Internship Training Summary at

Ace Micromatic Group Companies

PLASTIC AND METAL MACHINING
Batch No: 246
Team Members:
• Sunil Kumar K
• Mohan Kumar S
• Manthesh
• Likith C
• Jashwanth Reddy A

Internship Training at Ace Micromatic Group Companies 1

Companies Visited

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BRIEF OF COMPANIES
ACE DESIGNERS
India’s largest manufacturing of CNC Turning center . Ace
Designers play a pivotal role in Indian machine tool industry by
offering a comprehensive range of turning machines to cater to
needs of several Industry segments .O
CNC TURNING CENTERS
PRAGATI TRANSMISSION PVT LTD
Largest manufacturer of high precision machine tools
automation accessories in India .CNC TURNING CENTERS

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 AUTO CNC MACHINING LTD UNIT 1,2
It’s the one of the largest manufactures of machining center
in India . Strong R&D facility passion to excel and a young
dynamics team led by experienced professionals has fueled the
rise of AMS to this premier position.

Internship Training at Ace Micromatic Group 4

 ABSTRACT
When creating a part, one of the most important decision is what
type of material to use. Material selection will determine a great
PROJECT
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deal about the functionality and appearance of a given component,
as well as how well it will hold up over time.
% in today’s
In the past, material options were fairly limited, but
manufacturing environment, the list of available materials can
seem endless. New metals and plastics are hitting the market each
week, all having unique benefits in form and function. Because of
the daunting array of materials available to designers and
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engineers. 46
%

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 INTRODUCTION
❖ Machining Plastics
Plastics are continuing to grow
in popularity. They are light-
weight, easy to machine,
and are often less expensive
than their metal counterparts.
Machining plastics come in an
endless variety, all with their
own strengths and weaknesses.
Plastics should be used for light-
weight applications and
prototyping.

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 ❖ Machining Metals
• When strength and toughness are
critical to a part’s function, metals are
the way to go. Machining metals hold
up far better to adverse conditions,
making them a more reliable option
than their plastic counterparts.
• When considering which metal is right
for your job, it is important to take into
account factors like hardness,
machinability, chemical/temperature
resistance, overall weight, etc. These
characteristics will all play a part in how
a part is manufactured, and how well it
will hold up in the field.

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 PLASTIC MACHINING
One of the main attributes of plastics
materials is their ability to be moulded into a
finished component with no need for
subsequent work to be carried out. Not all
plastics materials can be machined. the more
rigid a plastic then the easier it is to be
machined. The more flexible and the softer
plastics are not suitable for machining.
https://www.bpf.co.uk/plastipedia/processes/Machining_of_Plastics.aspx

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Main points to note when machining plastics

• The cutting tools used in

the machining of all materials
rely on the rigidity of the
component being cut.
• In the case of cutting
metals, the materials' natural
rigidity is good. Therefore the
component resists distortion
when the cutter (saw, drill or
machine bit) cuts the metal.

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 Further Insight on Topic
• In the case of plastics, machining
tends to lend itself better to rigid
materials, such as fibre reinforced
thermosetting plastics materials,
glass reinforced nylons, acrylic or
PEEK have good relative
stiffness. Less rigid plastic tends to
deform and bend away when the
cutter attempts to cut the
component, making the achievement
of fine dimensional tolerances
difficult.
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Metal Machining
Machining is a process in
which a material (often metal)
is cut to a desired final shape
and size by a controlled
material-removal process. The
processes that have this
common theme are
collectively called subtractive
manufacturing, carried out
with the help of machine
tools.
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 Cutting tool
•A cutting tool is a device used to remove
material from a solid block of material. It is
fitted to the spindle of a CNC machine,
which follows computer instructions to
guide the cutting tool where it needs to
go.
•Cutting tools remove material from the
workpiece by a process of shear
deformation. That is, the sharp tool rotates
at high speed and cuts from the workpiece
many tiny chips, which are then ejected
away from the workpiece. Some tools
make contact with the workpiece at one
point only, while others, such as end mills,
hit the material at multiple points.

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 Cutting tool materials
• Carbon steel
Carbon steel is an affordable steel alloy containing
0.6-1.5% carbon, as well as silicon and manganese.
• High-speed steel
The more expensive HSS is harder and tougher than
carbon steel thanks to its blend of chromium,
tungsten and molybdenum.
• Carbide
Usually sintered with another metal like titanium,
carbide tools are wear-resistant and heat-resistant,
providing an excellent surface finish.
• Ceramic
Used to cut superalloys, cast iron and other strong
materials, ceramic tools are resistant to corrosion
and heat.

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• Titanium Nitride (TiN)
TiN is a general-purpose coating with a high
oxidation temperature that increases the
hardness of a cutting tool.
• Titanium Carbo-Nitride (TiCN)
TiCN adds surface lubricity and hardness to a
cutting tool.
• Diamond
Diamond provides a high-performance coating for
cutting abrasive materials.
• Chromium Nitride (CrN)
CrN adds corrosion resistance and hardness to
cutting tools.
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Types of Cutting Tools
• End mill
• Roughing End mill
• Face mill
• Fly cutter
• Thread mill
• Drill Bit
• Reamer
• Gear Cutter
• Slab mill

Internship Training at Ace Micromatic Group 15

Points of interest
•The different devices used for inspection(CMM, Faro arm, etc.)
•Different kinds of methods used work holding(Vacuum, Fixtures, Jigs)
•Variety of machines classified based on their working axis(Vertical,
Horizontal)
•Different materials used for plastic machining(FR4, Bakelite, Delrin,
Finotic, etc.)
•Design Drawing

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Points for Improvements
•Dedicating a machine for the interns, to get
hands-on experience
•Providing a basic design drawing, and teaching
students the basic procedure involved in
programming
•Having a flowchart that shows the order in
which a work is processed
•Having included amace in the list of
companies, to give an exposure to additive
manufacturing

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Doubts to get Clarified
•Is there a difference between the tools
used for plastic and metals?
•Why is additional clamping required even
after vacuum fixture?
•How was the workforce managed during
the pandemic, as medical parts are also
being manufactured?
•What is the procedure if a machine breaks
down while in working condition?

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Closing note
•The overall learning experience
was excellent
•Exposure to the various
machines helped us have an
clearer understanding
•The operators were very
helpful and taught about the
machines working

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