CHAPTER - 01

OVERVIEW OF THE ORGANIZATION

1.1 Description

The company manufactures machine tools for turning, milling, grinding, and
automation processes.Products & Services: CNC Turning centres, CNC lathes,
CNC Turn mills, CNC Vertical Turning Lathes, CNC Chucker’s, tooled up
Solutions, Gantry Automation Solutions, Foundry, Robot Automation Solutions,
Automotive parts machining, Sliding head automats, Centre lathes, and
Conventional lathes.Ace Designers Limited is an unlisted public company
incorporated on 25 September 1986. It is classified as a public limited company and
is in Bangalore, Karnataka. Its authorized share capital is INR 20.00 cr and the total
paid-up capital is INR 11.88 cr.ACE Designers Limited's operating revenues range
is Over INR 500 cr for the financial year ending on 31 March 2022.Ace Designers,
led by the three experienced design engineers and powered by a dynamic team of
more than 500 members is one of India’s largest machine tool manufacturing
companies. With a spread of 50000 square meters, its manufacturing plants, located
in Bangalore, India, equipped with state-of-the-art technology to deliver large-scale
high-quality products. Ace Designers was founded in 1979 as a design-consulting
firm. Initially, the team developed product designers for various machine tools
including special purpose machines. Three years hence, in 1982, Ace stepped into
the world of manufacturing with a range of special purpose import substitution
machines for the I C engine valve Industry. Since then, Ace has rapidly grown to
become India’s largest manufacturing of CNC turning centres and has remained the
undisputed leader for nearly two decades. With a strategic focus on manufacturing
of CNC turning centres, Ace has developed a wide range of indigenous cost-
effective products to meet the changing.

Figure 1.1 Company profile

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1.2 Founding fathers of ACE designers limited.

Figure 1.2 Company founders

Figure 1.3 Company founders

Ace Designers is the flagship company of the Ace Micromatic Group. The
company was founded in 1979 as a design-consulting firm by three engineers from
CMTI. Initially, the team developed product designs for various machine tools
including special purpose machines. In 1982, Ace stepped into the world of
manufacturing with a range of special purpose import substitution machines for the
I. C. Engine valve Industry.

2
 Figire 1.4 Company logo [1]
Since then, Ace has rapidly grown to become India’s largest manufacturer of CNC
turning centres and has remained the undisputed leader for nearly two decades. With
a strategic focus on manufacturing of CNC turning centres, Ace has developed a
wide range of indigenous cost effective products to meet the changing needs of its
customers. Ace has ensured product excellence through quality driven
manufacturing processes supported by meticulously planned world class
infrastructure.This below figure 1.5 shows company history

Figure 1.5 Company history

3
1.3 Vision and mission of the organization
1.3.1 Vision.
We will deliver Value Driven Customer Experience by providing Engineered
Products & Solutions with Leading Edge Technologies in Turning and Beyond
having Smart Agile Manufacturing to become an Admired Organization enabled by
Vibrant Inspired People achieving Accelerated Growth.
1.3.2 Mission.
We at Ace Designers are driven by our three-core values Creativity, Quality and
Service. These guiding principles help us infuse the best processes and
craftsmanship in our projects.
We believe in:
• Honesty is the best policy.
• Protecting our environment and future.

1.3.3 Mission (2022).

• We will Achieve.
• Sales turnover: 2500 crore.
• Domestic market share: 40% in turning.
• Exports: 15% of sales.
• Service income: 10% of Revenue.
• New product beyond turning: 500 crores.
• Winner of the EFQM Business Excellence Award.

1.3.4 Values.
• Customer delight.
• Cost effective working.
• Passionately ensuring quality.
• Empowering people.
• Business ethics & transparency.

4
1.4 Organization structure

Figure 1.6 Company organization structure [2]

1.5 Department and functions

Figure 1.7 Company departments and functions [3]

5
1.6 Products and market performance.
Ace Marketing department is also known as Technical Service Group (TSG).
Team aids and acts as a link between the customer and ACE MICROMATIC to get
all the technical requirements fulfilled for the customers. ACE holds globally,
market share value of ~ 26 – 27% World leading CNC Turning manufacturing.

• VTL Series.
• Jobber Series.
• JE Series.
• Vantage Series.
• Conventional Lathe.
• Auto Lathe.
• LT Series.
• Marketing Sales and service are headed by MS Micrometric (Group
company)
• Vantage Series: 1. Vantage 800
Having played a vital role in the Indian industrial renaissance, Ace machines have
established their footprint in the global arena too. They have found acceptance in
Europe, USA, South America, UK, Middle East, China, Southeast Asia, Japan and
Australia.

