Last Year Project

Savitribai Phule Pune University
AISSMS College of Engineering Pune, Mechanical Engineering (Sandwich)
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Index
Serial Title Page No
No
1 Figure Table 7
2 Company Profile 8
3 Introduction 8
4 History 9
5 Mission 10
6 Vision 10
7 Company objective 11
8 Company Goals 12
9 Organization Chart 12
10 Quality Policy 13
11 Customers 14
12 Customers Sale Study 16
13 Products 17
14 Machine Facility 19
15 Plastic Moulding Machine Facility 24
16 SWOT Analysis 25
17 Assignment 1 26
18 Assignment 2 33
19 Learnings 41
20 References 42
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Figure Table
Serial Description
Number
1 Mission Of Company
2 Organization chart for Unit 1
3 Customers
4 Tool Room Products
5 Plastics Products
6 Vertical Machining Centre
7 Computerized Numerical Control
8 Spark Erosion
9 Strainer
10 Strainer Drawing
11 Face Milling Cutter
12 New Developed Tool
13 Sprue –bush before VMC machining
14 Sprue –bush after VMC machining
15 Sprue –bush ready to dispatch
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Company Profile
Introduction
Ultra-Enterprises is high-tech and innovative engineering group founded in 1997 offering advanced
products and Services that enhance our customers' productivity. profitability and safety. We
manufacture precision components like Carbide dies & Punches for Sintered products various Moulds
for plastic & rubber products industries warm forging & cold forging Dies press tools, Jigs & fixtures
etc. We consider every call as a challenge & every task as a chance to grow.
We are ISO 9001:2015 certified company. We maintain close cooperation with our customers and
suppliers. Our business is mainly organized into three areas.
Precision Component machining

Plastic Components Production
Tooling manufacturing
Our Mission is to set our own standards to create a benchmark in the respective industry.
We will achieve this, not only through technology and Expertise, but equally importantly, through our
employees and the relationships we build with customers and stakeholders. Setting the industry
standard requires a high level of innovative thinking within the company across all processes and within
how we operate in our day-to-day business.
The vision reinforces and enhances the importance of constantly striving toward being the leader in the
industry and in our chosen segments.
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History
Ultra-enterprises was founded in 1997 by Mr. Rohidas Shinde and has been profitably running the
business till date. Started with two conventional machines, today runs various machines like Vertical
Machining Centre (VMC), Computerized Numerical Control (CNC) and Horizontal Machining Centre
(HMC). Customer delightment has always been the goal of Ultra-enterprises and so has been able to
reach to the level where there are varied customers like Mahindra, Godrej, Forbes Marshal, SKF, Virgo,
etc. With the varied machining setup the product range available is never ending.
In 2008, another plant was setup for Advanced Machining like Spark Erosion or Electro-Discharge
Machining and wire cut. Ultra-enterprises started design and manufacturing of plastic Injection moulds
for various farm products and Automobile parts. With number of mould manufactured increasing every
month a goal of setting up a new plant was taken in consideration.
In 2015 Ultra Enterprises opened a new plant under the brand name of Ajinkya Industries as a sister
concern for Plastic Injection Moulding. Today a number of home products like buckets, tubs, crates,
dustbins are sold under the brand name of Ajinkya Industries directly in to the market. Also automobile
plastic parts are supplied to customers like TATA and Bajaj.
The future goal of Ultra enterprises is to setup advanced machinery in machining of heavy components
and develop a new plant in Chakan by the year 2022.
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Mission and Vision
Lead in the innovation and Delivery of the Brand’s Customer Experience through best Customer
Service.
Fig :-1. Mission Of Company
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Company Objectives
 Technology leadership and innovation: -

We set standards for technology and innovation. We want our products from all divisions to be
the industry leaders when it comes to accuracy, quality, life and green technologies.
 Delighted customers: -
We aim to finish at the top of all relevant customer-satisfaction rankings and convince
customers with our outstanding quality..
 Best teams: -
Our employees are proud to work at Ultra enterprises. Our core corporate values passion,
respect, integrity and discipline-form the basis of our actions. Integrity is particularly important
to our company.
 Profitable growth: -
We want to grow in all the possible aspects and also provide our employees the opportunity to
make progress in personal life along with the professional life. We have set ourselves the goal of
increasing the turn over to 20 crores in 2022.
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Company Goals
 Leader in technology and innovation

