1904042

Shravani Gogawale

GOVERNMENT POLYTECHNIC, PUNE.-411016

(An autonomous Institute of Govt. Of Maharashtra)
University road, Pune –41106 Tel: 256555907,25666764
Format A

Daily Progress Report of the student during online In-plant

Training at Sandvik Asia pvt. Ltd.

Name of the student: Shravani Anil Gogawale Option: 4th (work from home)
Semester: 4th semester (even2020)
Enrollment No.: 1904042
Diploma in Mechanical engineering.
 1904042
Shravani Gogawale

Daily report during online In-plant training at

Sandvik-Asia pvt.ltd.

♦ Date: 16 Aug 2021 Monday

Time: 12 afterwards

On first day of the work my Mentor Anagha Patil suggested me the Online training METAL
CUTTING e-learning. This learning includes the Basics of New metal cutting techniques and
technologies. The whole program includes total 8 topics with assessment exam. Certification
will be provided on completion of the exam with required grades.

My first lesson was Machinability. The following subtopics I learned in this particular chapter.
▫ Definition, importance of Machinability of the materials
Iso standard Material group – 1. P steel 2. M stainless steel 3. K cast iron
4. N nonferrous 5. S heat resistant super alloy
6. H harden material.
▫ Major parameters which influences cutting parameters.
▫ Key for succesful machining process – workpiece materials, cutting edge, tool
materials
▫ MC code for material. Ex.- P1.2.ZAN
▫ Material subgroup for P, M, K, N, S, H.
▫ Design and insert geometry of cutting edge.
▫ Calculation of Fc (tangential force)
▫ ER treatment
▫ Positive and negative rake angle
▫ Basic requirements for the turnig and milling machining ( roughing, medium
turning/milling, finishing)
▫ Cutting tool materials
▫ Factors influencing the behaviours of the inserts
▫ What is PVD and CVD coating. Difference between these two
▫ Powder production
▫ ISO nomenclature in the ISO-P area.
▫ Wear, Cause, Remedy for inserts.
▫ Advantages of PVD and CVD.

After completion of these topics I gave the assessment test.

 1904042
Shravani Gogawale

♦ Date: 17 and 18 Aug 2021 Monday

Time: 12 afterwards

The lesson of the day was Turning. Following subtopics were covered by me-
▫ Three common operations- longitudal turning
▫ - Facing
▫ - Profiling
▫ What is spindle speed and cutting speed.
▫ Formula for the calculation of cutting speed
▫ Terms related to turning- n= spindle speed (rpm)
Vc= cutting speed (m/min)
Fn= cutting speed (mm/rev)
ap= depth of cut (mm)
KAPR= entering angle
PSIR= lead angle
▫ Inclination angle (lamda) and rake angle (gamma)
▫ Fn= the feed rate(Fn) is the distance the edge moves long the cut per revolution along
the cut per revolution.
▫ Various shapes of the inserts.
▫ Formula for power consumption
▫ How to choose the right insert and types of chipbreaking.
▫ Various aspects of insert like positive or negative inserts, clearance angle, KAPR, PSIR,
nose radius, rule of thumb.
▫ Tool holder types
▫ Effects of larger and smaller entering angles on the cutting and chip formation
▫ Code keys for for inserts, tool holder, boring bars.
▫ Troubleshooting (causes/solutions) I
learned the solutions for following problems-
▫ Long unbroken snarls winding around tool or workpieces.
▫ Very short chips, often sticking together, caused by too hard chip breaking.
▫ The surface looks and feels "hairy” and does not meet the tolerance requirements.
▫ Burr formation at the end of the cut when the cutting edge is leaving the workpiece.
▫ Vibrations.

After the study of these I Completed the assessment test.

 1904042
Shravani Gogawale

♦ Date: 19th Aug 2021 Monday

Time: 12 afterwards

Today's lesson was Parting and Grooving. Following subtopics was included in the lesson-
▫ Terms related to Parting -
▫ n = spindle speed (rpm)
▫ Vc = cutting speed (m/min)
▫ Fnx = radial cutting speed (mm/r)
▫ OH = overhang recommended (inch/r)

▫ Terms related to Grooving.

