STUDENT INDUSTRIAL WORK EXPERIENCE SCHEME (SIWES)

REPORT ON
POYMER COMPOSITES AND QUALITY CONTROL
UNDERTAKEN AT

SPECIAL EQUIPMENT FACTORY, DEFENCE INDUSTRIES

COOPERATION OF NIGERIA KAKURI, KADUNA STATE.

BY

UBA GODWIN

U16TX1218

UNDER THE SUPERVISION OF

HAJ. JAMILA BABA ALI

SUBMITTED TO THE
DEPARTMENT OF POLYMER AND TEXTILE ENGINEERING
FACULTY OF ENGINEERING

AHMADU BELLO UNIVERSITY

ZARIA, NIGERIA.
IN PARTIAL FULFILLMENT OF THE REQUIREMENTR FOR THE
AWARD OF BACHELORS DEGREE (B.Sc.) IN TEXTILE SCIENCE AND
TECHNOLOGY

JANUARY, 2022.

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DECLARATION
I UBA Godwin, with university registration number U16TX1218 declare that this Student

Industrial Work Experience Scheme (SIWES) titled “Polymer composites and Quality control”

was written by me. It is a summary of the work experience I gathered on the successful

completion of my Six (6) months industrial attachment training.

……………………………………………… ..…………………
UBA, Godwin DATE
U16TX1218

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CERTIFICATION

This is to certify that this report is in alignment with the regulation governing the award of

Bachelor of Science (B.Sc.) degree in Textile Science and Technology, and was written from the

experience gained during the course of my Industrial Attachment at Special Equipment Factory

Defense Industries Cooperation of Nigeria (DICON), Kakuri Kaduna state.

……………………………………………. ……………………....
HAJ. JAMILA BABA ALI DATE
SIWES SUPERVISOR

…………………………………………. …………………..
DR. E.B. ILIYA DATE
SIWES CORDINATOR

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 Table of Contents
DECLARATION.......................................................................................................................................ii
CERTIFICATION....................................................................................................................................iii
CHAPTER ONE........................................................................................................................................1
1.0 INTRODUCTION.........................................................................................................................1
1.1 AIMS AND OBJECTIVES OF SIWES………………………………………………………………………………………….1

1.2 BRIEF HISTORY OF DEFENSE INDUSTRIES CORPORATION OF NIGERIA (DICON).…2

1.3 SECTIONS OF SPECIAL EQUIPMENT FACTORY(DICON)................................2
1.4 VISION OF DICON………………………………………………………………………………….…………………………..…….2
1.5 MISSION OF DICON…………………………………………………………………………………………………………………2
1.6 DICON MANDATE……………………………………………………..……………………………………………………………..2

CHAPTER TWO.......................................................................................................................................4
2.0 INTRODUCTION TO COMPOSITE MATERIALS.................................................................4
2.1 DEFINITION OF COMPOSITE MATERIALS.........................................................................4
2.2 DEFERENT TYPES OF COMPOSITE MATERIALS..............................................................5
2.3 IMPORTANCE OF COMPOSITES............................................................................................6
2.4 EXAMPLES OF COMPOSITE USES........................................................................................8
2.4.1 PRINCIPLE OF OPERATION..................................................................................................8
2.5 APPLICATION OF HYDRAULIC PRESS...............................................................................9
2.5. PARTS OF HYDRAULIC PRESS MACHINE.......................................................................10
2.5.2 APPLICATION OF HYDRAULIC PRESS MACHINE.......................................................10
2.5.3 TYPES OF HYDRAULIC PRESS MACHINE.....................................................................10
2.5.4 ADVANTAGES AND DISADVANTAGES OF HYDRAULIC PRESSING
MACHINE
CHAPTER THREE.................................................................................................................................11
3.0 SCOPE OF WORK...........................................................................................................11
3.1 SECTIONS VISITED.........................................................................................................11
3.1.1 POLYMER DEPARTMENT/SECTIONS ........................................................................12
3.1.1 (A) STRIKE FACE UNIT/SECTIONS.................................................................................14
3.1.1(Ai)MATERIALS NEEDED FOR STRIKE FACE PRODUCTION..................................15
3.1.1 (Aii) PROCESS/ PROCEDURES FOR STRIKE FACE PRODUCTION ......................16
3.1.1 (Aiii) TYPES OF STRIKE FACES.......................................................................................17

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 3.1.(1B) BALLISTIC HELMET SECTION..................................................................................19
3.1.1(Bi) MATERIALS NEEDED FOR HELMET PRODUCTION...........................................19
3.1.1(Bi) PROCESSES OF HELMET PRODUCTION....................................................................
19
3.2 QUALITY CONTROL DEPARTMENT/SECTION ..........................................................22
3.2(A) TAILORING UNIT..............................................................................................................23
3.2 (B) THE CUTTING UNIT:.......................................................................................................23
3.2 (C) WAREHOUSE/STORE......................................................................................................24
3.3 SOME MACHINES USED IN SPECIAL EQUIPMENT FACTORY:................................24
3.3.1 HYDRAULIC PRESS MACHINE:.......................................................................................25
3.3.1(A) WORKING PRINCIPLE:................................................................................................26
3.3.1(B) APPLICATION OF HYDRAULIC PRESS MACHINE:..............................................26
3.3.1 (C) PARTS OF HYDRAULIC PRESS MACHINE.............................................................27
3.3.1. (D) TYPES OF HYDRAULIC PRESS.................................................................................27
3..3.2 ELECTRIC ANGLE GRINDER MACHINE.....................................................................28
3.3.3 STRAIGHT KNIFE CLOTH CUTTING MACHINE.........................................................28
3.3.4 INDUSTRIAL SEWING MACHINE :.................................................................................29
3.3.5 INDUSTRIAL WEAVING MACHINE:...............................................................................29

CHAPTER FOUR...................................................................................................................................32
4.0 LIMITATIONS AND DUFFICULTIES:.................................................................................35
4.1 SOLUTIONS AND RECOMMENDATIONS:.......................................................................39
4.2 INNOVATION…………………………………………………………………………………40
4.3 CONCLUSION………………………………………………………………………..42
REFERENCES

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 CHAPTER ONE

1.0 INTRODUCTION
The Students Industrial Work Experience Scheme (SIWES) was an acceptable skill training

program which Forms part of approved minimum academic standards in various degree

programs for all Nigeria Universities. It is an effort to bridge the gap existing between theory and

practical aspect of Science and Technology, Engineering, Medical, Management and others

professional programs in Nigeria tertiary institutions. SIWES is a six months program that

expose students to practical work, teamwork and gain experience in company’s activities. This

technical report creates an avenue for us to apply our theoretical knowledge into practical work.

