INDUSTRIAL TRAINING REPORT

Submitted by

VENUGOPAL KULKARNI

01FE19BME175

At
Astr Defence Pvt Ltd
4/2A, Kadankoppa, Karnataka 581204

This Report is submitted to

School of Mechanical Engineering

KLE Technological University

Hubballi 580031

2022-23
KLE Technological University
 School of Mechanical Engineering

CERTIFICATE
Certified that the Internship Training carried out by Mr.VENUGOPAL KULKARNI
USN 01FE19BME175, a bonafide student of KLE Technological University,
Hubballi, in partial fulfillment for the award of Bachelor of Engineering /Bachelor of
Technology in SCHOOL OF MECHANICAL ENGINEERING of the KLE
Technological University, Hubballi during the year 2022-23. It is certified that all
corrections/suggestions indicated for Internal Assessment have been incorporated in the
Internship Training report deposited in the school library. The Internship report has been
approved as it satisfies the academic requirements in the said Degree.

Name: Prof.Shreeshail.M.L Name:Dr.B.B.Kotturshettar Name:Dr.Basavaraj S.Anami

Signature: Signature: Signature:

(University Guide) (Head, SME) (Registrar)

External Viva

Name of the examiners Signature with date

1.

2.

KLE Technological University

 Astr Defence Private Limited.
4/2A, Kadankoppa, Hubli-581204, Karnataka, India

CERTIFICATE

This is to certify that VENUGOPAL KULKARNI, USN 01FE19BME175, a student of

KLE Technological University, Hubballi has undergone an internship training program
with our company from 16/01/2023 to 15/03/2023.

We wish him all the very best for his future endeavors.

For Astr Defence Private Limited

Name: Yajnesh Poojari

Signature: Date:
(Industry Guide / Mentor)

KLE Technological University

 LIST OF CONTENT
Chapter Title Page
No. No.

1 INTRODUCTION 1-2
1.1 Introduction 1
1.2 Industrial Training Objective 1
1.3 The Importance of Industrial Training to students 2

2 COMPANY BACKGROUND AND 3-4

ORGANIZATION STRUCTURE
2.1 Brief 3

2.2 Location 3

2.3 Organization Chart 3

2.4 Business Activity 3

2.5 Organization Logo 4

3 WEEKLY JOBS SUMMERY 5-6

3.1 Weekly Jobs Summery 5

4 TECHNICAL CONTENT 7-22

4.1 CAD Software 7

4.2 CAM Software 8

4.3 Phospahting 13

4.4 LASER marking 16

4.5 Wire EDM 19

4.6 Gauges 21

5 FINDINGS AND RECOMMENDATIONS 23

6 CONCLUSION 23

KLE Technological University

1. INTRODUCTION
1.1 Introduction:
Astr Defence Pvt Ltd. Is a licensed defence equipment innovator developing
advanced next generation weapon systems catering to the needs of our military and
security forces to counter our technologically advancing adversaries.
Astr Defence Private Limited is a Private incorporated on 10 September 2019. It is
classified as Non-Govt Company and is registered at Registrar of Companies,
Bangalore.

1.2 Internship Training Objective:

The objectives set by industry the training are:
1. The intern should be ready to work in any given department like design.
Production, stores, quality control, purchase, or any other sector.
2. The intern should be able to do inspection, and prepare documents.
3. The intern should be able to understand the flow of process by observing the
drawings.
4. He should be self-decisive to solve problems in any given situation.
5. He should be able to operate the machines.
6. He should be able to program any given design to manufacture.
7. He should be able to understand the critical features in a specific part.
8. He should be able to design any given complex drawings.
9. He should be able to plan and execute the projects within the time.
10. He should know the specific requirement and usage of the Metro-logy

1.2 The Importance of Industrial Training to students:

The goal of industrial training is to expose students to real work in an industrial setting
while also allowing them to learn via practical application. Students will learn new skills
along with work ethics, project management, time management, communication, and
other practical skills.

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 The following are the key goals of industrial training:
1. Before joining any industry or organization, industrial training gives students the chance
to evaluate their interest in a specific profession.
2. Those who take part in industrial training improve their ability to apply theory to
real-world situations.
3. Industrial training aids in the development of skills and methods directly related to their
ultimate objectives.

