Internship Corrected

PLANSEE INTERNSHIP REPORT
SEMICON
1. MACHINE SHOP OVERVIEW

1.1 Application of Machine Shop Parts:
1. Tungsten and Molybdenum Parts - Ion Implantation.
2. Nozzles – Plastic Injection Moulding.
3. Anodes & Rotors - Medical (CT Scanning Machines).
4. Electrodes - Automobile Industries (Resistance Welding).
1.2 Overall Process Flow of Work:
The major steps involved in the process flow of work as follows.
1. Customer Enquiry or our approach to the Customer.
2. Equipment / Tools / Process feasibility study.
3. Developing the program.
4. Sample preparation for approval from customer end.
5. Estimation and Quotation by Estimators.
6. Customer approval and order confirmation.
7. Planning and scheduling by the production team.
8. Production of order.
9. Quality inspection.
10. Cleaning, Packing and Dispatch.
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2
1.3 Types of Raw Materials

1.3.1 Molybdenum: Molybdenum is a refractory metal is widely used as an alloying
element.
• Silvery Grey in color

• Good Thermal conductivity
• Good Electrical conductivity
• High Melting Point
• Low Thermal expansion and coefficient.
Applications:
• Ribbons and Wires for Lighting Industry.

• Semiconductor Plates for Power Electronics.
• Glass Melting Electrodes.
• Hot Zones for High temperature furnaces.
• Sputtering targets for Solar Cells and Flat Screens.
1.3.2 Tungsten: Tungsten, also called as Wolfram is a very hard, dense, silvery-white,
lustrous metal that tarnishes in air, forming a protective oxide coating. In powder form tungsten
is gray.
• Very Low Thermal expansion and coefficient

• High Dimensional stability
• Nearly indestructible
Applications:
• Lamp Components
• Medical and Thin film technology
• Furnace Components
• Electrodes
• Ballistics (Defense equipment)
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1.3.3 TZM: TZM an acronym for the molybdenum alloy “titanium-zirconium-

molybdenum”, is a molybdenum alloy containing 0.5% titanium, 0.08% zirconium, 0.02%
carbon and the balance molybdenum. TZM, like pure molybdenum, can be produced by
powder metallurgy or arc-cast processes.
• Higher recrystallization temperature

• Better creep resistance
• Strong corrosion-resistance
• High elastic modulus
• Good electrical and thermal conductivity
Applications:
• Rotating Anodes in X-Ray tubes

• Forging tools (demands high temperature and mechanical loads)
• Military Equipment’s
• Nozzle Throat linings
1.3.4 WCu (Tungsten-Copper): WCu is a composite consist of porous Tungsten matrix

infiltrated with approx. 10-40% by weight of copper.
• Has low arc erosion tendency.

• Exhibits good electrical conductivity.
• High thermal conductivity.
• Low thermal expansion.
Applications:
• High voltage circuit breakers.

• EDM electrodes
WCu Materials Applications:
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Infiltrated:
• Electrical contacts.
• Heat sinks.
• Jet vanes and Nozzles.
Back casted:
• Electrical contacts.
• Plasma Nozzles.
• Stationary Anodes.
• Welding Electrodes
1.3.5 Tantalum: Tantalum belongs to a class of metals known as refractory metals, which
are defined by their strong resistance to heat and wear. It has a melting point of 5,463 °F
(2,996 °C), the fourth highest of all metals. In terms of mechanical properties, tantalum is
highly ductile, making it suitable for processes such as bending, stamping, and pressing.
When combined with other metals, it can produce alloys with enhanced strength and higher
melting points.
• High Corrosion Resistance

• Easy to work at below room temperature
Applications:
• Heat Exchangers
• Riveted racks for furnace construction
• Implants for medical technology
• Capacitor Components
Powder Metallurgy Process: Powder metallurgy is the process of blending fine

powdered materials, pressing them into a desired shape or form (compacting), and then heating
the compressed material in a controlled atmosphere to bond the material (sintering).
Steps involved in powder metallurgy:
1. Powder preparation.
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2. Mixing of other metal powder and Additives/binders.
3. Compacting.
4. Sintering.
5. Machining and finishing.
Back Casting Process: Back Casting is an extended Powder metallurgical process where
the semifinished base metal from first process is again sintered with different metal powder.
Steps involved in Back Casting Process:
1. Base Metal Preparation.
2. Powder preparation.
3. Mixing of other metal powder and Additives/binders.
4. Compacting.
5. Sintering.
6. Machining and finishing.
Advantages:
• Minimizes machining by producing parts at, or close to, final dimensions.

• Minimizes scrap losses by typically using more than 97% of the starting raw material
in the finished part.
• Permits a wide variety of alloy systems.
• Produces good surface finish.
Disadvantages:
• Tooling cost is generally and can only be justified in mass production.
• Raw material cost is very high.
• Mechanical properties of the parts are of low quality as compared to cast or machined
parts.
• In some cases, density of different parts of final product can very due to uneven
compression.
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Characteristics of Metals:
Material Mass Density Melting point

(g/cm3) (⁰C)
Copper (Cu) 8.96 1085

Molybdenum (Mo) 10.28 2620
TZM 10.22 2623
Tungsten (W) 19.4 3400
Graphite (C) 2.26 >3600
Bar Chart:
Density of the Metals

25
Density in g/cm3
19.4
20
15
10.28 10.22
8.96
10
5 2.26
0
Copper Molybdenum TZM Tungsten Graphite
Metals
Melting Point of Metals

4000
3600
3400
3500
Temperature in ⁰C
3000
2620 2623
2500
2000
1500
1085
1000
500
0
Copper Molybdenum TZM Tungsten Graphite
Metals
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OVERALL PROCESS AND MACHINE OPERATION

Plant Capacity:
MACHINES CAPACITY
Cutting Machines
1. METCO BAINCUT 01 Nos
2. MULTICUT VBM (500H Vertical Bandsaw) 01 Nos
3. INDO TECH (210 LMGA RF Double Column Bandsaw) 01 Nos
4. INDO TECH (SPM ITM 100 V3 H) Vertical Machine 01 Nos
VMC Machines
1. FEHLMANN (PICOMAX 80 CNC 2/3) 01 Nos
2. ACE MICROMATIC (ACE MCV 400) 01 Nos
3. ACE MICROMATIC (AMS ACER) 07 Nos
4. OKUMA (MB 56 VA) 01 Nos
CNC Turn Mills
1. ACE MICROMATIC (LT-2LM 500 MSY) 02 Nos
2. DMG MORI (NLX 1500) 08 Nos
3. ACE MICROMATIC (VANTAGE 1000) 02 Nos
CNC Turning Machines
1. ACE MICROMATIC (LT 2XL 500S) 02 Nos
2. ACE MICROMATIC (LCXT-20G) 01 Nos
3. MORI (SEIKI SL 154) 02 Nos
Surface Grinding Machines
1. PMT (SG 42 CONV) 01 Nos
2. COSMOS (JR 800 NC) 01 Nos
3. ELB Surface Grinding 01 Nos
Cylindrical Grinding Machine
1. KELLENBERGER (KEL VITA) 01 Nos
Wire EDM Machines
1. CONCORD (VERSA CUT 01) 03 Nos
2. CHMER (G32 2) 02 Nos
3. CHMER (GX 360 L) 01 Nos
4. SODIC (VL 400 Q) 04 Nos
Electron Beam Welding Machine 01 Nos
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Machine Capacity and Specification:

METCO MULTICUT VBM INDO TECH 210 INDO TECH
BAINCUT 500H Vertical LMGA RF Double SPM ITM 100 V3
Bandsaw Column Bandsaw (H) Vertical
SPECIFICATION
Machine
Cutting Size Dia. or Height Ø 60 mm 500 mm Ø 210 mm 100 mm
Cutting Size (L x B) _ 900 x 900 mm 210 x 210 mm _
Cutting Speed m/min _ 25 100 20 - 100 20 - 100
Work Table 60 x 190 x 8 mm slot 900 x 900 mm _ 600 x 600 mm
FEHLMANN ACE ACE OKUMA

PICOMAX 80 CNC MICROMATIC MICROMATIC (MB 56 VA)
2/3 (ACE MCV 400) (AMS ACER)
SPECIFICATION
Driver Controller HEIDENHAIN TNC 415 FANUC 01MF/ SIEMENS FANUC 01MF/ SIEMENS
No. of Axis 4 - Axis 3 - Axis 3 - Axis 3 - Axis
Table size 1230 x 410 mm 900 x 450 mm 1000 x 510 mm 1300 x 560 mm
Travel distance (X-Y-Z) 700 x 315 x 178 600 x 450 x 500 mm 800 x 510 x 500 mm 1050 x 560 x 460 mm
Max. Load on Table 250 kgs 400 kgf 500 kgf 898 kgs
Spindle Speed 9200 rpm 60 6000 rpm 60 6000 rpm 50 8000 rpm
Spindle Nose Taper SK 30 BT 40 BT 40 CAT 40
Tool Magazine Capacity 32 24 24 32
ACE MICROMATIC DMG MORI ACE MICROMATIC