1.7 CNC turning machine.

• Jobber Junior
• J300
• JE 06 LM/XL
• JE 08 LM/XL
• SJE 06 LM/XL
• SJE 08 LM/XL
• SJE 10 LM/XL
• CS-16-LM-200
• CS-2 LM 200 figure 1.7.1 J300 machine [4]
• Tutor
• COLT-LM

Figure 1.7.2 Jobber junior machine. [4]

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 Figure 1.7.3 COLT-LM machine [4]

1.8 Premium machines.

• VTL 25 L
• VTL- 40
• VTL- 30-PLUS
• LT-25-630
• LT-25-1000
• ‘LT-25-1500
• LT-30 - 630
• LT-30 - 1000
• LT-30 - 1500
• LT-40- 2000
• LT-40- 4000

Figure 1.8.1 VTL 25L machine [4]

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 Figure 1.8.2 VTL-30-PLUS [4]

Figure 1.8.3 LT-40_4000 [4]

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 CHAPTER - 2
ON JOB TRAINING 1(OJT)
In the (OJT – 1) department of component manufacturing division, manager
gave us good opportunity to do some project like a component to require to their
need of company.
Ex: height pad

2.1 Height pad

Component manufacturing details
2.1.1 Component material and its uses
C45 material carbon steel grade commonly supplied as flame cut pieces with
datively to the hole of UK. This grade can the flame introduction hardened to
produce a good surface hardness with moderate work resistance.
2.1.2 Capacity of C45
Tensile breaking load - 650mpa
Density - 7.87g\cm
Melting temperature - 1495. e
Hardness - 205 Brinell
Yield strength - 300mpa
C45 grade steel is medium carbon steel offering tensile strength. the material
capable of through hardening by quenching and tempering on limited selection but
can also flame o the induction hardened.
C45 material used.
This grade can be flame or indication hardened to produce a good surface
hardness. with a moderate wear resistance c45 is widely used for components that
require belters properties than mild steel but does not justify the cost of an along
steel.
2.1.3 C45 material equant to
Cross reference table for the steel c45 (iso)
And it is European equant c45 (1.0503) (EN)

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 EUEN USA ENGLAND BS
C45 1042 070M46
C1.0503 GR.1042 50 HS
Table 2.1 Material equant
2.1.4 USA thickness of c45 material
Shape - rectangular
C45 alloy steel sheet thickness - 2-150mm
Thickness - 2 -150mm
Msg application - all
Technique - hot rolled.
Material grade - c45
C45 steel quality
C45 is medium steel carbon steel grade. Commonly supplied as flame cut pice
with delivery.to the hole of uk. this grade can be flame. Or induction to produce a
good surface hardness with moderate wear resistance.En8 steel is also known as
c45 is a medium carbon steel. That has a higher strength and hardness then mild
steel is typically used in application that require high strength. such as a year shaft
and other machines parts mild steel is a low carbon steel. That has a relatively
strength and hardness of c45 material.
Application of c45 material
• General Aneles
• Spindles
• Studies
• Various machines
• Fixtures
• Many automotive engineering company.

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2.2 Variations of c45 material
• ability C45 basic grade with chemical composition
• C45E modified with limited p and s levels
• C45R modified with limited p levels and minimum s level enhanced machines.
• Conditions of c45 material
• New- designation
• A – soft annealed
• N - normalized
• Qt -quench tempered
• H – with addition hardenability test
• HH – with enchanted hardenability test
2.2.1 Mechanical properties of c45
C45 is the medium strength steel with good machine. and tensile properties.
C45 round steel is generally supplied in the block. hot rolled in the normalized
condition. With a tensile strength range 570 -700mpa. And Brinell hardness range
170 -210 in condition. This material capable through the hardening by quenching
and tempering on limited section. and also can be flame or indication hardened to
surface hardness min 55hr it offers moderate the tensile strength. wear resistance
and good machinability.
2.2.2 Chemical composition of c45 steel
• The maximum percentage of carbon is o.50 percent
• Maximum percentage of manganese is 0.9 percent
• And minimum percent 0.5 percent.

Carbon 0.42 - 0.50% Phosphorous

Manganese 0.50 - 0.80% Sulphur

Silicon 0.15 - 0,40%

Table 2.2 Chemical composition of C45 steel

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2.2.3 C45 grade
C45 grade steel is medium carbon steel offering tensile strength. the material
capable of through hardening by quenching and reperching on limited selection but
also flame on induction to

Height pad

Figure 2.1 Height pad

2.3 Operations
• marking
• making point
• drilling
• tapping
• chamfering
• surface grinding

2.4 Cutting parameters.

Cutting parameters are the changes in setup that affect the quality and efficiency of
a cutting operation.
Cutting parameters in machining:
• Cutting speed or cutting velocity.
• Feed rate.
• Depth of cut

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2.4.1 Cutting speed formula.
Cutting speed [VC] = (𝜋𝐷𝑁)/1000
Diameter 5.5 Drill bit
Feed = 0.5mm
Speed = 630rpm
Depth of cut = 10mm
Diameter 14mm drill bit
Feed = 0.1mm
Speed = 315rpm
Depth of cut = 3mm
Chamfer 90⁰ [2mm]
Speed = 60mm
Depth of cut = 0.3mm [chamfer]

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The whole milling project of height pad done through by two milling machines.
1. Manford milling machine.
2. Radial drilling machine
2.5 Manford milling machine

Figure 2.5.1 Manford milling machine.