4. Industrial training also improves students' moral standing and responsibility.

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2. COMPANY BACKGROUND AND ORGANIZATION
STRUCTURE
Disclaimer! Astr Defence Pvt Ltd. works closely with armed forces. Hence everyone
working in the organization has to sign a non-disclosure agreement (NDA) which
restricts its endorsement from sharing work-related information.

2.1 Brief:
Astr Defence Pvt Ltd. Is a licensed defence equipment innovator developing
advanced next generation weapon systems catering to the needs of our military
and security forces to counter our technologically advancing adversaries.

2.2 Location:
Astr Defence Pvt Ltd. 4/2A, Kadankoppa, Karnataka 581204

Fig 2.2.1 Location of the Organization

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2.3 Organization Chart:

2.4 Business Activity:

Astr Defence is focused on developing the next generation ARMAMENTS,
AMMUNITION and ELECTRO OPTICS.

2.5 Organization Logo:

Fig 2.5.1 Organization Logo

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3. WEEKLY JOBS SUMMARY
3.1 Weekly Summary:
Table 3.1.1 Weekly Activities

DATE ACTIVITIES
Reported to the Office.
 Learned about Types of Engineering Drawings:
Detailed Drawings, Section Drawings, Assembly
Drawings, And Isometric Drawings.

Week 1  Prepared Detailed Drawings for some parts.

(16/01/2023 to 22/01/2023)  Learned about Title Block and Bill of Material

 Introduced to 3D Modelling and Drawings in Fusion
360 CAD Software
 Learned about Incorporation GD&T Standards in
Engineering Drawings

 Introduction to CAM workbench in Fusion 360.

Week 2  CAM Program Setup and Post processing.
(23/01/2023 to 29/01/2023)  Tool-path programming using 2D Contour, 2D Pocket
features in Fusion 360.

 Introduction to Manganese Phosphating process.

Week 3
 Demonstration of Phosphating process.
(30/01/2023 to 05/02/2023)
 Practice of Phosphating process.

 Prepared a Process Chart.

Week 4
 Phospahting of various components.
(06/02/2023 to 12/02/2023)
 Carried out iterations for suitable parameters.

 Introduction to LASER marking.

Week 5
 Demonstration of LASER marking machine.
(13/02/2023 to 19/02/2023)
 Introduction to EzCad software.

 Practice of LASER marking.

Week 6
 Laser marking on various components.
(20/02/2023 to 26/02/2023)
 Carried out iterations for suitable parameters.

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  Introduction to Wire EDM.
 Demonstration of Wire EDM.
Week 7
 Introduction to AutoCut software.
(27/02/2023 to 05/03/2023)
 Practice of Wire EDM.
 Machining of Gauges on Wire EDM.

 Learned about Work holding devices.

Week 8 and Week 9
 Learned about Fixtures Design and Gauges.
(06/03/2023 to 15/03/2023)
 Designed Fixture for a part to be machined on VMC.

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4. TECHNICAL CONTENT
4.1 CAD SOFTWARE
Fusion 360 is a cloud-based 3D CAD, CAM, and CAE software designed by Autodesk. It is
an all-in-one product development solution that combines industrial design, mechanical
engineering, and manufacturing capabilities in a single package. Fusion 360 has a wide
range of features that make it a versatile tool for product design and manufacturing. In this
document, we will discuss the features of Fusion 360 in detail.

Part Modelling Features: Fusion 360 offers a robust set of features for creating 3D
parts. Some of the key features are:

Parametric Modelling: Fusion 360 offers a parametric modelling approach that

allows users to create and modify designs with ease.

Direct Modelling: Users can also use direct modelling techniques to create or modify
designs without worrying about the underlying parametric constraints.

Assembly Modelling: Fusion 360 allows users to create complex assemblies with ease.
Users can import parts from other CAD systems and assemble them in Fusion 360.

Sheet Metal Design: Fusion 360 has a comprehensive set of sheet metal design tools
that enable users to create 3D sheet metal designs and generate flat patterns.

Surface Modelling: Users can create complex surfaces with ease using the surface
modelling tools in Fusion 360.