1.1 AIM AND OBJECTIVES OF SIWES IN DICON

 To enable the industries and companies to participate in the training of students and thus

educate them on the challenges they are bound to pass through on completion of their studies.

 To enable students complement what they have learned theoretically with practical

knowledge.

 To create a feed-back process between the industries and the institutions of higher learning.

 To expose students to work method and technical in handling equipment and machineries

that may not be in the universities.

 To enable students, acquire practical knowledge along their line of professions.

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2
1.2 BRIEF HISTORY OF DEFENSE INDUSTRIES CORPORATION OF NIGERIA

(DICON)

The defense Industries Corporation of Nigeria (DICON) was established by an Act of Parliament

in 1964 Consequently a West German manufacturing firm Fritz Werner was assigned the task of

providing technical expertise and set up the ordnance factory in Kaduna.

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The first Technical Partner of the defense Industries Corporation of Nigeria (DICON) was Fritz
Werner of Western Germany.FW designed and built the Kaduna Ordinance Factories in 1964
with the following production capacities:
 5000 units of BM 59 Rifles per annum
 18,000 units of SMG 12 per annum,
 12,000,000 rounds of 7.62mm x 51 per annum and
 4,000,000 rounds of 9mm x 19 per annum.

The Nigeria civil war which occurred between 1967- 1970 necessitated the tripling of the above
production rates and the factory was thud able to make a significant contribution to the war
effort. After the war in 1970, the lucrative arms market for DICON ended. Therefore, in order
to remain in business DICON decided to use its equipment to produce civilian items like rural
water supply equipment, industrial spare parts and furniture for sale to the public.

1.3 SECTIONS OF DEFENSE INDUSTRIES

CORPOREATION OF NIGERIA

DICON is divided into three major sections which are;

1. Ordnance Factory Complex
(ORDFAC)
2. Research and Development Centre (RDC)
3. Special Equipment Factory (SEF)
1. ORDANANCE FACTORY COMPLEX (ORDFAC)
DICON Ordnance Factories Complex is the production nerve Centre of the corporation. It is
comprised of ORDFAC’S A, B, C and D; a tools workshop, training school and other workshops
rendering support services. It is currently headed by an air commodore from the Nigerian Air
Force, who is under the direct supervision of the director General at the DICON headquarters.
DICON has achieved an unprecedented feat in the engineering field. The achievements
can be traced to 2004 when DICON successfully produced prototype medium range weapons
namely 60mm mortar, 81mm mortar and RPG-7. The weapons were successfully test fired at the
kachia range with the former president, Chief Olusegun Obasanjo in attendance. The ceremonial
swords used at the N.D.A passing out parade on 28 th September, 2007 were all produced in
DICON.

2. RESEARCH AND DEVELOPMENT FACTORY

This was established in order to bring development, innovation and ideas to simplify their
production and work. The 81mm mortar and RPG-7 were developed by the Centre using local

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raw material and prototype of these weapons are being looked into to contrast out some research
and development work to universities, companies and individuals. New projects have been
planned and are waiting funding and execution. Additional to its primary responsibility to
produce defense equipment, the research and development Centre was mobilized by the
leadership of Maj. Gen Victor Ezugwu to research, develop, produce and clinically test and
produce several covid-19 essential and lifesaving equipment. First, is the production of over
1500 dozens of DICsanz,a high quality hand sanitizer produced under very strict environmental
conditions for supply to troops of the Nigerian Army by the Chief of Army Staff LT Gen. TY
Buratai and other lifesaving equipment were also produced.

3 SPECIAL EQUIPMENT FACTORY (DICON)

This was re-established by Maj. Gen Victor Ezugwu in 2019. He was the then director general,
the special equipment factory is currently being managed by a civilian who is consultant to
DICON by name Eng. Shedrack Oguche, and he is in charge of the overall affairs of the factory.
Special equipment was commissioned officially on 2nd July, 2012 by the former president his
Excellency Dr. Goodluck Ebele Jonathan GCFR. This factory is divided into; 1. Polymer
composite department/ section 2. Quality control department/section

1.4 VISION OF DEFENCE INDUSTRIES CORPORATION OF NIGERIA(DICON)

The vision of DICON is summarized as follows;
‘To meet the material requirement of the Nigerian Armed Forces and other security Agencies as
well as foreign policy needs through improved production, collaboration and commitment to
international best practices’

1.5 MISSION OF DEFENSE INDUSTRIES CORPORATION OF

NIGERIA(DICON)
The mission statement of DICON is summarized as follow;
‘To catalyze the effort of all Directorate and units as well as streamline the interest of other stake
holders for maximum output towards national defense and enterprise’

1.6 DICON MANDATE/ CORE VALUES

DICON core values are summarized as follows;
 Integrity

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  Excellence
 Customer focus
 Teamwork
 Result driven
 Care and respect for others.

CHAPTER TWO

2.0 INTRODUCTION TO COMPOSITE MATERIALS

Continuous technological innovation has pushed the physical limitations of conventional

materials, and required the development of new materials solutions to meet application demands.

Composite materials have emerged as an increasingly common replacement for metals in many

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structural components. Their high specific stiffness-to-mass ratio, in particular, has made them

idea candidates in the aerospace, automotive, biomedical, military, and renewable energy

industries. Despite their desirable material performance, however, the anisotropic nature of

composites prohibits the usage of well-studied models for isotropic material behaviors. The

practical implementation of composite material into engineering applications requires the

development of new, economic methods to simulate their design and failure.

A composite material is a combination of two materials with different physical and

chemical properties. When they are combined, they create a material which is specialized to do a

certain job, for instance, to become stronger, lighter, or resistant to electricity. They can also

improve strength and stiffness.

The reason for their use over traditional materials is because they improve the properties of their
base materials and are applicable in many situations.

These constituent materials have notably dissimilar chemical or physical properties and are
merged to create a material with properties, unlike the individual elements. Within the finished
structure, the individual elements remain separate and distinct, distinguishing composites from
mixtures and solid solutions.

Typical engineered composite materials include:

 Reinforced concrete and masonry

 Composite wood such as plywood
 Reinforced plastics, such as fiber-reinforced polymer or fiberglass
 Ceramic matrix composites (composite ceramic and metal matrices)
 Metal matrix composites
 and other advanced composite materials
There are various reasons where new material can be favored. Typical examples include
materials that are less expensive, lighter, stronger, or more durable when compared with
common materials. More, recently researchers have also begun to actively include sensing,
actuation, computation, and communication into composites, which are known as robotic
materials.

Composite materials are generally used for buildings, bridges, and structures such as boat hulls,
swimming pool panels, racing car bodies, shower stalls, bathtubs, storage tanks, imitation

7
granite, and cultured marble sinks, and countertops. They are also being increasingly used in
general automotive applications.

The most advanced examples perform routinely on spacecraft and aircraft in demanding
environments.

2.1 DEFINITION OF COMPOSITES

A composite is a material which is produced from two or more constituent materials. These
constituent materials have notably dissimilar chemical or physical properties and are merged to
create a material with properties, unlike the individual elements.

Simply also, composites are a combination of components. In our industry, composites are
materials made by combining two or more natural or artificial elements (with different physical
or chemical properties) that are stronger as a team than as individual players.

The component materials don’t completely blend or lose their individual identities; they combine
and contribute their most useful traits to improve the outcome or final product. Composites are
typically designed with a particular use in mind, such as added strength, efficiency, or durability.
Composites, also known as Fiber-Reinforced Polymer (FRP) composites, are made from a
polymer matrix that is reinforced with an engineered, man-made, or natural fiber (like glass,
carbon, or aramid) or other reinforcing material.

The matrix protects the fibers from environmental and external damage and transfers the load
between the fibers. The fibers, in turn, provide strength and stiffness to reinforce the matrix and
help it resist cracks and fractures.

Composite Materials
In many of our industry’s products, polyester resin is the matrix, and glass fiber is the
reinforcement. But many combinations of resins and reinforcements are used in composites and
each material contributes to the unique properties of the finished product: Fiber, powerful but
brittle, provides strength and stiffness, while more flexible resin provides shape and protects the
fiber.

FRP composites may also contain fillers, additives, core materials, or surface finishes designed
to improve the manufacturing process, appearance, and performance of the final product.
Composite materials can be natural or synthetic. Wood, a natural composite, is a combination of
cellulose or wood fiber and a substance called lignin. The fibers give wood its strength; Lignin is
the matrix or natural glue that binds and stabilizes it. Other composites are synthetic (man-
made).

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Plywood is an artificial composite that combines natural and synthetic materials. Thin layers of
wood veneer are adhesive together to form flat laminate sheets that are stronger than natural
wood.

2.2 DIFFERENT TYPES OF COMPOSITE MATERIALS

Some common composite materials include:

 Ceramic matrix composite: Ceramic spread out in a ceramic matrix. These are
better than normal ceramics as they are thermal shock and fracture resistant
 Metal matrix composite: A metal spread throughout a matrix
 Reinforced concrete: Concrete strengthened by a material with high tensile
strength such as steel reinforcing bars
 Glass fibre reinforced concrete: Concrete which is poured into a glass fibre
structure with high zirconia content
 Translucent concrete: Concrete which encases optic fibres
 Engineered wood: Manufactured wood combined with other cheap materials.
One example would be particle board. A speciality material like veneer can also
be found in this composite
 Plywood: Engineered wood by gluing many thin layers of wood together at
different angles
 Engineered bamboo: Strips of bamboo fibre glued together to make a board.
This is a useful composite due to the fact it has higher compressive, tensile and
flexural strength than wood
 Parquetry: A square of many wood pieces put together often out of hardwood. It
is sold as a decorative piece
 Wood-plastic composite: Either wood fibre or flour cast in plastic
 Cement-bonded wood fibre: Mineralised wood pieces cast in cement. This
composite has insulating and acoustic properties
 Fibreglass: Glass fibre combined with a plastic which is relatively inexpensive
and flexible
 Carbon Fibre reinforced polymer: Carbon fibre set in plastic which has a high
strength-to-weight ratio
 Sandwich panel: A variety of composites that are layered on top of each other
 Composite honeycomb: A selection of composites in many hexagons to form a
honeycomb shape.
 Papier-mache: Paper bound with an adhesive. These are found in crafts
 Plastic coated paper: Paper coated with plastic to improve durability. An
example of where this is used is in playing cards
 Syntactic foams: Light materials created by filling metals, ceramics or plastics
with micro balloons. These balloons are made using either glass, carbon or plastic

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2.3 IMPORTANCE OF COMPOSITES
Composites have permeated our everyday lives: They are used in the cars we drive, golf clubs
we swing, pipes that remove wastewater from our neighborhoods, and much more. Some
applications, such as rocket ships, probably wouldn’t get off the ground without composite
materials.

Composites offer many benefits. Key among them are strength, light weight, corrosion
resistance, design flexibility, and durability.

 Strong. Per pound, composites are stronger than other materials such as steel. The
two primary components of composites – fibers and resins – contribute to their
strength. Fibers carry the load, while resins distribute the weight throughout the
composite part as required.
 Lightweight. Composites are light in weight compared to most woods and
metals. But why is lighter better? Lower weight contributes to fuel efficiency in
cars and airplanes. And lighter objects, ranging from utility poles to bridge decks,
are easier to transport and install.
 Resistant. Composites resist damage from weather and harsh chemicals that can
eat away at other materials. That makes them good choices for applications that
face constant exposure to salt water, toxic chemicals, temperature fluctuations and
other severe conditions.
 Flexible. A wide range of material combinations can be used in composites,
which allows for design flexibility. The materials can be custom tailored to fit
unique specifications of each application. Composites also can be easily molded
into complicated shapes.
 Durable. Simply put, composites last! Structures made with composites have a
long life and require little maintenance. Many products made with composites,
such as boats, have been in service for more than half a century.

Weight saving is one of the main reasons for using composite materials instead of conventional
materials for components. While composites are lighter, they can also be stronger than other
materials. For example, reinforced carbon fibers can be up to five times stronger than 1020 grade
steel and only one-fifth the weight, which makes them perfect for structural purposes.

Another advantage of using a composite material over a conventional type of material is the
thermal and chemical resistance as well as the electrical insulation properties. Unlike traditional
materials, composites can have multiple properties that are not often found in a single material.

Fiber-reinforced composite materials such as fiber-reinforced plastic (GRP composite materials)

are increasingly being used in the development and manufacture of end products for marketing.

2.4 USES OF COMPOSITES

10
  Electrical equipment
 Aerospace structures
 Infrastructure
 Pipes and tanks
 Homes can be framed using plastic laminated beams

Figure 2.4. production of composite use for strike face

CHAPTER THREE

3.0 SCOPE OF WORK

At the course of my SIWES, I was privileged to do my training in two departments;

polymer department/section (strike face and ballistic helmet production lab), Quality

11
 control department (ballistic vest section, cutting section, packaging section and

warehouse/store).

3.1 SECTIONS VISITED

The departments are divided into two which are as follows;

1. Polymer department/section

A. Strike face unit

B. ballistic helmet

2. Quality control department/section

A. ballistic vest unit/ tailoring unit

B. cutting unit

C. packaging unit

D. warehouse/store

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 Figure 3.1 front angular metal plate prepared to be wrapped by glass fiber

3.1.1 POLYMER DEPARTMENT/SECTION

Polymer department are divided into two sections which deals with composites production in the

form of the following;

a. Strike face and,

b. Ballistic helmet

13
3.1.1 STRIKE FACE UNIT/SECTION

This section deals with the production of strike face from the angular metal plate to the strike

face itself.

FIGURE 3.1.1A; Diagram showing a glass fibre

being cut into 4 -square shape

3.1. A i) MATERIALS NEEDED FOR STRIKE FACE PRODUCTION

Are as follows;

- 2 layers of Glass fibre (fiber reinforce plastics)

- Angular metal plate

- Hardener (acetyl acetone peroxide) -1 bottle cup cover

- Unsaturated polyester resin(100-200mls)

- Catalyst (Methyl ethyl ketone peroxide) - 1 bottle cupcover

- Plastic measuring cylinder

- Hand cutter/scissors

- Industrial nose mask and glass

- Rubber Hand gloves

14
 - Container for the chemical mixture

- Ballistic sponge rubber foam (called ‘Marco’)

- Gum/adhesive

Figure 3.1.1 ai) a newly produced strike face placed on macho (polymer)

3.1.1 A ii) PROCESSES / PROCEDURES FOR STRIKE FACE

PRODUCTION

The glass fiber is cut into either a four square shape or rectangular shape as the case may

be, using the hand cutter/scissors and then taken to the fiber glass wrappers where 2

layers of glass fiber is use to wrap with the angular metal plate and arranged for

15
 chemicals to be applied. It is then taken to the chemical appliers where the wrapped metal

plate is applied with the chemicals and kept in a dry place to be cured for 15-20mins.

After which it is separated from each other because they are kept on top of each other and

therefore join with each other. The fringed edges are trimmed and then a polymer (known

as ‘macho’) are applied on them on both faces i.e. front and back of the front strike face

and back strike face using a gum/adhesive and it is finally clothed with cloths carrying

the label and trade name of the company.

Figure 3.1.1aii) back strike face prepared to be wrapped with glass fiber

3.1.1 A iii) TYPES OF STRIKE FACES

There are two types of strike face

1. Front strike face and,

2. Back strike face.

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 1. Front strike face : is the strike face that covers the chest region when inserted on

the vest

2. Back strike face: which covers the back region when inserted on the vest to

prevent the wearer from attacks from behind.

Figure 3.1.1a (iii) a finished and clothed front and back strike face

3.1.1B BALLISTIC HELMET SECTION

This section deals with the production of helmet from the glass fiber to the composite

(helmet mold). The main material for this production is the glass fiber. To achieve this, the

section is divided into various units/groups as follows;

17
1. Cutting unit: which are involved in the marking and cutting of glass fiber. Their

work includes unwinding of the glass fibers, marking, cutting and transferring

them to the next unit. The cutting is in two stages

Cutting from the main mat of the fiber in four-squared shape according to

the dimension given to them.

Cutting of the four squared shape fiber at the six different points in such

a way to create a circle in the middle that head can fit in it.

2. Layers unit: their work is to pick the cut fiber and lay it for the chemical appliers/

laboratory units.

3. Chemical appliers/ laboratory unit: This group of people are involved in the

mixing of the chemicals and applying them on the laid glass fibers.

4. Fiber placer: Their main duty is to pick the fiber that chemicals has been applied

on and place them on the mold of the helmet machine and remove the composite

formed from the mold of the machine.

5. Machine operators: Are involved in the operation of the helmet press machine.

Their work includes opening and closing of the mold of the machine by pressing

a button from the control panel of the machine.

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 Figure 3.1.1 b) glass fiber being prepared for chemical application in the helmet

section.

3.1 B i) MATERIALS NEEDED FOR HELMET PRODUCTION

The materials are as follows;

12 layers of 4 squared shape Glass fiber (fiber reinforce plastics) cut in 6 points to form

a circle in the middle

Hardener (acetyl acetone peroxide) -1 bottle cup cover

Unsaturated polyester resin(100-200mls)

Catalyst (Methyl ethyl ketone peroxide) - 1 bottle cup cover

Plastic measuring cylinder

Hand cutter/scissors

Industrial nose mask and glass

Rubber Hand gloves

Container for the chemical mixture

Adhesive

Ballistic sponge rubber foam (called ‘Marco’)

Painting machine

Hennessey

Screwing machine

Filing/ angular grinding machine

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 Figure3.1b i) a newly produced helmet composite with trimmed/shaped edges.

3.1B ii) PROCESSES OF HELMET PRODUCTION

Measure one bottle cover cup of hardener (Acetyl acetone peroxides) and pour into the
container , then measure 200mls of unsaturated polyester resin and mix thoroughly, then add the
catalyst (Methyl ethyl ketone peroxide). Join 6 layers of glass fibers using the hand cutter cut it
into 4 equal parts creating a round or circle shape in such a way that it can size the head. Do this
for the remaining 6 layers making it a total of 12 layers. Place the 12 layers on the table then
pick each layer and apply the chemicals on each 12 layers and transfer each single layer into the
female Helmet mold of the machine until it completes the 12 layers then the operators brings the
male mold down, joining the female mold containing the 12 layers of glass fibers. Allow it to
cure for 5-10mins then remove the helmet mold and place it under the sun to further cure. After
curing, the fringed edges are trimmed following the shape of the mold using a filing/trimming
machine.

20
Ballistic sponge rubber foam (called ‘Marco’) is used to wrap the edges of the helmet compsite

using an adhesive. It is taken to the painter where it is sprayed with paint and allowed to cure and

finally taken to the warehouse where all the other accessories like the Hennessey are fixed and

packaged.

Figure 3.1bii) Helmet prepared for packaging

3.2 QUALITY CONTROL DEPARTMENT/SECTION

This section deals with the production of products from the cutting section down to the finishing.

The strike face produced are inserted in the finished ballistic vest in this section. To achieve this

the work are divided into various units which are shuffled or changed daily.

21
 Figure 3.2 diagram of front soft ballistic vest

3.2A TAILORING UNIT

Tailoring unit deals with the ballistic vest itself and other products that are produced. There are

sometimes divided into various sub-groups/units depending on the nature of the work and the

urgency to meet up the demands and targets of the customers. But, there are majorly divided into

two groups/ units.

1. Those that sew soft ballistics , and

2. Those that sew the ballistic vest

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1. Those that sew soft ballistics: are those that are selected specifically by the quality

control officers to specifically sew/ produce the soft ballistic. The ballistic sponge

rubber foam popularly known as ‘marco’ is a polymer material that looks like a

palm shoe sole specifically design according to specification of the company which is

cut into the shape of the vest both the front and back, which is distributed to the

tailors together with landing and it is sewn with the landing. The ballistic sponge

rubber foam is also use to produce various products in the factory like the strike face,

shoes, bags, vest etc.

2. Those that sew the ballistic vest: are the tailors who are experts in sewing the

specific design of the ballistic vest given by the quality control units. The materials to

be sewn are marked and cut by the cutting units and distributed to the tailors together

with every other accessories use in producing that specific vest. The vest is called

ballistic vest when the soft ballistic is inserted into it.

23
 Figure 3.2a diagram showing front view of a vest

3.2 B THE CUTTING UNIT

This is the section were the work of ballistic vest starts and finishes. The cutting unit is

where the fabric/material is marked and cut using various machines. After the materials are

cut, they are also responsible in the distributions of this materials to the tailors in

conjunction with both the production manager and quality control officer.

Figure 3.2b Diagram showing a fabric being cut with a circular cutter

machine in the quality control department.

The cutting unit also deals with the cutting of ballistic sponge rubber foam and all activities

involving cutting.

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3.2 C PACKAGING UNIT/SECTIONS

The packaging section ensures that the product produced meets up to the standard design of the

template given. This is carried out by checking for improperly sewn products (such as the vest,

jungle bags etc.), loosed threads, trimming of loosed threads, marking, cutting and distribution of

accessories to tailors and finally packaging of the finished goods/product and taking them to the

warehouse for assembling. The packaging unit works hand-in-hand with the warehouse/store.

25
 Figure 3.2c a jungle bag ready to be transferred to the warehouse.

3.2 D WAREHOUSE/STORE

This is where all the finished goods in both departments are collected, company’s

logo printed upon, packaged and prepared for delivery. The warehouse in divided into

two main sections which are;

The store ,and

Printing section

The store: is where all the finished products are kept for delivery. It is also the place where

the accessories or raw materials for the production of the goods are kept.

The printing section: is the section where the company’s logo, customers brand and name

are printed on the products produced.

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 Figure 3.2d a packaged ballistic vest with strike face in the store

3.3 SOME MACHINES USED IN SPECIAL EQUIPMENT

FACTORY

Some of the machines used in the factory are listed below;

1. Hydraulic press machine.

2. Electric angular grinder machine

3. Straight knife cloth cutting machine

4. Cloth End cutting machine

5. Electric Industrial sewing machine

6. Electric industrial weaving machine

3.3.1 HYDRAULIC PRESS MACHINE

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A hydraulic press is a machine press that generate compressive force by the use of a hydraulic

cylinder. It is a device that is used for lifting’s heavyweight with the application of much smaller

force. The hydraulic press was invented by joseph bramah in England. He accomplished the

project in the 17th century. Bramah who has also developed some toilet flushing material used in

our daily life. The hydraulic press work based on Pascal’s law. This law state that the intensity of

pressure in a static fluid is transmitted equally in all directions.

Figure 3.3.1 four pillar double action hydraulic press

3.3.1 A WORKING PRINCIPLE

The working principle of hydraulic press is quite interesting and easy. Just as earlier mentioned,

it uses Pascal’s law for its working. There are two cylinders of different diameter and it carries

the ram, the other small cylinder carries the plunger.

These two cylinders are connected by a pipe which contain a liquid through which is transmitted

to all directions and let the ram play it role by upward direction. While the heavier weight place

on the ram move along with it.

3.3.1 B APPLICATION OF HYDRARAULIC PRESS

Below are the application of hydraulic press machine;

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Due to the wide application of this presser machine, it is used for converting any metal block to

sheet. The machine tool is used for blanking, forging, clinching, molding, deep drawing,

punching, and metal forming operations.

Some other applications include;

 Thermoplastics

 RTM(Resin Transfer Molding)

 Composites

 Carbon Fiber molding

 GMT(Glass Mat transfer), and

 SMC(Sheet Molded Composites)

3.3.1 C PARTS OF HYDRAULIC PRESS MACHINE

There major parts that the hydraulic press comprises of, these parts includes;

Safety door: the safety door is a correction gate that allow any work piece to be fix when

damage.

Limit switch: this part prevents the travel of an object in a mechanism. It is mechanically

operated by the motion of the object.

Manual control valve: it aids the operation to be carryout manually using valve.

Relief valve: the relief valve is used to release or control the pressure whenever it exceeds the

limit of the valve.

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Pressure gauge: this part is used to measure the pressure.

Hydraulic cylinder: is a mechanical actuator that is used to give a unidirectional force through

a unidirectional stroke.

Oil tank: this is the reservoir that is used to store and supply the hydraulic oil.

Passing plate: this plate is of high strength used for exerting pressure to the work piece.

Bailing compartment: the work piece is placed this part so it can be pressed. It can be adjusted

to any shape and size of the piece.

3.3.1 D TYPES OF HYDRAULIC PRESS

The hydraulic press is cauterized into five different types that plays their effective role according

to the feature. These include:

Four pillar double action hydraulic press: this type is vast in its working, making it useful in

most pressing operation like bending, punching etc.

Universal hydraulic press: this presser is used on almost all pressing process such as punching,

forging, etc. without any external attachment.

Single column hydraulic press: it is also known as C-type. It is only one column and a c-type

frame just as it is being called.

Horizontal hydraulic press: pressure is applied horizontally or parallel to the axis of axis of

the machine. The work piece remains between the vertical plate.

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Vertical hydraulic press: unlike the single column, this type has two column and there is an

overarm connected to the column. Yet, the pressure is applied vertically.

3.3.2 ELECTRIC ANGLE GRINDER MACHINE

An angle grinder is a handled power tool that can be used for a variety of metal fabrication jobs

that includes cutting, trimming, grinding, deburring, finishing and polishing. The most common

types of angle grinders are powered by electricity; either corded or battery powered.

Figure 3.3.2 electric angle grinder machine

WORKING PRINCIPLE

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Electric angle grinders use electric motor that supplies motion power to the grinding wheel using

wheel using pulley and belt. For the portable grinder, the rotor is inside the grinding machine and

the power switch is located beside the handle of a grinder. So, the switch must be pressed before

the grinder works. For grinders that features an electric motor, the motor rotates at a certain rpm

(from 150 to 1500 RPM, it may change according to the types of grinding machine.) The grinder

works with the help of a v- belt and cone pulley when its transfers to the grinder’s head.

Operating Regulations of Electric Angle Grinder

Angle grinder is an abrasive tool used for cutting and polishing glass fiber reinforced plastic.

Lightweight multi-purpose angle grinder, suitable for deburring and polishing. The angle

grinders of specific brands and models are different, the manual must be checked for use.

1. with protective goggles.

2. After turning on the switch, wait for the grinding wheel to rotate stably before working.

3. Employees with long hair must tie up their hair first.

4. The cutting direction cannot be towards people.

5. After working continuously for half an hour, stop for 15 minutes.

6. Do not hold small parts with your hands to process the angle grinder.

7. Consciously clean the working environment after the work is completed.

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 Figure 3.3.1 Straight knife cutting machine

3.3.3 STRAIGHT KNIFE CLOTH CUTTING MACHINE

Straight knife cutting machine is used to cut components of differing size. This is the most
frequently used equipment for cutting garments in bulk. It is moved along the cut contours, while
the fabric spread remains in a fixed position. The machines are maneuverable and capable of
curvilinear cutting. Straight-knife cutting machine is the world’s most popular and most
versatile. Available in all standard electrical configurations, with the largest variety of sizes and
blade speeds in the industry. It is the most useful cutting instrument in garment cutting. In
apparel industry, more than 99% cases this knife is used. This machine is called
straight knife cutting machine because its cutter is straight in shape. It is used for both woven and
knit fabric. In this machine different types of straight knife are used according to the different
cutting objects. This machine provides good efficiency. The maximum height of a cut spread is
300 mm. The weight of the machines varies between 5 and 20 kg. Heavier machines are less
manoeuvrable. Small-capacity production units may use only straight-knife machines. It is
widely used in Bangladeshi garment industry.

Features of Straight Knife Cutting machine:

The main parts of this machine are straight knife, electric motor, handle, grinder, base plate,
stand/ knife holder, lubricating unit, wheel etc. Could be used to cut higher depth of fabric.

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Knife height is 10 cm to 33 cm.
Knife stroke is 2.5 cm to 4.5 cm.
Motor r.p.m. is 3000 to 4000.
Auto grinder is used.
Auto lubricating unit works for this machine.
Different types of knife edge are used for cutting different objects. Such as, straight edge, wave
edge, sew edge and serrated edge.
A Handle for the cutter to direct the Knife.
Knife guard is attached to the front of the knife.
Sharp and heavy corners can be cut.
Maximum 70% of knife height is used for fabric lay.
Wheels are under the base plate to move the machine smoothly.
Machine weight is around 12-15 kg.
Knife cut the fabric very fast due to high speed of motor. That increases the risk of fabric
damage.
Suitable for mass trimming cotton, woolen, linen leather and chemical fiber goods, etc.
Neat cutting, small-curvature radius curvilinear cutting.
Low noise, stable running, easy to operate and high efficiency.
Incorporated with an auto knife-grinding device, easier to operate.
Structure of Straight Knife Cutting Machine:
The straight knife cutting machine consists of a base plate, an upright stand to hold the vertical
blade, motor, a handle for moving assembly, a sharpening device and a handle to transfer the
whole assembly from one place to another.

Two kinds of power are required to operate a straight knife. Motor power drives the
reciprocating blade and operator power drives the knife through the lay. Normally the available
blade heights vary from 10 cm to 33 cm and normally available strokes vary from 2.5 to 4.5 cm.
The greater the blade movement the faster the blade cuts the fabric and more easily the operator
can move the machine.

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Structure of straight knife cutting machine
The most important consideration is selecting a straight knife is the power required from the
operator to move the knife is the power required for the operator to move the knife through the
lay. Operator effort is affected by the weight of the motor, the shape of the stand, handle height,
stroke, sharpness of blade and the base plate movement.

The normal blade has a straight edge that varies from coarse to fine depending upon the type of
fabric being cut. Wavy edged knifes are used to reduce the heat generation and hence can be
used for cutting synthetic materials without fusing difficulties. The speed of the blades can also
be adjusted by having variable speed mechanism.The straight knife is a common means of
cutting lays in conventional cutting rooms because it is versatile, portable, chapter than a band
knife and easy to maintain. Even if a band knife is used for main cutting operation, a straight
knife will be used to separate the lay into sections for easier handling.

Different Parts of Straight Knife Cutting Machine

A straight knife machine has the following main parts;
 Upper handle,
 Electrical cable,
 Motor,
 Side handle,
 Knife sharpener,
 Stand,
 Presser foot,
 Straight knife, and
 Base plate with rollers.

Straight knife:
The main functional part of the machine is a vertically oscillating straight knife with a sharp
blade. In more powerful machines, the knife is longer, and higher spreads can be cut (80–300
mm). The width of the knives is between 10 and 20 mm and the thickness from 0.40 to 0.45 mm.
The thickness of the knife is directly proportional to its length. Double-bevel knives with
straight-edged blades are normally used to cut textile materials.
The cutting blades for straight knife cutting machine comes in three grades and also in several
shapes for the cutting of unusual or difficult material.

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Knife sharpener:
It is small band with grinder/sharpening material on it and its main function is to sharpen the
blade. It is necessary to stop the work process during the sharpening. The frequency of
sharpening depends on the material being cut and on the knife blade.

Fabric presser foot

It is a device in the machine which holds the layers of the fabric tight so that it will easy for
cutter to cut the fabric. A presser foot is used to ensure compression of the spread directly in
front of the knife and to decrease displacement of fabric plies during cutting. It also prevents any
loosening of the plies during the return movement of the knife. The height of the presser foot is
changed according to the height of the spread.

Base plate and its rollers

A base plate with the lowest possible profile is needed to ensure the stability of the machine.
This facilitates its manoeuver ability and minimizes the risk of deforming the material plies
during the work process. Independently moving rollers are fixed under the base plate to ensure
easy movement of the machine. Wheels are under the base plate to move the machine smoothly.
Machine weight is around 12–15 kg.

Electric Cable:
An electrical cable supplies the motor with electricity. During the cutting process, it must be
secured away from the surface of the cutting table to avoid the possibility of electric shock.

Motor:
Motor rpm is 3000–4000 and its main function is to move the blade up and down and also
slightly in front direction to create a stroke on fabric. Knife cuts the fabric very fast due to high
speed of motor. That increases the risk of fabric damage.

Moving handle:
This handle is to hold the machine as well to move in predefined direction. The straight knife is a
common means of cutting lays in conventional cutting rooms because it is versatile, portable,

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cheaper than a band knife and easy to maintain. Even if a band knife is used for main cutting
operation, a straight knife will be used to separate the lay into sections for easier handling.

Safety devices:
A presser foot is used to compress the fabric plies and helps to protect operator’s hands from
accidental cuts. A machine may be also equipped with an auto stop trigger that switches the
power off when the operator’s hand is removed from the lever. During cutting, the operator must
wear special protective gloves (Figure-5). These are made from stainless steel chain mail and
give a certain level of protection against stab wounds or cuts that could occur when the blade
moves close to the operator’s hands.

Cutting machine safety gloves

The gloves may be a universal size or of different sizes, fitting to either right or left hand and
covering the whole hand or separate fingers. Unfortunately, the protective gloves are heavy and
limit hand movement. Therefore, some operators may not use the gloves, putting themselves at
risk of serious injury.

ADVANTAGES OF STRAIGHT KNIFE CUTTING MACHINE:

A large number of fabric lays can be cut by the machine due to high length of knife and r.p.m. of
the motor. So, productivity is high.
Automatic grinding.
Automatic lubrication.
Comparatively cheap.
Can be moved easily by wheel.
Suitable for straight line and curve line.
Can be cut high curve line than round knife.
Fabric can be cut from any angle.

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DISADVANTAGES OF STRAIGHT KNIFE CUTTING MACHINE:
High speed of the machine causes high risk of damage.
Faulty knife could damage fabric layer.
Motor weight creates knife deflection which may be creates faulty pieces.
Risk is high for physical damage of operator.
Knife required to replace.
Uses/Application of Straight Knife Cutting Machine:
It’s suitable for straight line cutting, curve line cutting and for large part cutting. It is used for
large production. Most commonly used in Garments Industry of Bangladesh (99%).

Figure 3.3.4 End cutter machine being used

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3.3.4 END CUTTER MACHINE
End cutter machines are typically used for cutting fabric. They allow the cutting process to be
fast and accurate and are often used in a workplace setting to maximize efficiency in the
manufacturing process. Most end cutters are mounted on a table and have a rotary blade that is
pushed across the fabric in a horizontal motion to make the cut. This blade is fitted with a guard
to prevent injury.
TYPES OF END CUTTERS
There are two main types of end cutters on the market:
1. Automatic cutters and
2. Manual cutters.

ADVANTAGES
Both types of end cutter have their advantages;
1. Automatic end: cutters are amazingly fast and efficient. They are incredibly easy to
operate: all you do is load the fabric and push a button. These machines have other
controls to change certain parameters, such as the length of the cut and the height of the
machine. Automatic end cutters are usually the higher-end option, making them less
suited for those on a budget. However, despite the higher price, they do make a valuable
investment in an industrial setting

2. Manual end: cutters are typically operated by hand, although they may still be partially
automatic. Some are designed to be table-mounted, and some are not, and they are
incredibly basic in comparison to the automatic end cutter. These machines tend to have a
lower upfront cost, but at the sacrifice of the efficiency of automatic end cutters.

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 Figure 3.3.4 industrial sewing machine in operation

3.3.4 INDUSTRIAL SEWING MACHINE

Industrial sewing machines are typically found in factories, and are mostly used to mass produce
clothing and other goods. Industrial machines are built to last, and stand up to a lot of rigorous
use. They are usually much bigger, not to mention more expensive, than domestic machines.
They are also faster, capable of sewing more stitches per minute than domestic models.
Industrial machines are usually made of strong, sturdy materials, like iron and aluminum. This is
part of the reason they can handle thick, heavy fabrics (like leather, suede and canvas) with
relative ease .Each type of industrial machine is usually made to serve a specific function. So a
shirt made in a factory, for example, will typically pass through several different machines on its
way to completion. Unless you’ve had a lot of training, industrial sewing machines can be very
hard to use. On the other hand, they can withstand continuous use. Some industrial machines can
run for 9 or 10 hours without overheating or malfunctioning.
Industrial sewing machines are normally used in mass garment production. An industrial sewing
machine is power-driven and runs at a very high speed. There are different types of industrial
sewing machines. There are some special sewing machines developed for making specific seam
and stitch classes.

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To have in-depth knowledge of sewing machines, different types of sewing machines are listed
in this post. The application of these machines is also mentioned with an example. This would
help beginners to visualize the machine’s application in making the common products.

1. Single Needle Lock Stitch Machine

This machine makes lock stitches (stitch class 301). Lock stitches are formed with one needle
thread and one bobbin thread. This is a widely used sewing machine and used for sewing stitch
class 301. Basic to computer-controlled version is available in this machine category.

Purpose: Single needle lock stitch machines are used for joining two or multiple fabric plies
together. The machine is used to sew lightweight, medium weight, and heavy materials.

2. Overlock Sewing Machine

Overlock machines are available in 3 threads, 4 threads and 5 threads over edge sewing. An
overlock machine can form various types of stitches like stitch class 503, stitch class 504 and
stitch class 512.
Purpose: This machine is used for serging garment panels (for example: trouser panels serging)
and for overedge stitch. These types of machine are mostly used in knitted garment sewing for
overedge stitch. Like side seam stitch of a t-shirt is done using an overlock machine.

3. Flat lock sewing Machine

This machine is called a cover-stitch sewing machine. Flatlock sewing machines normally come
with 2-3 needles. For the bottom cover stitch machine 2 needle threads pass through the material
and inter loop with 1 looper thread with the stitch set on the underside of the seam. Flatlock
sewing machine form stitches like Stitch class 406.Flatlock machines are available in two types -
A flatbed and Cylinder bed.
Purpose: Flatlock machines are used for hemming sleeve and bottom of the knits products. A
cover-stitch machine can be used in any part of the garment for decorative purpose.

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 Figure 3.3.5 Industrial weaving machine

3.3.5 INDUSTRIAL WEAVING MACHINE

Weaving machines are very important to tailors who do not want to give their customers the
impression that they have an untidy finishing. Industrial weaving machines are absolute necessities
for professional tailors and dressmakers who give refined finishing to clothes. Weaving machines
help to trim and enclose seam allowance or edge of the fabric inside a woven thread casing.
Although, there are manual weaving machines, industrial weaving machines are more preferable
as they offer more functions and come with better features. Weaving machines are very
important to tailors who do not want to give their customers the impression that they have an
untidy finishing. Although, there are manual weaving machines, industrial weaving machines are
more preferable as they offer more functions and come with better features.

BENEFITS OF USING INDUSTRIAL WEAVING MACHINES

Below are some of the benefits you will enjoy if you use an industrial weaving machine;
1. It requires lesser energy and works at a faster speed
2. Can allow several fabrics or clothes at a time thereby saving your time
3. Provides decorative finishings or serge with its features making your work presentable.
4. Requires less input or control when compared to the manual sewing machines

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 CHAPTER FOUR

4.0 LIMITATIONS AND DIFFICULTIES

 ABSENCE OF HEALTHCARE FACILITIES: This has resulted to many cases of

workers that may have accidents during working and not health and still insist on coming

to work being rushed to a general hospital very far away from the factory which in my

own opinion is very sad.

 BAD ROAD NETWORK: The road to the factory from the main gate is very far and bad

this has contributed to late coming of workers and many cases of road accidents has

occurred.

 WORKER’S WAGES AND SALARIES: Are being delayed and when paid, some of

their salaries are being slashed as a result has generated low motivation in their work.

 POOR MANAGEMENT SYSTEM: This has resulted in the retrogression of the

company as the management system seem to be biased in their decision makings.

 LACK OF TRAINED/EXPERIENCED INSTRUCTORS: Instructors who are trained

and experienced are being given lead positions in the company and has resulted to

blunder/wreck in terms of job execution as workers get confused.

 DISALLOWANCE OF WORKER VIEWS AND LACK OF IMPLEMENTATIONS OF

THEIR IDEAS: Some workers are experienced on the job, but their opinions and ideas

are not considered and has lead poor output on some of the products produced.

 FAR- DISTANCE BARRIER TO THE FACTORY: The distance from the main gate to

the factory is very far and as result the workers resume work late.

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4.1 SOLUTIONS AND RECOMMENDATIONS

 Healthcare facilities such as hospital or clinic

should be built inside the factory to avoid worker

be taken to a far distance before they can be

treated.

 Good road network should be constructed or

repaired to avoid workers having accidents on the

road by the company.

 Workers’ salaries and wages should be paid on

time to motivate in their job executions.

 The company should set up an unbiased

management system to enhance the growth of the

company.
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  The management should employ expert instructors that know their job descriptions

and execute it effectively/properly.

 The management should give attention to the views of the workers most especially

those who are experienced among them.

 The management should provide a transport system that will convey workers from

the main gate to the factory to curb the issue of late coming.

4.2 INNOVATIONS

1. Some of the products should be produced and stored in the warehouse and given to the

customers when demanded as produce on demand tends to over work the workers.

2. A committee should be set-up the company to give monthly awards the best workers so

to increase their motivation for the job.

3. The management should set-up a forum like a trade-fair for exhibition/ display of their

products to generate more customers and buyers.

4. Researchers section should be created and researchers in the field should be employed to

produce new technogy and improve the one available.

5. A joint collaboration should be made between organizations most especially abroad to

bring new technology and designed to the company as well as their expertise.

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4.3 CONCLUSION

An the end of my six-month industrial training at the DICON Special Equipment Factory, I

have successfully learnt the processes involved in the manufacturing of polymer composites

and the operations of the machine used.

I also learnt how to produce a ballistic vest, garments, bags and some work ethics, sampling

of a garment, safety rules/guide as well as teamwork ship. With this experience I have

acquired during the course of my six-month SIWES, my long-term dream is to make effort

and contribute my experience in making innovation by bringing my ideas into reality in order

to improve the textile technology as a whole.

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 REFERENCES

Industrial Cutting of Textile Materials, 2nd Edition by Ineta Vilumsone-Nemes

Apparel Machinery and Equipments by R. Rathinamoorthy, R. Surjit
Apparel Manufacturing Technology by T. Karthik, P. Ganesan, D. Gopalakrishnan
Garment Manufacturing Technology by Rajkishore Nayak, Rajiv Padhye
Hashin Z, Analysis of composite materials- A survey.Journal of Applied Mechanics.
1983; 50(3):481-505
Miracle DB,Donaldson SL. Introduction to Composites.ASM Handbook.2001;21:3-17
Christen RM 2005.Mechanics of Composite Materials. Mineola, New York;2012
DICON Magazine. A magazine of the Defense Industries Corporation of Nigeria

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Vol.1//No.3// December 2018

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