This above figure 2.5.1 shows manford milling machine.
2.5.1 Specification
• Bed length 1000*1000mm
• 3 axis machine x y z
• x and y position control
• z axis 0.2mm one rotation 2.5mm motor 1hp
• angle of drill x axis 0-90º degree
• y axis 0 -45º
• spindle depth 300mm

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2.5.2 Component being manufacturing.
• Roller
• Flinger
2.5.3 Raw material
• Cast iron
• Mild steel
• Aluminium
2.5.4Cutting tools
• End mill
• Face mill
• Reamer
• Tap
• Drill bit
• Inside mill cutter

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 2.6 Radial drilling machine

Figure 2.6.1 Radial drilling machine

2.6.1 Parts of Radial Drilling Machine:
The Parts of the Radial Drilling Machine are as follows.
1. Base
2. Column
3. Radial Arm
4. Motor for elevating the arm
5. Elevating screw
6. Guideways
7. Motor for driving drill spindle
8. Drill head 9. Drill spindle
10. Table.

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This below above 2.3 shows radial drilling machine.

2.6.2 Operation performance varies machines.

• Milling: machining is a process in which is material is cut to a desired final shape
and size by a controlled material removal process.
• Drilling: drilling operation is the first contact between the formation and the
nonnative fluids and equipment.
• Chamfering: chamfering assembly, edge the instruction of bolts into holes or nuts.
• Tapping: tapping is the machining process for producing internal threads.
• Surface grinding: surface grinding is the finishing process that uses abrasive wheel
to a smooth the flat surface of metallic or non-metallic materials to give than a more
refined look by removing the oxide layer and impurities on work piece surface.

2.7 Heat treatment process.

Heat treatment involves the use of heating or chilling, normally to extreme
temperatures, to achieve the desired result such as hardening or softening of a
material. Heat treatment techniques include annealing, case hardening, precipitation
strengthening, tempering, carburizing, normalizing, and quenching. Common types
of heat-treating methods include annealing, hardening, quenching, and stress
relieving, each of which has its own unique process to produce different results.
2.7.1 Annealing
Annealing is a heat treatment process used to modify the microstructure of a
metal to improve its ductility while reducing internal stress and overall hardness.
This allows the material to be more easily shaped without cracking. This process is
particularly useful for steels, which can be too hard or brittle for forming processes.
The annealing process involves heating metal to a temperature at which the
crystalline structure becomes fluid, but the metal remains in a solid form. The metal
is held at this temperature, which allows for any defects in the material to repair
themselves. The metal is then allowed to cool back to room temperature at a slow
pace to produce a more ductile crystalline structure.
2.7.2 Hardening
Hardening heat treatments are used to enhance the hardness of the metal’s
surface through heating and rapid cooling. The material is heated in a hardening
furnace to a temperature that transforms its internal structure without melting it.
The metal is then held at this temperature for one hour per every inch of thickness,
followed by rapid cooling. The quick cooling process establishes a harder, more
stable crystalline structure.

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2.7.3 Quenching
Quenching refers specifically to heat treatments that rely on rapid cooling of the
metal to achieve the desired physical or mechanical properties. Heated materials
are often cooled in oil, but can also be quenched using air, water, and brine,
depending on the material and desired qualities. As with other heat-treating
processes, the metal is heated to a point below the melting point where the
crystalline structure is fluid. It is held for a specific period of time, depending on
the desired properties, and then quenched in one of the abovementioned media to
reduce the temperature of the material and establish the required internal structure.
2.7.4 Stress Relieving
Stress relieving processes involve heating the material above the point where
the internal structure transforms and then air cooling it at a particular rate. This
process allows the structure to become more stable, reducing internal stress and
enhancing the strength and hardness of the metal. It is particularly useful for metals
that have been subject to stress-inducing forming processes, such as machining,
straightening, and rolling.