(LT-2LM 500 MSY) (NLX 1500) VANTAGE 1000
SPECIFICATION Main Side Sub Side Main Side Sub Side Side - 1 Side - 2
Driver Controller FANUC FANUC
No. of Axis 3 3 2
Travel distance (X-Z-Y) X- 3 mm, Z- 500mm, Y- ±40mm X-260 mm, Y-100 mm, Z-590 mm X-300 mm, Z-1105 mm
Swing over Bed 610 mm 923.8 mm 640 mm
Max. Turning Dia. 386 mm 52 mm 580 mm
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Max. Turning Length 480 mm 515 mm 1000 mm
Max. Bar Capacity 51 mm 480 mm 51
Bore through Spindle 63 mm 47 mm 63 mm 63 mm
Spindle Nose A2-6 FLAT A2-6 A2-6
Max. Spindle Speed 4000 rpm 6000 rpm 6000 rpm 4000 rpm 4000 rpm
Turret type & Capacity Radial 12 Tool Stations Radial BTP 100 12 Tool
Stations
ACE MICROMATIC ACE MICROMATIC MORI

(LT 2XL 500 S) (LCXT 20 G) (SEIKI SL 154)
SPECIFICATION
Driver Controller FANUC FANUC 875
No. of Axis 2 2 2
X & Z Axis Stroke X-213 mm, Z-500 mm X-190 mm, Z-190 mm X-230 mm, Z-520 mm
Swing over Bed 610 mm 458 mm 680 mm
Max. Turning Dia. 350 mm 360 mm 430 mm
Max. Turning Length 190 mm 519 mm
Max. Bar Capacity 51 mm 51 mm 41 mm
Bore through Spindle 63 mm 63 mm 56 mm
Spindle Size / Nose A2-6 A2-6 A2-5
Max. Spindle Speed 500 4000 rpm 3500 rpm 6000 rpm
Turret type & Capacity Rotary Tool Turret 10 Tool Servo BTP 10 Tool Station 12 Tool Station
Station
SURFACE GRINDING PMT COSMOS ELB

(SG 42 CONV) (JR 800 NC) Germany
SPECIFICATION
Table Size/Grinding Area 400 x 200 mm Día 800 mm Rotary Table 550 x 1880 mm
Stroke (X-Y-Z) X-450 mm, Y-300 mm, Z-200 400 mm X-550 mm, Y-1200 mm
mm
Max. Table Load 200 Kgs 650 Kgs
Spindle Speed 2800 rpm 1000 rpm
Table Feed 18 m/min 2 m/min
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WIRE CONCORD CHMER CHMER SODIC

(DK 7732 VC) (G32 S) (GX 360 L) (VL 400 Q)
SPECIFICATION
Wire Material Molybdenum Brass Brass Brass
Wire Size Range Ø 0.10 mm Ø 0.18 mm Ø 0.15 mm Ø 0.3 mm Ø 0.15 mm Ø 0.3 mm Ø 0.10 mm Ø 0.30 mm
Axis Travel (X-Y-Z) 320 x 400 x 500 mm X-360 mm, Y-250 mm 360 x 250 x 220 mm 400 x 300 x 220 mm
Max. Weight of Work 400 kgs 300 kgs 300 kgs 500 kgs
Table Feed 100 mmsq/min 800 mm/min 1500 mm/min
Max. Wire Feed 300 mm/sec 300 mm/sec
Machining Calculations:
Milling Calculations:
1. Cutting Speed:
where, π = Constant (3.14)
D = Effective Día of Cutter in mm
N = RPM in mins
𝐕𝐜 = 𝛑 × 𝐃 × 𝐍 ….mm/min
2. Feed per Tooth:

where, Z = No. of teeth
Vf = Table Feed in mm
𝑽𝒇
fz= 𝒏×𝒁 ……mm
3. Table Feed / Feed per revolution:

where, Z = No. of Teeth
fz = Feed per Tooth in mm
Fn = Z × fz
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4. Metal Removal Rate:

where, Ae = Radial depth of cut
Ap = Axial depth of cut
𝑸 = 𝑽𝒇 × 𝑨𝒆 × 𝑨𝒑
Turning Calculations:
1. Cutting Speed:
where, N = Revolutions / Rotations per minute
Dm = Work Diameter, mm
𝝅 ×𝑫𝒎 ×𝑵
𝑽𝒄 = ….m/min
𝟏𝟎𝟎𝟎
2. Feed:
where, I = Cutting Length/min
𝑰
𝑭 = 𝑵 ….mm/rev
3. Cutting Time:
where, Im = Work Length, mm
𝑰𝒎
𝑻𝒄 =
𝑰
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MACHINERIES
CNC Turning Machine
CNC turning is a manufacturing process that involves holding bars of material in a chuck and
rotating them while feeding a tool to the piece to remove material until the desired shape is
achieved. As the desired shape is achieved through the removal of material, it is also known
as subtraction machining. All of the work can be completed from one side if the CNC turning
center has only one turret, but some turning centers have a main spindle and sub-spindle for
even faster operation. With this configuration, the main spindle partially machines the
workpiece, which is then moved to the sub-spindle to complete the job on the other side of the
part. The speed of CNC turning operations makes it an ideal process for large production runs
with short lead times. Few major Operations are:
• Boring
• Drilling
• Facing
• Grooving
• Knurling
• Parting
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CNC Milling Machine
CNC Milling is a machine process which produces custom-designed parts or components by

progressively removing material from the workpiece using rotating multi-point cutting tools
and computerized controls. These systems usually have three linear degrees of freedom. They
can move freely around the X, Y, and Z axes while the workpiece remains stationary. This
limited dimensional operation reduces the speed of operations, making milling more suitable
for prototyping and smaller production runs.
The general principle for a CNC milling machine or CNC machining center is that the part to
be machined is clamped on top of the machine table. It could be clamped directly on the table
itself, or held in place by a vice or fixture.
The spindle (moving section) including the cutting tool is then either vertically or horizontally
positioned. In that configuration, the tool can reach various X-Y-Z positions on the work piece
and commence cutting and shaping actions. As it does so, the work piece or part may either be
fixed, mounted, or moved/positioned by the table in a linear direction to the spindle with the
cutting tool. This allows material to be removed according to the desired shape needed for the
machined part. CNC milling machine may either be horizontal or vertical.
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CNC Turn Mill Machine
CNC Mill/Turn Machines are multi-tasking, multi-function CNC machines used for producing
complex workpieces in one operation. These machines are capable of turning a workpiece and
applying rotating tooling operations such as cross-drilling, tapping, slotting, and milling. A
part requiring a variety of operations can be machined in one setup, particularly if a sub-spindle
allows the part to be passed from one spindle to another during machining, essentially
machining two parts simultaneously. All these processes combined in one complete cycle
allows for faster part making, higher accuracy (no re-chucking), and less set-up times. CNC
turning and milling machines are computer-controlled tools that are used to create precise,
intricate parts for a variety of industries. The machines work by using a rotating cutting tool to
remove material from a workpiece. The turning process is used to create cylindrical parts,
while the milling process is used to create flat or irregularly shaped surfaces. Both processes
can be performed on a variety of materials, including metals, plastics, and composites.
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Wire EDM Machine
Wire EDM machining (Electrical Discharge Machining) is an electro thermal production

process where a thin single strand metal wire, along with de-ionized water (used to conduct
electricity) allows the wire to cut through metal by the use of heat from electrical sparks, while
preventing rust.
Wire EDM machining works by creating an electrical discharge between the wire or the
electrode and the work piece. As the spark jumps across the gap, material is then removed from
the work piece and the electrode. Due to the inherent properties of the process, Wire EDM can
easily machine complex parts and precision components out of hard conductive materials.
To stop the sparking process from shorting out, a non-conductive fluid or dielectric is also used
in the process. The waste material is removed by the dielectric, and the process continues.
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Electron Beam Welding Machine
When the electron voltage is given a high voltage dc source, the tungsten filament wire heats
up, and the temperature rises to 2500 ° c. Due to these high temperatures, electrons are emitted
from the tungsten filament. These electrons are guided by a grid cup to travel downward and
are attracted by the anode. Electrons passings through the anode are accelerated to achieve a
velocity as high as half the velocity of lights (i.e., 1.6 x 10 ^ 8 m / s) by applying 50 to 200 kV
at the anode. The high velocities of these electrons are maintained until they strike the
workpiece. This becomes possible because electrons travel through a vacuum. This high-
velocity electron beam, after leaving the anode, passes through the tungsten diaphragms and
then through the electromagnetics focusing lens. Focusing lenses are used to focus the
electrons beam to the desired location of the workpiece. When the electron beam affects the
surface of the workpiece, the kinetic energy of high-velocity electrons is immediately
converted to heat energy. It melts high-intensity heat and vaporizes the work material in place
of the beam effect. Since power density is very high (about 6500 billion w / mm ^ 2), it takes
a few microseconds to melt and evaporate the material for impact. This process is done in
repeated pulses of short duration. Pulse frequency can be from 1 to 16,000 Hz, and the duration
can be from 4 to 65,000 microseconds. By alternately focusing and closing the electron beam,
the cutting process can be continued as long as it is needed. A suitable viewing device is always
included with the machine. Therefore, it becomes easier for the operator to observe the progress
of the machining operation.
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Surface Grinding Machine
A Grinding Machine is a power tool that grinds or polishes the surface to make it free from
any aberrations. The abrasive wheel rotates at high speed that is used for the application of
polishing. A Surface Grinding Machine is an excellent tool used for the purpose of surface
grinding. The surface grinder is opted for removing any kind of up and down on a surface and
give it smoothness. Due to the robustness, the surface grinder machine has found its use in
many industries. The surface grinding machine has grinding wheels making this the perfect
tool for abrasive surfaces. The grinding machine moves forward and backwards to perform its
task of removing any element present on the surface. The process of surface grinding is then
followed by polishing process performed by different other tools.
Types of Surface Grinding Machine