▫ n = spindle speed (rpm)
▫ Vc = cutting speed (m/min)
▫ Fnz = axial cutting speed (mm/r)
▫ Fnx = radial cutting speed (mm/r)
▫ ar = depth of groove (mm)
▫ ap = depth of cut in turning

▫ Terms relate to Fce Grooving

▫ n = spindle speed (rpm)
▫ Vc = cutting speed (m/min)
▫ Fnz = axial cutting speed (mm/r)
▫ Fnx = radial cutting speed (mm/r)
▫ ar = depth of groove (mm)
▫ DAXIN= minimum 1st groove dia.
▫ DAXX = maximum 1st groove dia.

▫ Selection procrdure for tools, inserts, machines.

▫ Tools – 1. multiple grooving 2. plunge turning 3. ramping
▫ Deep/ medium/ shallow parting.
▫ General recommendation of tool selection
▫ Troubleshoot – cause and solution for bad surface, bad solution on aluminium,
Bad chip breaking, vibration, poor tool life.

At the end I attented the assessment test.

 1904042
Shravani Gogawale

♦ Date: 20th Aug 2021 Monday

Time: 12 afterwards

The lesson name was Threading. Following subtopics I learned in this particular lesson.
▫ Different ways of making threads - molding, metal cutting, rolling.
▫ Metal cutting threading method – thread turning, thread milling, tapping,
thread,whirling, grinding
▫ Terms – Vc = cutting speed (ft/min)
n = spindle speed
ap = total depth of threads
nap = number of passes.
▫ Pitch, different major and minor diameter, helix angle.
▫ Marking of the threading insertd and shims.
▫ Tools – 1.Multi point inserts 2.Full profile inserts 3.V-profile inserts
▫ External and internal threads.
▫ Different thread forms
▫ Insert geometry
▫ Variety of tool holder
▫ Infeed methods – 1.modified flank indeed 2.radial infeed 3.incremental infeed
▫ Insert choice preferences
▫ Troubleshooting – cause and solutions of following
1. Plastic deformation
2. Built-up edge
3. Insert breakage
4. Rapid flank wear
5. Abnormal flank wear
6. Vibration
7. Poor surface finish
8. Poor chip control
9. Shallow profile
10. Incorrect thread profile
11. Excessive edge pressure
▫ Tapping – long / medium / short chamfer
▫ Different standards – 1. ISO and ANSI
2. DIN and ANSI
 1904042
Shravani Gogawale

▫ Tapping processes
▫ Types and advantages of use of coolant supply.

Then I attended the test.

♦ Date: 21th Aug 2021 Monday

Time: 12 afterwards

The next topic of the day was Milling. The following subtopics I did learn in the lesson.
▫ Basic terms for milling -
1. n= spindle speed
2. Ve = effective cutting speed (m/min)
3. DC = cutter dia, mm
4. DCX = maximum cutting dia, mm
5. Fz = feed per tooth, mm/tooth
6. Vf = table feed, mm/min
7. Zn = number of cutter teeth
8. Zc = effective no of teeth
9. Fn = feed per revolution, mm/rev
10. Ae = radial depth of cut, mm
11. Ap = axial depth of cut, mm
▫ Formula fpr calculation of Net power (metric/inch)
▫ Climb mlling and conventional milling
▫ Basic requirements of procedure
▫ Selection procedure – 1. cutter with round inserts
2. 45 degree face mill
3. 90 degree square shoulder face mill
▫ Face milling/ profile milling/ slots and grooves cutters
▫ Insert design (rake angle, primary land)
▫ Difference between coarse pitch, close pitch, extra close pitch.
▫ Advantages of wiper.
▫ Feed compensation for different entering angles.
▫ Application hints.

The lesson finished with a assessment test.

