilogram to one hundred tons capacity, and
are used to melt iron and steel, copper, aluminum, and precious metals.
❖ The one major drawback to induction furnace usage in a foundry is the lack of refining capacity;
charge materials must be clean of oxidation products and of a known composition, and some
alloying elements may be lost due to oxidation (and must be re-added to the melt).

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2.2.14 Casting Defects

Figure 2.10: casting defect

❖ Cavities
❖ Porosity
❖ Discontinuities
❖ Defective surfaces
❖ Incomplete casting
❖ Incorrect dimensions or shapes

To test the quality of a melted cast iron a triangular pyramidal sand mold is used

Figure 2.11: test sample of solidify cast iron

Upper small silver layer should be less than 3 mm if it was a correctly melted cast iron.

❖ To increase the quality of a melted cast iron the following ingredients were added;

• Silicon carbide
• Graphite(carbon)
• Manganese

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2.2.15 Pouring process

Figure 2.12: Pouring melted cast iron into sand molds

In jinasena casting division, pouring process is done by manual hands. Molten liquid Metal was poured
into the crucible and then two or four workers took it and go where the molds are to be filled. Molds
are existed 2 hours in case of hardening

In here there are lots of safety issues should be considered deeply.

❖ Still use traditional system

❖ No safety wears
❖ Works have to handle crucible by hand

2.3 Central Machining Division

2.3.1 Lathe machine

2.3.1.1 Types of Lathe

Engine lathes (center lathe): These are probably the most popular among the lathe machines. In fact, no
machine shop is seen without this type of lathe. The good thing about engine lathes is that it can be used in
various materials, aside from metal. Moreover, the set-up of these machines is so simple that they are easier
to use. Its main components include the bed, headstock, and tailstock. These engine lathes can be adjusted
to variable speeds for the accommodation of a wide scope of work. In addition, these lathes come in various
sizes.

Capstan and Turret Lathes: These types of lathes are used for machining single work pieces sequentially.
This means that several operations are needed to be performed on a single work piece. With the turret lathes,
sequential operations can be done on the work piece, eliminating errors in work alignment. With this set-
up, machining is done more efficiently. Correspondingly, time is saved because there is no need to remove

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and transfer the work piece to another machine anymore. Used in mass production, Semi-automatic, Wide
range of operations can be performed.

Capstan and Turret lathe which have multiple tools mounted on turret either attached to the tailstock or the
cross-slide, which allows for quick changes in tooling and cutting operations. Used when many duplicate
parts required

Equipped with multisided tool post (turret) to which several different cutting tools mounted Employed in
given sequence

Figure 2.13: center lathe

Figure 2.14: turret lathe

❖ Bed is mainly support the whole machine

❖ Carriage is assembly that moves the tool post and cutting tool along the ways, Carriage Hand wheel
is a wheel with a handle used to move the carriage by hand by means of a rack and pinion drive
❖ A chuck is a clamping device for holding work in the lathe
❖ Apron is the front part of the carriage assembly on which carriage hand wheel is mounted
❖ Cross slide is a platform that moves perpendicular to the lathe axis under control of the cross slide
hand wheel is mainly support the whole machine

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 ❖ Cross slide hand wheel is a wheel with handle used to move the cross slide in and out.
❖ Half nut lever is the lever to engage the carriage with lead screw to move the carriage under power
❖ Lead screw is a precision screw that runs the length of the bed. it is used to drive the carriage under
power for turning and thread cutting operations.
❖ Swing is a dimension representing the largest diameter work piece that a lathe can rotate
❖ Tailstock is a cast iron assembly that can be slide along the ways and be locked in place. used to
hold long work in place or mount a drill chuck for drilling into end of the work
❖ Ram is a piston type shaft that can be moved in and out of the tailstock by turning the tailstock hand
wheel.
❖ Tool is a Bed is mainly support the whole machine
❖ Carriage is assembly that moves the tool post and cutting tool along the ways
❖ A chuck is a clamping device for holding work in the lathe
❖ Apron is the front part of the carriage assembly on which carriage hand wheel is mounted
❖ Cross slide is a platform that moves perpendicular to the lathe axis under control of the cross slide
hand wheel is mainly support the whole machine
❖ Cross slide hand wheel is a wheel with handle used to move the cross slide in and out.
❖ Ways is a precision ground surfaces along top of the bed on which saddle rides. The ways are
precisely aligned with the centerline of the lathe

2.3.2 Cutting tools

Cutting tools are depended according to the shape of the work piece. Normally it was made in high speed
steel which has high strength. Cutting speed is directly affected for the life time of the tool. So it was cooled
by supplying liquid while cutting process is ongoing. The correct geometry of the cutting tool shown in
Figure 17 is helps for the smooth finish of the work piece.

Figure 2.15: Cutting tool

We observed that the manufacturing process of pump bodies, shaft &impellers were done in center lathe.
First cutters were fixed according to the sizes and shapes in the tool post. Next bed was adjusted
according to the necessary dimensions. Then pump body or shaft was fixed to the spindle with precisely.

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There, object must be straight otherwise it unable to cut the work piece according to the dimensions. So it
must make straight. After making all the requirements, lathe process was started. It was supplied liquid in
order to control heat while metal cutting. It helped to protect the life time of the tool as well as for the
smooth surface finish. We could control the cutting speed by adjusting the gears.

2.3.3 Drilling Machine

2.3.3.1 Introduction

The drilling machine or drill press is one of the most common and useful machine employed in industry for
producing forming and finishing holes in a work piece. The unit essentially consists of

Figure 2.16: bench drilling machine

1. A spindle which turns the tool (called drill) which can be advanced in the work piece either automatically
or by hand.

2. A work table which holds the work piece rigidly in position.

2.3.3.2 Working Principle

The rotating edge of the drill exerts a large force on the work piece and the hole is generated. The removal
of metal in a drilling operation is by shearing and extrusion.