• Horizontal spindle and reciprocating table
• Vertical spindle and reciprocating table
• Horizontal spindle and rotary table
• Vertical spindle and rotary table
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Cylindrical Grinding
The Cylindrical Grinder is a type of grinding machine used to shape the outside of an object.
The cylindrical grinder can work on a variety of shapes; however, the object must have a
central axis of rotation. This includes but is not limited to such shapes as a cylinder, an ellipse,
a cam, or a crankshaft.
Cylindrical grinding is defined as having four essential actions:
• The work (object) must be constantly rotating

• The grinding wheel must be constantly rotating
• The grinding wheel is fed towards and away from the work
• Either the work or the grinding wheel is transversed with respect to the other.
There are five different types of cylindrical grinding:
• Outside Diameter Grinding

• Inside Diameter Grinding
• Plunge Grinding
• Creep Feed Grinding
• Centerless Grinding.
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Bandsaw
The bandsaw is one of the most versatile power tools available. Bandsaws (also referred to as
band saws) are used for cutting many different types of materials including wood, metal, tile
and plastic. This powerful machine represents one of the easiest and fastest ways to cut metal.
Metal bandsaws can be either vertical or horizontal, with the description of the bandsaw type
referring to the direction in which the blade rotates and the axis on which the material is being
cut.
Both types of band saws come in very handy for metal cutting projects. Bandsaws can cut all
kinds of metal and can carry out both straight cuts and irregular ones.
Types of Bandsaws
• Horizontal Bandsaws: The horizontal metal band saw holds your work piece
stationary while the blade swings down through the cut and is normally used to cut
stock down to more manageable sizes.
• Vertical Bandsaws: The vertical metal bandsaw has a blade which rotates
continuously permitting a smooth, flexible cutting action and remains in an upright
position while it moves and your material is guided through it. This type of bandsaw is
generally used for jobs involving more complex shapes and angles such a polishing,
filing, and contour cutting.
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Barreling Machine
Metal parts tend to go through a lot of stress which can cause damage to these parts leaving
burrs behind such as scratches, roughened edges, sharp points, rust, and many other
imperfections. And that is where barreling machines come in handy. The barreling machine is
very popular in the finishing industry.
Centrifugal barrel tumbling machines are the fastest and most cost-effective method for
deburring and/or polishing large quantities of metal parts at once. Also known as an industrial
tumbler, rotary tumbler or harperizer system, a centrifugal barrel finishing machine uses a
cyclical sliding action to grind the metal surface. Centrifugal barrel finishing is a type of mass
finishing.
Blast Cleaning Machine
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The removal of sand or scale from metal objects by the impinging action of a current of
abrasive material (such as sand, shot, or grit).
Ultrasonic Cleaner
Ultrasonic cleaners are suitable for cleaning a wide variety of materials, including metals,
glass, rubber, ceramics and some hard plastics. An ultrasonic parts cleaner is especially useful
for removing tightly-adhered contaminants from intricate items with blind holes, cracks and
recesses. Examples of contaminants removed through ultrasonic cleaning include dust, dirt,
oil, grease, pigments, flux agents, fingerprints and polishing compound. The fluid used in
industrial ultrasonic cleaning systems can be either water-based (aqueous) or solvent-based.
Both types of cleaning solutions contain wetting agents (surfactants) to reduce surface tension
and increase cavitation. Aqueous cleaning solutions are generally more limited in cleaning
effectiveness but better for the environment than solvent cleaning solutions. In ultrasonic parts
cleaning, the parts are typically placed in a basket or tray and then immersed in the ultrasonic
cleaning tank. On occasion, parts may be racked and the rack is lowered into the tank. Items
with blind holes may benefit from a rotating basket in an ultrasonic parts cleaner.
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GRAPHITE
Graphite
They are made from petroleum coke after it is mixed with coal tar pitch. They are then extruded
and shaped, then baked to carbonize the binder (pitch), and finally graphitized by heating it to
temperatures approaching 3000 °C, at which the carbon atoms arrange into graphite.
The availability of the graphite raw material for manufacturing in the form of billets in a
standard sizes different grades depending on the applications and also available in the form of
round shape material. And the graphite materials which are manufacture in the
company(plansee) are manly for the application of heat resisting, specially they are used as the
shielding for components.
• The Graphite material as 63/68 HRC.

• Specific gravity is 1.9–2.3.
• The density of the material is 2.09–2.23 g/cm3.
Graphite Classifications
Graphite can be divided into two main types
• Natural
• Synthetic
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Natural Graphite
Natural graphite is a mineral composed of graphitic carbon. It varies considerably in

crystallinity. Most of the commercial (natural) graphite’s are mined, and typically contain other
minerals. After graphite is mined, it usually requires a considerable amount of mineral
processing like froth flotation to concentrate the graphite. Natural graphite is an excellent
conductor of heat and electricity, stable over a broad range of temperatures, and a highly
refractory material with a high melting point of 3650 °C. There are three types of natural
graphite: High crystalline, Amorphous, Flake
Crystalline Graphite
It is said that crystalline vein graphite came from crude oil deposits that have transformed into
graphite through time, temperature, and pressure. Vein graphite fissures typically measure
between 1 cm and 1 m in thickness and usually have a purity of more than 90%. Although this
type of graphite can be found globally, only Sri Lanka commercially mines it, using
conventional shaft or surface mining techniques.
Amorphous Graphite
Amorphous graphite is the least graphitic among the natural graphites. However, the term
“amorphous” is incorrect as the material is still crystalline. Amorphous graphite can be found
as minute particles in beds of mesomorphic rocks such as coal, slate, or shale deposits. The
graphite content varies from 25% to 85% according to the geological environment.
Conventional mining techniques are used to extract amorphous graphite, which occurs mainly
in Mexico, North Korea, South Korea, and Austria.
Flake Graphite
Flake graphite can be found in metamorphic rocks evenly spread through the body of the ore
or in concentrated lens-shaped pockets. The range of carbon concentrations varies from 5% to
40%. Graphite flake can be found as a lamella or scaly form in specific metamorphic rocks
such as limestone, gneisses, and schists. Froth flotation is used to extract flake graphite.
“Floated” graphite has 80%–90% graphite content. Over 98% of flake graphite is made using
chemical beneficiation processes. Flake graphite can be found in numerous places worldwide.
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Synthetic Graphite
Synthetic graphite can be produced from coke and pitch. Although this graphite is not as
crystalline as natural graphite, it is likely to have higher purity. There are basically two types
of synthetic graphite. One is electrographite, pure carbon produced from coal tar pitch and
calcined petroleum coke in an electric furnace. The second is synthetic graphite, produced by
heating calcined petroleum pitch to 2800 °C. Essentially, synthetic graphite has higher
electrical resistance and porosity, and lower density. Its enhanced porosity makes it unsuitable
for refractory applications. Synthetic graphite contains mainly graphitic carbon that has been
attained by graphitization, heat treatment of non-graphitic carbon, or chemical vapor
deposition from hydrocarbons at temperatures over 2100 K.
Key Properties
Property Commercial graphite
Bulk Density (g/cm3) 1.3-1.95
Porosity (%) 0.7-53
Modulus of Elasticity (GPa) 8-15
Compressive strength (MPa) 20-200
Flexural strength (MPa) 6.9-100
Coefficient of Thermal Expansion (x10-6 °C) 1.2-8.2
Thermal conductivity (W/m.K) 25-470
Applications
Refractory Materials
On account of its high-temperature stability and chemical inertness, graphite is the perfect
candidate for refractory material. It is used in the production of refractory bricks as well as
“Mag-carbon” refractory bricks (Mg-C). In addition, graphite is used to produce crucibles,
ladles, and molds for holding molten metals. Moreover, graphite is one of the most basic
materials used in the production of functional refractories for the continuous casting of steel.
Here, graphite flake is mixed with alumina and zirconia, and then isostatically pressed to create
components like stopper rods, subentry nozzles, and ladle shrouds used for regulating the flow
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of molten steel and also for safeguarding against oxidation. This type of material could also be
used as protection for pyrometers.
In the production of iron, graphite blocks are used to produce a portion of the lining of the blast
furnace. Their structural strength at high temperature, thermal shock resistance, high thermal
conductivity, low thermal expansion, and good chemical resistance are highly important in this
application. The electrodes used in many electrical metallurgical furnaces are mass-produced
from graphite, for instance, the electric arc furnaces used for processing steel.
Chemical Industry
In the chemical sector, graphite is employed in many high-temperature applications, like in the
production of phosphorus and calcium carbide in arc furnaces. Graphite is used as an anode in
specific aqueous electrolytic processes such as the production of halogens (chlorine and
fluorine).
Nuclear Industry
Large amounts of high-purity electrographite are used for producing moderator rods and
reflector components in nuclear reactors. The suitability of electrographite comes from its low
absorption of neutrons, high thermal conductivity, and high strength at higher temperatures.
Electrical Applications
Graphite is mainly used as an electrical material in the manufacture of carbon brushes in

electric motors. Here, the component’s service life and performance largely depend on grade
and structure.
Mechanical Applications
Graphite is widely used as an engineering material across a variety of applications such as

piston rings, thrust bearings, journal bearings, and vanes. Carbon-based seals are used in the
fuel pumps and shafts of several aircraft jet engines.
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Other Applications
Amorphous graphite is used in:
• Metallurgy
• Coatings
• Lubricants
• Refractories
• Paint production
• Pencil production
Areas where crystalline graphite can be used include:
• Lubricants
• Powder metallurgy
• Grinding wheels
• Batteries
Flake graphite is used in refractory applications, typically in secondary steelmaking. Apart