Fusion 360 methodology (gauges)

Making a design in Fusion 360 involves several steps, including creating a new design,
sketching the design, creating 3D models, adding components, and creating assemblies.
Here is a step-by-step guide to making a design in Fusion 360:
Open Fusion 360 and create a new design: Open Fusion 360 on your computer and select
"New Design" from the home screen.
Sketch the design: Use the sketching tools to create 2D designs of the part you want to
create. You can create sketches on different planes, and you can use different sketching
tools such as lines, circles, and arcs.
Extrude the sketches to create 3D models: Once you have created your sketches, you can
extrude them to create 3D models. Select the sketches you want to extrude, then use the
extrude tool to specify the height and other dimensions of your 3D models.
Add components: Once you have created your 3D models, you can add components to your
design. Components are separate parts of the design that can be assembled together to
create a complete product.

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Create assemblies: After you have created your components, you can create assemblies to
bring all the parts together. Assemblies allow you to see how the different parts fit together
and how the product will look once it is assembled.
Make any necessary modifications: Once you have created your design, you can make any
necessary modifications by going back and editing the sketches, models, or assemblies.
Export your design: Finally, you can export your design in a variety of file formats,
including STL, OBJ, and DXF, depending on your needs.
This is a simplified overview of the steps involved in making a design in Fusion 360. The
software offers many powerful tools and features that allow you to create detailed and
complex designs. It is recommended to follow tutorials or take courses to learn more about
the software and its functionalities.

4.2 CAM SOFTWARE

2D Milling Process
Milling is a machining process that involves a tool advancing into a piece of stock material.
Excess stock is removed, until the actual part remains. Machine code, for example a
G-Code file, instructs the tool's movements.
A typical milling operation entails moving the tool in the X, Y, and Z machine axes. The
process is known as 3-axis milling. 3-axis milling is frequently used in the manufacturing
sector to produce prototypes and prismatic parts. The use of 5-axis milling technology is
necessary for complex precision items. The machine instruction file is produced using a
variety of 3-axis and multi-axis operations that may be created with Fusion 360.

Setup Overview
A setup outlines what and how you wish to machine. It serves as a container for
manufacturing processes and is the first thing you build in the Manufacture workspace.
Depending on the kind of manufacturing you plan to undertake, different items need to be
specified while constructing a setup.

Fig 4.2.1 Example of a project with 2 setups.

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Subtractive
For subtractive manufacturing (milling, turning or mill/turn, and cutting), in general, you
specify:

The machine and operation type that you want to use.

The work coordinate system’s orientation and origin location.

The models that represent the parts you want to make.

The stock to define the size and dimensions of the work piece you want to machine away.

The settings for the post processor.

Work coordinate system
For subtractive manufacturing, the work coordinate system (WCS) defines the orientation
of the work piece and establishes the location of the origin. The origin is the point from
which all operations are referenced.

Model
The model specifies the object being created. By default, every model on the canvas is
already chosen. You can individually choose which models you wish to be included in the
setup if you have many models that each represents a number of different pieces. The
model can also be used to specify where the work coordinate system's origin is.
Moreover, you can designate any model as a fixture for subtractive manufacture. A fixture
is a piece of equipment, such as a vise, a clamp, or a chuck, that holds or supports the work
piece while it is being machined. During stock simulation, collisions with fixtures are
highlighted.

Stock
For subtractive manufacturing, the stock represents the size and shape of the work piece
from which a part is machined. Defining the stock lets you visualize the raw material being
removed during the manufacturing process when you simulate operations. The size of the
stock is automatically determined based on the model, but you can define it manually.

Post Processing
You have a number of options for post-processing the operations in a setup for subtractive
manufacturing, including the ability to set a numerical work offset. The work offset is the
separation between the work coordinate system and the machine-tool coordinate system,
and it is associated with a particular G-code on a machine tool (for instance, 0 or 1 would
equate to G54).

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2D Adaptive Clearing Overview
2D Adaptive Clearing is a roughing toolpath that avoids abrupt direction changes. You can
clear a cavity, open pocket, or the area around a boss by selecting edges, sketches, or solid
faces as the machining area.

Fig 4.2.2 Adaptive toolpath around two circular boss features.

Sudden changes in how much of the tool is engaged while cutting material around it can
cause tool breakage. To avoid sudden changes in tool engagement, 2D Adaptive Clearing
maintains a constant engagement between the tool and its surrounding material.
The Optimal Load parameter sets the level of engagement and can be adjusted depending
on the tool manufacturer's recommendations. The 2D Adaptive Clearing toolpath is
preferred for roughing simple pockets and other simple geometry whereas 3D Adaptive
Clearing offers more control and can be used for more complex geometry.

2D Pocket Overview
The 2D Pocket toolpath is a roughing operation with options for creating a finishing pass.
You can clear a cavity, open pocket, or the area around a boss. The toolpath resembles the
shape of the boundary being machined. The machining area can be selected from edges,
sketches, or a solid face. The toolpath also includes options for tapered walls and
pre-drilling entry positions.

Fig 4.2.3 2D Pocket toolpath machining internal pockets.

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Generally, 2D Pocket generates a smaller program file size when compared with 2D
Adaptive, which makes it more suitable for older machine tools that have a low memory
capacity. Another difference between 2D Adaptive and 2D Pocket is that 2D Pocket
assumes a boundary it must stay within. Where 2D adaptive has the ability to approach
from the outside and move in to cut the stock.

Face Overview
The Face toolpath is often the first operation performed on raw stock material to prepare it
for further machining. Typically, the depth of material to be removed is the distance
between the top of the stock and the top of the model. The Face toolpath helps ensure
flatness on a surface so it can sit flat on a vise for accurate machining. It can also be used for
clearing flat areas in general.

Fig 4.2.4

Face toolpath that removes stock up to the model top.

Controls exist for containing the toolpath to a specific stock area. You can use Stock
Contours to contain the machining area in X & Y and the Heights parameters to contain
the machining areas in Z, but as a default, it assumes that you want to face the entire stock.
You can change the direction of the passes using the Pass direction to run along a different
axis, which can be useful if the passes are running along an axis that may not have enough
length of travel on the machine.

2D Contour Overview
2D Contour creates a toolpath based on a contour selection, which is an outline of a part.
You can select a sketch or an edge on the part for the contour selection. The contour
selections can be open chains or closed chains and can be on the inside or outside a part. In
2D Contour, the cutting motion always takes place on a 2D plane.2D Contour is commonly
used as a finishing toolpath. You can use multiple finishing passes to avoid cutting with the
full width of the cutter. You can also machine tabs to help hold a part in place, useful when
cutting on a sheet of material.

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Fig 4.2.5 2D Contour toolpath finishing the outside face a part.

Use the Minimum Cutting Radius parameter to avoid binding of the tool in tight corners.
Use Compensation Type to allow the machine operator to compensate the final size of the
cut at the machine by moving the tool towards the part, or away from the part. An example
of when you may want to move the tool closer to the part is if the tool is worn-out, and the
diameter is slightly smaller than what was used when programming the toolpath. The 2D
Contour toolpath is ideal for straight walls whereas 3D Contour is useful for tapered walls
and organic surfaces.

Thread Overview
The Thread toolpath is used for milling threads into a hole or a boss, with straight or
tapered walls. The heights and depths are automatically derived from the circular or conical
face selections.

Fig 4.2.6 Thread toolpath on a straight (circular) wall and a tapered (conical) wall.

You can choose to mill right-handed or left-handed threads. Right-handed threads are the
most common type of threads, which require a fastener to turn clockwise to progress down
the thread. To speed up the geometry selection process; you can use the options in
the Geometry tab to automatically select geometry with the same diameter, or to
automatically select holes and bosses based on minimum and maximum diameter ranges.
The Do Multiple Threads parameter lets you create multi-lead threads. While maintaining
the same thread pitch, multi-lead threads let a fastener travel longer distances per turn when
compared with single-lead threads.

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2D Chamfer Overview
2D Chamfer is used to create a bevelled edge on a part. Select edges or sketches to drive the
tool path. A tapered tool is required to create the chamfer. How you select the geometry and
what parameters you use depends on whether the chamfer is modelled or not.

Fig 4.2.7 2D Chamfer toolpath with a tapered tool

The Chamfer Width determines the size of the chamfer on the part. For non 45-degree
chamfers, the diagram below illustrates the Chamfer Width. The Chamfer Tip
Offset adjusts the position of the tool relative to the chamfer.

Fig 4.2.8 Chamfer width

For longer tool life, adjust the position so that the tip of the tool does not align with the
sharp edges of the chamfer. You can also use the 2D Contour toolpath to create chamfers.
When using the 2D Contour toolpath on a modelled chamfer, select the bottom edge and set
the Chamfer Width to 0.

4.3 PHOSPHATING
Manganese phosphating is a well-known and often used wear prevention technique. In
bigger diesel engines, this treatment is commonly applied to the gearwheels in the gearbox,
the crown and pinion gears in the differential, the camshafts, the valves, the valve steams,
and the pistons. It is frequently used to enhance the sliding characteristics of gear, engine,
and power transmission systems. Of all general phosphate coatings, it possesses the highest
hardness as well as the best corrosion and wear resistances. Components in refrigerator
compressors or oil pumps, along with the hydraulic rams that go with them, are treated
using this method in other sectors.
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The use of manganese phosphate coatings for improved corrosion resistance can be found
in virtually all branches of the metal working-industry. Typical examples mentioned here
include motor vehicle components in brake and clutch assemblies, engine components, leaf
or coil springs, drill bits, screws, nuts and bolts, washers, anti-vibration washers, tools,
magnet cores, casting interiors and many other small items.

Fig 4.3.1 Machined metals with and without manganese phosphating process.

Process Line

Whether a post-treatment such as oil application is to be used or not, it is invariably applied

by the immersion method. The processing sequence can be summarised as follows:

1. Degreasing and Cleaning

2. Water Rinse
3. Pickling In Mineral Acid (Where Necessary)
4. Water rinse (Only after Pickling)
5. Activation
6. Manganese Phosphating
7. Water Rinse
8. Final Oven Drying (Optional)
9. Lubricating With Special Oils

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Degreasing and Cleaning
The pieces need to be thoroughly cleaned before they can begin the phosphating process.
Acidic, neutral, or alkaline degreasing chemicals can be employed for this purpose.
Alkaline degreasing agents are typically selected for an efficient cleaning, and these
alkaline chemicals are utilized at a concentration of 1-5% and at 65-95 0C. The processing
time ranges from 5 to 15 minutes.

Pickling In Mineral Acid

If the surface of the parts to be treated has a layer of rust and oxide, this layer is removed by
pickling following degreasing. Phosphate coating won't form on the rusted regions if they
aren't cleansed.

During degreasing and phosphating, there should be more than one water rinse bath to
prevent the alkaline or acidic content from transferring to the phosphating bath. The acidic
balance of the manganese phosphate bath must be maintained in order for it to function
steadily, thus it is best to totally replace the rinsing baths at brief intervals or to continually
renew them with flooding.

Activation

To assure the creation of uniform and finely crystalline phosphate layers, the parts are
cleaned with alkalis and acids before being submerged in a conditioning bath, commonly
referred to as "activation." Manganese phosphate with tiny grained particles makes up
activation baths. The issues brought on by thick crystalline coatings have been eliminated
by the efficient activation chemicals created in recent years. Manganese phosphating offers
a thicker coating and a larger crystalline coating than zinc phosphating, but an extremely
high corrosion resistance is obtained by using the activation technique to create a small
crystalline coating.

Manganese Phosphating

Manganese phosphating is mainly by immersion. Concentrated chemical products are

generally used at a concentration of 15-20% by weight to prepare manganese phosphate
coating baths. As the coating is made, necessary product additions are made according to
the bath analysis. Total acid, free acid and dissolved iron values are measured and checked
to see if they are in the appropriate range. The phosphate sludge formed in the bath with the
coating should be cleaned at regular intervals. Treatment times range from 5-20 minutes,
the optimum time depending on the surface condition. The bath operating temperature is
around 95 °C and only in special cases can satisfactory coatings be formed at temperatures
between 70-80 °C.