 Inspire our customers and achieve Customer delightment
 Continue to grow profitably 4. Strengthening our core business
 Be the best for plastic products in market
Organization Chart
Mr.
R.G.Shinde
Mr.T.K.
Ghogare
Production Quality Planning Dispatch

Department Department Department Department
Mr.More Mr.Satish Mr.Pramod Shinde

Mr.Sagar Mr.Raka
(CNC) (VMC,HMC) Mr.Vinayak Yadav
s
Fig 2. Organization Chart for Unit-1
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Quality Policy
Ultra-enterprises is a ISO 9001-2008 certified company. We as a team are committed to achieve

customer satisfaction by providing Quality products as per the requirements of the customer.
We will strive to continually improve our processes, Methods & resources to improve Quality of our
Products in line with the needs & expectations of the customer.
Objectives:
 Complete customer satisfaction through on-time Delivery, Excellent quality & minimum cost.
 Achieve "Zero" rejection level.
 Increase in Productivity.
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Customers
Ultra-Enterprises has customers spread all over India, mainly in the states of Maharashtra and Gujarat.
The customer’s are-
 NTB Hitech Ceramics, Pune

 Rapicut Carbide Ltd. Ankaleshwar Gujurat
 Sintercom India Ltd. Talegoan Pune
 Shamraj Enercom, Chakan
 Bharat Forge India, Mundhawa Punc
 Bundy India Ltd, Chakan, Pune
 SKF India Ltd, Chinchwad
 H.M.H. Metal Industries, Surat
 Grupo Antolyne, Ranjangaon
 Shree Ganesh Engineering, Bhosari
 Pune Polymers, Bhosari
 Venus, Bhosari
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Fig 3:- Customers
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Customers Sales Study
Sr.no Customers %
1 BHARAT FORGE 1
2 BUNDY 8
3 VIRGO 1
4 GODREJ 31
5 IGTR 9
6 L.G.B. 14
7 M.C.A. 1
8 MERIL ENDO 3
9 MERIL LIFE 2
10 MTS 3
11 RAPICUT 1
12 SINTERCOM 14
13 SKF 9
14 S.N.I.PL 1
15 VARDHMAN 2
 The chart shows sales of the company as per the customer.

 It can be clearly noted that Godrej is the number one client as per the sales per month and alone
comprises of 31% of the sales.
 It is followed by Sintercom and MTS tooling.
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Products
Ultra-Enterprises has a wide range of products. As it is a tool room based industry different customers
have different demands as per the project. It is also engaged in machining of castings. Ultra has been a
supplier of plastic automobile parts for TATA and BAJAJ and now is entering into market with newer
and better quality home products like buckets, tubs etc under the brand name of Ajinkya Industries
 Dies and punches

 Plastic injection moulds.
 Sprue bush and diffusers
 Carriages
 Electrodes
 Sheet metal parts Plastic trays
 Automobile parts
Fig 4.Tool Room Products
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Ultra-Enterprises has a wide range of plastic products used in houses under the brand name of Ajinkya
Industries, sister concern. Recently various products are launched in the market. Newer products with
better designs are launched every two months. The moulds for the products are designed and
manufactured in house in Ultra-Enterprises. Also the maintenance of the moulds are carried out in
house. Presently the vegetable crates are supplied all over Maharashtra and other Home products are
supplied in Pune and Mumbai. The product photographs are shown below. New products launch is
expected in 2022 and the goal is to bring upto 35 different products in the market by the end of 2022.
Fig 5. Plastic Products