from this, it may also be used in pencils, powder metallurgy, coatings, and lubricants. Many
of the sources of natural graphite are also used in the development of graphite foil. Areas where
synthetic graphites are used include:
• Aerospace applications
• Carbon brushes
• Graphite electrodes for electric arc furnaces, for metallurgical processing
• Moderator rods in nuclear power plants
• Batteries
The higher level of porosity of synthetic graphite makes it unsuitable in refractory applications.
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PROCESS:
CUSTOMER ENQUIRY
A customer request to a company for a quotation or sales information that is not binding. The
request can refer to materials or services, conditions, and, if necessary, delivery deadlines.
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Six tips for managing the workflow of your customer service inquiries for positive results.
1. Develop a Proper Organizational Chart.
2. Prioritize Support for Customer Service Inquiries.
3. Categorize Inquiries.
4. Enable Self-Service.
5. Analyze the Data.
6. Test Different Approaches.
7. Better Handling of Your Customer Service Inquiries.
SALES (MARKETING)
A sale is a transaction between two or more parties in which goods or services are exchanged
for money or other assets. In the financial markets, a sale is an agreement between a buyer and
seller involving the price of a security and its delivery for agreed-upon compensation.
Types of Selling
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• Transaction Selling: Transaction selling works well with simple, commodity products.
• Relationship Selling: Relationship selling usually involves simple or moderately
complex products.
• Solution Selling: Solution selling, as the name implies, solves a customer's business
problem.
• Partnership Selling.
NPD [NEW PRODUCT DEVELOPMENT]
New product development is a cross-functional activity. It involves people from many different
groups across your business. Cross-functional teams come together in the idea generation
stages to develop the initial product concept.
New product development is the ideation, design, production, pricing, and launching of new
products to your target customers to provide a solution that addresses an important need.
The 7 stages of a new development product:
• Stage 1: Idea Generation.

• Stage 2: Idea Screening.
• Stage 3: Concept Development & Testing.
• Stage 4: Market Strategy/Business Analysis.
• Stage 5: Product Development.
• Stage 6: Deployment.
• Stage 7: Market Entry/Commercialization.
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PLANNING
Production planning is the planning of production and manufacturing modules in a company

or industry. It utilizes the resource allocation activities of employees, materials and production
capacity, in order to serve different customers.
Planning and control refer to two strategies that work cohesively throughout the manufacturing
process. Production planning involves what to produce, when to produce it, how much to
produce, and more. A long-term view of production planning is necessary to fully optimize the
production flow.
Production planning has the purpose of ensuring all necessary preparation is completed before
a production cycle begins, so it can run smoothly. This involves allocating resources effectively
so that everything is in place for each stage of production to start.
Some of the benefits that come with production planning include:
• Decreased errors
• Fewer bottlenecks
• Deliver more on time
• Less downtime
• More organised workspace
• Fewer defects
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PRODUCTION
Production is similar to manufacturing but broader in scope. It refers to the processes and
techniques that are used to convert raw materials or semi-finished goods into finished products
or services with or without the use of machinery.
▪ MT PRO CUTTING
▪ DM KITTING.
▪ DM OKU MILLING.
MT PRO CUTTING:
Cutting flat materials into rectilinear shapes is best done with a shear. Shearing is performed
by firmly holding material against a stationary blade while another blade moves against the
material, ultimately cutting, or shearing, it. Shearing metal is no different from using scissors
to cut fabric. Powermatic bad saw machine the graphite material is cut into required shape and
size.
DM KITTING:
Kitting means gathering a set of products into a collection or kit. In manufacturing, the full
kitting process assembles all the components a worker needs to complete a task. In order
fulfilment, kitting is the practice of placing multiple SKUs together under a new SKU. Kitted
items are often sold together as a set.
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DM OKU MILLING:
CNC milling is a machining process that utilizes computerized controls to manage the
movement and operation of multi-point rotary cutting tools. As the tools rotate and move across
the surface of the workpiece, they slowly remove excess material to achieve the desired shape
and size.
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QUALITY CONTROL
Quality control (QC) is a procedure or set of procedures intended to ensure that a manufactured
product or performed service adheres to a defined set of quality criteria or meets the
requirements of the client or customer. QC is similar to, but not identical with, quality
assurance (QA). Inspection is the process of measuring, examining, and testing to gauge one
or more characteristics of a product or service and the comparison of these with specified
requirements to determine conformity.
A coordinate measuring machine, also known as a CMM, is a piece of equipment that measures
the geometries of physical objects. CMMs using a probing system to detect discreet points on
the surfaces of objects. The very first CMM made its appearance in the early 60s
Vernier Calipers is for measuring the distance between two opposite sides of a surface. We can
measure the internal and external dimensions and even the height of an object with accuracy.
It can measure up to one-hundredth of a millimeter. The least count 0.01mm
A micrometer, sometimes known as a micrometer screw gauge, is a device incorporating a

calibrated screw widely used for accurate measurement of components. the least count 0.01mm
Gauge, also spelled gage, in manufacturing and engineering, a device used to determine, either
directly or indirectly, whether a dimension is larger or smaller than another dimension that is
used as a reference standard.
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CLEANING
Cleaning the graphite components using the ultrasonic cleaning and backing at oven at 177⁰C
Ultrasonic cleaning: Ultrasonic cleaning works through high-frequency sound waves

transmitted through liquid to scrub clean the surface of immersed parts. The high-frequency
sound waves, typically 40 kHz, agitate the liquid solution of water or solvent, and cause the
cavitation of solution molecules.
Backing at oven: Such ovens are also sometimes known as kilns, though they do not reach
the same high temperatures as are used in ceramic kilns. Baking ovens – Combines the
function of curing and drying ovens.
PACKING
The primary purpose of packaging is to protect its contents from any damage that could happen
during transport, handling and storage. Packaging retains the product intact throughout its
logistics chain from manufacturer to the end user.
The four main elements of packaging are Colours, Visuals, Typography and Format. These
elements help the consumers to relate to the brand easily and tend to have a high recall.
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COMPONENTS & PRODUCTS
Components / Products Images
Linear anodes for Generating X-Rays
Shielding’s for X-ray detectors
Bolts, Nuts and Washers
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Tungsten and molybdenum electrodes for

resistance welding
Components and spare parts for ion

implantation
Semi-Conductor Base Plates
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Nozzle tip for Hot Runner Nozzles
Tungsten-copper for use in circuit breakers
Molybdenum stirrers and tappets for glass

production
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DRAWING STUDY
Geometric Dimensioning and Tolerances:
Manufactured items differ in size and dimensions from the original CAD model due to
variations in the manufacturing processes. To optimally control and communicate these
variations, engineers and manufacturers use a symbolic language called GD&T, short for
Geometric Dimensioning and Tolerancing.
GD&T tells manufacturing partners and inspectors the allowable variation within the product
assembly and standardizes how that variation is measured.
The Tolerancing falls into five main groups and fourteen subcategories.
Anatomy of GD&T annotation

Feature control frame:
Feature control frame
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In GD&T (Geometric dimensioning and tolerancing), a feature control frame is required to

describe the conditions and tolerances of a geometric control on a part's feature. The feature
control frame includes four parts:
• GD&T symbol/control symbol
• Tolerance zone type and dimensions
• Tolerance zone modifiers - such as features of size
• Datum references (if required by the GD&T Symbol)
Combined, the feature control frame provides all the information you need to measure the
geometric tolerance of the features of the part and determine if the part is in spec.
Leader Arrow: This points to the feature that the geometric control is placed on. If the arrow
points to a diametric dimension, then the axis is controlled by GD&T. If the arrow points to a
surface, then the surface is controlled by GD&T. The arrow is optional and may not be present
on some drawings.
Geometric Characteristic Symbol: This is where geometric control is specified.
Diameter Control / Cylindrical Tolerance Zone (if required): If the geometric control is a
diametrical tolerance, then the diameter symbol will be in front of the tolerance. There are a
variety of tolerance zones.
Tolerance: The numerical value defines the tolerance zone. The unit of measure is the same
for the whole drawing and will be defined in the title block.
Modifier for the Tolerance: This is max material condition or a projected tolerance in the
feature control frame.
Primary Datum (if required): If a datum is required, this is the main datum used for GD&T.
The letter corresponds to a feature somewhere on the part which will be marked with the same
letter. This is the datum that must be constrained first when measuring the part. The order of
the datum is important for measurement of the part. The primary datum is usually in 3 places
to fix 3 degrees of freedom.
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Secondary Datum (if required): When a secondary datum is required it will be to the right
of the primary datum in the feature control frame. Like the primary datum the letter
corresponds to a feature somewhere on the part which will be marked with the same letter.
During measurement this datum is fixated after the primary datum.
Tertiary Datum (if required): When a tertiary datum is required it is to the right of the
secondary datum in the feature control frame. During measurement, this datum is fixated last.
The importance of GD&T: Geometric Dimensioning and Tolerancing (GD&T) is

a discipline developed to communicate engineering configuration from the designer to the
manufacturer through engineering drawings. It is used primarily to alleviate misunderstandings
and, thus, provide complete and concise meanings to the production team members.
In 1966, industry, the Department of Defense and educational institutions adopted a common
American standard dealing with GD&T application and interpretation: American National
Standard Institute standard Y14.5.
The latest Dimensioning and Tolerancing standard, Y14.5-2009, was released in 2009. The
majority of the GD&T symbology has remained unchanged, however there has been some
symbol modifications and additions, and a considerable amount of new material added.
Knowing the language is the key: Geometric Dimensioning and Tolerancing

(GD&T) is a language used to communicate engineering configuration from the designer to
the manufacturer through a mechanical drawing. When properly applied, GD&T promotes a
uniform understanding and interpretation among all persons involved with the drawing.
The universal problem experienced with the Y14.5 standard is the failure to adequately educate
the drawing originators, manufacturers, and quality control personnel in a complete
understanding of this communicative tool. As a result, both design and manufacturing suffer
due to this training oversight. Until GD&T literacy exists in the United States, productivity
will suffer, lawsuits will continue, and production costs will not be minimized.
A complete understanding of GD&T is vital for tearing down the walls of misunderstanding.
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Surface Texture Symbols:
ISO Surface Finish Symbols and Callouts:
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Surface Roughness of Abrasive Grits and Sandpaper:
One approach to Surface Finish is to use abrasives or sand the surface. This chart converts
from abrasive grit to Surface Finish Ra values:
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Surface Finish Values Table:
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QUALITY CONTROL & INSPECTION

Quality is the totality of features and characteristics of a product or service that bear on its
ability to satisfy given needs. Quality, an inherent or distinguishing characteristic, a degree or
grade of excellence.
Quality Glossary Definition: Standard. Quality standards are defined as documents that
provide requirements, specifications, guidelines, or characteristics that can be used
consistently to ensure that materials, products, processes, and services are fit for their purpose.
Quality is critical to satisfying your customers and retaining their loyalty so they continue to
buy from you in the future. Quality products make an important contribution to long-term
revenue and profitability. They also enable you to charge and maintain higher prices.
Quality is essential to satisfy customers in order to retain their loyalty so that they will be
willing to buy in the future as well. Quality products make a significant impact on revenues in
the long run. Quality is what differentiates a company in a crammed market.
High-quality products that meet customers' needs results in higher customer satisfaction. High
customer satisfaction, in turn, can lead to increased market share, revenue growth via upsells
and word-of-mouth marketing initiated by customers.
It helps an organization achieve greater consistency in tasks and activities that are involved in
the production of products and services. It increases efficiency in processes, reduces wastage,
and improves the use of time and other resources. It helps improve customer satisfaction.
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Instruments used in the quality
Vernier Caliper
Vernier Caliper is a widely used linear measurement instrument with a least count of 0.02 mm.
It is used to measure linear dimensions like length, diameter, depth.
It is a Basic Instrument of measurement, consisting of two types of scale
The main scale and the Vernier scale can slide along the main scale. Two types of measurement
we can do, the first one is through the external jaw (measure external dimensions) and another
one is the internal jaw (measure internal dimensions).
Outside Micrometer
External Micrometer is also known as Outside Micrometer or External Micrometer. It is used

to check the outside diameter of the circle by the means of the accuracy of 0.01 mm or up to
0.001 mm.
Vernier type Micrometer gives highest acceptable accuracy of 1 micron such gauge is vernier
type micrometer.
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Vernier Height Gauge
Vernier height gauge used to measure vertical dimension from reference ground. Vernier
Height Gauge consists of a graduated scale or bar that is held in a vertical position by a finely
ground fixed base.
The graduated scale has the least count of 0.02 mm as Vernier Caliper has. And the way of
taking a reading of measurement in Vernier Height Gauge is the same as in Vernier gauge.
learn more about Vernier height gauge in our Advance Engineering Metrology Course.
Steel Scale
Steel scale is a single piece linear measuring instrument.
The steel scale indicates two units that are cm and inches, cm division on one side and inches,
on another side.
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Vernier Depth Gauge
Vernier Depth Gauge as the name suggests is used to measure the depth from the surface of
reference of an object.
Vernier caliper also has a depth bar but this cannot be used as the standard measurement.
Vernier Bevel Protractor
A simple protractor is a basic device used for measuring angles with a least count of 1° or ½°.
Bevel Protractor is an angular measuring instrument capable of measuring angles with a least
count of 5’.
The protractor dial is graduated in degrees with every tenth degree numbered. The sliding blade
is fitted into this dial i.e., it may be extended to either direction and set at an angle to the base.
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Plunger Dial Gauge
The dial indicator or the Plunger dial gauge is one of the simplest and the most widely
used mechanical comparators.
First of all, the use of plunger dial gauge used to compare work-pieces against a master
Lever Dial Gauge
Lever Dial Gauge is also known as Test Indicator. It is used to measure sensitive contact.
Lever Dial gauge usually measure up to 0.80 mm. But some special type lever dial design for
measurement up to 2 mm.
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Engineering Square
A ruler can be used to draw straight lines but there is no guarantee that the line drawn is
accurate and exactly straight, this is where the engineering square is brought into use.
An engineering square also known as a machinist square is similar in size and construction to
a try square. It is a tool used for making straight lines and is used to measure angles.
V Block
In Industries where precise marking and firm holding of objects is required, V-Blocks play a
major role and are extremely important metalworking jigs. The construction had two clamps:
a screw clamp and a U-shaped handle like a clamp and a V-block.
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Radius Gauge
Gauges are derived from the French word “jauge” which means the result of the measurement.
We are all aware that gauges are used to measure the thickness, size or capacity of something.
Likewise, radius gauges are instruments that are used to measure the radius of the object.
The radius gauge is combined with another gauge known as fillet gauge which in mechanics
means a rounding of the part design.
Digital Vernier Caliper
Digital Vernier Caliper is upgrading the version of Analog Vernier Caliper, which is a widely
used linear measurement instrument with a least count of 0.01 mm, more accurate than Analog.
This Digital type of vernier is similar to Analog Vernier Caliper Instead Dimension output in
Digital Manner is more convinces than the analogue type.
It also consists of two types of scale:
The main scale and the Digital display can slide along the main scale. Two types of
measurements we can do, the first one is through the external jaw (that measures external
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dimensions like shaft) and another one is the internal jaw (measure internal dimensions like a
hole).
Digital Micrometer
Digital Micrometer is a very popular instrument these days because of its ease of compactness
of taking an observation.
Digital Micrometer can observe measurement in mm or inch depending upon our need basis.
Inside Micrometer
Inside Micrometer is used to measure the larger internal dimension. Inside Micrometer can
measure the internal Diameter of holes and registers.
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Types of Micrometers
There are various types of micrometers available in the industry each used for a specific
purpose. One such micrometer is the “Inside Micrometer”.
The inside micrometer is used to measure the inner diameter of objects that are bounded by
walls, cylindrical bore or hollow pipe. There are two types of Inside Micrometer
1. Analog type Inside Micrometer
2. Digital type Inside Micrometer
Depth Micrometer
We also measure depth through the Vernier caliper, but the Vernier caliper does not deliver as
much accuracy and precision, because the extension rod of the Vernier caliper has no standard,
it is used only for comparison purposes.
A depth micrometer is used to measure the depth of an object with precision and accuracy with
least count of 0.01 mm. The measuring span is 25 mm just like in micrometer, which can
change by changing upsetting rod.
Measuring Tape
Measuring tape is used to measure long distances.
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Digital Height Gauge
The electronic Height gauge is a very compact, simple, easy to use instrument widely used in
industries, tool rooms, workshops etc.
Some think you should consider while handling Electronic Height Gauge, Because of the cost
of Electronic Height gauge matter in any industries or organization.
Electronic Height Gauge
An electronic height gauge is an advanced form of the height gauge. It has higher accuracy and
multifunction.
An Electronic height gauge can measure diameter, angle, parallelism, squareness along the
length.
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Digital Universal Caliper
Digital universal caliper is widely used to measure the inner and outer length of work-piece
Sine Bar
Sine bar is a precision angle measuring instrument along with slip gauges. The name suggests
that the Sine bar work on the sine principle. Slip gauge is used to build up the height of the
sine bar.
The required angle is obtained when the difference in height between the two rollers is equal
to the sine of the angle multiplied by the distance between the centres of the rollers.
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Digital Protractor
Digital Protractors measure an angle over 360 degrees with high accuracy of 0.1 degrees.
Digital Protractor is very simple and easy to measure the angle by just putting it between levels
or surfaces.
Spirit level
To check the level of any surface or table, a spirit level is used for levelling. Typically, the
vials in a spirit level are a yellowish-green color with additives for UV protection and
maximum performance in temperatures ranging from -20 degrees F to 130 degrees F. The best
spirit level is accurate to within plus or minus 0.5 millimeters/meter, or 0.005 inches/inch or
.029 degrees. The next level of accuracy displayed is 0.75mm/m or.043 degrees.
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Slip Gauge Set
Slip Gauge is a set standard size rectangular shape block. Slip gauges are available in standard
sets in both metric and inch units.
In metric units, sets of 31, 48, 56, and 103 pieces are available.
For example, the set of 103 pieces consists of the following:
1. One piece of 1.005 mm
2. 49 pieces ranging from 1.01 to 1.49 mm in steps of 0.01 mm
3. 49 pieces ranging from 0.5 to 24.5 mm in steps of 0.5 mm
4. Four pieces ranging from 25 to 100 mm in steps of 25 mm
Bore Dial Gauge
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Bore Dial Gauge is used to measure the inner diameter of the hole, it is a gauge fitted with a
plunger dial gauge. In this video, you are able to know how to measure diameter with a bore
dial gauge.
Bore dial gauge used within the standard range that means bore dial gauge have a standard set
of pins(anvils) with the variable range of up to 2 mm.
Feeler Gauge
A Feeler gauge is used to measure the clearance between two parallel flat faces for example
piston and cylinder. As the name suggests, the feeler gauge is called to measure neither tide
nor freely.
Feeler gauges are used for the measurement of clearances.
It is a tool that measures air or narrow gap widths between two surfaces in engines and
machinery.
Feeler gauge available in no. of the blade-like 10,13,20 and 28. With a step of 0.05 and 0.10
mm.
Snap gauge
Snap gauge is GO and NOGO type gauge. That means snap gauges consist of 2 fixed measured
distances or gaps, one is known as GO and another one is known as NOGO.
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Plain Plug gauge
Plug gauge is used for the assessment of the hole or diameter of an object. With specified
tolerance of GO and NOGO side, plug gauge is also known as pin gauge.
Behalf of checking the diameter plug gauge also use in comparing, setting, calibrating of other
gauges.
Ring Gauge
A ring gauge, or ring gage, is a cylindrical ring of a thermally stable material, often steel,
whose inside diameter is finished to gauge tolerance and is used for checking the external
diameter of a cylindrical object.
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Surface Gauge
A surface gauge is very useful when finding the centre of a piece of round section material. It
is normally used to ‘scribe’ parallel lines. Its base is heavy and this means it is stable when in
used. Surface gauges sometimes have magnetic bases and this means they can be locked onto
metal surfaces making it easier to use.
Surface Roughness Tester
A roughness tester is used to quickly and accurately determine the surface texture or surface
roughness of a material. A roughness tester shows the measured roughness depth (Rz) as well
as the mean roughness value (Ra) in micrometers or microns (µm). Measuring the roughness
of a surface involves applying a roughness filter.
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Coordinate Measuring Machine (CMM):
A coordinate measuring machine, also known as a CMM, is a piece of equipment that measures
the geometries of physical objects. CMMs using a probing system to detect discreet points on
the surfaces of objects.
A coordinate measuring machine (CMM) is either a contact model that uses touch probes, a
spherical object used to perform measurements, or a non-contact model, which uses other
methods such as cameras and lasers.
A coordinate measuring machine (CMM) measures the height, width, and depth of the part
using coordinate processing technology. In addition, such machines can automatically measure
the target, record the measured data, and obtain GD&T measurements.
Basic CMM Model:
A. Moving Bridge
B. Trigger Probe
C. Stage
D. Controller
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CMM Accessories:
Stylus / Probe Tip: Stylus of contact type CMM generally has a spherical diameter. Hard
materials are often used at the probe tip - ruby and zirconia being the most common. In addition
to the spherical shape, a needle type with a sharp tip may be used.
Types of Probes:
▪ Single Probe
▪ Master Probe
Types of Probe Head Utilized:
▪ RDS - Rotation Probe Head
▪ Fixed Probe Head
Granite Table: In order to realize highly accurate measurement, the surface of a coordinate
measuring machine is often a surface plate made of stone. The stone surface plate has a very
small change in shape over time and is not easily scratched, so it has the advantage that it can
be used stably for a long time. The Bed size is 600 600 700.
Fixtures: The reason measurement target is fixtured it does not move during CMM operation
because part movement will lead to errors. It is common to use tools such as a fixture plates,
clamps, and magnets
Air Compressor: Mechanically driven coordinate measuring machines require an air

compressor with a dryer. This can be found is standard bridge or gantry-type CMMs. 5 Bar of
pressure is required for the operation.
Software: Zeiss Calypso is the most widely used software in the industry.
Datum Spheres: These are used to qualify or calibrate the CMM measuring tool, whether it
be a touch probe stylus or optical sensor.
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TOOLINGS
Different types of Tools and Inserts used for machining
Boring:
Tool Holder: S25H SVNR 12N [KYOCERA]
Insert: VNBR 0511 02 - KW10
VNBR 0311 02 KW10
VNBR 0630 02NB KW1
Some of the standard Tool Holders and Inserts using in Turning application are listed below.
Facing and OD Turning:

Tool Holder: SCLCR 2020 K12 [CERATIZIT]
Inserts: Roughing- CCGT 120408 FN 25PH 210T
Finishing- CCGT 120402 FN 25PH 210T
Contour & Cornering:

Tool Holder: SVJCR 2020 K16 [CERATIZIT]
Inserts: VCGT 160404 FN 25P H2 10T
(Corner Radius varies depending on application)
DCGT 070204 FN 25P H2 10T
Parting / Cut-off:
Tool Holder: MSS E20 L00 2020J [CERATIZIT]
Insert: FX 3.1 N0.15 27P H210T
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Threading: (External)
Tool Holder: KTNR 202 K16 [KYOCERA]
Insert: 16ER 175ISO TF - PR1115
16ER 100 ISO - GW15
16ER200ISO TF - PR1115
Boring:
Tool Holder: S25H SVNR 12N [KYOCERA]
Insert: VNBR 0511 02 - KW10
VNBR 0311 02 KW10
VNBR 0630 02NB KW1
Types of cutting Tools:

Drill Bit: Drill bits have a conical cutting point and a shaft with one or more flutes-the helical
grooves that run down the exterior of the tool.
CNC Machining drill bits typically come in three varieties-center, twist, and ejector drills- with
each type having different important functions.
You should use center drill bits to precisely create small spots on the workpiece, which can
then be drilled properly using a twist drill. In contrast, ejector drills are better suited for deep
hole drilling
End Mill: End mills are similar to drill bits but are much more versatile in the operations they
perform. They typically have up to eight sharp flutes on their ends and sides, allowing them to
remove large amounts of materials within a short period. An end mill should be your go-to tool
if you want to cut straight down into a material without requiring a pre-drilled hole (or spot).
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End mills come in many varieties, with the roughing end mill type being the most common.
Roughing end mills have up to eight flutes, just like the regular end mills. However, the flutes
in the roughing end mills are serrated, allowing you to remove larger amounts of materials
compared to the regular end mills.
Face Mill: More often than not, the starting material (or workpiece) used in CNC milling
machines requires some sort of preparation before you can perform major milling operations.
Face mills are specialty cutting tools that allow you to make flat sections of the workpiece
before detailed cutting operations are carried out. This tool features a solid body with multiple
interchangeable cutters inserts that can be swapped as needed.
You might want to consider using a “side and face cutter” for more demanding complex
operations. For instance, side and face cutters allow you to cut a groove or slot workpiece while
also cutting the sidewalls of the workpiece.
Reamers: Let’s say you need to create a 1/2” hole in a workpiece. You can proceed to use a
1/2” drill bit, right? Wrong! Do this, and you can expect to have an oversized hole when you’re
done drilling your workpiece.
An ideal way to create this hole is to start with a smaller drill bit, say 31/64”, before widening
the hole to 1/2” using a reamer. Reamers allow you to expand the size of existing holes while
achieving dimensional accuracy and tight tolerances.
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Gear Cutters: As the name suggests, gear cutters are used to make gears for manufacturing
industries. You can use it to fabricate a wide variety of gears, including spur, bevel, worm,
screw, and helical gears.
Hollow Mill: Hollow mills are pipe-shaped cutting tools with three or more cutting edge that
enclose and revolve around a cylindrical workpiece. This cutting tool allows you to create a
consistent pre-thread diameter quickly and efficiently. You can also use them in drill press
work for finishing projections that must be in a given position
Thread Mill: As the name suggests, thread mills are CNC cutting tools used for cutting
threads. They are similar to taps in the purpose they serve. But unlike taps that cut only internal
threads, CNC machines fitted with thread mills can cut both internal and external threads.
You should opt for thread mills if you’re looking to penetrate hard metals or asymmetrical
parts.
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Slab Mill: Slab mills, also known as slab cutters or plain mills, are used to cut flat surfaces.
These cutters typically only have teeth on their periphery and are ideal for creating wide and
narrow cuts quickly.
Fly Cutter: Fly cutters are single-point rotary tools that make broad or shallow cuts and
produce a smooth surface finish. Compared to most face mills, fly cutters are inexpensive and
offer a better surface finish. It should be your go-to tool for plane surfacing operations.
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INSERTS
Specifications
The inscribed circle (I.C.), or the diameter of the circle that fits entirely within the insert
geometry, generally categorizes insert size. This is used for most indexable inserts, except for
rectangular and some parallelogram inserts, where length and width are used. Important
specifications for cutting tool inserts include thickness, radius if applicable, and chamfer angle
if applicable. Common features for cutting tool inserts include unground, indexable, chip
breaker, and dished. Insert attachments can be screw-on or no hole.
Some of inserts as below
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Cutting Tool Geometry:

Cutting tools for metal cutting have many shapes, each of which are described by their angles
or geometries. Every one of these tool shapes have a specific purpose in metal cutting. The
primary machining goal is to achieve the most efficient separation of chips from the workpiece.
For this reason, the selection of the right cutting tool geometry is critical. Other chip formation
influences include:
• The workpiece material

• The cutting tool material
• The power and speed of the machine
• Various process conditions, such as heat and vibration.
Turning & Single-Point Cutting Tools

Nearly all turning processes use single point cutting tools, this is, tools that cut with only a
single edge in contact with the work. Most turning is done with coated indexable carbide
inserts, but the tool material may also be high-speed steel, brazed carbide, ceramic, cubic boron
nitride, or polycrystalline diamond. 75 percent of turning operations use just a few basic tool
geometries. When turning with inserts, much of the geometry is built into the tool holder itself
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rather than the actual insert. However, let's first focus on the inserts. The geometry of an insert
includes:
• The insert's basic shape

• Its relief or clearance angle
• The insert types
• The insert's inscribed circle or "IC" size
• The insert's nose radius
• The insert's chip breaker design
Cutting tool consists of various angles and shape to which the cutting portion of a cutting
tool are ground.
There are seven important angles included in a single point cutting tool.
Back Rake Angle: Important for smooth chip flow needed for a uniform chip and Good
Surface Finish.
Side Rake Angle: Directs the chip flow away from the point of cut.
End Relief Angle: Prevents front edge of the tool from rubbing on the work.
Side Relief Angle: Provides for cutting action by allowing the tool to feed into the work
material.
Side Cutting Edge Angle: May vary considerably depending on the metal removal.
End Cutting Edge Angle: Prevents the front edge of the tool rubbing axially while cutting.
Nose Radius: Point where both cutting edge meets. It varies depending on the finish
required.
71
Tool holding Collets:

A collet is a form of chuck, but it is not identical. While a chuck is tightened around an
object, a collet utilizes clamping pressure by forming a collar around the object being held,
holding it securely in place. This clamping force is typing applied through a tapered design
that uses a sleeve and inner cylindrical surface. While there are varying designs, all collet
types operate by being pressed over the element to be held, resulting in both accurate
alignment and static friction. While the collet is not suitable for every tool and operation, it
does allow for self-centering, resistance against loosening, fast-chucking and steady
clamping pressure.
ER COLLET CLAMPING RANGE
ER 11 Ø 0.5 mm - Ø 7 mm
ER 16 Ø 0.5 mm - Ø 9 mm
ER 20 Ø 1 mm - Ø 13 mm
ER 25 Ø 1 mm - Ø 16 mm
ER 32 Ø 1 mm - Ø 21 mm
ER 40 Ø 3 mm - Ø 26 mm
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Work Holding Collets:
This phenomenon of the staying power of the collet, in light of the rapidly changing
technology in machine tool design, is attributed to the utility and the elegant simplicity of
the device. The collet is a small but powerful component for the machine tool industry,
incorporating all of the following features:
• The capability to accurately grip a workpiece or a tool, resisting both rotational forces
and multi-directional cutting loads.
• The capability to amplify the actuation force, converting it into workpiece or tool
gripping.
• The inherent ability to rapidly release the workpiece or the tool.
• The ability to operate at high repetition levels without loss of accuracy or material
failure.
• The ability to operate at a wide range of rotational speeds with minimal loss of
gripping force.
• The ability to accomplish all of the above with a minimum of rotational inertia.
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SPERONI Tool Presetter & Measuring System
The standard control offered with a SPERONI tool presetter.

• Single window graphical interface
• Flying cross-hair
• Full screen function and 120x zoom
• 45x standard magnification
• Over 150 measuring icons
• Dial indicator and runout functions
• MaxP function
• Tool management for 1,000 tools
• Adapter & zero-point management
• Base post processor
• Data backup function
• Print management
• Powerful online help function.
Features:
• The new standard in bench-top precision tool presetting & measuring systems.
• All MAGIS models are constructed with Pearlitic class 40 cast iron
• Equipment is fully isostatic and will not deform or distort over time or temperature
change
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• 270-degree access to the tools while in the spindle

• Fast manual axis movement
• ISO 50 spindle accuracy and T.I.R. (Maximum .0003" at 400mm)
• Sub-pixel & sub-micron resolution of less than 0.000039" (< 1 micron)
• Display resolution .001mm (.0001 inch) for added detail and accuracy
• CNC options available.
75
LEAN MANAGEMENT
PDCA Cycle:
PDCA cycle is an iterative process for continually improving products, people, and services.
It became an integral part of what is known today as Lean management. The Plan-Do-Check-
Act model includes solutions testing, analyzing results, and improving the process.
Plan: At this stage, you will literally plan what needs to be done. Depending on the project's
size, planning can take a major part of your team’s efforts. It will usually consist of smaller
steps so that you can build a proper plan with fewer possibilities of failure.
Before you move to the next stage, you need to be sure that you answered some basic concerns:
• What is the core problem we need to solve?
• What resources do we need?
• What resources do we have?
• What is the best solution for fixing the problem with the available resources?
• In what conditions will the plan be considered successful? What are the goals?
Do: After you have agreed on the plan, it is time to take action. At this stage, you will apply
everything that has been considered during the previous stage.
76
Be aware that unpredicted problems may occur at this phase. This is why, in a perfect situation,
you may first try to incorporate your plan on a small scale and in a controlled environment.
Standardization is something that will definitely help your team apply the plan smoothly. Make
sure that everybody knows their roles and responsibilities.
Check: This is probably the most important stage of the PDCA cycle. If you want to clarify
your plan, avoid recurring mistakes, and apply continuous improvement successfully, you need
to pay enough attention to the CHECK phase.
Here, you need to audit your plan’s execution and see if your initial plan actually worked.
Moreover, your team will be able to identify problematic parts of the current process and
eliminate them in the future. If something went wrong during the process, you need to analyze
it and find the root cause of the problems.
Act: Finally, you arrive at the last stage of the Plan-Do-Check-Act cycle. Previously, you
developed, applied, and checked your plan. Now, you need to act.
If everything seems perfect and your team managed to achieve the original goals, then you can
proceed and apply your initial plan.
It can be appropriate to adopt the whole plan if objectives are met. Respectively, your PDCA
model will become the new standard baseline. However, every time you repeat a standardized
plan, remind your team to go through all steps again and try to improve carefully.
5S:
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5S is often summarized by the philosophy “a place for everything and everything in its place.”
5S originated as 5 Japanese words: Seiri, Seiton, Seisou, Seiketsu, and Shitsuke. In English
these have come to be known as:
Sort: Eliminate that which is not needed.
Straighten: Organize what remains after sorting.
Shine: Clean and inspect the work area.
Standardize: Write standards for 5S.
Sustain: Consistently apply the 5S standards.
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7 QC TOOLS
Cause and Effect Diagram
Cause and Effect Diagram also known as Fishbone Diagram helps in identifying the potential
causes of an effect or a problem. In addition to sorting ideas in respective categories, it also
helps in understanding the areas of opportunity through effective brainstorming. Fishbone
training empowers you to identify the potential cause in the problem.
Control Chart
Control charts are used to study how the processes have changed over a period of time. Further,
by comparing current data to historical control limits, one could lead to the conclusion about
whether the process variation is consistent as in under control or unpredictable as in out of the
control due to being affected by special causes of variation.
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Pareto Chart
Pareto Chart is based on the 80/20 rule where it shows the significant factors that have the
highest impact on the identified problem.
Check Sheet
Check sheet is a structured process which helps to collect and analyzing data. It is an effective
tool that can be for a variety of purposes.
80
Histogram
Histogram is commonly used a graph that shows the data and its frequency of distribution to
help users identify each different value in a set of data occurs.
Scatter Diagram
Scatter diagram shows the relationship between two important factors i.e., pairs of numerical
data, one variable on each axis to demonstrate the relationship.
81
Stratification
Stratification also known as a flow chart or run chart is a technique that separates the data
gathered from a variety of sources so that patterns can be seen i.e., the path an entity has taken
through a defined process
82
CONTINOUS IMPROVEMENT
KAIZEN
Kaizen: Kaizen is a Japanese term meaning “change for the better” or “continuous
improvement”. It is a Japanese business philosophy regarding the processes that continuously
improve operations and involve all employees.
Kaizens done in the Shop Floor Area are listed below:
• Part No. 11371936 [Pattern Bottom] Complexity of checking Ø 9.53 mm each

time at CMM has been replaced with Pin Gauge Inspection Method.
• Part No. 11372874 [Nozzle Gas] Parallelism problem with 15.34mm

dimensions has eliminated by making new fixture.
• Part No. 11858353 [End Liner Cathode] Edge cracking due to vice clamping
force has been eliminated due with new fixture design.
• Part No. 12629287 [Mo stud 2 3/8” x 16 UNC-45mm] Edge cracking due to
clamping force has been eliminated with new fixture design.
• Part No. 11633879 & 11633880 [Filament Clamp] Finishing problem with
the curve area has beensolved with changing the feed rate at curve area by using
Macro Programming.
• Part No. 11536787 [Base Support sup elec] Chip off problem has been
eliminated with new fixture design.
• Chamfer perpendicularity issue

due to butting has been improved with new Aluminium Fixture.
83
DOCUMENTATION
Documentation is the key to Good Manufacturing practices compliance and ensures
traceability of all development, manufacturing, and testing activities. Documentation provides
the route for auditors to assess the overall quality of operations within a company and the final
product.
• The management of each operational site is required to define responsibility for

origination, distribution, maintenance, change control, and archiving of all GMP
documentation and records within that department or unit.
• Document owners are required to ensure that all aspects of documentation and records
management specified in form of standard operating procedures (SOPs).
• All associates have the responsibility of ensuring that all GMP activities are performed
according to the official SOPs; any deviations in procedure are reported to their
supervisor and are adequately documented.
• The local quality assurance unit has the responsibility of ensuring via organizational
measures and auditing that GMP documentation and records systems used within the
operational unit are complete and comply with the relevant GMP requirements, and
also that the requirements of the SOPs are followed.
• Requirements for specific documents or record, including ownership, content,
authorization, and change control procedures, has to be described or cross-referenced
in the quality modules which relate to the subject of the document.
ISO STANDARDS:
ISO-9000(Quality Management Systems): This International Standard provides the