Lubricating With Special Oils

The phosphated components, after drying, are immersed in the oil or lubricant baths for
0.5-2 minutes, allowed to drain. The thickness of the resulting oil film depends on the oil
used and its concentration.

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Coating Color and Appearance

Compared to zinc phosphate coatings, the image created following manganese phosphating
is a darker grey that is almost black. As a result, factors including the kind of metal, the
color of the surface prior to coating, the usage circumstances for activation, and the kind of
oil to be used as the final treatment all have a significant impact on the coating's ultimate
shade.

The surface color of the component that needs to be treated has a direct impact on the final
color. In contrast, the appearance of a darker cast part after coating may be in a
considerably darker tone. As an illustration, the appearance of a light grey machined
component after manganese phosphating may be in the light grey to dark grey range.

Application of lubricant makes the color of the coating darker and brighter. Therefore, oils
with different properties provide different degrees of darkness. Water-based boron oils,
mineral-based oils, solvent-containing oils, oils with high corrosion resistance additives
and oils with high friction resistance can be given as examples of oil types used in the
sector.

4.4 LASER MARKING

Laser marking is a permanent process that uses a beam of concentrated light to create a
lasting mark on a surface. Typically performed with a fiber, pulsed, continuous wave,
green, or UV laser machine, laser marking encompasses a wide variety of applications. The
most common types of laser marking applications are:
Annealing
Carbon migration
Discoloration
Engraving
Etching
In addition to leaving permanent traceable markings on a variety of materials, including
steel, titanium, aluminum, copper, ceramic, plastic, glass, wood, paper, and cardboard,
laser marking can also be automated and performed at high speeds. It is possible to mark
components and goods using text (such as serial and part numbers), machine-readable
information (such barcodes, Unique IDs, and 2D Data Matrix codes), or images.

How Laser Marking Works

A concentrated light beam is used in laser marking to leave marks on the surface of a
material. The surface of the material is where the beam interacts, changing the
substance's characteristics and appearance. The laser marking machine can produce
precise, high-quality, high-contrast marks that are simple to read or scan on almost any
surface thanks to this concentrated beam that only focuses on a specific area. Laser
marking is the best option because of this characteristic for situations where success
depends on accuracy and permanence.
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Product Specifications

Fig 4.4.1 Laser Marking Machine

Product Specifications
Table 4.4.1 Machine Specifications

Supporting Format Support PLT, DXF, BMP File etc., Using

SHX TTF Character Storage Directly

Wavelength 290 nm

Cooling Method Air Cooled

Brand Mehta

Output Power 30 W

Power Adjustment 0 to 100 %

Min. Line Width 0.03 mm (Depend on Material)

Max. Speed 10000 mm/s (Max. Linear Speed)

Marking Depth 0.01~0.3mm (Depends on Material)

Min Character Height 0.5 mm

Repetition Frequency Range 20-60 KHz

Max Power Consumption 200 Watt

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EzCad Software

The software programme EZCAD is adaptable and strong, perfect for engraving
applications and it is compatible with many cutting-edge imaging technologies like
QR codes and barcodes. Because of EZCAD's versatility, DXF and other file types
may be loaded and sent to the engraving machine using it as a communication platform
as well as a separate CAD and graphics processing programme.

Fig 4.4.2 EzCad Software User Interface

Laser marking operation

 Turn on the electrical switch, release emergency button, turn on key, and push
green button for power supply.
 Switch on the computer and open the EzCad software.
 Adjust focal length according to the object height.
 Click “FI” to input contents, you can choose font which you like.
 Import vector file if you have files generated from other software.
 Import DXF files if you need.
 Click “H” to make hatching for contents.
 Set appropriate number of loops according to material and required depth.
 Set speed and power accordingly.
 Click “Red” to adjust suitable marking position.
 Then, click “Mark” to start engraving on working position.
 Click “Esc” to turn off stop marking.
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  To turn off machine press green button, turn off key, push emergency button
and switch off electricity.

4.5 WIRE EDM

Wire EDM
Wire EDM (Electrical Discharge Machining) is a manufacturing process that uses a thin
metal wire to cut intricate shapes and profiles in conductive materials such as metals,
alloys, and some ceramics. The wire is controlled by a computerized system and is used to
create precise cuts and shapes that are difficult or impossible to achieve with traditional
machining methods.