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 Figure 2.17: drilling operation principle

2.3.3.3 Construction
The machine has only a hand feed mechanism for feeding the tool into the work piece. This enables the
operator to feel how the drill is cutting and accordingly he can control the down feed pressure. Drill presses
are manufactured in bench or floor models. The base of machine may be mounted on a bench or floor. The
main operating parts of a machine/drill press are Base, Column, Table, and Drill Head.

Figure 2.18: construction of drilling machine

2.3.3.4 Types of Drilling Machine

❖ Bench Drilling Machine

❖ Portable Drilling Machine
❖ Sensitive or Bench Drill
❖ Upright Drilling Machine(Single Spindle)
❖ Upright Drilling Machine(Turret Type)
❖ Radial Drilling Machine

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 ❖ Multiple Spindle Drilling Machine
❖ Deep Hole Drilling Machine
❖ Gang Drilling Machine
❖ Horizontal Drilling Machine
❖ Automatic Drilling Machine

2.3.3.5 Bench Drilling Machine

The simplest type of sensitive drilling machine is shown in figure. This is used for light duty drilling work.

❖ Motor:- An electric motor supplies the required driving force to stepped pulley.
❖ Base: - Base is the bottom part of machine in which the column is fitted upright.

❖ Feed handle: - Handle is provided to feed the drill in to the work piece. A rake and pinion mechanism
is provided to drive the chuck.

❖ 4. Column: - Column is the main cylindrical part of drill machine on which the other components
are mounted.

❖ Belt guard:- Belt guard is provided to cover the belt and pulley drive mechanism to minimize the
hazard of accident.

❖ Chuck:- Chuck is provided to hold the drill of different sizes up to 6.5 mm. Drill size of more than
6.5 mm are to be fitted directly in the Morse taper of spindle

❖ Work Table: - Work pieces are mounted and held in position by the table. This table can be tilted
for drilling at an angle.

Figure 2.19: sensitive drilling machine

2.3.3.6 Radial Drilling Machine

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This machine is very useful because of its wider range of action (widely used central machine division in
jinasena). Its principal use is in drilling holes on such work is difficult to be handled frequently. With the
use of this machine, the tool is moved to the desired position instead of moving the work piece to bring the
position for drilling.

Figure 2.20: Radial Drilling Machine

2.3.4 Milling Machine

2.3.4.1 Introduction
❖ Milling is the process of machining flat, curved, or irregular surfaces by feeding the work piece
against a rotating cutter containing a number of cutting edges. The usual Mill consists basically of
a motor driven spindle, which mounts and revolves the milling cutter, and a reciprocating adjustable
worktable, which mounts and feeds the work piece.
❖ Milling machines are basically classified as vertical or horizontal. These machines are also classified
as knee-type, ram-type, manufacturing or bed type, and planer-type. Most milling machines have
self-contained electric drive motors, coolant systems, variable spindle speeds, and power-operated
table feeds
❖ Milling is a process of producing flat and complex shapes with the use of multi-tooth cutting tool,
which is called a milling cutter and the cutting edges are called teeth.

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 ❖ The axis of rotation of the cutting tool is perpendicular to the direction of feed, either parallel or
perpendicular to the machined surface. The machine tool that traditionally performs this operation
is called milling machine.

Milling is an interrupted cutting operation in which the teeth of the milling cutter enter and exit the work
during each revolution. This interrupted cutting action subjects the teeth to a cycle of impact force and
thermal shock on every rotation. The tool material and cutter geometry must be designed to withstand these
conditions. Cutting fluids are essential for most milling operations.

2.3.4.2 Types of milling

There are two basic types of milling
1. Down (climb) milling, when the cutter rotation is in the same direction as the motion of the work piece
being fed.
2. Up (conventional) milling, in which the work piece is moving towards the cutter, opposing the cutter
direction of rotation

Figure 2.21: basic types of milling

2.3.4.3 Milling machines

The conventional milling machines provide a primary rotating motion for the cutter held in the spindle, and
a linear feed motion for the work piece, which is fastened onto the worktable.

Milling machines for machining of complex shapes usually provide both a rotating primary motion and a
curvilinear feed motion for the cutter in the spindle with a stationary work piece.

Figure 2.22: cutting tool profile

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2.3.4.3 Milling Machine Types
Various machine designs are available for various milling operations.

❖ Column-and-knee milling machines

❖ Bed type milling machines
❖ Machining centers

2.3.4.4 Other Classifications According to the nature of purposes of use

❖ General Purpose Milling Machine

Conventional milling machines, ex. Up and down milling machines
❖ Single Purpose Milling Machine
Thread, cam milling machines and slitting machine
❖ Special Purpose Milling Machine
Mass production machines, ex. duplicating mills, die sinkers, thread milling etc.

Figure 2.23: Horizontal Milling Machine Figure 2.24: Vertical Milling Machine

2.3.4.5 Milling cutters

Classification of milling cutters according to their design

❖ HSS cutters: Many cutters like end mills, slitting cutters, slab cutters, angular cutters, form cutters,
etc., are made from high-speed steel (HSS).
❖ Brazed cutters: Very limited number of cutters (mainly face mills) are made with brazed carbide
inserts. This design is largely replaced by mechanically attached cutters.
❖ Mechanically attached cutters: The vast majority of cutters are in this category. Carbide inserts are
either clamped or pin locked to the body of the milling cutter.

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2.3.4.6 Milling Cutter Nomenclature

Figure 2.25: Milling cutter nomenclature

❖ The pitch refers to the angular distance between like or adjacent teeth.
❖ The pitch is determined by the number of teeth. The tooth face is the forward facing surface of the
tooth that forms the cutting edge.
❖ The cutting edge is the angle on each tooth that performs the cutting.
❖ The land is the narrow surface behind the cutting edge on each tooth.
❖ The rake angle is the angle formed between the face of the tooth and the centerline of the cutter.
The rake angle defines the cutting edge and provides a path for chips that are cut from the work
piece.
❖ The primary clearance angle is the angle of the land of each tooth measured from a line tangent to
the centerline of the cutter at the cutting edge. This angle prevents each tooth from rubbing against
the work piece after it makes its cut.
• This angle defines the land of each tooth and provides additional clearance for passage of
cutting oil and chips.
❖ The hole diameter determines the size of the arbor necessary to mount the milling cutter.

Plain milling cutters that are more than 3/4 inch in width are usually made with spiral or helical teeth. A
plain spiral-tooth milling cutter produces a better and smoother finish and requires less power to operate.
A plain helical-tooth milling cutter is especially desirable when milling an uneven surface or one with holes
in it.

❖ End milling cutters

➢ The end milling cutter, also called an end mill, has teeth on the end as well as the periphery

25
 Figure 2.26: End milling cutters

❖ Face milling cutter

Figure 2.27: Face milling cutters

2.4 CNC Division

2.4.1 CNC Machine?

CNC: Computer Numerical Control, Conventionally, an operator decides and adjusts various machines
parameters like feed, depth of cut etc. depending on type of job, and controls the slide movements by hand.
In a CNC Machine functions and slide movements are controlled by motors using computer programs.

2.4.2 Types of CNC Machine

There are many different types of CNC Machines used in industry, Such as:

❖ Mills and Machining Centers

❖ Lathes and Turning Centers
❖ Drilling Machines
❖ EDM Sinker and wire cut Machines
❖ Laser-Cutting Machines

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2.4.3 Types of CNC Machine Control Units
❖ Fanuc control
❖ Siemens
❖ GSK

2.4.4 Program input

Different ways of data input are:
❖ MDI : Manual Data Input
❖ Program data transfer from PC to CNC (Program preparation with CAD)

2.4.5 Operational Features of CNC Machines

❖ For a CNC machine control unit (MCU) decides cutting
❖ Speed, feed, depth of cut, tool selection, coolant on off and tool paths.
❖ The MCU issues commands in form of
Numeric data to motors that position slides and tool accordingly.
A numerical control, or “NC”, system controls many machine functions and movements which
were traditionally performed by skilled machinists.

Figure 2.28: schematic diagram of CNC control system

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2.4.6 CNC Coordinates System

Figure 2.29: Consist of axis on CNC

❖ Absolute Coordinate Programming (G90) Of The Machining Center

In absolute programming, all coordinate values are relative to a fixed origin of the coordinate
system. Axis movement in the positive direction does not require inclusion of the sign; while
negative movements do require signs.
❖ Incremental Coordinate Programming (G91) Of the Machining Center

In incremental systems, every measurement refers to a previously dimensioned position

(point-to-point). Incremental dimensions are the distances between two adjacent points. The
coordinate notations for the points on the drawing (in absolute and incremental systems)
appear in the chart as follows

Figure 2.30: Absolute and Incremental Coordinates for CNC Machining Centers

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 For G90 Absolute For G91 incremental

P1 G90 X0 Y0 P1 G91 X0 Y0

P2 G90 X0 Y4 P2 G91 X0 Y4

P3 G90 X2 Y4 P3 G91 X2 Y0

P4 G90 X2 Y5 P4 G91 X0 Y1

P5 G90 X4 Y6 P5 G91 X2 Y1

P6 G90 X4 Y7 P6 G91 X0 Y1

P7 G90 X6 Y6 P7 G91 X2 Y-1

P8 G90 X8 Y8 P8 G91 X2 Y2

P9 G90 X8 Y4 P9 G91 X0 Y-4

P10 G90 X5 Y4 P10 G91 X-5 Y0

Table 2.2: Absolute and Incremental Coordinates For Figure 2.38

2.4.7 How CNC machines Works

❖ Controlled by G and M codes.
❖ These are number values and co-ordinates.
❖ Each number or code is assigned to a particular operation.
❖ Typed in manually to CAD/CAM by machine operators.
❖ G&M codes are automatically generated by the computer software.

2.4.8 Features of CNC Machines

❖ The tool or material moves.
❖ Movement is controlled by motors.
❖ Feedback is provided by sensors.
❖ Tool magazines are used to change tools automatically

2.4.9 Tools
❖ Most are made from,
high speed steel (HSS)
Tungsten carbide or ceramics
Some tools need coolant such as oil to protect the tool and work.

29
2.4.10 important things to know
❖ Coordinate System
❖ Units, incremental or absolute positioning
❖ Coordinates: X,Y,Z,
❖ Feed rate and spindle speed
❖ Coolant Control: On/Off,
❖ Tool Control: Tool and tool parameters

2.4.11 Programming consists of a series of instructions in form of letter codes Preparatory

Codes:
❖ G codes-Initial machining setup and establishing operating conditions
❖ N codes-specify program line number to executed by the MCU
❖ Axis Codes: X,Y,Z -Used to specify motion of the slide along X, Y, Z direction
❖ Feed and Speed Codes: F and S-Specify feed and spindle speed
❖ Tool codes: T –specify tool number
❖ Miscellaneous codes –M codes For coolant control and other activities

2.4.12 Programming Key Letters

❖ O -Program number (Used for program identification)
❖ N -Sequence number (Used for line identification)
❖ Y -Y axis designation
❖ Z -Z axis designation
❖ R -Radius designation
❖ F –Feed rate designation
❖ S -Spindle speed designation
❖ H -Tool length offset designation
❖ D -Tool radius offset designation
❖ T -Tool Designation
❖ M -Miscellaneous function
❖ G -Preparatory function
❖ X - axis designation X

2.4.13 Explanation of commonly used G codes

❖ G00 –Preparatory code to control final position of the tool and not concerned with the path that is
followed in arriving at the final destination.

