Aditya Industries

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Company Profile

Name of Company Aditya Industries

Address E-57, M.I.D.C, Shiroli, Kolhapur

Contact 9763716548

Total No of Supervisor 5

Management 2

Workers 100

Products Water Pump parts, Disc, Pulley, PG Housing

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History of Krishna Industry: -

Krishna Industry Private Limited is a Private incorporated on 1 December 1988. It is

classified as Non-govt company and is registered at Registrar of Companies, Pune. Its authorized
share capital is Rs. 400,0000 and its paid up capital is Rs. 34,00, 000.It is involved in
Manufacture of general purpose machinery.

This one is the best finished casting suppliers in India. We have been supplying
manufacture parts to various industries since 1988.Our product line includes machining of Cam
shaft bearing, housing, etc. We work hard to provide value added solutions to customer's casting
needs. The Group's experienced work force is dedicated to deliver effective engineering,
production and scheduling response to each customer's needs. In-house machining capability
includes turning, milling, boring, slotting, drilling and tapping operations. The Group with its
experience and expertise has acquired.

We feel pleasure to provide solution for customized query.

Organizational Chart

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Owner

Quatliy Superwiser
Engineer Clark

Workers

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Plant Layout

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Machinery and Equipment details

Machine / No. of
Technical Controller Cost in
Sr. no. Equipment Make Machines
Specification details Rs
Name
COSMOS Vertical
1 VMC INDIA Milling 1 Fanuc 30lakh
CVM 640 Machine

2 CNC INDIA CNC Lathe 4 Siemens 15lakh

Askar
CNC Turret
3 Microns INDIA 1 Siemens 20lakh
Lathe
(CNC)

Drilling Radial
4 INDIA 2 Kirloskar 1.25lakh
Machine Machine

Bench
5 Drilling INDIA Pillar type 3 Kirloskar 1lakh
machine

6 Lathe INDIA Centre Lathe 5 Kirloskar 1.5lakh

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Machine / No. of
Technical Controller Cost in
Sr. no. Equipment Make Machines
Specification details Rs
Name
COSMOS Vertical
1 VMC INDIA Milling 1 Fanuc 30lakh
CVM 640 Machine

2 CNC INDIA CNC Lathe 4 Siemens 15lakh

Askar
CNC Turret
3 Microns INDIA 1 Siemens 20lakh
Lathe
(CNC)

Drilling Radial
4 INDIA 2 Kirloskar 1.25lakh
Machine Machine

Bench
5 Drilling INDIA Pillar type 3 Kirloskar 1lakh
machine

6 Lathe INDIA Centre Lathe 5 Kirloskar 1.5lakh

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Eisher pulley
Pump Pulley Bearing Housing

End Bell Disc (Brake) Back Plate

Manufacturing Processes for Water Pump Pulley:

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Process
Process
Sr. no. Machine Tool Gauges time
details
(min)
Facing,
Vernier
1 Rough Lathe TNMG 1.30
Caliper
Turning

Finish Plug Gauge,

2 CNC TNMG 1.5
Turning Height Gauge

Position
Carbide
3 Drilling VMC Checking 0.40
Tool
Gauge

Chamfering M6 Thread
4 VMC Carbide Tip 0.30
Tapping Gauge

Manufacturing Processes for Disc Brake:

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Proces
Process
Sr. no. Machine Tool gauges s time
details
(min)
Facing,
Vernier
1 Rough Lathe HS Tool 2
Caliper
Turning

Finish Plug Gauge,

2 CNC TNMG 1
Turning Height Gauge

Drilling
3 Drilling HSS Fixture 0.4
Machine

Drilling
4 Chamfering HSS 0.30
Machine

Casted
Disc Brake
Manufactured Disc Brake

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Manufacturing Processes Back Plate:

Proces
Process
Sr. no. Machine Tool gauges s time
details
(min)
Facing,
1 Rough Lathe HS Tool OD Gauge 2
Turning

Finish
2 CNC TNMG OD Gauge 0.45
Turning

Drilling
3 Drilling HSS Fixture 0.5
Machine

Radial
4 Tapping Drilling HSS Fixture 0.30
Machine

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Manufacturing and Processes

The following Process Is Described for Eisher Pulley (Mahindra and Mahindra Tractors)

Casting:

Production of water pump pulley starts with casting if job made up of cast iron (BHN-
42). This casting is casted in Aditya Founders, Shiroli. In casting process a liquid metal is poured
in cavity and let it cool for 7 hours for atmospheric temperature 26 degree Celsius the Weight of
cast product is near about 1.5 to 2 kg and thickness of product is 15 to 16mm should be made for
proper machining process.

Combination: Scrap (70%) +Pig Iron (20%) +Runner Riser (10%)

Shot Blasting:

Shot blasting is a surface finishing technique that involves rapidly impacting the
surface of an object with a controlled stream of abrasive shot material. Shot blasting also useful
for removing burrs, scale and rust that may interface with the parts integrity, appearance. A
product is rotated in a machine in 360 degree and moved along a definite path for proper
cleaning.

Fettling:

After shot blasting process fettling process done on job in same industries. Raw
casting often has irregularities and imperfections in casting as example: Water pump pulley has
outer profile and has hole at middle portion so after casting there are some irregularities which
are removed during fettling process by using a corner wheel rotating near about speed of 900 to
1000 rpm.

Machining:

1) Facing: In this process a job is gripped in chuck, in CNC machine .Initially the
thickness of casting is near about 15 to 16 mm and for first side it is reduced to 13
mm by using facing operation. After facing 85mm diameter with 10 mm deep is
bored and then a 15 mm part of bore face is turned. The last operation for first side is
chamfer for both diameters.

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2) Facing and Groove: The operation on CNC is facing and turning a 82.4 mm radius
for that a job is gripped in 85 mm diameter on three jaw chuck and a face is grooved
to 30 mm with angle 30˚.
3) Boring: After this 25 mm diameter*13mm boring is done on the CNC machine.
4) Drilling: This operation is done on the VMC machine, by developing program.
Drill dimensions are: 4 Holes on 63.5 PCD of depth 10mm.
5) Tapping: This is the last operation on the VMC machine,
Dimensions are: 4 Tap Holes M8*1.25mm thru equispaced on 63.5 P.C.D.
6) At the end CR(Casting Rejection) And MR(Machining Rejection) are separated and
not accepted

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Details of CNC operation:

Product Name : Water Pump pulley

Daily Quantity : 200 numbers

CNC machine used : 4

Workers : 12

Tool Material : Used Inserts of CNC and VMC machines i.e. TNMG & HSS

Measuring equipment’s : Vernier Caliper, Digital height Vernier

Gauges : Bore and Ring gauge

There are different CNC machine parts for these two CNC machines in this industry which
can be given as

1) Horizontal Machining Center

2) Three Jaw Foot Operated Self Centering Chuck
3) Hydrostatic sideways
4) Driving motor for spindle
5) Single heavy drum type turret with external and internal working tools
6) Safe guard glass door
7) Coolant sprayers
8) Automatic Tool Changers
9) Numerical Control Panel with current operation progress display
10) Safety button in case of emergency etc.
These are some of the important components of CNC machine. Computer Numerical Control
in CNC machine is handled with help of computer programs. Computer program executes with
different coding regarding particular operation. For this program there are different codes which
are known as G- codes, M- codes etc.
In this industry four CNC machines have following M- codes, which are as,

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M- Codes

M00 Program stop M14 Steady rest close

M01 Optional stop M15 Spindle brake OFF

M02 Program end M16 Spindle brake ON

M03 Spindle rotation C.W. M17 Job change (gantry robot)

M04 Spindle rotation C.C.W. M18 Spindle rotation mode ON

M05 Spindle stop M19 Spindle orientation/Index mode ON

M07 Coolant(flushing) ON M20 Tailstock quill left

M09 Coolant OFF M22 Chip conveyor forward

M10 Chuck clamp M23 Chip conveyor OFF

M11 Chuck unclamp M24 Parts catcher IN

M12 Chuck high pressure select M25 Parts catcher OUT

M13 Chuck low pressure select M27 Bar feeder OFF

M30 Program end and rewind M37 Feed override enable

M31 Steady rest close M38 Spindle speed override disable

M32 Steady rest open M39 Spindle speed override enable

M33 Live tool C.W. M40 Auto door close

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M34 Live tool C.C.W. M41 Auto door open

M35 Live tool stop M98 Sub-program call

M36 Feed override disable M99 Sub-program end

Drilling:

The drilling operations are done in VMC section, there is 1 machines are used for
drilling operation. These are

1) VMC (CVM640) - Fanuc

Between these two the BFW is faster and robust machine with Fanuc controlled.

First the job is clamped in fixture by using washer and nut. A job is located on the fixture
by using locator.

Drilling Specifications:

Drill
Sr. Quantity of
Diameter(mm Tool Used
No. Holes
)
1 14 Carbide drill 4
2 9 Carbide drill 4
3 8 Carbide drill 4
4 8 Carbide tap 4

Type of program: Absolute Coordinate Method

Process:

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1) When cycle starts a 8 mm drill comes and a 4 drill at 63.5 PCD is drilled at spindle speed
1400 rpm. Now spindle go to its home position and ATC changes tool by 8 mm drill to
M8 mm Tap.
2) An 8mm of 4 numbers are tapped in cross manner i.e. front to front. After that spindle
goes to home position.
3) The last operation is chamfer is done with a 9 mm chamfer tool and width of chamfer is
kept 1mm.

Inspection Details

Instrument /
Sr.No. Parameter Tolerance
Gauge
1 25.4 mm Hole Dial Gauge +-0.01
2 8 mm Hole Receiving Gauge +-0.01
3 8 mm Tapping Tapping Gauge +-0.01

Surface Grinding:

The Final operation of Water pump pulley is Surface Grinding Operation In

which A Thickness of a job is controlled and also Flatness and Parallelism is controlled as per
designer specifications.

1) In Surface Grinding operation a rotating wheel of aluminum oxide is used to remove a

small amount of material from a work piece in the form of particles and these
particles looks like burning while there is very high temperature due to friction.
2) A magnetic chuck is located on a table which gives longitudinal strokes per minute.
A Magnetic chuck which operates on electricity also called electromagnetic chuck,
produces a magnetic field and tend to stick flat surface to it.
3) These machines are fully hydraulic operated and require most precautions while
working.

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4) On this machine a final thickness of component is controlled.

Sr.No. Parameter Instrument / Gauge Tolerance

Micrometer Screw
1 Thickness 0.1
Gauge
2 Flatness Three Point Method 0.1
3 Surface Roughness Surface Tester Ra:1.2

Quality Control

Quality Engineer: Mr.Eknath Mandurkar.

The Quality is the most important part of any industry to sustain in the competition of
global market here some tools are used in industry for inspectional purpose.

Plug Gauge

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This gauge is used for checking the internal thread diameter. This gauge used for the part: Water
pump pulley

Ring Gauge
Dial Gauge

This two gauges are used for checking the

internal diameter of job by setting the dial gauge at
zero reading by inserting in ring gauge and
then dial is used for inspection of I.D.

Snap Gauge

This gauge is
used for the inspection of external diameter of job. This is used for checking the diameter of
pump pulley.

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Plug Gauge

Plug gauge used for inspection of internal thread diameter. This is specially used for End bell

which is part of Shakti pumps.

Height Gauge

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A height gauge is a measuring device used either for determining the height of objects, or for
marking of items to be worked on. This instrument used at the last stage of machining.

Vernier Caliper

The Vernier Caliper is a precision instrument that can be used to measure internal and external
distances extremely accurately. This caliper is used after the Centre lathe machining process.

Digital Vernier

A popular refinement replaces the analog dial with an electronic digital display that displays the
reading as a numeric value. This caliper is used after the CNC and VMC machining process.

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Maintenance

Maintenance is nothing but to maintain the machine in which it will run with full
efficiency. Basically there are two main methods of maintenance.

A) Preventive maintenance

B) Break down maintenance

In Aditya industry there is one main maintenance department namely Machine shop
maintenance

Along this only machine maintenance is taken, instrument maintenance is not part of this
department.

a) Preventive Maintenance

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Preventive maintenance is nothing but maintenance before failure of machine or

in short periodic inspection. It is very essential in productivity point of view. Preventive
maintenance basically consist of rechecking the machine parameters e.g.:-lubricating system,
vibration etc.

In industry Preventive maintenance is done with successive interval and they are
trying to increase their productivity and it is done on every Monday.

b) Breakdown Maintenance

Break down maintenance is maintenance of machine after failure of machine or break

down. It is essential to make the “history card” of that particular machine along with in detail
study of that corresponding machine. Using that knowledge the defect is detected and by solving
it is removed. If break down maintenance is low, the productivity increases correspondingly i.e.
it is adversely affecting the productivity.

Packaging:

Packaging is done in following steps:

1) Apply corrosion resistant oil to component faces.

2) Put a job in cardboard box on that jib put a cardboard sheet this process done for
4 job in one box.

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Packed components in plastic Box Packing

CONCLUSION

An undergraduate student I would like to say that this training program is an excellent
opportunity for us to get to the ground level experience the things. I am grateful to the Shivaji
University for giving us this wonderful opportunity. The main objective of the industrial training
is to provide an opportunity to undergraduates to identify, observe and practice how engineering
is applicable in the real industry. It is not only to get experience on technical practices but also to
observe management practices and to interact with fellow workers.

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I learned about various aspects of industry, machine, and processes. The firsthand experience
provided me that knowledge which can only be possible by gained from the practice work done
during training. The knowledge will help me in my understanding of the various subjects in my
academics.

Also I learned the way to work in an organization, way of customer interaction, the importance
of being punctual and the importance of team spirit. In my opinion. I have gained lots of
knowledge and experience needed to be successful in a great engineering challenge.

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