VRITUAL INTERNSHIP REPORT

AT

JYOTI CNC AUTOMATION PVT LTD

BY
Siddhesh Raul
3rd year Student MBA (Tech)
Mechanical SVKM’s NMIMS,Shirpur

Guided by: SHASHANK SRIVASTAVA

And VISHAL CHAUHAN.

Date: 08/05/2021 to 23/05/2021

Duration: 15 Days
 ABSTRACT

The internship at Jyoti CNC Automation PVT. Ltd., Rajkot emphasizes

the production of all the components of CNC by casting process, their
surface finishing by machining process, and finally the assembly of all the
CNC components and their testing through the various quality process. A
detailed explanation of the manufacturing, assembly, and testing of CNC
Machines of various capacities has been mentioned in the report. It is
about the 15 days of virtual internship training of the company.

The whole focus of the training involves basic manufacturing processes

like casting, machining sheet metal bending, cutting, various quality
control techniques that are used in the research and development of
Computer Numerical Control machine.

I have tried to collect all the necessary information and had tried to
prepare this report with best of my knowledge and ability.

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 ACKNOWLEDGEMENTS

It is one among the foremost difficult tasks in life to settle on the

acceptable words to precise one’s gratitude towards the beneficiaries.
I take this chance to precise my gratitude and appreciation to all or
any those that directly or indirectly motivated and encouraged me
during the internship.
This internship has had the assistance and support of several people
whose time and expertise have facilitated us within the successful
completion of our internship. We wish to thank all of them for his or
her contributions.

I am very grateful to Mr. Shashank Srivastava sir, and Mr. Vishal

Chauhan sir for granting my industrial training in Jyoti CNC
Automation PVT Ltd. and supporting me throughout my training.

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 LIST OF FIGURES

Sr no. Topic Page no.

1 History & Development V

2 MISSION AND VISION OF THE 2

COMPANY
3 AWARDS 2

4 Company’s aims 3

5 COMPONENTS OF CNC 8

6 ASSEMBLY OF CNC MACHINE 13

7 DIFFERENT TESTS AND 17

QUALITY CONTROL

8 Various departments 23

9 Tools 28

10 Programming and controls 41

10 Conclusion 46

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VI | P a g
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 History & Development
“JYOTI CNC AUTOMATION PVT. LTD.,” is a story of a small unit that has made
itself big. In 1989 Mr. Parakramsinh G. Jadeja started a “TINY UNIT” in Metoda
GIDC with an initial capital of Rs. 60,000/- and with 20 workers. Today after 15
years, the company has spread over an area of 36.000 square meters with a dedicates
work force of more than 400 people.

The company has grown into a marginally large producer of CNC machines. From
production of 10 CNC machines per month in the initial stage, today they
manufacture and export 400 CNC machines annually. Their target is 1000 CNC
machines for export by year 2007.

A company headed by Mr. P.G. Jadeja and Mr.S.V.Jadeja, techno crafts with a rich
12 year of grass roots engineering experience, JYOTI CNC AUTOMATION
PVT.LTD. Has been in the field of machine tool manufacturing since 1989.

Jyoti has a good trajectory of growth rate. Export penetration and inclination have
helped them to establish goodwill among the foreign buyers and distributors. The
company's expanding footprint ensures its global presence with export operations in
countries like Italy, Russia, Poland, Argentina, Brazil, and the rest of South America,
Tanzania, and some African countries, the Middle East, and Other Asian Countries
like Malaysia.

Figure 1. Jyoti CNC Automation Pvt. Ltd.

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 MISSION AND VISION OF THE COMPANY

 Have a presence in all major engineering hubs globally.

 Contribute humbly to the making of a developed Nation by Technological
advancements, catering to 20% of the Domestic Market, establishing
 Technology Centres in 10 major cities. iii. Patronize technical education by
Instituting a Machine Tool Academy. iv. Promote Eco-friendliness by
developing energy-efficient solutions.

 Facilitate all the team members to enjoy the higher standards of living for a
happier & healthier life.
 Create a work environment that fosters- passion, creativity, and optimism
with fun, respect, and pride for all individuals.
 Being exceptionally customer-centric, delight all our customers by all means
and action.
 Deeply admire the brand among the Machine Tool fraternity.