fundamental concepts, principles and vocabulary for quality management systems (QMS) and
provides the foundation for other QMS standards. This International Standard is intended to
help the user to understand the fundamental concepts, principles and vocabulary of quality
management, in order to be able to effectively and efficiently implement a QMS and realize
value from other QMS standards.
This International Standard proposes a well-defined QMS, based on a framework that

integrates established fundamental concepts, principles, processes and resources related to
quality, in order to help organizations, realize their objectives. It is applicable to all
84
organizations, regardless of size, complexity or business model. Its aim is to increase an

organization’s awareness of its duties and commitment in fulfilling the needs and expectations
of its customers and interested parties, and in achieving satisfaction with its products and
services.
Scope:
This International Standard describes the fundamental concepts and principles of quality
management which are universally applicable to the following:
• Organizations seeking sustained success through the implementation of a quality

management system;
• Customers seeking confidence in an organization’s ability to consistently provide
products and services conforming to their requirements;
• Organizations seeking confidence in their supply chain that product and service
requirements will be met;
• Organizations and interested parties seeking to improve communication through a
common understanding of the vocabulary used in quality management;
• Organizations performing conformity assessments against the requirements of
ISO 9001;
• Providers of training, assessment or advice in quality management;
• Developers of related standards.
ISO-14000 (ENVIRONMENTAL MANAGEMENT SYSTEM): ISO 14000 is a family of

standards related to environmental management that exists to help organizations to minimize
how their operations (processes, etc.) negatively affect the environment (i.e., cause adverse
changes to air, water, or land) and comply with applicable laws, regulations, and other
environmentally oriented requirements; and continually improve in the above.
ISO 14000 is similar to ISO 9000 quality management in that both pertain to the process of
how a product is produced, rather than to the product itself. As with ISO 9001, certification is
performed by third-party organizations rather than being awarded by ISO directly. The ISO
19011 and ISO 17021 audit standards apply when audits are being performed.
85
The requirements of ISO 14001 are an integral part of the European Union's Eco-Management
and Audit Scheme (EMAS). EMAS's structure and material are more demanding, mainly
concerning performance improvement, legal compliance, and reporting duties.
Basic principles and methodology:

➢ Plan: Establish objectives and processes required
➢ Do: Implement the processes
➢ Check: Measure and monitor the processes and report results
➢ Act: Take action to improve performance of EMS based on results.
AUDITING IN DOCUMENTATION:
Audit documentation is very important for auditor especially in the areas of quality control of
the audit. It is required by ISA that the audit documentation should be prepared in the form
that others senior auditor who is not involved with the audit engagement previously could
understand the work that performs when he reviews the documents. The following is the key
information that should have in the audit documentation:
• The nature of information or data that being prepare or documents

• Timing including the audit period that covers, and the date prepare
• Name of the auditor who prepares audit working papers
• The extent of the audit procedures performed to comply with the ISAs and
applicable legal and regulatory requirements.
• The evidence that auditor obtains, the procedures that they use for testing and the
result of testing should properly and clearly document in the audit working papers.
DOCUMENT CATEGORY:
• Public
• Internal Limited External
• Internal-Internal
• Confidential Limited
• Confidential-limited external
• Confidential Internal use only
• Secret
86
KEY PERFORMANCE INDICATORS: It is important to grow the top line of your

business on an annual basis, but you also need to make sure the bottom line is healthy which
can help fund that growth.
This is particularly important if you are a manufacturing company and need to be efficient in
your production process. In most cases, the two biggest expenses in manufacturing business
are labor and raw materials. There are exceptions, of course, in machine intensive automated
manufacturing plants, but let’s focus on the former. So how can we make sure the
production line is running at peak performance? One very effective way is to put the right
balance of production KPIs in place. Some of these are leading indicator KPIs that help
provide insight into future performance.
Some of key performance indicators as below
• Asset utilization
• Availability
• Avoided cost
• Capacity utilization
• Compliance rates (for government regulations, etc.)
• Customer complaints
• Customer satisfaction
• On-time orders
• Process capability
• Productivity
• Quality improvement
87
INDUSTRIAL SAFETY
Industrial safety management helps you maintain the safety of everyone and everything at your
facility. Safety management helps you avoid unscheduled downtime and legal liabilities, both
of which cost you time and money. The Occupational Safety and Health Association (OSHA)
is the main regulatory body that maintains and enforces the standard procedures and
requirements for ensuring industrial safety in the United States. Generally, if there is a question
about safety, OSHA is part of the answer.
The Importance of Industrial Safety
Although every workplace and job task carry some safety hazards, industrial hazards are often
higher risk and have the potential to cause severe injury, extensive property damage, or
devastating environmental harm. Given the highly specialized nature of the work, many of the
jobs are carried out by trained and skilled employees. Workers who sustain lost time injuries
can be difficult to replace, even temporarily. Because of this, injuries can have significant
effects on a company's production output, shipping schedules, fulfilment, vendor relationships
and customer satisfaction. Good safety practices, then, not only keep workers safe but also help
maintain employee, vendor, and client satisfaction.
Industrial Safety Planning
Industrial safety takes place long before the work begins. In fact, it should be part of the job
planning and site design. Some important early and ongoing considerations include:
• Plant layout
• Fire prevention systems
• Health and hygiene
• Safety training
• Alarms and warning systems
• Adequate lighting in work areas and corridors
• Flooring and working areas that are easy to clean and organize
• Signboards and written safety instructions.
88
Industrial Safety Equipment:
Type of industrial safety equipment varies by industry. But there is often a lot of overlap. For
example, most industries use personal protective equipment (PPE).
• Safety glasses protect the eyes when welding or using specific tools. Because dust and
debris can cause injuries, make sure they fit and protect the eyes from the sides.
• Hearing protection using muffs or earplugs prevents hearing damage or loss when
exposed to extreme noise.
• Safety gloves are critical when working with chemicals, sharp objects, or extremely
hot or cold temperatures. Make sure the gloves fit to avoid burns or lacerations.
• Face shields like safety glasses, employees should wear face shields to avoid flying
debris while using equipment.
• Safety shoes close-toed, non-slip shoes made from a thick material help prevent slips,
trips, and falls. They also protect against burns and lacerations.
In many industries, including for example oil and gas, many injuries are from falling objects.
Safety helmets protect the brain from falling tools and equipment. Because head injuries are
so often life changing or even fatal, people onsite need to wear head protection even when just
quickly passing through certain high-risk areas.
89

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PLANSEE INTERNSHIP REPORT

1. MACHINE SHOP OVERVIEW

1. Tungsten and Molybdenum Parts - Ion Implantation.

2. Nozzles – Plastic Injection Moulding.

3. Anodes & Rotors - Medical (CT Scanning Machines).

4. Electrodes - Automobile Industries (Resistance Welding).

1.2 Overall Process Flow of Work:

The major steps involved in the process flow of work as follows.

1. Customer Enquiry or our approach to the Customer.

2. Equipment / Tools / Process feasibility study.

3. Developing the program.

4. Sample preparation for approval from customer end.

5. Estimation and Quotation by Estimators.

6. Customer approval and order confirmation.

7. Planning and scheduling by the production team.

10. Cleaning, Packing and Dispatch.

1.3 Types of Raw Materials

• Silvery Grey in color

• Ribbons and Wires for Lighting Industry.

• Very Low Thermal expansion and coefficient

1.3.3 TZM: TZM an acronym for the molybdenum alloy “titanium-zirconium-

• Higher recrystallization temperature

• Rotating Anodes in X-Ray tubes

1.3.4 WCu (Tungsten-Copper): WCu is a composite consist of porous Tungsten matrix

• Has low arc erosion tendency.

• High voltage circuit breakers.

WCu Materials Applications:

• High Corrosion Resistance

Powder Metallurgy Process: Powder metallurgy is the process of blending fine

Steps involved in powder metallurgy:

2. Mixing of other metal powder and Additives/binders.

5. Machining and finishing.

Steps involved in Back Casting Process:

1. Base Metal Preparation.

3. Mixing of other metal powder and Additives/binders.

6. Machining and finishing.

• Minimizes machining by producing parts at, or close to, final dimensions.

Material Mass Density Melting point

Copper (Cu) 8.96 1085

Density of the Metals

Melting Point of Metals

OVERALL PROCESS AND MACHINE OPERATION

Machine Capacity and Specification:

Cutting Size (L x B) _ 900 x 900 mm 210 x 210 mm _

Cutting Speed m/min _ 25 100 20 - 100 20 - 100

Work Table 60 x 190 x 8 mm slot 900 x 900 mm _ 600 x 600 mm

FEHLMANN ACE ACE OKUMA

No. of Axis 4 - Axis 3 - Axis 3 - Axis 3 - Axis

Spindle Nose Taper SK 30 BT 40 BT 40 CAT 40

Tool Magazine Capacity 32 24 24 32

ACE MICROMATIC DMG MORI ACE MICROMATIC

Driver Controller FANUC FANUC

Swing over Bed 610 mm 923.8 mm 640 mm

Max. Turning Dia. 386 mm 52 mm 580 mm

Max. Turning Length 480 mm 515 mm 1000 mm

Max. Bar Capacity 51 mm 480 mm 51

Bore through Spindle 63 mm 47 mm 63 mm 63 mm

Spindle Nose A2-6 FLAT A2-6 A2-6

ACE MICROMATIC ACE MICROMATIC MORI

Swing over Bed 610 mm 458 mm 680 mm

Max. Turning Dia. 350 mm 360 mm 430 mm

Max. Turning Length 190 mm 519 mm

Max. Bar Capacity 51 mm 51 mm 41 mm