2.8 Systamatic diagram of heat treatment.

2.8.1 Surface Heat Treatments
• Surface hardening is a process where the surface of the metal is hardened without
changing the bulk properties. The main purpose of surface hardening is to improve
the metal’s wear resistance, fatigue strength, and corrosion resistance. In this
process, a thin layer of harder metal is deposited on the surface of the metal
• Types of Surface Hardening Process
2.8.1 Carburizing: Carburizing is a process where carbon is diffused into the
surface of the metal. This process is carried out at high temperatures in a furnace in
the presence of carbon-rich gases or liquids. After carburizing, the metal is
quenched in oil or water to harden the surface.
2.8.2 Nitriding: Nitriding is a process where nitrogen is diffused into the surface
of the metal. This process is carried out at high temperatures in a furnace in the
presence of nitrogen-rich gases or liquids. After nitriding, the metal is quenched in
oil or water to harden the surface.
2.8.3 Cyaniding: Cyaniding is a process where carbon and nitrogen are diffused
into the surface of the metal. This process is carried out at high temperatures in a
furnace in the presence of cyanide-based liquids. After cyaniding, the metal is
quenched in oil or water to harden the surface.
2.8.4 Carbonitriding : Carbonitriding is a process where carbon and nitrogen are
diffused into the surface of the metal. This process is carried out at high
temperatures in a furnace in the presence of carbon- and nitrogen-rich gases or

18
liquids. After carbonitriding, the metal is quenched in oil or water to harden the
surface.
2.8.5 Induction Hardening: Induction hardening is a process where an
electromagnetic field is used to heat the surface of the metal. This process is carried
out by passing an electric current through a coil which creates an electromagnetic
field around the metal. The heat generated by this process diffuses into the surface
of the metal and hardens it. After induction hardening, the metal is quenched in oil
or water to cool it down and complete the hardening process.

Figure 2.8.1 Surface heat treatment [5]

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2.9 Measuring instrument used.
Vernier Calliper
A vernier calliper is defined as a measuring device that is used for the
measurement of linear dimensions. It is also used for the measurement of diameters
of round objects with the help of the measuring jaws.
Vernier Calliper Diagram

Figure 2.5 Vernier calliper [6]

French mathematician Pierre Vernier invented the vernier scale in 1631. The main
use of the vernier calliper over the main scale is to get an accurate and precise
measurement.
Least Count of Vernier Calliper
The least count of vernier callipers is also known as the vernier constant. It is
defined as the difference between one main scale division and one vernier scale
division.
It is mathematically given as:
VC = 1 MSD – 1 VSD
When there are n divisions on the vernier scale, which coincides with (n-1) division
on the main scale, then the least count of vernier calliper is:
LC = (1-n-1/n) MSD
Therefore, the least count of vernier calliper is 0.1 mm. Were,
• VC is the vernier constant
• MSD is the main scale division
• VSD is the vernier scale division

• LC is the least count

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 CHAPTER - 3
ON JOB TRAINING (OJT) – 2
In the (OJT – 2) department of component manufacturing division, manager gave
us good opportunity to do some project like a component to require to their need of
company.
EX: A2-5 SPINDLE

Figure 3.1 A2-5 SPINDLE

3.1 Process of A2-5 spindle.

This above figure 3.1.
• 0010 proof materials OD turning and ID boring.
• 0020 carburizing
• 0030 OD turning, PCD holes, drive button etc…,
• 0040 long length boring operation
• 0050 Harding>54 HRC
• 0060 finish OD turning, threading, keyway slate.

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 • 0070-1 ID boring
• 0070-2 ID long length boring
3.2.1 Inserts using in milling cutter.
• WNMG → 800
• VNMG → 350
• DCMT → 550
• CNME → 800
• CNGA → 800
• TNMG → 600

3.2 Types of tool holders.

1. DWLNL 2525 M08
2. HELIL 252 3T20
3. SGTBU 25 -5G
4. MTJNL 2525 M16
5. SDUCL 11 F3
6. PDNNL 2525 M15

Figure 3.2 Intern working in vantage.

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3.3 Raw material used.
20MnCr5 is a case-hardening steel with low carbon content but good
hardenability reaching good wear resistance due to high surface hardness after
hardening. The small grain size benefits in good ductility and fatigue strength.
Suitable for gearboxes and axle gears. Ovako 236F is a standard variant with
controlled sulphur content for consistent machining properties. Ovako 236Q is an
IQ (isotropic quality) variant. IQ-Steel® is an isotropic quality ultra clean steel
optimized for high fatigue strength under multi axial loading.
Similar designations
20MnCrS5, 1.7147, 20MnCr4, 1.7149

3.4 Heat treatment recommendations

Temperature
Treatment Condition Cooling/quenching
cycle

Hot forging 850 - 1 200 Slowly or in air

Annealing +A 670 – 710 Slowly (15°C/h) until 600°C
+FP 950 - 1 000 Quickly to following stage
Keeping about 3 hours, after
+FP 630 – 650
that: in air
Normalizing 860 – 890 In air
Stress relieves
650 – 680 In air
annealing
Carburizing 860 – 900 In air
Hardening 830 – 870 Quenching in oil or water
Tempering 150 – 200 In air
Table 3.1 Heat treatment recommendations
3.4.1 Heat Treatment Guide generated Graphs.
The following graphs are generated from a theoretical model. For further info see
the Heat treatment guide module. Select a specific grade version for individual
display. This below figure 3.3 shows tempering diagram (7)

23
 Figure 3.3 Tempering diagram [7]

3.5 Hardenability.
The hardenability is estimated from cast analysis. The hardenability can be verified
with the end quench test if agreed on enquire and order. Jominy hardenability of
Ovako 236F: Measured average value with +/-standard deviation. This below
figure 3.4 shows hardenability (8)

24
Figure 3.4 Hardenability [8]

25
3.6 Other properties (typical values)

Youngs
module Poisson´s ratio (-) Shear module (GPa) Density (kg/m3)
(GPa)

210 0.3 80 7800

Average
Specific heat Thermal Electrical
CTE 20-
capacity 50/100°C conductivity Ambient resistivityAmbient
300°C
(J/kg°K) temperature (W/m°K) temperature (µΩm)
(µm/m°K)

12 460 – 480 40 – 45 0.20 - 0.25

Table 3.2 Material properties

3.6.1 Carbon steels
Types of carbon steels
1. Low carbon steels (mild steel)
2. Medium carbon steel
3. High carbon steel
4. Alloy steel

3.6.2 Low carbon steel: - it is also called as a mild steel

• The carbon percentage varies from 0.05% to 0.35% carbon
• The steel is very soft in nature and mostly used for small load application such as
steel wires, sheets, screws, steel pipes etc.,
• It has tensile strength of 390N/mm2 and hardness of 115BHN
3.6.3Medium carbon steel: The carbon percentage ranges from 0.3% to 0.7%
carbon.
• The steels containing 0.35% to 0.45% of carbon has tensile strength of
750N/mm2, they are used for making connecting rod shaft, break liver, etc.…,
• The steel containing 0.6% to 0.7% of carbon has tensile strength of 1230N/mm2
and hardness of 400 to 450 BHN. The uses of this steel and die breaks, punches,
washers, bearing etc.…,

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3.6.4. High carbon steel
• This contains the carbons from 0.7% to 0.8% carbon having tensile strength of
1400N/mm2 and the hardness varies from 500 to 660BHN. The uses of the steel for
making of chisels, drill bit, jaws for vise, hacksaw blades, etc.,
• The steels containing 0.8 to 0.9% of carbon having tensile strength of 1660N/mm2
and the hardness ranges from 500 to 650BHN.these steels for used making
rockdrill, railway tracks, punches, and die musical wires, disc brakes etc.,
• The steel containing 0.9 to 1.5% of carbon are called as high carbon tool steels
having the tensile strength of 2000N/mm2 and the hardness varies from 650 to
700BHN. The uses of the steels are from making various machine components
which are subjected to heavy loads, knife, cutters, internal thread cooling curve for
pure iron.

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3.7 Measuring instrument.
➢ Vernier calliper
Vernier calliper and its use
A vernier calliper is defined as a measuring device that is used for the measurement
of linear dimension, it is also used for the measurement of diameters of round
objects with the help of the measuring jaws.

➢A vernier calliper is usually used to measure the diameter of circular objects.

➢Vernier calliper consists of two scales, the main scale, which is fixed, and a
moving vernier scale the main scale readings in millimetres, (mm)

➢ Vernier callipers are widely used in scientific laboratories and in manufacturing

for quality control measurements.

➢ The vernier scale has 25 division, whereas the main scale has 24 divisions
in the same length.
3.7.1 Formula to find a least count of vernier.
Vernier callipers, least count= MSD/VSD

Figure 3.5 Vernier calliper [6]

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3.8 Micrometre
Overview

➢ A micrometre is a tool that measures the sizes of a target by enclosing it.

➢ Some models are even able to perform measurements in units of 1 micron.

Unlike hand callipers, micrometres adhere to abbes principle, which enables them
to perform more accurate measurements.

➢ Least count: - the smallest and accurate value in the uses/ purpose measured
quantity that can be resolved on the instruments scale.

➢ A micrometres are a measuring device used to measure flat surfaces or different

geometrics.
Example: -the inner diameter or thickness of pipe.
There are 2 types of micrometres.
1) mechanical (analogue) outside micrometre.
2) the outside micrometre is the most commonly used type of micrometre.
Formula
Pitch / (main scale division)
Least count =
Micrometre division on the
circular scale
example: -
0.5
least count =
50

Figure 3.6 Micrometre [9]

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3.9 Dial Indicator:
It operates on the principle, that a very slight upward pressure on the spindle at
the contact point is multiplied through a system of gears and levers. It is indicated
on the face of the dial by a dial finger. Dial indicators consists of a body with a
round graduated dial and a contact point connected with a spiral or gear train so that
hand on the dial face indicates the amount of movement of the contact point. They
are designed for use on a wide range of standard measuring devices such as dial
box gauges, portal dial, hand gauges, dial depth gauges, diameter gauges and dial
indicator snap gauge. Corresponds to a spindle movement of 1 mm. The movement
mechanism of the instrument is housed in a metal case for its protection. The large
dial scale is graduated into 100 divisions. The indicator is set to zero by the use of
slip gauges representing the basic size of the part. This below figure 3.7 shows dial
indicators (10)

Figure 3.7 Dial indicators [10]

3.9.1 Main components of dial indicator.

• Circular dial body
• Round graduated dial
• Gear train
• Lever
• Plunger

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 Figure 3.8 Dial indicator parts [10]
This below figure 3.10 shows the parts of the dial indicator.
3.9.2Types Of Dial indicators:
Types of dial indicators Several different types of dial indicators exist, differentiated
by factors such as their size, connection method and the type of information featured
on their face.
1. Balanced reading dial indicators
2. Continuous Dial Indicators
3. Reversed Balanced Dial Indicators
4. Reversed Continuous Dial Indicators
5. Test Dial Indicators
6. Plunger Dial Indicator
7. Lever Dial Indicator
Balanced reading dial indicators – Balanced reading dial indicators are so named
for the way that information is arranged upon the dial’s face. Figures are printed
upon the face of this dial running in two directions, starting from a zero in the centre.
Often, positive numbers are featured to the right of the zero and negative numbers
to the left.

31
 3.9.3 Plunger Dial Indicator – Plunger Dial Indicator also have a clock-like face
but are characterized by the plungers mounted on one of their sides. One common
use for plunger dial indicators is to measure the work of injection moulding
machines. The mechanism which allows this type of dial indicator to work is a rack
and pinion, which changes the linear thrust of the plunger into rotary motion for the
dial.
3.9.4 Lever Dial Indicator – Lever Dial Indicator are characterized by their lever
and scroll mechanisms, which cause the stylus to move. This type of dial indicators
are more compact and easier to use than plunger-type dial indicators and are
therefore quite often used.
3.9.5 Requirements of Good Dial Indicator:
1. It should give trouble-free and dependable readings over a long period.
2. The pressure required on measuring head to obtain zero reading must remain
constant over the whole range.
3. The pointer should indicate the direction of the movement of the measuring
plunger.
4. The accuracy of the readings should be within close limits of the various sizes
and ranges 5. The movement of the measuring plunger should be in either
direction without affecting the accuracy. 6. The pointer movement should be
damped, so that it will not oscillate when the readings are being taken.
3.9.6 Applications:
1. Comparing two heights or distances between narrow limits.
2. To determine the errors in the geometrical form such as ovality, roundness, and
taper.
3. For taking accurate measurements of deformation such as intension and
compression.
4. To determine positional errors of surfaces such as parallelism, squareness, and
alignment.
5. To Check the alignment of lathe centres by using a suitable accurate bar between
the centres.

32
3.10 Tools
Turning generates axially symmetric shapes with a single-point tool. A single
point tool removes material by means of one cutting edge. In most cases the tool is
held in a fixed position with the workpiece rotating about a turning axis. There are
also tools held on the spindle centreline (drills, reamers, taps) for hole-making
applications that have speed and feed limitations.
3.10.1 Audience
This class is intended for entry-level turning operators and students in a turning
operator training program who have a basic understanding of turning machines and
their operation. This lesson is also useful to anyone interested in the metalworking
industry who wants to gain knowledge about material removal in CNC machining.
3.10.2 Purpose
Learn how to identify the components of common turning tools and how those
tools are used in everyday turning processes. Students are introduced to ANSI
turning insert nomenclature, tool holders and boring bars. They also learn about
tools used for centreline machining such as twist drills, taps and reamers. Students
finish with an introduction to the concepts of spindle speeds and feed rates.
3.10.3 Lesson Objectives
At the end of this lesson, you will know how to:
• Identify the components of common turning tools
• Identify the basic shapes of turning inserts
• Identify basic tool holders for external and internal turning
• Identify common types of tools for drilling and threading
• Identify the main groups of cutting tool materials
• Understand the applications for common turning tools
• Understand the difference between cut speed and feed rate
• Understand the difference between Revolutions Per Minute (RPM) and Constant
Surface Speed (CSS)
•Understand the difference between Inches per Revolution (IPR) and Inches per
Minute
Anatomy of a turning tool
Most turning is done using a replaceable insert that is gripped in a turning tool body,
which is then mounted on the lathe turret. This below figure 3.9 shows turning tool.
(11)

33
 Figure 3.9 Turning tool.[11]

3.11 ANSI Insert Designations

The American National Standards Institute (ANSI) has developed a coding system
of numbers and letters to describe the shape, dimensions, and important parameters
of turning inserts. This below table 3.3 shows ANSI insert designations.