AWARDS
 Meaningful Technological Innovation Award at Engimach’08 held at
Ahmedabad.
 Black Pearl Award for Display & Demonstration of Best Innovative
Technology at ENGIMACH 2006.
 iii. Best Entrepreneurship Award for the year 2004-05.
 CMTI-PMT Trust Award in IMTEX' 2004 for the Best Innovative Machine
Design "VMC 70 Linear".
 FIE for Engineering Excellence in the IMTEX 2004 "SECT".
 Mr. Parakramsinh Jadeja, CMD, Jyoti CNC Automation Pvt. Ltd., has
recently achieved a National award for Best Entrepreneurship: The Year
2003 from his Excellency President of India Dr. APJ Abdul Kalam on behalf
of Ministry of Small Industries, Govt. Of India.

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iv. Award for the Best Innovative Technology Display in Engimach’02. viii.
CMTI-PMT Trust Award in IMTEX 2001 for the Best Innovative
Machine Design.
ix. The Machinist Award in IMTEX 2001.

Company’s aims:

 Having presence in all major engineering hubs globally.

 Contributing humbly in making of a developed nation by
technological advancements, catering to 20% of the domestic
market, establishing Technology Centres in 10 major cities.
 Patronizing technical education by instituting a Machine Tool
Academy.
 Promoting Eco-friendliness by developing energy efficient
solutions.
 Considered to be the most preferred organization to work with by
all our business associates including the team members
 Facilitating all the team members to enjoy the higher standards of
living for a happier & healthier life.
 Creating a work environment that fosters passion, creativity and
optimism with fun, respect and pride for all individuals.
 Being exceptionally customer centric, delighting all our customers
by all means and action.
 Deeply admired brand among the machine tool fraternity.

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 COMPANY PRODUCTS
The company mainly makes the following categories of CNC machines:

1. TURNING/TURN MILL CENTERS (TMC)

i. Horizontal turning
a. Simple turning
b. Twin Spindle turning
c. Turn-Mill Centre ii. Vertical turning center
a. Inverted turning line machine
iii. Oval turning center

These CNC machines are mainly used for facing, turning and center drilling
operations. An oval turning center is used for oval turning mainly for pistons of an
engine.

Figure 2. TMC 160 Figure 3. VMC 1260.

2. VERTICAL MACHINING CENTERS (VMC)

i. 3 Axis machines
a. C- frame machines (PX series, VMC series)
b. Fixed table traveling column
c. Double column machines
d. High-speed bridge-type machines
e. High-speed gantry machines
ii. 5-Axis machines

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 a. High-speed bridge-type machines
b. Double column high-speed machines
c. High-speed machines

VMC machines were developed for high speed and higher precision over TMC
machines. It has a moving table for easy access. The main difference between TMC
and VMC is tool holder (headstock) is rotating and the job clamped on the pallet
(table) moves in X-Y directions refer to Figure 4. Many operations like turning,
facing, profile cutting, milling, drilling, boring can be done easily with the help of
VMC.

Mainly machine has three axes to move the job and vertical column X-Y-Z.
Usually, the pallet can only move in the X-Y direction and the vertical column can
move in Z- direction. In addition to, these 3 axes two more axes are available
mainly for rotation and tilting action for easy machining of even complex profiles.

VMC has ATC (Automatic Tool Changer) controlled by three servo motors to
automatically change the tool during the machining process according to the
requirement. The vertical spindle can rotate up to 15000 rpm. The maximum torque
that is available in any axis is 700 Nm

For fast work, both two and six pallets VMC is also available which has APC
(automatic pallet changer) in which after completion of one operation in one job,
the other pallet is positioned for machining operation and the pallet is automatically
rotated. In the tool post, VMC can hold up to 120 tools.

Through bolt screw, All movements of pallet and vertical column are done. For
less friction movement of saddle and pallet over Linear Motion Guideways (LM)
either pneumatic or hydraulic system is used. The whole VMC machine is operated
by mainly Fanuc controllers and Siemens.

Job has to be cooled down while the operation is being done on it due to friction
between tool and job. The cooling system of the job is also installed along with the
vertical column. Generally, a 1000 liter coolant tank is used.

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Usually, cooling fluid is a mixture of water and cutting oil of job. A scrap cleaning
system is also installed in VMC so that accumulated chips or scrap can easily be
drained by the flow of fluid.

3. HORIZONTAL MACHINING CENTERS (HMC)

i. 4-Axis machines

HMC 560 is high speed, high-precision 4 axis Horizontal Machining Center with
the world's best available features to match the demanding requirement of the
industry. The machine has special features like Three Point Leveling, an axis rotary
table, and Electro Spindle. A maximum of 10,000 rpm is available for the spindle.
It is available either for single, double, or six pallets out of which all of them are
rotary tables.

All the features are almost the same as that of VMC but the major difference is
VMC has a vertical spindle axis whereas HMC has a horizontal spindle axis. Also,
HMC is used for machining bigger size components and is more precise.

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 Figure 4. General sketch of CNC

Figure 5. General block diagram of 3 axis CNC machine

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 4. COMPONENTS OF CNC
1. SPINDLE

The spindle is directly coupled with the spindle motor refer to Figure 4 and avoids
any errors in the indirect drive mechanism. Specially, this high-speed spindle is
designed to meet the requirement of small component machining with dynamism
and high precision. The spindle is having a BT-40 and 50Tool, HSK 100 interface
taper for VMC machines.

2. SADDLE
The saddle is the part of CNC which is mounted on the Linea Motion guideways

(LM). They provide for the linear motion in either the X or Y-axis.

3. BASE
The base is the base structure of CNC on which the entire operation of CNC is
performed. It is made of the rigid structure of Cast Iron because of its good
compressive strength and vibrational damping capacity. Refer Figure 4.

Figure 6. Saddle

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4. LINEAR MOTION GUIDE WAYS (LM)
Linear motion guideways or LMs are V or U-shaped solid structures mounted on
the base for the saddle and on the saddle for the pallet to allow the saddle and pallet
to slide over them linearly along the X and Y-axis respectively.

Figure 7. Linear Motion Guide Ways (L.M)

5. PALLET

Figure 8. Pallet

A pallet is used to clamp or unclamp the job piece. It is mounted on LM which is

mounted on saddle. They are perpendicular to the LM mounted on the base. That
is if one is in X- direction then the other one is in Y- Y-direction.

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6. AUTOMATIC TOOL CHANGER
Having a 12 Tool magazine in the tool changer. The tool changer is an umbrella-
type Servo ATC. The tool change time is 3.5 seconds. During the machining, its
main function is to change the tool according to the requirement. It works with 3
servo motors. One for rotary action about Z-axis, one for vertical motion up-down,
and one for releasing the tool and clamping.

Figure 9. Automatic Tool Changer (ATC)

7. HEADSTOCK
It supports chuck and its mechanism. It possesses a system which clamps and de-
clamps of work-piece.

Figure 10. Headstock

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8. TAILSTOCK

It possesses supporting elements. It is also used for supporting the long job pieces
and also used for cantering and drilling purposes.

Figure 11. Tailstock

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9. TURRET ASSEMBLY

It is that part of the machine which has tools to work on the job. Generally, it has
ten to twelve tools. For holding the tools to carry out machining operations, it is
used.

Figure 12. Turret assembly

10. CONTROLLER
It contains Fanuc or Heidenhain or Siemens controller which controls the whole
machine.

11. PUMPS
There are generally two pumps in CNC. One is for coolant circulation and
another for hydraulic oil transmission. Thus, the pump keeps the cooling and
the lubrication system of the CNC alive.

12. MOTORS
Mainly there are many different motors used for revolving of chuck, another two
for revolving of the turret, motion of work table i.e pallet in X and Y-axes, and
bolt- screw.

13. OUTER SHEET METAL BODY

It provides safety to the user and adds aesthetic value to the machine.

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5. ASSEMBLY OF CNC MACHINE

The first step of assembly is to do a three-point leveling system by spirit level and
then tight the other 3 points. Thus, the Base of CNC is fixed on the floor.

Figure 13. 3-Point leveling

The second step is to scrape the paint from guideways for fitting L.M. Then workers
clean the surface with diesel and air cleaner. Then fit the L.M. and it is supported by
eccentric head bolts.
Then worker uses a spray-cleaner to remove dust and mounts saddle on it. Then after
he does the
“Auto-collimator Test” for measuring allowances for the top and side of L.M. Same
process is carried out for L.M. of the saddle and then bolt-screw is mounted on the
saddle with two bearing and its run-out testing is carried out and then again top and
side of bolt-screw are maintained intolerance limit with help of dial-gauge
indicator.

Dial gauge indicator is the most important testing device for which range is between
2 µm to 10 µm for different purposes.

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After that saddle is mounted on a CNC bed. Then bolt-screw is mounted on the
CNC bed for the z-axis. Then the same process is carried out as it is carried out for
bolt-screw of the saddle. Then lock-nut is mounted on it.

If the surface plate is not accurately machined, scrapping is carried out till it slides
thoroughly on L.M. During this process, another worker mounts head-stock and
tailstock on its base.

After that chuck, pulley, motor, and spindle are mounted on head-stock. Then mandrel
is mounted on chuck.

Figure 14. Chuck

The Centerline of head-stock and tail-stock must be co-lined, if not then it must
carry out with the help of height-gauge. After that, the ATC is mounted and at the
same time all the wirings are connected with the motors and the pumps and After
that, the entire electrical system is mounted.
After that, to cover the sliding mechanism from the coolant. The telescopic cover is
mounted on the saddle.
Then after hydraulic oil system is fitted with its all mountings like oil sump with
nitrogen gas accumulator, solenoid valves, pipe.
Finally, the cold roll coil sheets are used for the final guard (from metal chips and
water-oil coolant). Copper stripes are rigidly fitted with silicone gel for preventing
leakage of coolant.

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Then, In the machine, Siemens or Fanuc controller is attached. Finally, the doors
are fitted so that the entire machine remains closed during operation for the safety
of the operators. The chip removal system and the cooling fluid system was
installed according to the demand Now the machine is started and data is loaded
on it.
Some of the CNC machine models are:
TMC-350, AM-430, TM-020, VMC-430, ATM-160, DX-250, VMC -
640 Given is an example of DX-250 and DX-200.
i. Complete CNC machine Dx-200 is completely assembled within 6-7 days,
while Dx- 250 takes 8 to 10 days.
ii. The minimum rpm is 1 and the maximum rpm can be up to 6000. iii. The
hydraulic power pack is installed (hydraulic pressure up to 70 bars is
generally used). iv. The hydraulic system used is oil-based.
v. It uses a 440V AC source.
vi. Has pneumatic pressured air cleaning gun?

vii. For all movement, a bolt screw is used. viii. Tool post (turret) can hold up to 24
tools at a time.
ix. Using the Siemens controller operation begins and can prepare most
complicated operation with high accuracy.
Model Dx-250 is also available which is bigger than Dx-200, main difference in
the assembling method between them is, In Dx-200 saddle is assembled at
inclination keeping base horizontal while in Dx-250 the saddle is assembled
keeping the base inclined at 45degree for assembly ease.

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 Figure 15. Dx-200

SADDLE

Figure 16. Dx-250

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 6. DIFFERENT TESTS AND QUALITY CONTROL

6.1 AUTO COLLIMATOR

For perfect alignment of L.M. with base, The first and very important test is “Auto-
collimator” is performed. In this process, an “Auto-collimator” which is a light-
sensing device is used. For the final fixing of L.M., they provide 5 µm for the side
and 10 µm for top allowances.

Figure 17. Autocollimator test

6.2 LASER INTERFEROMETRY TEST

For measuring distances with great accuracy, Laser interferometry is a well-
established method. Laser Interferometer contains a monitor, laser, retroreflector,
measurement retro reflector. The beam is passed from the laser which goes through
a retroreflector. This retroreflector allows a few of the beams to pass through and
it directly goes to the measurement retro reflector. This is connected to monitor
which some the variation. If the surface is fully flat then the intensity of rays is
higher. If there is any misalignment present then the rays will be deflected. It will
be monitored on the computer.

6.3 RENISHAW BALL BAR SYSTEM

The Renishaw QC20-W ball bar system consists of the ball bar itself (essentially a
very high accuracy, telescoping linear sensor with precision balls at each end) and
precision magnetic mounts, one (adjustable) attached to the machine table and the
other to the machine spindle or spindle housing. In use, the balls of the sensor are
kinematically located in the magnetic cups. This arrangement enables the ball bar

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to measure minute variations in radius as the machine follows a programmed
circular path around the mount on the machine table.
The data collected is sent to a PC, where Renishaw's software calculates overall
measures of positioning accuracy (circularity, circular deviation) by international
standards such as ISO 230-4 and ASME B5.54 or in Renishaw’s analysis reports.

Figure 18. Renishaw ball bar test

6.4 CNC COORDINATE MEASURING MACHINE (CMM)

For providing increased accuracy and measuring speed, a 3D Coordinate measuring
machine is compatible that helps to increase the quality of processes and products.

Figure 19. CMM test

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 7. CASTING

7.1 CASTING PROCESS

The casting process is used to make the main body parts of the CNC machine. For
sand casting, the process cycle consists of six main stages, which are explained below.
Mold-making - The first step in the sand-casting process is to create the mold for
the casting. In an expendable mold process for each casting, this step must be
performed. With the help of packing sand into each half of the mold, A sand mold
is formed. Around the pattern, the sand is packed which is a replica of the external
shape of the casting. When the pattern is removed, the cavity that will form the
casting remains.

Figure 20. Casting area

Clamping - Once the mold has been made, the cores are positioned and the mold
halves are securely clamped together and closed. To prevent the loss of any
material, the mold halves must remain securely closed.
Pouring – In a furnace, the molten metal is maintained at a set temperature. After
that, the mold has been clamped, the molten metal can be ladled from its holding
container in the furnace and poured into the mold.

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Cooling - The molten metal that is poured into the mold will begin to cool and
solidify once it enters the cavity. When the entire cavity is filled and the molten
metal solidifies, the final shape of the casting is formed.

Figure 21. Clamping the molds

Removal - After the predetermined solidification time has passed, the casting is
removed and the sand mold can simply be broken. Sometimes, This step is called
shakeout. It is typically performed by a vibrating machine that shakes the sand and
casting out of the flask. Once removed, the casting will likely have some sand and
oxide layers adhered to the surface. To remove any remaining sand Shot blasting
is sometimes used, especially from internal surfaces, and reduces the surface
roughness.
Trimming - The material from the channels in the mold solidifies and is attached
to the part during cooling. This excess material must be trimmed from the casting
either manually via cutting or sawing or using a trimming press.

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 Figure 22. Heavy Cast and Shot Peening Machine
7.2 CASTING DEFECTS
Various types of defects occur in the casting process which is categorized
by American Foundrymen's Society (AFS).

i. Broken or cracked castings

ii. Carbon floatation and other gross segregation
iii. Cuts
iv. Drops
v. Shrinkage defects
vi. Gas defects
vii. Hard spots, hand areas, and chilled spots
viii. Inverse chills
ix. Mass hardness
x. Metal penetration
xi. Rough surface
xii. Runouts – escape of molten metal from casting mold
xiii. Warped Casting – bend out of shape due to pressure or heavy heat

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Figure 23. Holding Furnace and Shot peening balls

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 8. VARIOUS DEPARTMENTS
The company has the following departments as well:

i. R & D center
ii. Grinding Shop
iii. Sheet metal shop
iv. Paint shop

8.1 R & D CENTER

To keep up the company with the international trends towards automation and
manufacturing excellence, Jyoti has developed a well-versed and versatile R & D
center. To carry on the research activity in a full-fledged manner, the research and
development center has been developed. For better quality, reliability & productivity
to cater to sophisticated Defense, Aerospace, and Automobile applications where a
high level of accuracies and reliabilities are inevitable, The exclusive R & D center
has been established to design and develop technologically advanced world-class
machines.

The Active R & D team of Jyoti has achieved Magnificent success by developing
TPM (Total Productive Maintenance) friendly machines, CNC Machines with
Linear Technology of higher productivity and dynamics, in-house developed
software like POTS, etc.

R & D activities here are conducted through a young team of 55 technocrat

professionals facilitated by the latest Softwares & assembly/testing and calibration
types of equipment from worldrenowned manufacturers.

8.2 GRINDING SHOP

There are different types of grinding machines in which are imported from Europe.

8.2.1 HARDINGE KELLENBERGER

For the grinding of ID as well as OD of the workpieces, This machine is used. This
machine uses a mixture of water and oil as a coolant. The machine is imported from
Switzerland.

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8.2.2 STUDER – KORBER SCHLEIFRING
This is used for the grinding of the OD of the workpiece. This machine is also
imported from Switzerland. It works around 1600 rpm.

8.2.3 ELB – SCHIFF

Edmund Lang Babenhausen is used for precision grinding. This machine gives very
high accuracy through grinding. This machine works around 1500 rpm. These
machines are mainly manufactured in Hessen, Germany.

8.2.4 VG 400
This is used for the ID as well as the OD grinding of workpieces.

8.2.5 HINDUSTAN MACHINE TOOL

This machine functions the same as VG 400.

8.2.6 VRG 60
This is the twin spindle grinding machine. It runs around 12000 rpm. Jyoti is one of
the customers of VRG 60 and Japan is the main manufacturer.

8.3 SHEET METAL SHOP

The types of machinery adopted by Jyoti are the world’s latest technologies. Sheet
Metal is equipped with very precise and versatile machinery producing precision
sheet metal components.

The most modern first of its kind in India is the Sheet Metal plant of Jyoti having the
following facilities:

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 Figure 24. Sheet Metal shop

Include Laser Cutting Technology in Trumpf Machine of Germany. Welding and

bending are some of the main areas of sheet metal shops. The Sheet Metal is finished
with an automated powder coating line and painting line and coated with CED
primer. In the welding area, Robotic Welding has also been carried out.
8.4 PAINT SHOP
Jyoti has established its paint shop which is fully automated and it comprises several
tanks pretreatment process followed by CED primer coating.

Figure 25. Sheet metal and Spray coating drying shop

Castings will be delivered with CED primer coatings and followed by backing and
Versatile paint shop which will deliver sheet–metal components duly powder
coated/painted with CED primer coating.

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8.4.1 DIVISIONS
There are some Tanks in the paint shop:

i. Degreasing tank
ii. Water rinse 01tank
iii. Water rinse 02 tank iv. Derusting tank tank
v. Water rinse 03
tank vi. Water
rinse 04 tank
vii. Surface activation tank
viii. Phosphating tank
ix. Water rinse 05 tank
x. Cathodic Electro Deposition – CED tank
xi. Permeate tank

Figure 26. Water rinse tank

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8.5 QUALITY ASSURANCE
Jyoti believes in the quote “After the product is shipped, Quality is avoidance of
financial loss to society.”

Through a systematic approach, Jyoti strives to achieve best-in-class quality and

reliability of performance of all products that emphasize quality at every stage of
product development through manufacturing. Before leaving the plant in Jyoti, the
CNC machine is passed through a series of quality assurance tests.

Jyoti has established a system of quality in line with the ISO 9001:2000. We are
aspiring to be recognized as the quality manufacturers in the industry we serve by
providing solutions to customer’s problems by engineering and manufacturing
quality machines at competitive prices.

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 9. TOOLS

9.1 VMC TOOLS

1. Face Mill

A face Mill cutter is used for the facing process in the Milling machine. Face
Mill’s cutting edges must be located on its sides. When It coming from
outside the stock, then it must cut in a horizontal direction at a given
depth.

2. Feed Mill
3. End Mill
• While endmills can take many forms, they typically have sharp cutting flutes
on the ends and sides and can be used in various cutting applications.

1. Side End Mill

• It is used for machining an edge surface on a workpiece.

2. Centric End Mill

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 • On both the end face of the cutter and the sides, the center cutting end mill
has cutting edges. For plunge milling, Center cutting end mills are essential.

3. Non- Centric End Mill

• A non-center cutting end mill only has cutting edges on the side and requires
either a pilot hole, ramping, or helical motion to plunge straight down.

4. Serration End Mill

1. Bull Nose
This tool has a flat bottom but a rounded corner and can create a fillet on
the bottom of a wall. The sharp corners are highly prone to breakage
than the corner radius on flat end mills. So, for roughing, bull nose end
mills are used.

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 2. Ball Nose
Ball-shaped is there at the end of this end mill. For 3D contour work, making
it
ideal. Their rounded ends construct high-quality curved surfaces.

5. V-bit (Chamfer)
These end mills are typically used to break sharp edges or chamfer on parts
and come to a sharp point. They typically come in 60 and 90 degrees, and the
tip can be ground flat or sharp.

6. Flat
It becomes for general-purpose end mills. Typically, it is used for milling
prismatic 2D features.

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7. Rough End Mill

While leaving a rough finish, the serration in a roughing tip can quickly
remove a large amount of material.

8. Thread Mill

A thread milling cutter operates the same as an endmill, traveling

around the workpiece in a helical interpolation. Whereas a hob
engages the workpieces the same as a mating gear would and cuts
the blank progressively until it reaches final shape.

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4. Slitting Cutter

5. Drill Tool
• It is used to do a hole on the workpiece.

1. Flat Drill
2. Modular Drill
3. U Drill
4. Indexable Drill
5. Rocket Drill
6. Step Drill
7. Twist Drill

It is similar to an end mill. Drill bits shape is

a conical cutting point with a shaft with one
or more flutes. The most common twist drills
are

made out of solid carbide or High-

Speed Steel (HSS). To increase the drill’s hardness, reduce wear, and
increase tool life, Gold-colored coatings such as TiN are typically used.

8. Center Spotting Drills

• To create an accurate conic hole before drilling, these stubby tools are used,
During operation or drilling the hole at an inaccurate location which helps
prevent drill bits from “walking”. To create a screw clearance hole and
countersink in one operation combined spotting-countersink drills can do
this process in one operation.

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6. Boring Bar
• It is used to enlarge the holes.

1. Finish Boring Bar

• This boring bar has 1 insert.

2. Rough Boring Bar

This boring bar has 2 inserts.

3. Adjustable Boring Bar

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7. Chamfer Cutter
8. Back Spot Cutter
• It is used to counterbore on the backside.

9. Tap Tool
• A tap forms or cuts an internal thread
on the surface of a hole, creating a
female surface that functions like a
nut.
1. Straight Flute Tap
2. Spiral Point Tap
3. Spiral Fuse Tap
4. Forming Tap
5. Tap + Drill
• It creates both holes and thread in one process.

10. Reamers

Reamers are used to expand existing holes to a specific tolerance while also
adding a nice surface finish. This is used to ensure a hole has an accurate
roundness and diameter. If we have a pre-drilled hole that’s close enough in
size then and then we can use reamers. During the process, it must remove a
small amount of material.

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9.2 TURNING TOOLS

1. Single Point Cutting Tool

2. Threading Tool
3. Grooving Tool
4. Boring Bar

9.3 TOOLS MATERIALS

1. Carbon Steel

This material includes a total of 0.6-1.5% of carbon with small amounts of

manganese and silicon and This material is the most inexpensive material of
the bunch. Typically, this material is used for low-speed operations in twist
drills, forming tools, milling cutters, and turning.

2. High-Speed Steel (HSS)

To improve HSS hardness, toughness, and wear resistance over carbon steel.
This material combines chromium, tungsten, and molybdenum. Generally,
HSS tools are more expensive than others, but they’re built to last and
provide a high material removal rate for both ferrous and nonferrous
materials.

3. Solid Carbide

To achieve more resistance to wear than HSS and prone to chipping instead
of wearing out evenly over time. Because of this, mainly solid carbide is
used in newer milling machines for finishing applications with less spindle
wear. Typically, from sintering carbides with another metal, like tungsten,
titanium, or tantalum, carbide tools are made. For high-quality surface
finishes, giving these tools high heat resistance and making them ideal.

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 4. Ceramics

Ceramics are made from silicon nitride and aluminium oxide. It is corrosion-
resistant. Because of, Its wear and heat resistance property. It can function
in high heat-cutting environments. Whereas, other material tools can’t do
this. Typically, these tools are ideal for superalloys, hard steels, and cast
iron.

9.4 TOOL HOLDERS

1. Solid End Mill Holders

To provide a strong grip and minimal concentricity loss to the End mill. We
used End mills with a Weldon flat which are secured by a set screw.

2. ER Collet Holder

ER collets can hold many different sizes and types of tools. They are less
secure than hydraulic, shrink-fit, and end-mill holders. They are known for
their versatility.

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3. Collet Chucks

collet chucks have high gripping power and are more rigid and accurate. It
is used in high-speed applications with larger tools.

4. Drill Chucks

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 For general hole drilling jobs, Drill chucks provide a convenient holder that
makes switching between drill bits simple. As a replacement for drill
chucks, we can also use a collet chuck.

5. Hydraulic & Shrink Fit Holders

These types of holders are used to either fluid or thermal expansion to center
and compress a tool. Both provide excellent tool concentricity.

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9.5 TOOLS INSERTS

• I have observed two inserts in the company

1. Rough Insert
2. Finish Insert
• The main difference between the two inserts is nose radius.
• In the finish, the insert nose is bigger than the rough insert.

9.6 COATING ON TOOLS

• Main purpose of coating on tool is to increase tool life, easily heat dissipate,
decrease wear and tear rate.
• If we have HSS tool and its material is ductile than on this tool coating is not
required.
• If we have HSS tool and its material is not ductile than on this tool coating is
required. On this tool, we do bright finish coating.
• If we want to do coating on carbide tool than we have 5 types of coatings are
there.
1. Titanium Nitride (TiN)
• It is used for general material coating and its color is golden.

2. Titanium Carbonitride (TiCN)

• It is used for cast iron material coating and its color is bluish and purple.
• It provides a better wear resistance than TiN.

3. Titanium Aluminum Nitride (TiAlN)

• It is used for hard material coating and its color is Dark Gray.
• For high feed/speed and high-temperature applications, this coating is used.

4. Titanium Aluminium Carbonitride (TiAlCN)

Its coating colour is Pinkish.

5. Black Oxide

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 There are two types of coating process.
1. PVD (Physical Vapor Deposition)
 In Physical Vapor Deposition process, coating is done with the help of
solid material.
2. CVD (Chemical Vapor Deposition)
 In Chemical Vapor Deposition process, coating is done with help of
Liquid deep chemical.

9.7 TOOL SELECTION PARAMETER

1. Material Machinability
2. Tool Material
3. Cutting Speed & Cutting feed
4. Depth of Cut
5. Coolant

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9.8 CATEGORIES OF TOOL FAILURE

1. Abrasive Wear
a) Flank Wear
2. Heat Failure
a) Build up edge
i) Rake face BUE
ii) Flank face
b) Thermal Cracking
c) Cratering
d) Thermal Deformation
3. Mechanical Failure
a) Notching

9.9 CLAMPING METHOD (Method of Holding)

• C = Clamp lock Assembly (PC Tool Holders)

• D = Top and Hole clamp
• M = Multiple lock assembly
= Pin and clamp lock
= M – type tool holders
• P = Pin-lock Assembly
• S = Screw lock
• T
• A = Back Clamp
• W = Wedge lock

9.10 FACTOR AFFECTING TOOL LIFE

1. Cutting Parameter
• Cutting speed
• Feed
• Depth of Cut
2. Material Properties Tool Material
• Workpiece Material
3. Coolant

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4. Tool Geometry 5. Clamping
• Tool
• Workpiece

10. PROGRAMMING AND CODES

• There are 3 things in programming.

1. Header
2. Footer
3. Body

• G54 G64 G90 G71 G94 TOOL

D1
M03 S1000 F0.12

• Above given things are Header part of Programming.

• G01 / G00 / G02 / G03

• Above given things are Body part of Programming.

• Where, G01= Feed travel

G00 = Rapid
G02 = Clockwise Rotation
G03 = Anticlockwise Rotation

• There are certain types of programs are there.

1. Manual
2. R- Loop for Repetitive program
3. Cycle
4. Shop mill

• I have learnt about some commands which are mention below:

1. Mirror command
2. Trans command
3. ROTRPL command

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 4. Sin, Cos
5. CR
6. IJK for arc
7. Swivel Cycle
8. Helical Loop for one line program

• The Measuring Instruments which I have observed in the company.

 Bore Gauge
 Vernier Caliper
 Height Gauge
 Micrometer
 Depth Gauge
 Plug Gauge
 Feeler Gauge
 Width Gauge
 Slip Gauge
 Ring Gauge
 Thread Gauge
 Radius Gauge
 OTT Gauge
 Air Gauge
 Inside Caliper
 Inside Micrometer
 Holtest Micrometer
 Portable Coordinate Measuring Machine
 2-D Height Gauge
 Baker Level type dial Gauge
 Baker External Micrometer
 Roundness Tester
 Surface Roughness Tester
 Profile Projector
 Coordinate Measuring Machine

• The CNC Machine that which I have observed in the company mention
below:
 MX-12 (HURON)

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 DMC 160U Duo Block Deckel Maho
 DMG 200U
 DMC 70H Duo Block Deckel Maho
 VMC-1260 JYOTI
 HMC-560 JYOTI
 HSM Huron Speed Machine KX 50
 Lathe Machine
 Drill Machine
 Make Nicolas Correa FP-50
 VMC-850 JYOTI
 VMC-650 JYOTI  PX-10 JYOTI
 NX2215 JYOTI
 NX3222 AHC JYOTI
 NX4222 nvu JYOTI
 VMC-850 nvu JYOTI
 KX 5 Huron (VMC)
 VMC RX-20 JYOTI
 KX50L Huron
 MX12L Huron
 DX250 (TC) nvu JYOTI
 AX300 (TM) JYOTI
 TMC 350 JYOTI
 PX 250 JYOTI (TC)
 DR 200 JYOTI (TC)
 TMC 250 JYOTI
 (K3X8) FIVE JYOTI
 VTL500 JYOTI (TC)
 DX200 5A JYOTI (TC)
 PX-40 JYOTI (VM)
 VMC 640 JYOTI
 SX4 JYOTI (VM)
 DX100 JYOTI (TC)
 HMC450 MPPro JYOTI (HM)
 SOLCO IGNITE (SG-2100/4) GRINDING MACHINE
 DX200 JYOTI (TC)
 DX200 12A JYOTI (TC)

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 DX350 JYOTI (TC)
 VMC 1050 JYOTI
 VMC 850 PRO JYOTI
 PX 30 JYOTI (VM)
 VG 750 7 SENCE JYOTI
 HMC 450 Huron
 HX 600 JYOTI (HM)
 HX 600 7 SENCE JYOTI (HM)
 HSX 860 JYOTI
 MX 8 Huron
 BFT 80
 HMT GRINDING
 SOLCO IGNITE (EG 600)
 SOLCO IGNITE (HCGE 450)
 VMC 1260 JYOTI
 TOYODA MITSUISEIKI (HM)
 DMC 80U DECKEL MAHO
 KX200 Huron
 SHIN NIPPON KOKI JAPAN (SNK)
 MADA LCG3015 AJ (LC) LESAR CUTTING
 TRUMABEND V1300 (PB) TRUMPF

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 11.CONCLUSION

 In the twenty-first century, there'll be a growing demand for very accurate

machining which will be completed during a short amount of your time . This internship at
Jyoti CNC Automation PVT Ltd provided an incredible learning opportunity within the field
of automated lathe machines, or CNC machines, and exploitation of their different
features, including casting in their casting sector, machining of casted components
for surface finishing, assembly of all components, and quality testing using various
methodologies.
 This training has been quite beneficial in bringing forth the sort of thinking that real
engineering necessitates, which is usually centred on manufacturing principles and an
engineer's creativity.
