Professional Documents
Culture Documents
ON
Submitted in the partial fulfillment of the requirement for the award of degree
OF
BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
BY
SESSION (2017-2021)
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ACKNOWLEDGEMENT
First of all we would like to thank the almighty above all. It is only this spiritual power which
blessed us with the aid of which we were successful to complete our report.
We are highly grateful to the authorities of DAV Institute Of Engg. & Technology, Jalandhar for
providing this opportunity to carry out this project work.
We would like to express a deep sense of gratitude and thank profusely to our project guide Mr.
Rajesh Mehra ,Mr. Sunil Kumar and Dr. Sanjeev Saini for their sincere & invaluable
guidance and suggestions. We are immensely grateful to Mr. Om parkash sharma incharge of
CNC lathe, under whom guidance and supervision we worked on CNC lathe for fulfillment of
our project.
We are also thankful to Dr. Gaurav Dhuria (H.O.D) and other faculty members of Mechanical
Engineering Department for their intellectual support.
Our special thanks to our family members and friends who constantly encouraged us to complete
this project.
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Index
CHAPTER 1 INTRODUCTION TO AUTOCAD
1.1 Introduction 4
1.2 Drawings 5
2.2.1 Bed 10
2.2.4 Carriage 11
2.3.1 Turning 11
2.3.3 Knurling 12
2.3.4 Drilling 12
2.3.5 Threading 12
2.3.6 Chamfering 12
2.3.7 Grooving 12
2.3.8 Parting 13
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3.1 Band Saw 15
3.1.1 Definition 20
3.2.4Casting 36
Metal Casting
Sand Casting
INDUSTRIAL VISITS
4.2 Consultancy 39
4.3 Machinary 39
4.5 Workshop 41
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CHAPTER- 5 VISIT TO JUPITER METAL INDUSTRY
5.2 Consultancy 45
5.5 Products 49
Conclusion 50
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Chapter-1
INTRODUCTION TO AUTOCAD
1.1 Introduction
Computer Aided Design and Manufacturing area is one of the fastest growing areas in the
engineering industry today. CAD/CAM systems have become basic systems that can help the
designer to design a product by using the speed and efficiency of a computer. At the same time
significant technological advances have been occurring in the areas of computer-aided design
and in computer-aided manufacturing.
CAD/CAM courses are normally taught with a combination of theory and practice. Side by side
with the theory, the course requires a student to undertake assignments with major commercial
software. (For example, solid works). The course involves theory and hands-on experiments. The
student participants are expected to procure a copy of the student version of the software. The
course is developed in such a manner that the participants can get the instruction in a self-paced
step-by-step manner with a combination of theory and practice.
AutoCAD is one of the most prominent software used for drawing objects. Every year its new
version is launched. The current version is AutoCAD 2012. Using AutoCAD, we can create two
dimensional drawings of an object, then convert it into three dimension or real dimension. The
file in it is saved as .dwg format. It supports various languages including English. There are
various commands used in AutoCAD such as Trim, Cut, Mirror, Extrude, Explode etc.
Apart from simple drawing, we can rotate and revolve the given drawing to generate a three
dimensional object. We can also create house maps, bridges, complex machines etc. from it.
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1.2 DRAWINGS MADE DURING TRAINING SESSION
Fig. 1.1
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Fig. 1.2
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Fig. 1.3
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Fig. 1.4
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Fig. 1.5
CHAPTER-2
A lathe is well-defined as /lelo. It is a piece of equipment which twirls the article on its middle
axis to bring out a diversity of procedures like cutting, sparkling , piercing, or curve with tools
that are applied to the object to create a part which has regularity about an axis of revolution.
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Lathes are used for woodturning, metalworking, metal spinning, as well as tumbler functioning.
The best-known design of lathe machine can be the tinker’s sweep. The majority suitably
capable of Metalworking lathes can properly capable of to generate most hard substances to
fabricate diverse machine parts. Plane exteriors as well as screw threads or helices can moreover
be made. Lathes can be used to form ceramic objects; smithy etc. Gold smiths use decorative
lathes to produce jewellery of astonishing complexity. The object can be secured in place by one
or two axis. To supply accommodation altered stuff distance end to end, at least one of which
can be twisted straight. Next bits and pieces can be produced on a lathe: candlestick holders, cue
sticks, table legs, crockery, etc.