C N M G - 4 3 2

1 2 3 4 5 6 7

Shape Clearance Tolerance Type I.C. Thickness Nose

Size
Radius

Table 3.3 ANSI insert designations.

34
1. Insert Shape

Turning inserts are manufactured in a variety of shapes, sizes and thicknesses. The shape can
be round to maximize edge strength, diamond-shaped to allow a sharp point to cut fine features,
square, or even octagonal to increase the number of separate edges that can be applied as one
edge after another wears out.

• A = parallelogram
85 • B =
parallelogram 82

• C = diamond 80

• D = diamond 55

• E = diamond 75

• H = hexagon
• K = diamond 55

• L = rectangle
• M = diamond 86

• O = octagon
• P = pentagon
• R = round
• S = square
• T = triangle
• V = diamond 35

• W - trigon 80

Figure 3.10 Tool insert shape. [11]

35
3.12 Tool Holders
It is essential that the insert be supported in a strong, rigid manner to minimize
deflection and possible vibration. Consequently, turning tools are supported in
various types of heavy, forged steel tool holders. This below figure 3.11 shows tool
holders (11)

Figure 3.11 Tool holders [11]

The turning tool body generally does not feature quite so much engineering as the
insert, but even here there are a range of choices for fine-tuning the process. Quick-
change tools involve modular bodies that allow replacement tool bodies to be
swapped in and out and locked in place quickly to minimize setup time. The turning
tool body can also channel high-pressure coolant more effectively to the cutting
edge of the tool. The ANSI numbering system for turning tool holders has assigned
letters to specific geometries in terms of lead angle and end cutting edge angle. The
primary lathe machining operations of turning, facing, grooving, threading and
cutoff are covered by one of the seven basic tool styles outlined by the ANSI system.
The designations for the seven primary tool styles are A, B, C, D, E, F and G

36
Tool Holders A - G

• A = 0° side-cutting edge angle,

straight shank
• B = 15° side-cutting edge angle,
straight shank
• C = 0° end-cutting edge angle,
straight shank (for cutoff and
grooving operations)
• D = 45° side-cutting edge angle,
straight shank
• E = 30° side-cutting edge angle,
straight shank (for threading
operations)
• F = 0° end-cutting edge angle,
offset shank (for facing operations)
• G = 0° side-cutting edge angle;
offset shank (this tool is an 'A' style
tool with additional clearance built
in for turning operations close to
the lathe chuck)

Figure 3.12 Tool holders [11]

37
 CHAPTER-4
USE CASE
4.1 Use case - 1
CMD is a department where singular batch components are manufactured and are
further forwarded to the stores where it gets. stored and can be obtained by the
assembly units and when required. It is the in-house machining division, where the
machinable assembly items of a machine-like bearing housing, saddle, top tables,
etc., are manufactured. This division comprises machining centres, grinding
machines and special lathes to machine the components. Here, certain raw materials
are brought in from outside. All components are manufactured according to their
process drawings specific to each component. The raw materials are then process
drawings specific to each component. The raw materials are then processed
according to their concerned drawings. A process drawing is extremely important
for the manufacturing of any component because it contains the step-by-step
procedure to machine the components after the proof machining by the vendor and
plays a major role in defining the final dimensional accuracy of the completed
component. In CMD, batch manufacturing of component takes place. This sort of
manufacturing takes immense amount of planning since excess processing will take
more lead time. Initially the batch sizes are identified and depending upon the
criticality of the component a batch size is decide upon. The number per batch
manufactured is specified by the vendor where the vendor managers the heat
treatment process. Excess components are stored for feature use. a specific routing
sequence is manufacturing sequence of any component. Also, its components
specific.CMD is the important department because of the main parts of CNC
machines manufacturing is here only.
CMD undertakes a few processes. It has 5 sub - division itself mentioned as follows:
• Planning: it handles all the planning of the manufacturing components
required by assembly division the software SAP takes care of the preparation
and planning.
• Manufacturing: The component manufacturing is according to their
importance. The work centres are termed as critical and noncritical based on
the quality and quantity of the operation.
• Quality Assurance: It exits to measure, evolve, analyse and feed in the data
top facilitate process improvements in the departments.
• Methods: this division provides for process improvements like jigs and
fixtures developments and tooling requirements.
• Vendor department: it involves inspection of those components that are
manufactured by vendors.
One of the modern concepts used in CMD goes by the name lean manufacturing
using this concept a lot of improvements are seen it the development.

38
Just in time (JIT) concept is implemented for obtaining standard components from
in-group companies.
In this department allotted by training head for me
There are 4 group of machines cells in this department.
• Machining cell
• Conventional cell
• Turning cell
• Grinding cell
Project given by the supervisor of the department.
In this project we are performing a component manufacturing and machining by the
given dimensions.
Ex: height pad
Conventional cell
Operation performed.
• Marking
• Through hole
Machines used to machining a component.
• Radial drilling machines
• Manford milling machine.
• Component material and its uses
• Heat treatment processes
• Surface treatment processes
• Measuring instruments used
• Raw material
• Tool used.