 1904042
Shravani Gogawale

♦ Date: 23th Aug 2021 Monday

Time: 12 afterwards

The week started with the topic Drilling. Following points and subtopics I learned in this
chapter-
▫ Methods of drilling- simple drilling, trepanning, chamfer drilling, step drilling.
▫ Most common types of holes.
▫ Basic terms- cutting speed
one effective cutting edge/rev.
Solid carbide tool cutting edge
▫ Point angles for solid carbide drills and HSS drill.
▫ Advantages of SCD over HSS drills
▫ Basic terms related to measurement.
▫ Effects of too high and low cutting speed.
▫ Formulae for feed rate/power consumption/torque.
▫ Short hole drills/ large hole drills.
▫ Precautions related to alignment.
▫ Types of radial offset
▫ Procedures for entering non-flat surfaces.
▫ Using proper chuck for best performance.
▫ Tips for chip formation and coolant supply.
▫ Tolerance charts.
▫ Methods for drilling
▫ Nomenclature of solid carbide and HSS drills.

After going through this detailed information I did attempt the assessment test.

♦ Date: 24th Aug 2021 Monday

Time: 12 afterwards

Today's lesson name was Boring. Following subtopics I learned-

 1904042
Shravani Gogawale

▫ Methods for boring- boring with a stationary tool

boring with a rotating tool
milling, helical interpolation
▫ Definitions and formulae for specific speed, penetration rate, feed rate, torque, net
power.
▫ Hole making methods –productive boring
single edge boring
reaming
▫ Rough boring tools – large dia tool with 2 inserts
tool with 1 insert and tool with 2 inserts
tool with 3 inserts
dampened adapter with 2 inserts
▫ Fine boring tools
▫ Roughing/Finishing operation
▫ Effects of smaller and larger entering angle.
▫ Factors affecting tolerance
▫ Factors that have an influence on chip breaking.
▫ How to apply reaming tool
▫ Vibration tendencies for entering/lead angle, corner radius, micro and macro geometry,
edge design, depth of cut (DOC).

The lesson finished with summary video and assesment test.

♦ Date: 25th Aug 2021 Monday

Time: 12 afterwards

Today I covered the topic Tool Holding.

Following topics were covered by this lesson-
▫ Vital important factors for successful machining
1. Stability
2. Handling
3. Time for tool changing
4. Accuracy
5. Storing
6. Flexibility
7. Modularity
▫ Quick change system can increase the cutting time by 25% in turning centers.
▫ History of machine tapers.
▫ Coromant Capto holding system.
 1904042
Shravani Gogawale

▫ Only 36% of the machine time is used for metal cutting.

▫ SL* Universal modular system of adaptors wit exchangeble cutting heads.
▫ 6 different coupling sizes
▫ Turning centers
▫ Machining centers
▫ Multi – task m/c
▫ Types of chucks.
The lsson finished with small assesment test.

♦ Date: 26th Aug 2021 Monday

Time: 12 afterwards

Today's lesson was based on Other Information about manufacturing.

▫ What factors affect the tool life most and least
▫ Formula for the calculation of productivity in turning and milling
▫ Machine economy – variable cost (cost incurred only during production)
fixed cost (costs which exist even when not in production)
▫ Machine tool utilization -
1. Decreased cost: A 30% decrease in price only reduces total cost per component by 1%.
2. Increased tool life: A 50% increase in tool life only reduce total cost per component by
1%.
3. Increased cutting data: A 20% increase in cutting data decrese total cost per component
by more than 15%.
▫ ISO 13399 international standard simplifying exchange of data for cutting tool
▫ Nomenclature of a tool.
After the completion of this part I did the revision of whole syllabus to attend the
certification test.

♦ Date: 27th Aug 2021 Monday

Time: 12 afterwards

Today I gave the final certification test. The exam was of 50 marks.
All questions was based on the syllabus covered earlier. I achieved total 45 marks out of 50.
The drive link of the certificate is -
https://drive.google.com/file/d/1mWkhrrgn0Ar-UM8O71wR5G26v_d3zrCz/view?usp=sharing

The whole course build the strong basic foundation of various machining processes.
 1904042
Shravani Gogawale

On the dates 23th and 30th Aug we had the training doubt session where all our doubts were
covered by our mentor.

♦ Date: 28th Aug 2021

Time: 12PM – 4PM

Today I didn't had anything particular work from Sandvik Asia. So I did visit the workshop
nearby my house. The workshop was owned by Supreme Enterprises.
I had spent nearly 3 hours in the workshop.
I observed the following m/c and watched the work performed by these m/c.
1. ALCERA milling m/c
2. Verticle milling m/c
3. Universal milling m/c with DRO
4. Lathe m/c
5. Radial drill m/c
6. MT TR m/c
I observed the various workpiece drawings too.