When an object is protected between the front stock moreover the back stock, it is well thought-
out to be permanently fixed in midpoints. When an article is held at both nail trimmings, it is
further steady. Consequently as working on the article more power can be applied to the object,
right through equipments and the object still remains in position and it does not get release.
When an article is fixed to the spindle at the front stock ending, it is freely held at one end only.
Here there are chances of releasing. When an object is fixed in this style, one can apply less force
to a thing, through kits, Care requirements to be taken or else calamity can transpire.
When an objective is preset through a definite affiliation of revolution, worked, then fixed with a
new bloc of mutiny it is identified as compound axial procedure. The outcome is that a diversity
of cross segments of an entity varies at different bloc.
The smallest amounts of lathes are used for watchmakers. They are small and can be picked up
in a hand. The object manufactured by a jeweller can be of gold or silver.
Minor metalworking lathes are bigger than jewellers’ lathes. They can put back into working
order on a work surface or counter. They cannot be used for repetitive production. They are for
single use only. Only few lathes are for second use, nut still they have intricate facilities.
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2.2Parts of Lathe Machine
Fig. 2.1
2.2.1 Bed:-
The bed is a heavy, rugged casting in which are mounted the working parts of the lathe. It carries
the headstock and tailstock for supporting the workpiece and provides a base for the movement
of carriage assembly which carries the tool.
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2.2.2 Headstock:-
The headstock is clamped on the left hand side of the bed and it serves as a housing for the
driving pulleys, back gears, headstock spindle or machine spindles, live centre and the feed
reverse gear. The headstock spindle is a hollow cylindrical shaft that provides a drive from the
motor to work holding devices. The spindle can be driven by a stepped pulley and a belt, or by
transmission gears. The lathe with a stepped pulley drive is generally called a belt-driven lathe,
and the gear driven lathe is referred to as a geared-head lathe.
2.2.3 Gear-Box:-
The quick change gear-box is placed below the headstock and contains a number of different
sized gears. This provides the feed rod and lead screw with various speeds for turning and thread
cutting operations. The feed rod advances the carriage for turning operations whereas the lead
screw does so far cutting threads.
2.2.4 Carriage:-
The carriage is located between the headstock and tailstock and serves the purpose of supporting,
guiding and feeding the tool against the job during operation. Main parts of carriage are saddle,
croos slide, compound rest, tool post, apron.
2.2.5 Tailstock:-
The tailstock is a movable casting located opposite the headstock on the ways of the bed. The
tailstock can slide along the bed to accommodate different lengths of workpiece between the
centres. A tailstock clamp is provided to lock the tailstock at any desired position. The tailstock
spindle has an internal taper to hold the dead centre and the tapered shank tools such as reamers.
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Lathe Machine is very basic machine tool which is capable of producing almost all kinds of
output jobs with its wide range of operations. In this article, I will try to explain some of basic
lathe operations which have brought importance to lathe machine.
2.3.1. Turning:
This is most basic and important lathe operation. It can be said that, Turning is the operation
which has brought lathe into existence. Job is held at chuck and rotates at particular RPM. Tool
held at tool post. With carriage assembly tool is fed into job parallel to axis of rotation of job.
This operation is used to make job circular and to reduce the diameter of the job as per need.
This is similar to turning. Apart from turning, tool path cuts the axis of rotation of tool at a
particular angle. This motion of tool is achieved through combined motions of carriage assembly
and cross slide.
2.3.3. Knurling:
Knurling is not a cutting operation. Knurling is achieved using knurling tool. This tool has two
wheels with slashed lines on it. This tool is pressed against rotating job to get knurled part.
Knurling is achieved using plastic deformation of job material.
2.3.4. Drilling:
Drilling at the lathe machine is achieved in bit different way than other lathe operations. Drilling
tool is held in the tail stock and fed into job using handle on tailstock.
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2.3.5. Threading:
For threading operations to be done accurately, tool must be fed into job with constant speed.
This constant motion is achieved by attaching carriage assembly with lead screw. Lead screw is
connected to the driving mechanism through gear trains. So, for particular rpm of job there is
constant rpm of lead screw. Threading is of two types viz. External Threading, Internal
Threading.
a.External Threading:
b. Internal Threading:
Internal threading is also done by V shaped tool. But in this case tool is mounted on thin bar
which can be able to go into bore of the workpiece where threading is to be done. Shaping tool
for this operation is work of skilled worker.
2.3.6. Chamfering:
Chamfering is slash cutting of the edges of the workpiece. It can be called as very small taper
turning but still taper turning needs a lot more accuracy and skill than chamfering. Also, both
have very different sets of uses.
2.3.7. Grooving:
Grooving is generally needed to be done before external threading. In this, grooving tool is fed
perpendicular to axis of rotation of job.
2.3.8. Parting:
Parting is like that of grooving. Parting is done for cutting of job into part.
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\
PROJECT REPORT
ON
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BANDSAW AND SPRAYER
Band Saw
A bandsaw (also written band saw) is a saw with a long, sharp blade consisting of a continuous
band of toothed metal stretched between two or more wheels to cut material. They are used
principally in woodworking, metalworking, and lumbering, but may cut a variety of materials.
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Advantages include uniform cutting action as a result of an evenly distributed tooth load, and the
ability to cut irregular or curved shapes like a jigsaw. The minimum radius of a curve is
determined by the width of the band and its kerf. Most bandsaws have two wheels rotating in the
same plane, one of which is powered, although some may have three or four to distribute the
load. The blade itself can come in a variety of sizes and tooth pitches (teeth per inch, or TPI),
which enables the machine to be highly versatile and able to cut a wide variety of materials
including wood, metal and plastic.
Almost all bandsaws today are powered by an electric motor. Line shaft versions were once
common but are now antiques.
The bandsaw is useful for cutting stock to size and roughing out shapes. It contains a serrated
blade that forms one continuous loop. The blade is stretched over two pulleys, the upper one idle,
the lower one driven by a variable speed electric motor.
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Parts of Band Saw
UPPER WHEEL GUARD
BLADE GUARD
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REAR BLADE GUARD
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BLADE GUIDES
TABLE
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LOWER WHEEL COVER
It protected the operator if the blade comes off of the lower wheel.
GUIDE POST
It protected the operator if the blade comes off of the lower wheel.
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MITER GAUGE
BLADE
It is a large band that revolves around the two wheels and cuts the wood.
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Air Compressor Sprayer
An air compressor is a device that converts power (using an electric motor, diesel or gasoline
engine, etc.) into potential energy stored in pressurized air (i.e., compressed air). By one of
several methods, an air compressor forces more and more air into a storage tank, increasing the
pressure. When tank pressure reaches its engineered upper limit the air compressor shuts off. The
compressed air, then, is held in the tank until called into use. The energy contained in the
compressed air can be used for a variety of applications, utilizing the kinetic energy of the air as
it is released and the tank depressurizes. When tank pressure reaches its lower limit, the air
compressor turns on again and re-pressurizes the tank.
An air compressor must be differentiated from an air pump which merely pumps air from one
context (often the surrounding environment) into another (such as an inflatable mattress, an
aquarium, etc.). Air pumps do not contain an air tank for storing pressurized air and are generally
much slower, quieter, and less expensive to own and operate than an air compressor.
Classification:
1. Low-pressure air compressors (LPACs), which have a discharge pressure of 150 psi or
less
2. Medium-pressure compressors which have a discharge pressure of 151 psi to 1,000 psi
3. High-pressure air compressors (HPACs), which have a discharge pressure above 1,000 psi[2]
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They can also be classified according to the design and principle of operation:
8. Axial Compressor
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PARTS OF SINGLE STAGE AIR COMPRESSOR SPRAYER
2. INLET-OUTLET NIPPLE
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In plumbing and piping, a nipple is a fitting, consisting of a short piece of pipe, usually provided
with a male pipe thread at each end, for connecting two other fittings. ½ inch nipple is used in
sprayer.
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3. SAFETY VALVE
A safety valve is a mechanism for the release of a substance from a pressurized vessel when
the pressure or temperature exceeds preset limits.270 mm (approx.) safety valve is used.
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4. PRESSURE GAUGE
Instruments used to measure and display pressure in an integral unit are called pressure
gauges or vacuum gauges
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5. COMPRESSOR
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6. TANK
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Specification of material used:-
Mild steel - It is a type of steel alloy, that contains a high amount of carbon, as a major
constituent. An alloy is a mixture of metals and non-metals, designed to have specific properties.
Alloys make it possible to compensate for the shortcomings of a pure metal by adding other
elements. To get what mild steel is, one must know what are the alloys that are combined to
make it.
Composition:
Carbon % - 0.50 to 0.60
Silicon % - 0.10 to 0.35
Manganese % - 0.50 to 0.65
Sulphur % - 0.05 max
Phosphorus % - 0.05 max
Physical properties:
Hardness: 200 HV max
Yield Strees: 270N/mm2 min
Tensile Strength: 590N/mm2 max
Elongation %: 30 min
Here is a compilation of mild steel properties and its uses in various fields of technology.
A high amount of carbon makes this steel different from other types. Carbon makes it
stronger and stiffer than other type of steel. However, the hardness comes at the price of a
decrease in the ductility of this alloy.
What is known as mildest grade of carbon steel or 'mild steel' is typically carbon steel,
with a comparatively mild amount of carbon (0.16% to 0.19%).
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It is the cheapest and most versatile form of steel and serves every application which
requires a bulk amount of steel.
The high amount of carbon, also makes it vulnerable to rust. Naturally, people prefer
stainless over mild steel, when they want a rust free technology.
[2] WELDING
[3] GRINDING
[5]DRILLING
[6] PAINTING
ARC WELDING:
Arc welding is a welding process, in which heat is generated by an electric arc struck between an
electrode and the work piece.
Electric arc is luminous electrical discharge between two electrodes through ionized gas.
Any arc welding method is based on an electric circuit consisting of the following parts:
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Welding leads (electric cables) connecting the electrode and work piece to the power
supply.
Electric arc between the electrode and work piece closes the electric circuit. The arc temperature
may reach 10000°F (5500°C), which is sufficient for fusion the work piece edges and joining
them.
GRINDING:
Grinding is a finishing process used to improve surface finish, abrade hard materials, and tighten
the tolerance on flat and cylindrical surfaces by removing a small amount of material.
Information in this section is organized according to the subcategory links in the menu bar to the
left.
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1. The material is too hard to be machined economically. (The material may have been
hardened in order to produce a low-wear finish, such as that in a bearing raceway.)
2. Tolerances required preclude machining. Grinding can produce flatness tolerances of
less than ±0.0025 mm (±0.0001 in) on a 127 x 127 mm (5 x 5 in) steel surface if the
surface is adequately supported.
3. Machining removes excessive material.
CASTING:
Casting is a manufacturing process by which a liquid material is usually poured into a mold,
which contains a hollow cavity of the desired shape, and then allowed to solidify. The solidified
part is also known as a casting, which is ejected or broken out of the mold to complete the
process. Casting materials are usually metals or various cold setting materials that cure after
mixing two or more components together; examples are epoxy, concrete, plaster and clay.
Casting is most often used for making complex shapes that would be otherwise difficult or
uneconomical to make by other methods.
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PIT FURNACE
Furnace is a device used for high-temperature heating. The name derives
from Latin word fornix, which means oven. The heat energy to fuel a furnace may be supplied
directly by fuel combustion, by electricity such as the electric arc furnace, or through induction
heating in induction furnaces.
The pit furnace is a vertical orientation batch furnace used for a variety of processes. Designs can
be provided for atmosphere or direct fired processes. Furnaces are available with retorts or
without depending on process requirements.
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METAL CASTING:
Create liquid metal – Melting
SAND CASTING
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Uses sand to hold the desired shape to
be cast
Chapter-4
Fig4.1
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CENTRAL INSTITUTE OF HAND TOOLS
DATE- 15-06-2018
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CIHT is an autonomous organization. It is a National Institute. It was established in 1983 with
assistance from UNDP, Government of India and Government of Punjab. It is aspiring for latest
technology to be a leader in region.
4.2 CONSULTANCY
Design & Manufacture of various toolings, jigs, fixtures and gauges used in hand tool and
other Engineering industry.
Induction Hardening processes applicable to various hand tools i.e Pipe Wrenches, Pliers,
all type of hammers and other engineering items.
Forging of various hand tools i.e. Spanners, Wrenches, Pliers, Claw Hammers, Pipe
Wrenches and other commercial forgings.
Chemical and Physical testing of ferrous material and calibration of gauges.