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Machining Facilities Avaliable
 CNC TURNING CENTRE
 VMC
 CNC WIRE CUT
 SPARK ERROSION
 SURFACE GRINDING
 CYLINDRICAL GRINDING
 LATHE MACHINE
 MILLING MACHINE
 MITR with DRO PRESS MACHINE
 VTL MACHINE
 HMC MACHINE
 OD LAPPING MACHINE
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Vertical Machining Centre (VMC)
Vertical Machining Centres, also referred to as Vertical Milling Machines are preferred for flat parts
that must have through holes. The Vertical Machine is preferred where three-axis work is done on a
single face as in mould and dies work. Vertical Machining Centres (VMC) have been leaders in
Machine Tools for the past 20 years in Aerospace, Die Mould, Medical and Energy Industries. For
these reasons:
 Increased Productivity
 High efficiency - short tool changing times
 High rigidity-stability completing heavy-duty cutting
 High speed - high spindle speed and rapid feed speed
 High accuracy-high precision, high rigidity in axis direction and radial direction
 High volume or low volume applications
 Small part and large part machining
 On-machine probing for inspection/setup
Fig 6. Vertical Machining Centre
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Computerized Numerical Control (CNC)
CNC Machining is a process used in the manufacturing sector that involves the use of computers to
control machine tools. Tools that can be controlled in this manner include lathes, mills, routers and
grinders. The CNC in CNC Machining stands for Computer Numerical Control.On the surface, it may
look like a normal PC controls the machines, but the computer's unique software and control console
are what really sets the system apart for use in CNC machining.
Under CNC Machining, machine tools function through numerical control. A computer program is
customized for an object and the machines are programmed with CNC machining language (called G-
code) that essentially controls all features like feed rate, coordination, location and speeds. With CNC
machining, the computer can control exact positioning and velocity. CNC machining is used in
manufacturing both metal and plastic parts.First a CAD drawing is created (either 2D or 3D), and then a
code is created that the CNC machine will understand. The program is loaded and finally an operator
runs a test of the program to ensure there are no problems. This trial run is referred to as "cutting air"
and it is an important step because any mistake with speed and tool position could result in a scraped
part or a damaged machine.
There are many advantages to using CNC Machining. The process is more precise than manual
machining, and can be repeated in exactly the same manner over and over again. Because of the
precision possible with CNC Machining, this process can produce complex shapes that would be almost
impossible to achieve with manual machining. CNC Machining is used in the production of many
complex three dimensional shapes. It is because of these qualities that CNC Machining is used in jobs
that need a high level of precision or very repetitive tasks.
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Fig 7.Computerized Numerical Control
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Electro Discharge Machine (EDM)
Electro Discharge Machining (EDM) is an electro-thermal non-traditional machining process, where

electrical energy is used to generate electrical spark and material removal mainly occurs due to thermal
energy of the spark. EDM is mainly or even on job-shop basis. Work material to be machined by EDM
has to be used to machine difficult-to-machine materials and high strength temperature resistant alloys.
EDM can be used to machine difficult geometries in small batches or even on Job –Shop basis. Work
material of EDM has to be electrically conductive.
Characteristics of Electro Discharge machining
 The process can be used to machine any work material if it is electrically electrically
conductive.
 Material removal depends on mainly thermal properties of the work material rather than its
strength, hardness etc.
 In EDM there is a physical tool and geometry of the tool is the positive impression of the hole or
geometric feature machined.
 The tool has to be electrically conductive as well. The tool wear once again depends on the
thermal properties of the tool material .
 Though the local temperature rise is rather high, still due to very small pulse on time, there is
not enough time for the heat to diffuse and thus almost no increase in bulk temperature takes
place. Thus the heat affected zone is limited to 2-4 µm of the spark crater Version 2 ME, IIT
Kharagpur
 However rapid heating and cooling and local high temperature leads to surface hardening which
may be desirable in some applications
 Though there is a possibility of taper cut and overcut in EDM, they can be controlled and
compensated.
Fig 8.Spark Erosion

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Plastic Injection Moulding Plant Facility-
SPECIFICATION UNIT 160T 200T 250T 450T 850T
Screw Diameter mm 42 45 50 75 95
Shot volume cm3 242 310 441 1485 3188
Shot weight G 220 290 410 1351 2901
Injection mpa 178 155 177 173 175