♦ Date: 30th Aug 2021

Time: 4:00 – 4:45 PM

Today we had a meeting regarding next Topic.

We started with the Topic – Manufacturing procedure for Inserts.
The whole procedure includes many processes which are important itself. In today's
Session we learned following sub-processes:
Pressing
Shaping
Sintering

♦ Date: 31th Aug 2021

Time: 4:00 – 4:30 PM

Today we continued the same topic "Manufacturing procedure for Inserts”.

The following sub-topics we covered -
 1904042
Shravani Gogawale

▪ Blank inspection
▪ Lapping
▪ Periphery grinding
▪ CNC Profile Grinding special

♦ Date: 1st Sep 2021

Time: -

Due to some issues we didn't had the meeting today.

♦ Date: 2nd Sep 2021

Time: 4 – 4:30 PM

The same topic was continued by us.

Topic - "Manufacturing procedure for Inserts”. Following subtopics were covered -
▪ ER Treatment
▪ Coating processes- CVD
PVD
▪ Post coating
▪ Subcontracting
We also had a detailed explanation on CVD and PVD coating with the videos

♦ Date: 3rd Sep 2021

Time: 4 – 4:30 PM

Today's discussion was related to the same topic - "Manufacturing procedure for Inserts”
We covered -
▪ Final Inspection
▪ Final operation – marking and labeling
▪ Packaging and delivery.
Safety majors, precautions to be taken and automation was also included in discussion.
 1904042
Shravani Gogawale

♦ Date: 4th Sep 2021

Time: -

This day was particularly given for the notes making of whole topic taught earlier.

♦ Date: 6th - 14th Sep 2021

Time: -

This whole period was for the completion of the project given by our mentor.
The mini-project was that to ‘design a insert in AutoCAD’.

▫ Notes: https://drive.google.com/file/d/1MjfXndY9te5E-v3xfo3woAkghD62a-
gc/view?usp=sharing
▫ Mini-project:
Insert 1:
https://drive.google.com/file/d/1rQEbTD_jDy_ThLHXJCfS0Dl_lxp1AgPe/view?usp=sharing
https://drive.google.com/file/d/1LW3JDg0cMA14irRc1L3uewcm0RznNenP/view?usp=sharing
Insert 2:
https://drive.google.com/file/d/1E46FhAX_IzxEpECQnoXmkVlZLXcLDn2k/view?usp=sharing
https://drive.google.com/file/d/17rNR9fSsG36SIT3a1aDls-s3xqYdmrNP/view?usp=sharing

Signature of student

Signature of teacher mentor

Industry Mentor

Government polytechnic, pune.

Organization-
Date:
 1904042
Shravani Gogawale

GOVERNMENT POLYTECHNIC, PUNE.-411016

(An autonomous Institute of Govt. Of Maharashtra)
University road, Pune –41106 Tel: 256555907,25666764

Format B

Weekly Progress Report of the student during online In-plant

Training at Sandvik Asia pvt. Ltd.

Name of the student: Shravani Anil Gogawale Option: 4th (work from home)
Semester:
Enrollment No.: 1904042
Diploma in Mechanical engineering.

Week Date Details of work done.

number
Week 1 9th-13th Aug Soft skills week: Industrial safety (HIRA),
Basic environment and environmental
aspect-impact training, Soft skills
development, Goal setting, VR-AR-MR
immersive technologies.
Week 2 16th-21th Aug Start of online In-plant training at Sandvik
Asia pvt.ltd.
Start of online metal cutting course:
machinability, turning, parting and grooving,
threading, milling.
Week 3 23th- 28th Aug Remaining course and assessment
certification test: Drilling, boring, tool
holding, other information.
Week 4 30thAug- 4th Sep Study of manufacturing procedure od an
insert: pressing, shaping, blank inspection,
lapping, grinding, ER treatment, coating
process, final inspection, marking and
labeling. Delivery.
Week 5 6th-14th Sep Period for mini-project completion.
 1904042
Shravani Gogawale

Signature of student

Signature of teacher mentor

Industry Mentor

Government polytechnic, pune.

Organization-
Date: