PROJECT REPORT

INDUSTRIAL TRAINING

NIT KURUKSHETRA

 STUDY OF CNC MACHINE AND QUALITY CONTROL

 TO REDUCE THE REJECTION RATE OF REAR CASES OF
GEAR BOX AT CMM
AT
JCB INDIA PVT. LTD.

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 ACKNOWLEDGEMENT

After completing the training report at “JCB INDIA PVT. LTD.”, it is a great pleasure for me
to thank all those who have helped me during the course of completion of my project.
I express my sincere thanks to JCB INDIA PVT. LTD for giving me a unique opportunity to
do project in such an esteemed organization.
I would also like to thank the training in charge of NIT KURUKSHETRA and all the faculty
members of Mechanical Engineering Department for their effort of constant co-operation,
which have been a significant factor in the accomplishment of my industrial training.
Last but not the least; I would like to place a word of appreciation on record for all those who
directly or indirectly supported me.

JATIN VIRMANI
NIT KURUKSHETRA

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 CONTENTS
1) Brief about the company ……………………………………………..4
2) Models produced in JCB ……………………………………………..6
3) What is CNC ? ……………………………………………..8
4) Block diagram of CNC ……………………………………………..9
5) Process flow chart of CNC…………………………………………….11
6) Project Report………………………………………………………….12
I. Objective
II. Problem Defined
III. Cause
IV. Solution for the problem
V. Measurements
7) Final Implementation…………………………………………………15
8) Conclusion…………………………………………………………….17
9) Challenges Faced……………………………………………………..17
10) References…………………………………………………………….18

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 ABOUT THE COMPANY
J.C. Bamford Excavators Limited, universally known as JCB, is a British
multinational corporation, with headquarters in Rocester, Staffordshire, manufacturing
equipment for construction, agriculture, waste handling and demolition. It is the
world's third-largest construction equipment manufacturer.
 Itproduces over 300 types of machine, including diggers (backhoes), excavators,
tractors and diesel engines. It has 22 factories across Asia, Europe, North America, and
South America; its products are sold in over 150 countries.

Founder: Joseph Cyril Bamford

CEO: Graeme Macdonald

Annual Turnover: £2.75 billion

Number of employees: 11000 (approx.)

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Jcb has 3 plants in india and one new plant set up recently in jaipur. The major plant is
in ballabgarh, Haryana. The factory in Ballabgarh, Faridabad, has undergone the huge
expansion which has doubled its capacity and enabled JCB to produce 100 backhoes a
day in India.
JCB India Ltd. started operations in 1979 as a joint venture company. In 2003 JCB UK
acquired 100% shares in the joint venture and today JCB is the fastest growing
company in the Indian earthmoving and construction equipment industry. The
company is a pioneer in the industry and has been recording excellent growth rates. It
has ambitious development and expansion plans through launching revolutionary
products and adherence to world class JCB corporate identity norms. Today in India,
JCB has a park of over 80,000 machines and out of every two construction equipments
sold in India one is a JCB product.

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MODELS PRODUCED AT JCB INDIA PVT. LTD.
BALLABGARH
1)2DX MODEL
Engineered for use in compact areas, the JCB 2DX backhoe loader has been
innovatively designed for enhanced productivity, durability and greater efficiency.
It has a compact size thus making it ideal for reaching and manoeuvring through
inaccessible areas and has excellent fuel efficiency. It has a 3.2L engine with a
power capacity of 49.5hp.

2)3DX MODEL
The new 3DX backhoe loader comes with 20% lower fuel consumption & is
the most efficient backhoe loader on the earth with incredible productivity & enhanced
performance in any application. All the materials of the 3DX Xtra ecoXcellence
backhoe loaders are critically tested to the very maximum. By exposing these materials
to extreme temperatures, chemicals, salt, oil and light, they have been tested and
proven to survive the most hostile conditions. It has a water cooled turbo-charged 4.4L
engine with a maximum power of 92hp.

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 3) 4DX MODEL
Apart from the robust structure and D-Section loader arm; the JCB Livelink -
the advanced telematics solution provides idle time monitoring, fuel level information,
engine status and GPS tracking which makes the 4DX ecoXcellence Backhoe Loader
one of the most modern Backhoes available in the marketplace. The 4DX ecoXcellence
Backhoe Loader provides the best-in-class operating cost. It is highest in output and
lowest in fuel consumption; with7% more fuel savings and 30% more savings on
maintenance cost. It has a turbo Charged, water cooled JCB engine ecoMAX for better
performance in hot and dusty working conditions and has a max power of 92hp.

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 WHAT IS CNC?
CNC stands for Computer Numerical Control. CNC Machining is a process used in the
manufacturing sector that involves the use of computers to control machine tools.
Tools that can be controlled in this manner include lathes, mills, routers and grinders.

computer numerical control

I. First G-CODES and M-CODES are given in the computer.
II. These commands are read by a reader and stores into the memory. This memory
is in turn converted into Binary codes or numbers.
III. These binary codes give electric pulses to the Servo drives which actuates the
motors and spindle.

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 BLOCK DIAGRAM OF CNC USED AT JCB INDIA PVT. LTD.

COOLANT STABILIZER +
SECONDARY AIR
PUMP COOLING FAN
FILTRATION DRIER
UNIT
LUBRICATION UNIT

CHIPS CHIPS
DRIVE
TROLL CONV
EY EYER

CONTROL
TOOL MAGAZINE MACHINING CENTER PANEL

GAUGING STATION LOLLOADING STATION

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  TOOL MAGAZINE : Tool magazine consists of all the tools required for
maching purposes. There are two types of tool magazines- ring type and matrix
type. At JCB, the tool magazine consisted of matrix type of tool magazine with
97 tools.
 GAUGING STATION : Gauging station is where the tools for measuring the
dimensions of machined part are kept. It includes dial gauges, vernier callipers,
etc. Least count of the gauge used is 1 micron.
 LOADING STATION : Loading station is where the casting is loaded into the
fixture with the help of nuts and bolts.
 MACHINING CENTER : Machining center is the place where actual
machining takes place. The spindle in which the tool rotates can move in X and
Y directions only and not in Z. Feed is given with the table which can move in
Z direction.
 CONTROL PANEL : At control panel G-Codes and M-Codes are entered in
computer which give commands to the drive and servo motors.
 DRIVE : Drive consists of integrated circuits . For each direction, there is a
separate drive. Commands received from control panel are converted into binary
at drive which then actuate the servo motor according to commands given.
 COOLANT : Coolant used in CNC is Blasocut universal 2000.
 COOLANT PUMP : It pumps the coolant to the entire machine.
 COOLANT FILTRATION : The coolant which comes out after circulating in
the machine consists of chips.These chips are first removed in primary filtration
unit and the remaining smaller chips get removed in secondary filtration unit.

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 PROCESS FLOW CHART OF CNC

CASTING
FROM
LOGISTICS

CNC
MACHINE

LOAD AT
FIXTURE

MACHINING

GAUGING

INSPECTIO
SCRAP/REWORK
N
CMM ( 1
COMP. PER
SHIFT)

SUPERMARK
ET

ASSEMBLY

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 PROJECT REPORT
OBJECTIVE : To reduce the rejection rate of rear cases of gear box at CMM
(coordinate measuring machine) due to deviation from tolerance limit.
PROBLEM DEFINED : The rear cases of gear box were machined at CNC and the
operator ensured that these components had dimensions within the tolerance limit. The
components were checked for whether they were in tolerance limit at the CNC and
they gave positive result. But when these components were sent at CMM there was a
5-6 % rejection of these components every day. So, I was given the project to find out
the reason of rejection of these components at CMM and to give a solution to this
problem so that it can be minimised.
CAUSE : With the help of my mentors , I found out that the reason for the deviation of
components from tolerance limit was the temperature difference between the CNC and
CMM. One of the dimensions in rear case of gear box was of mean dia 80mm. And
tolerance limit was 80.010mm to 80.040mm. Temperature of CNC was approximately
40 degrees Celsius. And the temperature of CMM was around (18-22 degrees
Celsius).So if the operator at CNC measures the diameter to be 80.015mm which is
within the tolerance limit , the same diameter goes out of tolerance limit at CMM and
hence the component is rejected.
SOLUTION FOR THE PROBLEM : I with the help of my mentors acknowledged
that if I could provide a certain constant to the operators at CNC machine which when
multiplied with the dimension at CNC will give a rough idea about the dimension of
component at CMM. This constant gives the effect of temperature on the dimensions
of the components.This constant will help operators to minimise rejection rate at CMM
by deciding before hand that what should be the range of dimensions so that they don’t
deviate from tolerance limit.

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MEASUREMENTS: ( initial report of the components )
COMPONENT CNC d1 CMM d2 CONSTANT R/A
NO. k=d2/d1
A17F311 80.022 80.018 0.99995 A
A17F312 80.020 80.017 0.99996 A
A17F313 80.021 80.018 0.99996 A
A17F314 80.010 80.006 0.99995 R
A17F315 80.022 80.017 0.99994 A
A17F316 80.024 80.019 0.99995 A
A17F317 80.016 80.013 0.99996 A
A17F318 80.028 80.022 0.99993 A
A17F319 80.030 80.025 0.99994 A
A17F320 80.027 80.023 0.99995 A
B17F311 80.024 80.020 0.99995 A
B17F312 80.033 80.030 0.99996 A
B17F313 80.015 80.009 0.99993 R
B17F314 80.022 80.017 0.99994 A
B17F315 80.026 80.022 0.99995 A
B17F316 80.030 80.026 0.99995 A
B17F317 80.035 80.028 0.99992 A
B17F318 80.021 80.015 0.99993 A
B17F319 80.018 80.013 0.99994 A
B17F320 80.024 80.020 0.99995 A
C17F311 80.028 80.025 0.99996 A
C17F312 80.037 80.034 0.99996 A
C17F313 80.026 80.020 0.99993 A
C17F314 80.019 80.013 0.99993 A
C17F315 80.021 80.014 0.99992 A
C17F316 80.029 80.025 0.99995 A
C17F317 80.031 80.027 0.99995 A
C17F318 80.033 80.027 0.99993 A
C17F319 80.025 80.020 0.99994 A
C17F320 80.026 80.020 0.99993 A
D17F311 80.032 80.027 0.99994 A
D17F312 80.034 80.030 0.99995 A

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 D17F313 80.020 80.017 0.99996 A
D17F314 80.019 80.015 0.99995 A
D17F315 80.031 80.026 0.99994 A
D17F316 80.037 80.032 0.99994 A
D17F317 80.026 80.020 0.99993 A
D17F318 80.029 80.023 0.99993 A
D17F319 80.035 80.032 0.99996 A
D17F320 80.024 80.020 0.99995 A
E17F311 80.028 80.025 0.99996 A
E17F312 80.030 80.027 0.99997 A
E17F313 80.034 80.029 0.99994 A
E17F314 80.017 80.012 0.99994 A
E17F315 80.025 80.020 0.99995 A
E17F316 80.014 80.009 0.99994 R
E17F317 80.022 80.019 0.99996 A
E17F318 80.036 80.031 0.99994 A
E17F319 80.032 80.026 0.99993 A
E17F320 80.024 80.018 0.99993 A

Constant VS Component no
1

1
Constant VS Component no
1

Mean value of constant k = ∑ki / 50 ( where 1 < i < 50 ) = 0.99994

Rejection % = ( 3/50 ) * 100 = 6 %

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FINAL IMPLEMENTATION : I provided this value of constant to operator at CNC
which he used to have a idea about what should be the range of tolerance so that the
component would not be rejected at CNC. There are five bores in the rear case of gear
box. And this constant , K is applicable to every bore because it just gives the effect of
temperature and is independent of the dimension being measured.
Initial tolerance limit at CNC ( for 80mm diameter ) : 80.010 - 80.040
Final tolerance limit at CNC : 80.015 - 80.045
So, now the operator will keep the dimensions of the components within the final
tolerance limit. And this will ensure that the components will not be rejected at CMM.
FINAL REPORT :

 WEEK 1

COMPONENT CNC d1 CMM d2 A/R

NO
A17F350 80.022 80.017 A
A17F351 80.025 80.020 A
A17F352 80.018 80.013 A
A17F353 80.029 80.024 A
A17F354 80.033 80.028 A
B17F350 80.021 80.016 A
B17F351 80.020 80.015 A
B17F352 80.022 80.017 A
B17F353 80.024 80.019 A
B17F354 80.025 80.020 A
C17F350 80.024 80.019 A
C17F351 80.027 80.022 A
C17F352 80.017 80.012 A
C17F353 80.030 80.025 A
C17F354 80.034 80.029 A
D17F350 80.021 80.016 A
D17F351 80.016 80.011 A
D17F352 80.025 80.020 A

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 D17F353 80.029 80.024 A
D17F354 80.024 80.019 A
E17F350 80.026 80.021 A
E17F351 80.035 80.030 A
E17F352 80.038 80.033 A
E17F353 80.025 80.020 A
E17F354 80.027 80.022 A

 WEEK 2

COMPONENT CNC d1 CMM d2 A/R

NO
A17F390 80.029 80.025 A
A17F391 80.025 80.020 A
A17F392 80.021 80.016 A
A17F393 80.016 80.011 A
A17F394 80.026 80.021 A
B17F390 80.030 80.025 A
B17F391 80.034 80.029 A
B17F392 80.028 80.023 A
B17F393 80.024 80.019 A
B17F394 80.024 80.019 A
C17F390 80.025 80.020 A
C17F391 80.019 80.014 A
C17F392 80.023 80.018 A
C17F393 80.031 80.026 A
C17F394 80.030 80.025 A
D17F390 80.024 80.019 A
D17F391 80.021 80.016 A
D17F392 80.022 80.017 A
D17F393 80.034 80.029 A
D17F394 80.020 80.015 A
E17F390 80.018 80.013 A
E17F391 80.026 80.021 A
E17F392 80.028 80.023 A

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 E17F393 80.025 80.020 A
E17F394 80.024 80.019 A
Rejection % = 0%
CONCLUSION : This project proved to be beneficial for the company as it reduced
the rejection of components at CMM (Coordinate Measuring Machine ) and also made
it easy for the operators to keep the dimensions within such a range so as to reduce the
risk of rejection. After doing my training at JCB India pvt Ltd , I felt the importance of
training in the industry and the practical applications involved.
During my training period at JCB , I got an exposure of the industrial culture and work
environment which is prevalent in the organization. All the staff members and
associates were very co-operative throughout the training and it was a learning
experience in all the way. JCB is a highly professional company with very strong
management fundamentals and extremely forward looking and cohesive approach with
a strong emphasis on total quality management.
Wishing JCB and its family all the best for the future endeavours and I look forward to
being associated with the company for giving positive contribution in any way
possible.
CHALLENGES FACED DURING THE PROJECT :
 Transportation of components from CNC to CMM was a challenge for me.
 Handling of components was a difficult task.
 CMM room was a small room and only five components could be kept in the
room at a time.

REFERENCES
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  www.google.co.in
 https://en.wikipedia.org/wiki/JCB
 https://www.jcb.com/en-in
 Google images

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