30
 ❖ G01 –Tool is required to move in a straight line connecting current position and final position. Used
for tool movement without any machining-point to point control. (linear interpolation)
❖ G02 –Tool path followed is along an arc specified by I, J and K codes.( circular interpolation)

2.4.14 Table of Important G codes

❖ G00 Rapid Transverse
❖ G01 Linear Interpolation
❖ G02 Circular Interpolation, CW
❖ G03 Circular Interpolation, CCW
❖ G17 XY Plane,
❖ G18 XZ Plane,G19 YZ Plane
❖ G20/G70 Inch units
❖ G21/G71 Metric Units
❖ G40 Cutter compensation cancel
❖ G41 Cutter compensation left
❖ G42 Cutter compensation right
❖ G43 Tool length compensation (plus)
❖ G43 Tool length compensation (plus)
❖ G44 Tool length compensation (minus)
❖ G49 Tool length compensation cancel
❖ G80 Cancel canned cycles
❖ G81 Drilling cycle
❖ G82 Counter boring cycle
❖ G83 Deep hole drilling cycle
❖ G90 Absolute positioning
❖ G91 Incremental positioning

2.4.15 Table of Important M codes

❖ M00 Program stop
❖ M01 Optional program stop
❖ M02 Program end
❖ M03 Spindle on clockwise
❖ M04 Spindle on counterclockwise
❖ M05 Spindle stop
❖ M06 Tool change
❖ M08 Coolant on
❖ M09 Coolant off

31
 ❖ M10 Clamps on
❖ M11 Clamps off
❖ M30 Program stop, reset to start

2.4.16 CAD/CAM
Two computer-based systems which impact the use of CNC technology are CAD (computer aided design)
and CAM (computer aided manufacturing).A computer aided design, or CAD, system uses computers to
graphically create product design sand models. These design scan be reviewed, revised and refined for
optimum end use and application. Once finalized, the CAD design is then exported to a computer aided
manufacturing, or CAM system. CAM systems assist in all phases of manufacturing a product, including
process planning, production planning, machining, scheduling, management and quality control.

2.4.17 CNC Machines-Advantages/Disadvantages

2.4.17.1 Advantages
❖ High Repeatability and Precision e.g. Aircraft parts
❖ Volume of production Is very high
❖ Complex contours/surfaces need to be machined .etc.
❖ Flexibility in job change, automatic tool settings ,less scrap
❖ More safe ,higher productivity ,better quality
❖ Less paper work, faster prototype production, reduction in lead times

2.4.17.2 Disadvantages:
❖ Costly setup, skilled operators
❖ Computers, programming knowledge required
❖ Maintenance is difficult

2.5 Winding Division

2.5.1 AC Induction Motors
❖ There are two types of AC induction motor
1. Single Phase
2. Three phase
❖ The stator works as the primary while the rotor works as the secondary.

2.5.2 It consists of two parts

❖ Stator - It is the stationary part of the motor.
❖ Rotor - It is the rotating part of the motor.

32
2.5.2.1 Stator

Slots

CORE

WINDINGS

Figure 2.31: Stator

2.5.2.1.1 Stator has three main parts:

❖ Outer Frame – It is the outer body of the motor.
• It protects the inner part of the machine.
❖ Stator Core – Built up of high grade silicon steel.
• Carries the alternating magnetic field.
❖ Stator winding – have a single or three phase winding.

2.5.2.2 Rotor
This is a main type of a rotor which is used in single phase and three phase motors.

Figure 2.32: Squirrel Cage Rotor

33
 ❖ It consists of a laminated cylindrical core having semi closed circular slots at the outer periphery.
❖ Copper or aluminum bar conductors are placed in these slots and short circuited at each end by
copper or aluminum rings called short circuiting rings.
❖ The rotor winding is permanently short circuited and it is not possible to add any external resistance.
❖ The rotor slots are not parallel to the shaft but skewed to
• Reduce humming.
• Provide smoother torque for different positions of rotor
• Reduce magnetic locking of stator and rotor.

2.5.3 Principle of Operation

❖ A rotating field is set up in the stator when a 1 OR 3 Phase supply is given.
❖ The stationary rotor cut the revolving field and due to electromagnetic induction an e.m.f. is induced
in the rotor conductor.
❖ As the rotor conductor is short circuited current flows through them.
❖ It becomes a current carrying conductor in magnetic field and start rotating.

Single phase induction motor is not a self-starting motor .because starting torque cannot be taken
by single phase power. Therefore two types of winding are added. (Starting winding and running)
capacitor is connected in series to get starting torque with phase different. Because current through
the capacitor leads the current.

Figure 2.33: NR-115 single phase induction motor with starting capacitor

Figure 2.34: inner frame of 3 phase induction Motor

34
2.5.4 Induction motor starting methods
2.5.4.1 Necessity of starter
❖ At starting, the speed of motor is zero so that the back e.m.f. In the armature is zero.
❖ Armature resistance is so low, if it is connected to power supply directly; huge current will pass
through armature. (But it is not necessary to add starting technique to single phase induction motor.
)

2.5.4.2 Function of starter

❖ Start and stop the motor.
❖ Limit inrush current where necessary.
❖ Permit automatic control when required
❖ Protect motor and other connected equipment’s from over voltage, no voltage, under voltage

2.5.4.3 Type of starter For AC Motor

❖ DOL Starter
❖ Star-Delta
❖ Auto-transformer

2.5.4.4 Difference between DOL, Star-delta and Autotransformer.

Table 2.2: Difference of DOL,Star-delta and Autotransformer

35
2.6 Motor Assembly Division
2.6.1 Thermal overload switch

Figure 2.35: Thermal overload switch

2.6.2.1 The Purpose of a Thermal overload switch

This overheating generally occurs when the motor is overloaded, when a bearing seizes up, when something
locks the motor shaft and prevents it from turning, or when the motor simply fails to start properly. A failure
to start may be caused by faulty start windings in the motor.

The thermal protector consists of one or more heat-sensing elements built into the motor or motor-
compressor, plus an external control device. The thermal protection is present to turn the motor off
excessive heat is generated within the motor circuitry, halting the temperature climb before it can burn up
the motor.

These thermal protectors reset themselves once the motor cools down to a safe operating temperature. There
is usually a visible red button located on the wiring side of the motor usually, though not always, located
opposite of the motor shaft. On motors equipped this way, we must press the reset button to reset and restart
the motor. On other motors without a reset button, the reset happens automatically as the motor cools.