Pressure(max)
Injection rate g/s 118 150 221 395 640
Plasticizing g/s 21 22 32 65 85
Capacity (PS)
Screw Speed r/min 0-190 0-195 0-180 160 110
Heating power KW 7.2 7.5 12.5 19.9 46.45
Clamping Forces KN 1600 2000 2500 4500 8500
Distance between mm 410x410 430x430 510x510 720x720 950x950

Tie bars (H X V)
Max mould height mm 430 480 550 800 960
Min mould height mm 170 180 200 280 400
Open stroke mm 380 460 480 700 950
Ejection force KN 33 40 65 110 280
Stroke of Ejector mm 115 120 140 160 200
Quantity of N 5 5 9 13 17
Ejector
Max pressure mpa 16 16 16 16 16
Table .Plastic Moulding Machine specifications.
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SWOT Analysis
Strengths
 Complete Manufacturing facility: It has entire manufacturing facility including various
machines of different table sizes. Entire machining is done in house and there is no outsourcing.
 Continuous product Study: Daimler parent company of Mercedes has always been known for
its technological advancement right from introduction of internal combustion engine in 1886 to
"Pre-safe" technology in 2013, Company has travelled far to establish itself in the premium
passenger car/trucks segment. Mercedes is concerned about safety features of the vehicle.
 Product portfolio: Ultra Enterprises has strong product portfolio ranging from dies and
punches, moulds and plastic parts.
Weaknesses
 Various customer demands: As there are more number of customers and all the customers
have varied demands it is difficult to keep track of all the parts in process.
 Conflicting deadlines of the suppliers: It may happen that different suppliers need the parts to
be delivered on the same timeline which creates a problem in planning due to excess workload.
Opportunities
 Expansion space: 5 acres space available for the expansion of the company. in Chakan, MIDC.
 Home products: Investing in developing new home products and directly launching them in
market as per the customer demand. Diverse Product catalogue as per the new design
requirements of the customers
 Technological advancement: Forecasting the changing demand for technology and investing in
new machining facilities
Threats
 High fixed cost and investment in R & D: Due to the fact that mature markets are already
overcrowded, Industry is shifting towards emerging markets by building facilities; R & D for
newer products is very costly and needs a bigger investment.
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ASSIGNMENT-1
Problem statement:
For boring of strainer, the tooling required is very costly and interpolation increase the lead time.
Aim:
The lead time of boring has to be reduced so the total lead time can be reduced. The tooling investment
should be less.
Methodology
Systematic development of alternate tooling as per the need.
Fig 9 Strainer
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Information:
Horizontal Machining, also known as milling, relies on rotary cutters to remove metal from a work
piece. Horizontal machining occurs on a horizontal machining centre (HMC), which employs a spindle
that is parallel to the ground floor. With a horizontally oriented spindle, tools stick out of the side of the
tool holder and cut across the side of a work piece, encouraging chips to fall away from the table.
Horizontal machining centres also allow for two-pallet changer integration to facilitate unattended
operation and reduce part cycle times.
Summary:
 The component called Strainer is a heavy casting which is to be machined. The machining scope
includes turning, boring, drilling, tapping and deburring.
 The drawing of the strainer is given below.
Fig 10.Strainer Drawing
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 The marked dimensions have to be bored.
 The machining of the bore is done on Horizontal Machining Centre (HMC). The arbour with
locating ring is available which can be used to mount the boring bar.
 Presently the boring is done by interpolation using a Face-milling cutter.Interpolation increases
the lead time by 45 minutes. The program for interpolation is also lengthy and complex. This
lead time can be reduced by using a boring bar.
 The problem in using a drill boring bar is that the cost of drill boring bar is around 1.2 lakh
rupees.
Solution-
A simple boring bar attachment can be designed as per the required parameters.
There are three Methods of Boring-
1. Using a Face Milling Cutter
A face mill is a cutter designed for facing as opposed to e.g., creating a pocket (end mills). The cutting
edges of face mills are always located along its sides. As such it must always cut in a horizontal
direction at a given depth coming from outside the stock. Multiple teeth distribute the chip load, and
since the teeth are normally disposable carbide inserts, this combination allows for very large and
Interpolation of the milling cutter has to be done. The cycle time in this process is very high which the
main drawback of the process. Also the surface finish is not good as compared to surface finish of
boring bar. The Face milling cutter requires efficient face milling two inserts.
It is shown in the picture below. The face mill cutter can be given a depth of cut of 2 to 3 mm. For
better surface finish a finishing cycle has to be given.
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Fig 11.Face Milling Cutter
2. Using a Drill boring bar-
The second process which can be used for machining is using Drill boring bar. The drill boring bar is
not available for 166mm Diameter and it is very costly to purchase a new one. Also the drill boring
weighs around 15 to 20kgs which makes it difficult for an operator to mount on the machine.
Boring, also called internal turning, is used to increase the inside diameter of a hole. The original hole is
made with a drill, or it may be a cored hole in a casting. Boring achieve three things
 Sizing: Boring brings the hole to the proper size and finish. A drill or reamer can only be used if
the desired size is "standard" or if special tools are ground. The boring tool can work to any
diameter and it will give the required finish by adjusting speed, feed and nose radius. Precision
holes can be bored using micro adjustable boring bars.
 Straightness: Boring will straighten the original drilled or cast hole. Drills, especially the
longer ones, may wander off-centre and cut at a slight angle because of eccentric forces on the
drill, occasional hard spots in the material, or uneven sharpening of the drill. Cored holes in
castings are almost never completely straight. The boring tool being moved straight along the
ways with the carriage feed will correct these errors.
 Concentricity: Boring will make the hole concentric with the outside diameter within the limits
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of the accuracy of the chuck or holding device. For best concentricity, the turning of the outside
diameter and the boring of the inside diameter is done in one set-up-that is, without moving the
work between operations.
Disadvantage
The cost of boring bar is too high. And separate diameter needs a separate boring bar which
increases the overall cost.
3. Designing Of Alternate tool
Alternate tool can be designed which will serve the purpose for boring and is more economical
then the Drill boring bar. The tool can be designed according to the parameters required. The
tool should have provision to be mounted on the machine arbor which is available.
Bore specifications-
 Bore diameter- 166 mm

 Tolerance - ±0.1 mm
 Bore Length- 20mm
 Stock available - +5mm
Arbour specifications-
 Locating ring diameter- 22 mm

 Tolerance - ±0.1 mm
 Locating ring length- 20mm
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Material Used For Tool-Mild Steel Plate
The tool is manufactured on a milling machine and MITR. Milling machine is used for forming a blank
and MITR machine is used for drilling and slotting. The center Drill is machined on a radial drilling
machine. The picture show the new tooling developed with the insert.
Fig 12.New Developed Tool
Advantages:
 Lead time reduction –
The process time is reduced from 45 minutes to 4minutes. Precious man-hours are saved. The
complete boring is done in one stroke. As the surface finish quality is high no finishing cut is
required thus saves more time.
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 Superior Surface Finish
Using only single point cutting tool provides a superior finish then the face milling cutter. The
complete boring is done in one stroke.
 Employee Fatigue Finish

The weight of the drill boring bar is 15kg. It is very difficult to mount drill boring bar on the
machine for an operator. Two operators are required to mount the drill boring bar. One operator
has to hold the bar in position and another operator to press the mounting button. The weight of
the new tool is very minimal and operator can easily mount the tool.
 Easy Programmable
The programming is also easy as only one line program has to be entered for boring using the
new tool. In interpolation the program was bigger and complex and a mistake in the program
may lead to error in machining.
Disadvantages:
 Accuracy
High accuracy cannot be achieved as the tool has vibrations. But it can be conveniently used up
to 0.1 tolerance limit. The tool is not rigid as the boring bar, hence has minor vibrations which
may result in deviations.
 Arbor
A similar tool is designed for boring diameter 190 mm. But only one arbor with locating ring
attachment is available of the type on which the tool can be mounted. Hence for boring 190mm
the tool has to be removed and again mounted which is time consuming.
Conclusion
Reducing the time for the boring process, reduced the overall lead time. Also the process was optimized
which reduced operator fatigue.
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Assignment-2
Aim-
To study the process flow of Sprue bush and to provide solutions for reducing the lead-time of
manufacturing
Problem statement-
The lead-time of manufacturing Spruebush is 18 days which needs to be reduced to meet the customer
deadline.
Note-Project of the customer includes Sprue-bush, Diffuser and Carriage. In this assignment only the
manufacturing of Spruebush and problems related to it are discussed.
Methodology-
The methodology used is to study the entire process and provide solutions to reduce the time in
manufacturing at various stages which will in turn reduce the overall lead-time.
Summary
 Spruebush is a project for a client which has a timeline of 18 days. Every month there are
around 15 projects which need to be delivered on the delivery date. All the projects are different
and have different process. One specific project drawing is shown in the figure below.
 It includes a number of processes which need to be carried out in sequence.
 The dead line given by the customer is 18days from the date of purchase order.
 The main issue is that 3 days are spent in material procurement as the material has to be
procured form verified Mumbai Supplier as per the demand of the customer. More 5 days are
lost in Heat treatment process which is a standard lead-time required for the process as per the
vendor who is also selected by the customer.
 So overall 8 days are lost in which there is nothing that can be done to reduce the lead-time as
the customer has a specific demand of the vendors.
 In the remaining 12 days all the other process have to be carried out which is still sufficient for
manufacturing but large number of projects and also the deadlines of other customers makes it
difficult to sequence the components and provide the delivery in time.
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Fig 13.Sprue –bush before VMC machining
Sprue-bush manufacturing process-
The manufacturing process of Sprue-bush is a long process in which the material has to move from
machine to machine for various operations. In this the material handling cost increases. Also the
material available is a round bar which needs to be turned to the required diameter.
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1. Material Procurement-
As the material has to be procured from Mumbai, a lot of time is consumed in Transportation. It
takes 1 day for making the material available and cutting the material in size. The transportation
of the material from Mumbai to Pune takes one day which increases the lead time. Including a
buffer of one extra day, total three days are planned for material procurement.
2. Rough Turning-
After the procurement of the material, rough turning process is carried out on lathe machine. As
shown in the drawing of the Spruebush, the material below the collar is removed which
consumes a lot of time. The length of the Spruebush normally is between 200 to 400mm. It
takes a lot of time for rough turning on a lathe machine as the length of the Spruebush is more
and the depth of cut is small to avoid vibrations.
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Fig 14.Sprue –bush after VMC machining
3. Drilling and Boring-

The center drilling and boring is done on the lathe machine. The boring is done using a long
boring tool. Rough turning, drilling and boring takes up an entire day. Hence the lead time
increases and the components keep pending in the lathe section for a day or two.
4. Pre-Turning-
The pre-turning is done on CNC and some material is kept to be finished after the hardening.
This process takes 4 to 5 hours.
5. Collar machining and Drilling-
The angular holes are drilled on VMC with the help of Forth axis attachment. The holes are long
and need to be drilled further in the next hole. The holes are drilled only up to half the entire
depth. The collar is machining is done in this program as well. For drilling the feed rate is kept
low as the depth of the drill is more. The drilling cycle is in 2D which takes a lot of time.
6. Drilling And Tapping-
The holes are drilled further in the next holes on a radial drilling machine. This diverts some
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load on the radial drilling machine. Also it is economical to use conventional machining. The
tapping of the holes is done manually on the machine.
7. Heat Treatment-
Heat treatment is a process which increases the lead time considerable. Heat treatment process
and transportation takes five days. It is the standard time process decided by the vendor in co-
ordination with the customer. Finished Turning.
8. Finished Turning-
After the heat treatment process the component is machined on a CNC. This is the finishing cut.
After the finishing cut blue matching of the Spruebush with the Diffuser is done on the machine.
9. Collar Finishing-
The Collar is finished on the machine. Dowel holes are machined if any and before giving the
Sprue bush to final quality the holes are re-tapped and all the edges are filled for leftover chips.
The programmed time for the process is different for different sizes. But average time of
finishing is 8 hours.
10. Quality (Inspection report)-
The quality of the Sprue-bush consumes a lot of time because the 2D drawing of the Sprue bush
is not available. Only the 3D model is received from the supplier which does not has all the
dimensions. The inspection report has to be sent for getting the dispatch clearance after only
which the goods can be dispatched to the customer. Sometimes the quality inspector from
suppliers end visits the company for checking the component as per the inspection report. The
inspection takes a lot of time and sometimes the component is in inspection phase for a day or
two if the inspector from the suppliers end is going to visit.
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Fig 15.Sprue –bush ready to dispatch
11. Dispatch
The dispatch process can be initiated only after the dispatch clearance is received from the
supplier. Also sending of goods from Pune to Mumbai takes an entire day.
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Observation-
Sr.No Process Time
1 Material Procurement 3days
2 Rough Turning 6 to 8 hours
3 Drilling And Boring 2hours
4 Pre turning 4 hours
5 Collar Machining And Drilling 8 to 10 hours
6 Drilling And Tapping 4 hours
7 Heat Treatment 5 days
8 Finished Turning 6 to 8 days
9 Collar Finishing ,Dowel Holes 8 to 10 hours
10 Quality (Inspection Report) 2 hours
11 Dispatch 1 days
It can be clearly observed that the time required for conventional machining is more. The time can be
reduced in rough turning and boring.
Solution for time reduction

 Rough turning which is done on lathe machine takes a lot of time because the length of the job
is more and the depth of cut which can be used is not more than 1 to 2 mm to avoid vibrations.
Also the feed rate is kept less. The material to be removed has a depth of around 45 to 50 mm
approximately depending on the diameter of the collar. Hence it takes a lot of time for
machining.
 The solution to this is that the rough turning of the Sprue bush can be done on Vertical turning
lathe (VTL) which is robust machine and hence can be given a high depth of cut and high feed
rate as well. This saves about half the time as compared to the machining process on normal
lathe machine.
 The center boring also is a time consuming process as the length and diameter of the bore is big.
The boring of the Spruebush can be done on Horizontal machining center by interpolation. It is
less time consuming and bigger depth of cut can be given.
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 The programmed time cannot be changed as it is standard time as per the model. The quality
inspection time is reduced by starting the inline quality by the quality department and checking
the necessary dimensions during the inline quality which also help in controlling the deviations
and reduce rework in the end.
Advantages:
 Lead time reduction -The process time is reduced by one day according to actual time
measurement The man-hours saved can be utilized for some other process
 Work distribution- There is a lot of work in the Lathe section as entire rough machining of all
the inserts, dies mould pins, pulleys and other parts is done. If the rough turning of the
Spruebush is done on normal lathe machine the other work is kept pending as an entire shift is
taken up in machining the Spruebush.
 In-line quality- Inline quality reduces the rework time required at the end after the final
inspection. Also if there any deviations in the process that can be checked which will reduce the
rejection or rework at the end.
Disadvantages:
 Material movement- The material movement is increased, as earlier both the turning and
boring processes were done on a single lathe machine but now the two processes are carried out
on two different machines, a Vertical turning lathe (VTL) and Horizontal Machining Center
(HMC) which increases the distance travelled.
Conclusion:
The lead time is reduced by one day which is 12 man-hours per Spruebush.
40
Learnings
 Project Planning
The planning of the manufacturing helped me to understand the routing of various parts and the
stringent timeline taught me to work under pressure and provide best solutions to avoid bottle
necks. Sometimes the sequence of operations was changed to make more effective use of time
and avoid delays of machining.
 Overview of manufacturing
I got a complete overview of the manufacturing of parts and learn about all the machines
including conventional and nonconventional machines as well as automated horizontal plastic
injection moulding machines.
 Software practice
The software of design needs a good command over the various functions of the software for
designing complex components. I got a good practice over the software and also support and
expertise of the colleagues in the design department.
 Problem Solving
Understanding and analyzing the problem first and then only thinking about the solution is the
most basic knowledge which I got from the project.
41
References
 https://libertymachinery.com
 https://www.americanmachinist.com/machining-cutting/cutting-tool applications-chapter-10-
boring-operations-and-machines
 Rajendra Singh: "Introduction to basic manufacturing processes and workshop technology",
2015
 Machining cloud Inc: "Introduction to Turning Tools and their Application", 2016.
42