Working of Wire EDM

During the wire EDM process, an electrical discharge is created between the wire and the
work piece. This discharge removes material from the work piece, creating a cut. The wire
is continually fed through the work piece, creating a path for the electrical discharge to
follow. The wire never actually touches the work piece, but rather cuts through it using a
spark erosion process.

Machine Components
The wire EDM machine consists of several components, including a power supply, wire
guide, worktable, and a control unit. The power supply generates the electrical discharge,
and the wire guide ensures that the wire remains straight and properly aligned with the
work piece. The worktable holds the work piece in place during the cutting process, and the
control unit manages the entire process, including the wire feed speed, spark frequency,
and other parameters.

Fig 4.5.1 Wire EDM Machine

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Product Specifications
Table 4.5.1 Machine Specifications

Capacity 33.5 x 40 Inch

Material Mild Steel

Model Name/Number DK7732Z,DK7740Z,DK7750Z,DK7763Z,DK7780Z

Voltage 380 V

Weight 1350-5600 Kg

Wire Diameter 0.13-0.2 mm(normally 0.18)

Automation Grade Automatic

Max Cutting Angle +/-3/100 D/m

Power 3-3.5 kW

Applications
Wire EDM is a highly precise and versatile manufacturing process that can be used for a
wide range of applications. Here are some common applications of wire EDM:

 Tool and die manufacturing: Wire EDM is commonly used to produce dies and
molds for use in the manufacturing of other products.
 Aerospace and automotive industries: Wire EDM can be used to create complex
shapes and contours in engine components, turbines, and other aerospace and
automotive parts.
 Medical device manufacturing: Wire EDM is used to produce small, intricate
components used in medical devices such as surgical instruments and implantable
devices.
 Electronics manufacturing: Wire EDM can be used to produce precision
components for electronic devices such as microprocessors and printed circuit
boards.
 Jewelry and watchmaking: Wire EDM is used to create intricate designs in precious
metals and other materials used in jewelry and watchmaking.
 Prototyping: Wire EDM is often used in prototyping to quickly and accurately
produce parts and components for testing and validation.

About AutoCut software

AutoCut is a type of software used in wire EDM machines that automates the cutting
process. AutoCut software allows the user to input the desired shape or profile to be cut,
and the software will automatically calculate the optimal cutting path and adjust the wire
feed speed and other parameters accordingly. This saves time and reduces the risk of
human error, as the software can create complex cuts with minimal user input.

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Additionally, AutoCut software can provide real-time monitoring of the cutting process,
allowing the user to make adjustments on the fly if necessary.

Wire EDM Operation

 Prepare the work piece: Secure the work piece onto the worktable using clamps or
other holding devices. Make sure the work piece is properly aligned and level.
 Load the wire: Load the wire into the wire guide and adjust the tension and
alignment as necessary.
 Set the cutting parameters: Input the desired cutting parameters into the control
unit, including the wire feed speed, spark frequency, and other parameters.
 Start the cutting process: Initiate the cutting process by pressing the start button on
the control unit. The wire will begin to feed through the work piece, creating a
cutting path.
 Monitor the cutting process: Monitor the cutting process and make adjustments as
necessary. Check the progress of the cut frequently to ensure that it is proceeding
according to plan.
 Finish the cut: When the cut is complete, turn off the power supply and remove the
work piece from the worktable.
 Clean and maintain the machine: Clean the wire guide and worktable after each use
to prevent buildup and maintain the accuracy of the machine. Perform regular
maintenance tasks as outlined in the manufacturer's instructions.

4.6 GAUGES
Go and no-go gauges are mechanical gauges that are used to check the conformity of a part
to a specified tolerance. They are often used in manufacturing and quality control processes
to ensure that parts are within the acceptable range of size and dimensions.
A go gauge is designed to ensure that a part is within the acceptable upper limit of size or
dimension, while a no-go gauge is designed to ensure that a part is within the acceptable
lower limit of size or dimension. When a part is checked with a go and no-go gauge, if the
part passes the go gauge but fails the no-go gauge, it is considered to be within the
acceptable tolerance. If the part fails the go gauge, it is considered to be too large, and if it
fails the no-go gauge, it is considered to be too small.

Go and no-go gauges are typically made to precise specifications, and are often customized
for a specific part or product. They can be used to check a wide range of dimensions, such
as diameter, length, and thickness, and are often used in conjunction with other measuring
tools, such as micrometers and calipers.

Some examples of go and no-go gauges include:

Plug gauges: Plug gauges are used to check the diameter of a hole or bore. A go plug gauge
has a diameter that is slightly larger than the maximum acceptable size, while a no-go plug
gauge has a diameter that is slightly smaller than the minimum acceptable size.

Ring gauges: Ring gauges are used to check the diameter of a shaft or rod. A go ring gauge
has a diameter that is slightly smaller than the maximum acceptable size, while a no-go ring
gauge has a diameter that is slightly larger than the minimum acceptable size.
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Snap gauges: Snap gauges are used to check the thickness of a part or the distance between
two surfaces. A go snap gauge has a width or thickness that is slightly larger than the
maximum acceptable size, while a no-go snap gauge has a width or thickness that is slightly
smaller than the minimum acceptable size.

Go and no-go gauges can be an important tool in ensuring the quality and consistency of
manufactured parts and products. They can help to identify defects or deviations from
specifications, and can ensure that parts are within the required tolerances for proper
function and performance.

Fig 4.6.1 Gauges

In general, mechanical gauges are reliable, durable, and easy to use. They do not require
power sources, and can often be calibrated and maintained by the user. However, they may
be less precise than electronic or digital instruments, and their accuracy can be affected by
environmental factors such as temperature and humidity.

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5. FINDINGS and RECOMMENDATIONS
5.1 Findings
Exposure and Experience: I gained knowledge of and practical experience in the field. I
now knew practically what I had only known conceptually about. This is a crucial
component of professional growth because it helped me gain a better grasp of how various
ideas and principles may be put into effect.

Learning about new technologies: I was given the opportunity to learn about Fusion 360,
and AutoCAD, ADAMS among other software programmes. CAM in particular, a
programme I've never used. It has demonstrated to me that I can acquire and using the latest
tools and technology required by the sector in order to remain competitive and pertinent.
Hands-on Experience: The company has provided the chance of working on product
development. I gained experience in machines including VMC, M1TR, Wire cut EDM.
Also, I gained exprince in the field of design and assembly.

5.2 Recommendations

Process of Product development is crucial one in any project. I my opinion company needs
to focus on this process including survey, design, analysis, prototype etc.

More focuses on CAE and analysis can be given.

6. CONCLUSION
The internship training was really helpful for university students. By actually using the
theoretical concepts, it has made them easier to understand. The main objective of
industrial training was to show undergraduates how engineering can be used in the real
world through observation and practise. It was also an opportunity to communicate with
co-workers and observe management techniques in addition to gaining knowledge in
technical procedures.

 acquired numerous opportunities during internship training to really feel and

visualise the functioning of machining on VMC and M1TR
 learned about inspecting quality, preventive maintenance, and other
manufacturing procedures.
 The opportunity to connect with various industry professionals and expand
professional networks were additional benefits of the internship.
 As a whole, it was an enjoyable one that will enable me to improve my
knowledge and skills as needed. We may have received the best industry
exposure to date through this, and I am quite appreciative of the chance.

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 References
1. Astr Defence map- Google Maps
2. Astr Defence Pvt ltd- https://astrdefence.com/
3. Astr Defence organization logo- https://astrdefence.com/
4. CAM images- https://help.autodesk.com/view/fusion360/ENU/courses/
5. Phosphating-http://www.phosphating.net/manganese-phosphating.html
6. LASER Marking
Machine-https://mehtaindia.com/fiber-laser-marking-machineevan-series/
7. EzCAD software-https://latelierdufeldenkrais.fr/ezcad2-k.html
8. Wire EDM-https://www.rselectro.com/edm-machine.html
9. Gauges-https://www.youtube.com/watch?v=nMIMiy12jxY

24 KLE Technological University