Having a motor shut down because it tripped a thermal limit is inconvenient, but it certainly is better than
having to replace a motor because it overheats. And the shut-down can alert us to problems with the motor
or connected devices, or to the load attached to the motor. When a motor fails to start or overheats during
operation, it may indicate that the motor has reached the end of its useful life and must be replaced. But
often the fault does not lie with the motor at all. There could be an obstruction on the load attached to the
motor, leading to excessive load that causes heat to build up in the motor—tripping the thermal protector
that saves the motor.

36
2.6.2 Centrifugal switch
❖ This switch is used to disconnect the starting winding connection after motor get specify speed.

Figure 2.36: Centrifugal switch connected to the rotor

A centrifugal switch is an electric switch that operates using the centrifugal force created from a rotating
shaft, most commonly that of an electric motor or gasoline engine. The switch is designed to activate or de-
activate as a function of the rotational speed of the shaft.

Perhaps the most common use of centrifugal switches is within single-phase, split-phase induction motors.
The switch is used to disconnect the starting winding of the motor once the motor approaches its normal
operating speed. In this case, the centrifugal switch consists of weights mounted to the shaft of the motor
and held near the shaft by spring force. At rest, levers attached to the weights press a low-friction, non-
conductive plate against a set of electrical contacts mounted to the motor housing, closing the contacts and
connecting the starting winding to the power source. When the motor approaches its normal operating
speed, centrifugal force overcomes the spring force and the weights swing out, raising the plate away from
the electrical contacts. This allows the contacts to open and disconnects the starting winding from the power
source. The motor then continues operating solely using its running winding. Motors using such a
centrifugal switch make a distinct clicking noise when starting and stopping as the centrifugal switch opens
and closes.

2.6.3 Rotor Balancing

2.6.3.1What is Rotor Balancing?
Rotor Balancing is a type of analysis that compares the vibration profile with the rotation of a mechanical
element to characterize inconsistent weight distribution around the diameter while calculating the amount
and position of the weight necessary to offset the net imbalance.

Rotating elements of a system are a common source of unwanted vibration. Any mass that is not rotating
around its center of mass will produce vibration. An everyday example of this would be car tires. Within
every tire, small changes in density and thickness of the rubber cause one section to be heavier than the

37
rest of the tire. This means that as the tire spins, that section will pull more than the rest, creating an
imbalance.

This imbalance in the tire is offset with the addition of weights directly opposite this heavy spot. With the
weight of the tire more uniformly distributed around the diameter, the vibration decreases and the car will
run more smoothly.

The same general concept is used for industrial machinery. The main difference is the accuracy to which
the weight is distributed and the types of rotating objects it is applied to. Rotating machinery is a common
element of any facility. Motors drive fans, gear boxes, rollers, and many other types of mechanical
systems.

Figure 2.37: Testing, identifying & add some additional weights for unbalance rotor

2.7 Pump Assembly Division

2.7.1 Pump testing
A pump test is a procedure carried out by a pump manufacturer, supplier, installer, or owner to confirm one
or more aspects of pump design or performance.
Pump tests are conducted to confirm that the pump meets the performance, design, and construction
standards required by the project specifications and data sheets. The most common types of pump tests
include
1) Pump performance tests: A performance test is used to determine that the head and flow produced
by a pump as well as the power required to operate a pump match the project requirements.
2) Hydrostatic pressure tests: A hydrostatic pressure test, or hydro test, involves putting the pump
casing under pressure that is considerably greater than the actual operating pressure to ensure that
the casing is strong enough to withstand operating pressures.

38
 3) Field tests: Most field tests are simple procedures used to demonstrate that the pump operates
without excessive vibration and noise or high bearing temperatures as installed in the field.

Pump test may be conducted either in the pump factory or in the field. Factory tests are typically much
more detailed than field tests.

Figure 2.38: J300 (25-H.P) pump testing

2.7.2 Mechanical Seal

Figure 2.39: Mechanical sealing kit

The mechanical seal acts as a check valve and a slider bearing. The obvious function is that of a check valve
to prevent liquid under pressure from leaking out of the pump, or from drawing air into the pump when
under vacuum conditions.

39
2.7.2.1 Seal Life
Since the seal must function as a slider or friction bearing, the seal has an unpredictable life span. The seal
of a centrifugal pump is usually replaced many times during the life of a pump. All bearing need lubricant
and the seal lubricant is the liquid being pumped. Liquid infiltrates between the contact faces of the primary
and mating rings. Some of this liquid does find its way through to the atmosphere but is so slight as to only
be noticed as corrosion of 'build up' on the pump adapter. The condition of the pumped liquid will greatly
affect seal life.

2.7.2.2 Abrasives
The number one enemy of a mechanical seal is abrasive particles in the liquid being pumped. Abrasives
may be anything from dirt to dissolved impurities in the liquid precipitating out of solution. These abrasive
particles infiltrate with the liquid between the seal faces and grind away the carbon primary ring. The
normal shiny face of the primary ring and mating ring.

2.7.2.3 Heat Damage

Excessive heat can damage the seal in two areas - the primary ring and the elastomer parts. The primary
ring is made primarily of carbon. Should the pump be operated without liquid - even for a very short period
of time - the primary and mating ring faces are denied lubricant. This causes the faces to become very hot.
The binder mixed with the carbon breaks down and the face of the primary ring turns to a dull black powder.
The O-ring, or cup, and flexible diaphragm of the seal are made of one of many types of rubber-like
substance called an 'elastomer'. The type of elastomeric material is selected to match the temperature limit
and types of material being pumped. Should the temperature limit be exceeded, the diaphragm and O-ring
will become hard and sometimes crack. The seal will then start to leak.

Figure 2.40: Pump seal in a centrifugal pump

40
2.8 Plastic Division
2.8.1 Plastic Injection Molding

Figure 2.41: AI-1 injection molding machine in plastic division

Injection molding is the most commonly used manufacturing process for the fabrication of plastic parts. A
wide variety of products are manufactured using injection molding, which vary greatly in their size,
complexity, and application. The injection molding process requires the use of an injection molding
machine, raw plastic material, and a mold. The plastic is melted in the injection molding machine and then
injected into the mold, where it cools and solidifies into the final part.

Injection molding is used to produce thin-walled plastic parts for a wide variety of applications, one of the
most common being plastic housings. Plastic housing is a thin-walled enclosure, often requiring
many ribs and bosses on the interior. These housings are used in a variety of products including household
appliances, consumer electronics, power tools, and as automotive dashboards. Other common thin-walled
products include different types of open containers, such as buckets. Injection molding is also used to
produce several everyday items such as toothbrushes or small plastic toys. Many medical devices, including
valves and syringes, are manufactured using injection molding as well.

2.8.1.1 What are the Thermoplastics?

A thermoplastic, also called a thermosetting plastic, is any plastic material which melts into a soft, pliable
form above a certain temperature and solidifies upon cooling. Thermoplastics can be re-melted and re-
shaped any number of times. They are usually stored in the form of pellets prior to the molding process.

Common examples of thermoplastics include acrylic, polyester, polypropylene, polystyrene, nylon and
Teflon. These materials see a wide variety of use in manufacturing products from clothing and non-stick
cookware to carpets and laboratory equipment.

41
2.8.1.2 What are the Thermosets?
In contrast to thermoplastics, thermosets (alternately known as thermosetting plastics or thermosetting
polymers) are materials which remain in a permanent solid state after being cured one time. Polymers within
the material cross-link during the curing process to perform an unbreakable, irreversible bond. This means
that thermosets will not melt even when exposed to extremely high temperatures.

Common examples of thermoset plastics and polymers include epoxy, silicone, polyurethane and phenolic.
In addition, some materials such as polyester can occur in both thermoplastic and thermoset versions.
Unlike thermoplastic pellets, the components of thermoset polymers are stored in liquid form, usually in
large tanks or containers.

Different thermosets provide different advantages when used as a production material. For example,
epoxies are highly elastic, tough and resistant to many chemicals while phenolic is highly flame resistant.

Figure 2.42: production material used in plastic division

2.8.2 Process cycle

Figure 2.43: Injection molding overview

42
The process cycle for injection molding is very short, typically between 2 seconds and 2 minutes, and
consists of the following four stages:

1. Clamping - Prior to the injection of the material into the mold, the two halves of the mold must first
be securely closed by the clamping unit. Each half of the mold is attached to the injection molding
machine and one half is allowed to slide. The hydraulically powered clamping unit pushes the mold
halves together and exerts sufficient force to keep the mold securely closed while the material is
injected. The time required to close and clamp the mold is dependent upon the machine - larger
machines (those with greater clamping forces) will require more time. This time can be estimated
from the dry cycle time of the machine.

2. Injection - The raw plastic material, usually in the form of pellets, is fed into the injection molding
machine, and advanced towards the mold by the injection unit. During this process, the material is
melted by heat and pressure. The molten plastic is then injected into the mold very quickly and the
buildup of pressure packs and holds the material. The amount of material that is injected is referred
to as the shot. The injection time is difficult to calculate accurately due to the complex and changing
flow of the molten plastic into the mold. However, the injection time can be estimated by the shot
volume, injection pressure, and injection power.

3. Cooling - The molten plastic that is inside the mold begins to cool as soon as it makes contact with
the interior mold surfaces. As the plastic cools, it will solidify into the shape of the desired part.
However, during cooling some shrinkage of the part may occur. The packing of material in the
injection stage allows additional material to flow into the mold and reduce the amount of visible
shrinkage. The mold cannot be opened until the required cooling time has elapsed. The cooling time
can be estimated from several thermodynamic properties of the plastic and the maximum wall
thickness of the part.

4. Ejection - After sufficient time has passed, the cooled part may be ejected from the mold by the
ejection system, which is attached to the rear half of the mold. When the mold is opened, a
mechanism is used to push the part out of the mold. Force must be applied to eject the part because
during cooling the part shrinks and adheres to the mold. In order to facilitate the ejection of the part,
a mold release agent can be sprayed onto the surfaces of the mold cavity prior to injection of the
material. The time that is required to open the mold and eject the part can be estimated from the dry
cycle time of the machine and should include time for the part to fall free of the mold. Once the part
is ejected, the mold can be clamped shut for the next shot to be injected.

After the injection molding cycle, some post processing is typically required. During cooling, the material
in the channels of the mold will solidify attached to the part. This excess material, along with any flash that

43
has occurred, must be trimmed from the part, typically by using cutters. For some types of material, such
as thermoplastics, the scrap material that results from this trimming can be recycled by being placed into a
plastic grinder, also called regrind machines or granulators, which regrinds the scrap material into pellets.
Due to some degradation of the material properties, the regrind must be mixed with raw material in the
proper regrind ratio to be reused in the injection molding process.

Figure 2.44: Injection molded part

2.8.3 Injection unit

The injection unit is responsible for both heating and injecting the material into the mold. The first part of
this unit is the hopper, a large container into which the raw plastic is poured. The hopper has an open
bottom, which allows the material to feed into the barrel. The barrel contains the mechanism for heating
and injecting the material into the mold. This mechanism is usually a ram injector or a reciprocating screw.
A ram injector forces the material forward through a heated section with a ram or plunger that is usually
hydraulically powered. Today, the more common technique is the use of a reciprocating screw. A
reciprocating screw moves the material forward by both rotating and sliding axially, being powered by
either a hydraulic or electric motor. The material enters the grooves of the screw from the hopper and is
advanced towards the mold as the screw rotates. While it is advanced, the material is melted by pressure,
friction, and additional heaters that surround the reciprocating screw. The molten plastic is then injected
very quickly into the mold through the nozzle at the end of the barrel by the buildup of pressure and the
forward action of the screw. This increasing pressure allows the material to be packed and forcibly held in
the mold. Once the material has solidified inside the mold, the screw can retract and fill with more material
for the next shot.

44
 Figure 2.45: Injection molding machine - Injection unit

2.8.4 Clamping unit

Prior to the injection of the molten plastic into the mold, the two halves of the mold must first be securely
closed by the clamping unit. When the mold is attached to the injection molding machine, each half is fixed
to a large plate, called a platen. The front half of the mold, called the mold cavity, is mounted to a stationary
platen and aligns with the nozzle of the injection unit. The rear half of the mold, called the mold core, is
mounted to a movable platen, which slides along the tie bars. The hydraulically powered clamping motor
actuates clamping bars that push the moveable platen towards the stationary platen and exert sufficient
force to keep the mold securely closed while the material is injected and subsequently cools. After the
required cooling time, the mold is then opened by the clamping motor. An ejection system, which is
attached to the rear half of the mold, is actuated by the ejector bar and pushes the solidified part out of the
open cavity.

Figure 2.46: Injection molding machine - Clamping unit

45
2.8.5 Mold channels
In order for the molten plastic to flow into the mold cavities, several channels are integrated into the mold
design. First, the molten plastic enters the mold through the sprue. Additional channels, called runners,
carry the molten plastic from the sprue to all of the cavities that must be filled. At the end of each runner,
the molten plastic enters the cavity through a gate which directs the flow. The molten plastic that solidifies
inside these runners is attached to the part and must be separated after the part has been ejected from the
mold. However, sometimes hot runner systems are used which independently heat the channels, allowing
the contained material to be melted and detached from the part. Another type of channel that is built into
the mold is cooling channels. These channels allow water to flow through the mold walls, adjacent to the
cavity, and cool the molten plastic.

Figure 2.47: Mold channels

2.8.6 Mold design

In addition to runners and gates, there are many other design issues that must be considered in the design
of the molds. Firstly, the mold must allow the molten plastic to flow easily into all of the cavities. Equally
important is the removal of the solidified part from the mold, so a draft angle must be applied to the mold
walls. The design of the mold must also accommodate any complex features on the part, such
as undercuts or threads, which will require additional mold pieces. Most of these devices slide into the part
cavity through the side of the mold, and are therefore known as slides, or side-actions. The most common
type of side-action is a side-core which enables an external undercut to be molded. Other devices enter
through the end of the mold along the parting direction, such as internal core lifters, which can form
an internal undercut. To mold threads into the part, an unscrewing device is needed, which can rotate out
of the mold after the threads have been formed.

46
 Figure 2.48: Mold - closed view Figure 2.49: Mold - Exploded view

2.9 Die & Mold Division

2.9.1 What is Electrical Discharge Machining?

Electrical discharge machining is a machining method primarily used for hard metals or those that would
be very difficult to machine with traditional techniques. EDM typically works with materials that are
electrically conductive, although methods have also been proposed for using EDM to machine
insulating ceramics. EDM can cut intricate contours or cavities in pre-hardened steel without the need for
heat treatment to soften and re-harden them. This method can be used with any other metal or metal alloy
such as titanium, hastelloy, kovar, and Inconel. Also, applications of this process to shape polycrystalline
diamond tools have been reported.

EDM is often included in the "non-traditional" or "non-conventional" group of machining methods together
with processes such as electrochemical machining (ECM), water jet cutting (WJ), laser cutting and
opposite to the "conventional" group (turning, milling, grinding, drilling and any other process whose
material removal mechanism is essentially based on mechanical forces).

2.9.2 Wire EDM

Figure 2.50: schematic view of WEDM cutting Mechanism Figure 2.51: wire EDM

47
1. Wire.
2. Electrical discharge erosion (Electric arc).
3. Electrical potential.
4. Work piece.

Wire EDM machining (also known as "spark EDM") works by creating an electrical discharge between the
wire or electrode and the work piece. As the spark jumps across the gap, material is removed from both the
work piece and the electrode. To stop the sparking process from shorting out, a non-conductive fluid or
dielectric is also applied. The waste material is removed by the dielectric, and the process continues. The
wire-cut process uses de-ionized water as its dielectric fluid, controlling its resistivity and other electrical
properties with filters and de-ionizerunits. The water flushes the cut debris away from the cutting zone.
Flushing is an important factor in determining the maximum feed rate for a given material thickness. Wire-
cutting EDM is commonly used when low residual stresses are desired, because it does not require high
cutting forces for removal of material. If the energy/power per pulse is relatively low (as in finishing
operations),little change in the mechanical properties of a material is expected due to these low residual
stresses, although material that hasn't been stress-relieved can distort in the machining process.

2.9.2.1 Part programming

The geometry of the profile and the motion of wire electrode tool along the profile is fed to the part
programming system through key board, in terms of various definitions of points, lines and circles as the
tool path element, in a totally menu driven, conversational mode.

The wire compensation and taper gradient can be specified for each path element separately. After the
profile is fed to the computer, all the numerical information about the path is calculated automatically and
its printout is generated. The entered profile can be verified on the graphic display screen. After successful
profile definition, it is recorded by the computer which is then put in the generator for execution of the
program.

2.10 Jinasena Agricultural & Machinery (JAM) Division

48
2.10.1 The range of Jinasena ‘Agrimec’ & 'Sinha' Products are

Thresher ground master multi grinder maize thresher tea cutter

Bush Cutter pepper thresher Roto master straw cutter Multi chopper

Mini multi chopper tractors Roto tiller (cultivator)

Figure 2.52: JAM Products

In this division mainly made agriculture machines. Steel fabrication processes were done in this division.
Welding processes, designed the chassis of shredding machine, sheet metal bending, cut gear wheel by
using manual milling machine processes and assembling the agricultural machines were done in this
section.

2.10.2 The following types of welding’s are used in JAM

1. Electric arc welding

2. Gas welding
3. TIG welding

2.10.2.1 Electric arc welding

Arc welding process is most popular in the industry. In arc welding process should be chosen the correct
current according to material. For Small thickness metal low current chosen. And also high current rate
used for lager thickness metal.