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Savitribai Phule Pune University

AISSMS College of Engineering Pune, Mechanical Engineering (Sandwich)

AISSMS College of Engineering Pune, Mechanical Engineering (Sandwich)

AISSMS College of Engineering Pune, Mechanical Engineering (Sandwich)

AISSMS College of Engineering Pune, Mechanical Engineering (Sandwich)

AISSMS College of Engineering Pune, Mechanical Engineering (Sandwich)

AISSMS College of Engineering Pune, Mechanical Engineering (Sandwich)

AISSMS College of Engineering Pune, Mechanical Engineering (Sandwich)

Precision Component machining

AISSMS College of Engineering Pune, Mechanical Engineering (Sandwich)

AISSMS College of Engineering Pune, Mechanical Engineering (Sandwich)

Fig :-1. Mission Of Company

AISSMS College of Engineering Pune, Mechanical Engineering (Sandwich)

 Technology leadership and innovation: -

AISSMS College of Engineering Pune, Mechanical Engineering (Sandwich)

 Leader in technology and innovation

Production Quality Planning Dispatch

Mr.More Mr.Satish Mr.Pramod Shinde

AISSMS College of Engineering Pune, Mechanical Engineering (Sandwich)

Ultra-enterprises is a ISO 9001-2008 certified company. We as a team are committed to achieve

AISSMS College of Engineering Pune, Mechanical Engineering (Sandwich)

The customer’s are-

 NTB Hitech Ceramics, Pune

AISSMS College of Engineering Pune, Mechanical Engineering (Sandwich)

Fig 3:- Customers

AISSMS College of Engineering Pune, Mechanical Engineering (Sandwich)

 The chart shows sales of the company as per the customer.

AISSMS College of Engineering Pune, Mechanical Engineering (Sandwich)

 Dies and punches

Fig 4.Tool Room Products

AISSMS College of Engineering Pune, Mechanical Engineering (Sandwich)

Fig 5. Plastic Products

 CNC TURNING CENTRE

 CNC WIRE CUT

 MITR with DRO PRESS MACHINE

AISSMS College of Engineering Pune, Mechanical Engineering (Sandwich)

Fig 6. Vertical Machining Centre

AISSMS College of Engineering Pune, Mechanical Engineering (Sandwich)

AISSMS College of Engineering Pune, Mechanical Engineering (Sandwich)

Fig 7.Computerized Numerical Control

AISSMS College of Engineering Pune, Mechanical Engineering (Sandwich)

Electro Discharge Machining (EDM) is an electro-thermal non-traditional machining process, where

Fig 8.Spark Erosion

SPECIFICATION UNIT 160T 200T 250T 450T 850T

Shot volume cm3 242 310 441 1485 3188

Shot weight G 220 290 410 1351 2901

Injection mpa 178 155 177 173 175

Heating power KW 7.2 7.5 12.5 19.9 46.45

Clamping Forces KN 1600 2000 2500 4500 8500

Distance between mm 410x410 430x430 510x510 720x720 950x950

Min mould height mm 170 180 200 280 400

Open stroke mm 380 460 480 700 950

Ejection force KN 33 40 65 110 280

Stroke of Ejector mm 115 120 140 160 200

Table .Plastic Moulding Machine specifications.

AISSMS College of Engineering Pune, Mechanical Engineering (Sandwich)

AISSMS College of Engineering Pune, Mechanical Engineering (Sandwich)

AISSMS College of Engineering Pune, Mechanical Engineering (Sandwich)

Fig 10.Strainer Drawing

AISSMS College of Engineering Pune, Mechanical Engineering (Sandwich)

There are three Methods of Boring-

1. Using a Face Milling Cutter