4.3 MACHINERY
The Tool Room is equipped with following indigenous as well as imported machinery: -
CNC Wire Cut Machine
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CNC Machining Centre (VMC-800) HMT
CNC Turning CL 2050 Make Batliboi
CNC Vertical Machining Centre, DAEWOO
Fig 4.3 CNC - Vertical Machining Centre Fig 4.4 CNC 3D Co-Ordinate
Measuring Machine
CNC Turner Lathe Machine
CNC Trainer Milling Machine
Injection Moulding Machine
Lathe HMT
Vertical Milling Machine (HMT)
Universal Milling Machine (HMT)
Cylindrical Grinding Machine
Horizontal Surface Grinding Machine
Tool & Cutter Grinder
Shaper Machine
Power Hacksaw
CNC 3D Co-Ordinate Measuring Machine
4.4 Heat Treatment Shop
Induction Heater (High Frequency), 60 KW
Induction Heater (High Frequency), 20 KW
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4.5 WORKSHOP
Fig 4.5
FORGE SHOP
Fig 4.6
The Forge Shop is equipped with the following hammers and presses to provide technical
training and common facilities services to the industries: -
Forging Press, Capacity 600 Ton
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Fig 4.7
Forging Press - 600 Ton
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Fig 4.8Testing Lab Fig 4.9 Standard Room
This department is providing assistance to the industry by way of testing various materials i.e.
chemical composition, physical properties etc. The section is also carrying out the inspection of
various screw gauges and measuring instruments.
Testing & Quality Control Section has the following main equipments: -
Equipment for chemical testing for iron, steel brass and bronze etc.
Dead Weight Pressure Gauge Tester
Metallurgical Micro-scope for Testing Micro Structure
Ultrasonic Flaw Detector
Universal Testing Machine
Torque Testing Equipment and Hand Load Testing Fixture
Vickers / Rockwell Hardness Tester
Tool Makers Micro-scope
PVC Insulation Testing Equipment
Monometer Thickness Gauge
Profile Projector
Screw Thread Measuring Machine
Spectrometer for Analysis of Metals
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4.8 TRAINING SERVICES
CHAPTER- 5
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Jupiter Metal Industry
DATE- 22-6-2018
Jupiter Metal Industries (JaL), an ISO 9001 Certified Company. It was established in 1993-94 as
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a small scale unit. This Company was another milestone achieved by this business family who is
in the field of MCI Pipe fittings since 1959 with their parental concern namely Jupiter Metal
Industries (Regd.). The company is engaged in manufacturing of Malleable Cast Iron Pipe
Fittings in full range (Size ranging from 1/8” to 6') under the name of 'KIRTI'.
5.2 CONSULTANCY
Design and manufacturing of various pipe fittings such as Structure Pipe, Gas Pipe,
Hydraulic Pipe, Chemical Fertilizer Pipe, Pneumatic Connections etc.
Manufacturing of various brass ball valves, gas valves, Teflon tapes, and other products
of pipe fittings.
Casting of various pipe fitting.
Induction Furnance(500KW)
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Sand Mullers
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Shot Blast Machine
Lathe Machine
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5.4 SAND CASTING
Sand casting, the most widely used casting process, utilizes expendable sand molds to
form complex metal parts that can be made of nearly any alloy. Because the sand mold must be
destroyed in order to remove the part, called the casting, sand casting typically has a
low production rate. The sand casting process involves the use of a furnace, metal, pattern, and
sand mold. The metal is melted in the furnace and then ladled and poured into the cavity of the
sand mold, which is formed by the pattern. The sand mold separates along a parting line and the
solidified casting can be removed.
Sand casting is used to produce a wide variety of metal components with complex geometries.
These parts can vary greatly in size and weight, ranging from a couple ounces to several tons.
Some smaller sand cast parts include components as gears, pulleys, crankshafts, connecting rods,
and propellers. Larger applications include housings for large equipment and heavy machine
bases. Sand casting is also common in producing automobile components, such as engine blocks,
engine manifolds, cylinder heads, and transmission cases.
5.5 PRODUCTS
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Conclusion
The port 1st year Workshop Training was extremely beneficial not only to me, but to my class as
well- Mechanical Engineering- as we all worked as a team.
Personality Development classes taught us many things and in AutoCAD classes we tried to give
shape to our ideas using the software. The project works done in the workshops provided us with
ample knowledge as we ourselves made the projects.
The industrial visit to CHIT us to know about various machines and how tools were made and
visit to JUPITER METAL INDUSTRY come us to know about the casting process in industries.
Last but not the least, the expert lecture on Auto cad helped us to know various features of the
software which gave us knowledge of various such techniques and their need as both of these are
very important in Mechanical Engineering.
On the whole, the post 1st year training was extremely beneficial.
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