49
 Figure 2.53: AC Arc Welding Plant

2.10.2.1.1 Electrode Identification

The American Welding Society (AWS) has a numbering system that offers information about a specific
electrode, such as what application it is best used for and how it should be operated for maximum
efficacy. (See table)
Digit Type of Coating Welding Current
0 High cellulose sodium DC+
1 High cellulose potassium AC, DC+ or DC-
2 High titania sodium AC, DC-
3 High titania potassium AC, DC+
4 Iron powder, titania AC, DC+ or DC-
5 Low hydrogen sodium DC+
6 Low hydrogen potassium AC, DC+
7 High iron oxide, potassium powder AC, DC+ or DC-
8 Low hydrogen potassium, iron powder AC, DC+ or DC-

Table 2.3: Electrode identification

The E indicates an arc welding electrode. The first two digits of a 4-digit number and the first three digits
of a 5-digit number stand for tensile strength. For example, E6010 means 60,000 pounds per square inch
(PSI) tensile strength and E10018 means 100,000 psi tensile strength. The next to last digit indicates
position. So, 1 stands for an all position electrode, 2 for a flat and horizontal electrode, and 4 for a flat,
horizontal, vertical down and overhead electrode. The last two digits specify the type of coating and the
welding current.

E 60 1 10
Electrode Tensile Strength Position Type of Coating & Current

Table 2.4:E6010 definition

2.10.2.2 Gas welding

In gas welding process firstly should be adjusted the flame. For welding processes Neutral flame was chosen. Oxygen
and Acetylene ratio should be 1: 1 Adjusted the flame operating the control nobs of Oxygen and Acetylene.

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 Figure 2.54: Gas welding Unit

2.10.2.3 TIG welding

Tungsten Inert Gas welding is an Arc welding process that uses a non- consumable tungsten electrode to
produce the weld. In the Jinasena company TIG welding process is used to weld the stainless steel
fabrication processes. Because of TIG welding process is very high strength welding with good finishing.
Therefore after welding process not needed removing slags and grinding processes.

Firstly cleaned the metal plates have to be weld. Then opened the gas nob to 5bar pressure and get spark
toughing the work piece surface and welding arm was carried through the have to weld line. Eye goggles
should be wear during the welding processes.

Figure 2.55: TIG welding process

2.11 Panel Board & Project Division

In this division mainly made panel board for motor controlling. We were observed the control panel
assembling main parts and impotent parts of panel.
1. Rubber expansion joint(Bellow)
2. Non return valve
3. Gate valve
4. Air valve
5. Flow switch

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2.11.1 Rubber expansion joint (Bellow)
Is used to absorb the shock while pump Running, installing or transport. Otherwise pipes & fitting items
will damage.

Figure 2.56: Rubber expansion joint

2.11.2 Non return valve

N.R.V is used to prevent system from back water flow

Figure 2.57: Non return valve

2.11.3 Gate valve

A gate valve is generally used to completely shut off fluid flow or in the fully open position, provide full
flow in a pipeline. Thus it is used either in the fully closed or fully open positions. A gate valve consists
of a valve body, seat and disc, a spindle, gland, and a wheel for operating the valve. The seat and the gate
together perform the function of shutting off the flow of fluid.

Figure 2.58: Gate valve

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2.11.4 Air valve
When water is flowing through the manifold all air is release through the air valve

Figure 2.59: Air valve

2.11.5 Flow switch/pressure control switch

These switches are used to measure the flow rates & control the pressure

Figure 2.60: Flow switch

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Chapter 3

3.1 Conclusion

As a trainee I got following experiences.

1. Mass production in a workshop can be achieved effectively only when there are proper safety
measurements. Any replacement or repairs to the machine would cost very much. So the safety of the
machines is something equally important just as the safety of a worker. Standard safety measures taken for
the protection of the worker as well as the machines. Safety measurements Taken in the workshop are as
follows.
• All the workers are instructed to wear shoes
• Everybody should wear gloves if they are working with risky instruments like furnaces etc.
• Cleaning the machines is an essential task for the workers at the end of the day.
• Servicing the machine is to done at a period of one month.
• Company inspection to the machines should be done regularly.
• Any repair to the machine or the tool should be reported to the office without any delay

2. Management is also an important factor that should be considered in the workshop. There would be many
works and targets to achieve. So the most important and the demanded work should be accomplished first
even if there are many other works that entered the workshop before. So the work should be done as per
requirement
3. It was really helpful to understand the exact practical method of operating the machines. More than
theory I had done, this practical experience gave a clear picture regarding the subject.

Overall I can say that the training experience was good. But since this was my first training experience as
well as my first time establishment in the industry apart from university, at the beginning of the training I
didn’t have any idea of how to get the training. I had to struggle with that. But after few weeks I understood
about the situation and I was able to improve my knowledge step by step with the help of foremen,
technicians and even from the labors. It was a great first time experience for me. I think it would help me
in the future to survive in the industry when nobody wants to guide me. Apart from technical knowledge I
got a rare opportunity to interact with various types of people. I consider that knowledge of interacting with
people will help me in the future to work with anybody and get the work done by them without being a
horrible harsh environment.

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3.2 Suggestions

When considering a company, the company workforce can be considered as the main strength of the
company organization. It becomes working together with the workers and the leaders of the work place.
Jinasena (PVT) Ltd has highly experienced and highly educated (technical knowledge according to their
occupation level) employees to working at their best to provide a good service for the customers. But there
are resources ravage because they used old technology in the workshops & also workers are highly ignoring
their safety by own. Therefore during my training session, I came up with following ideas to increase the
efficiency of the outputs from the workshops.
❖ Give the instructions about the employee’s safety and advise them to follow the safety instructions.
❖ Also introduce organization for the new technology.
❖ Take employers and giving promotions for them according to the organization rules. Also give
opportunity to young person with better experience for join the higher designations in organization.
❖ Annually organize a get together for all of the employees.
❖ Also do the medical test for the employees in annually or advice those to do its own.

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