39
4.2 Use case - 2
CMD is a department where singular batch components are manufactured and
are further forwarded to the stores where it gets. stored and can be obtained by the
assembly units and when required. It is the in-house machining division, where
the machinable assembly items of a machine-like bearing housing, saddle, top
tables, etc., are manufactured. This division comprises machining centres,
grinding machines and special lathes to machine the components. Here, certain
raw materials are brought in from outside. All components are manufactured
according to their process drawings specific to each component. The raw
materials are then process drawings specific to each component. The raw
materials are then processed according to their concerned drawings. A process
drawing is extremely important for the manufacturing of any component because
it contains the step-by-step procedure to machine the components after the proof
machining by the vendor and plays a major role in defining the final dimensional
accuracy of the completed component. In CMD, batch manufacturing of
component takes place. This sort of manufacturing takes immense amount of
planning since excess processing will take more lead time. Initially the batch sizes
are identified and depending upon the criticality of the component a batch size is
decide upon. The number per batch manufactured is specified by the vendor
where the vendor managers the heat treatment process. Excess components are
stored for feature use. a specific routing sequence is manufacturing sequence of
any component. Also, its components specific. CMD is the important
department because of the main parts of CNC machines manufacturing is here
only. CMD undertakes a few processes. It has 5 sub - division itself mentioned as
follows:
• Planning: it handles all the planning of the manufacturing components
required by assembly division the software SAP takes care of the
preparation and planning.
• Manufacturing: The component manufacturing is according to their
importance. The work centres are termed as critical and noncritical based
on the quality and quantity of the operation.
• Quality Assurance: It exits to measure, evolve, analyse and feed in the data
top facilitate process improvements in the departments.
• Methods: this division provides for process improvements like jigs and
fixtures developments and tooling requirements.
• Vendor department: it involves inspection of those components that are
manufactured by vendors. One of the modern concepts used in CMD
goes by the name lean manufacturing using this concept a lot of
improvements are seen it the development.
Just in time (JIT) concept is implemented for obtaining standard components from
in-group companies.
In this department allotted by training head for me

40
There are 4 group of machines cells in this department.
• Machining cell
• Conventional cell
• Turning cell
• Grinding cell
Project given by the supervisor of the department.
In this project we are performing a component manufacturing and machining by
the given dimensions.
Ex: A2-5 SPINDLES
This below figure 3.13 shows A2-5 spindle.
A2-5 SPINDLE

Figure 3.13 A2-5 Spindle.

4.3 Turning cell.

Operation performed.
PROCESS OF A2-5 SPINDLE
• 0010 proof materials OD turning and ID boring.
• 0020 carburizing
• 0030 OD turning, PCD holes, drive button etc…,
• 0040 long length boring operation
• 0050 Harding>54 HRC
• 0060 finish OD turning, threading, keyway slate
• 0070-1 ID boring

41
 CHAPTER - 5
Conclusion
5.1 Conclusion
Some organizations offers internship to provide the necessary training and work
experience to students who have completed their academic journey or wish to
pursue higher education after gaining some hands on experience. Internships can
shape a career by giving the necessary exposure during or after academic journey.
Importance of internship
• Gain Competitive advantage.
• Can Explore beyond comfort zone.
• Chance to polish networking skills.
• Learn new skills.
• Good communication skills.
• Experience of practical knowledge.
• Provide huge opportunity for students to network with professional and
• build new relationships.
• Internships are an opportunity to network with great people and sharpen.
• skills before entering the workforce.
• Gain experience by watching, learning, and participating in work.
• 50
• This experience can help to land a permanent position, perhaps even at the
same company.
• Apply theoretical knowledge in real world.
• Expand on transferable skills.
• Develop professional connections.
• Make new friends.
• Direct job stability.
• Better job stability.
• Higher salary potential.

42
 CHAPTER - 6
REFERENCE
6.1 Reference
[1] Website: https://in.indeed.com [company logo]
[2] Website: https://www.acemicromatic.net [ organizational structure]
[3] Website: https://in.linkedin.com [company department and functions]
[4] Website: https://www.linkedin.com/company/acemicromaticgroup [machines
photos
[5] Website: https://r.search.yahoo.com [surface heat treatment process]
[6] Website: https://www.chronos.ltd.uk [vernier calliper photos]
[7] Website: https://r.search.yahoo.com [tempering diagram graph]
[8] Website: https://r.search.yahoo.com [hardenability]
[9] Website: https://r.search.yahoo.com [micrometre]
[10] Website: https://r.search.yahoo.com [dial indicator]
[11] Website: https://www.machiningcloud.com [turning tools and holders]

43