REPORT ON INDUSTRIAL ATTACHMENT

[3 December 2023 – 14 December 2023]

Course No: IPE-360
Course Tittle: Industrial Training - I

BANGLADESH INDUSTRIAL & TECHNICAL ASSISTANCE CENTER

116 (Kha), Tejgaon Industrial Area, Dhaka-1208

DEPARTMENT OF INDUSTRIAL AND PRODUCTION ENGINEERING

SHAHJALAL UNIVERSITTY OF SCIENCE AND TECHNOLOGY
Submitted By:
Details of Team Captain(s)
Group Name Student ID
IPE 1 Anisha Ahmed 2019334015
IPE 2 Arman Rashid 2019334019
IPE 3 Md. Ferdous Alam Taj 2019334043
IPE 4 Md. Ziad Khan 2019334057
IPE 5 Md. Iqramul Haque 2019334061
IPE 6 Asif Ahmed Anik 2019334068
IPE 7 Sabrina Afroz Mitu 2019334076

Details of the Student(s):

IPE 1 Student ID IPE 2 Student ID
Md. Wali Borkatwlla 2018334056 Arman Rashid 2019334019
Md. Shakil Ahmed 2019334002 Shah Musfeq Us Saleheen Maruf 2019334022
Rabiul Islam 2019334013 Zobayer Hasan 2019334035
Monem Shahriar Udoy 2019334014 Abdur Rahman 2019334037
Anisha Ahmed 2019334015 Md. Nurul Karim 2019334039
Akash Mazumder 2019334016 Md.Khairul Basar 2019334041

IPE 3 Student ID IPE 4 Student ID

Md. Adnan Hossen 2019334042 Wahid Faisal 2019334056
Md. Ferdous Alam Taj 2019334043 Md. Ziad Khan 2019334057
Gazi Fahmidur Rahman 2019334047 Kamrul Huda Himel 2019334058
Md. Ahsanul Alam Naiem 2019334051 Rifat Hossain 2019334059
Md. Julkar Naeem 2019334054 Md. Palash Bakhtiyar 2019334060

IPE 5 Student ID IPE 6 Student ID

Iqramul Hoque 2019334061 Rezwanul Islam Rifat 2019334067
Sajjad Bepari 2019334062 Asif Ahmed Anik 2019334068
Md Kabirul Islam 2019334063 Ajmianur Rahman 2019334069
Montasir Mahamod 2019334064 Md Denar Ahmed 2019334071
Md. Naimul Islam 2019334066 Shahoriar Muttaki Utshaw 2019334072

IPE 7 Student ID
Avijit Saha 2019334073
Tahmin Tanvir Prottoy 2019334074
Sabrina Afroz Mitu 2019334076
Md Sadman Sami 2019334077
Rahatun Nesa Priti 2019334078

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Contents
Acknowledgement: ................................................................................................................................ 4
Objectives: ............................................................................................................................................. 4
Introduction: ........................................................................................................................................... 4
BITAC At A Glance: ............................................................................................................................. 4
History: .................................................................................................................................................. 5
Departments Of BITAC: ........................................................................................................................ 5
Industrial engineering division (IED) .................................................................................................... 6
Production control division (PCD) ........................................................................................................ 8
Foundry and Pattern shop: ................................................................................................................... 10
Pattern shop:................................................................................................................................. 10
Foundry: ....................................................................................................................................... 13
Welding & Fabrication Section: .......................................................................................................... 18
Welding Process........................................................................................................................... 22
Machine (Light) Shop .......................................................................................................................... 31
Heat Treatment and Mould .................................................................................................................. 35
Heat Treatment............................................................................................................................. 35
Mould ........................................................................................................................................... 36
Machine maintenance & Automobile Section ..................................................................................... 37
CNC (Computer Numerical Control)................................................................................................... 40
TTI(Tool and technology institute) ...................................................................................................... 45
Conclusion: .......................................................................................................................................... 53

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Acknowledgement:
We express our profound gratitude to the esteemed Directors, Additional Directors, Section
In-charges, and all dedicated members of the Bangladesh Industrial Technical Assistance
Center (BITAC), Dhaka. The successful completion of our training would not have been
possible without their unwavering support and collaborative efforts. Their cooperation and
assistance played a pivotal role in enabling us to acquire invaluable practical knowledge.
Our heartfelt appreciation extends to the honorable teacher and training coordinator, Shanta
Saha, Associate Professor in the Department of Industrial and Production Engineering (IPE)
at SUST. Her guidance was instrumental throughout the training period, and we are sincerely
thankful for her valuable insights and continuous support.

Objectives:
1. After graduation, the student will have opportunities related the industrial affiliation.
2. Every student must subsequently complete an industrial attachment during their three-
or four-year degree and remain up to date on the labor market knowledge.
3. The goal of the attachment period is to support students while they work in a new
setting under new leadership.
4. It gives students a better understanding of what is actually done in organizations and
the divide between industry and academics.
5. It helps students understand how to communicate effectively with coworkers rather
than as individuals.
Introduction:
Shahjalal University of Science and Technology, Sylhet has introduced a required practical
industrial attachment Training program as part of the student curriculum in order to support
the Government of Bangladesh's goal of making Bangladesh’s economy a higher middle-
income country and to achieve this mission. Every engineering student needs firsthand
experience with the course that is completed during their student life. As a result, industrial
attachment is critical in assisting engineering students to perform well in the real world.
Being a student at Shahjalal University of Science and Technology, we need to understand
how various aspects of the sector function to fit in well here. That is primarily why industrial
attachment is used. Understanding the practical applications of the ideas learned in class is
made easier by the industrial attachment. The student gains first-hand knowledge of the
activities of the industry through industrial attachment, which supports the efforts of lecturers
and instructors. The goal of the industrial attachment is to provide students with a way to put
the theory they have learned into practice. Additionally, it has the benefit of connecting the
university to industries, increasing the prospects of employment among university students.
BITAC At A Glance:
BITAC is playing a positive role in the industrialization of the
country by determining the production process and designing
and manufacturing machinery and parts to increase production,
improving the quality of products, reducing production costs,
and increasing the use of local products. In this case, all the
machines and parts used in different factories of Bangladesh had
to be imported from outside the world, now BITAC is preparing
Figure 1: BITAC
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all those machines and parts and supplying them all over the country. This saves both money
and time. By adding new CNC machine tools to BITAC's workshops, measures have been
taken to provide better technical services to the service-receiving industries.

History:
Brief history of the organization The Bangladesh Industrial Technical Assistance Centre
(BITAC) is an organization established in Bangladesh to provide technical assistance to
small and medium-sized enterprises (SMEs) in the country. It was established in 1962
merging the Industrial Research and Development Centre (IRDC) and Industrial Productivity
Services (IPS). Initially the name was PITAC and in 1972 it was renamed BITAC after
independence of Bangladesh. It was established by the government of Bangladesh with the
support of the United Nations Development Program (UNDP) and the International Labor
Organization (ILO). Its main objective is to promote the development of SMEs in Bangladesh
by providing them with technical assistance, training, and other support services. BITAC has
played an important role in the growth and development of the SME sector in Bangladesh
and continues to be a valuable resource for SMEs in the country.

Vision: Transforming BITAC into an excellent hub for providing technical assistance to the
industrial sector of the country.

Mission: Enhancing technical skills through training to assist the industrial sector. Innovation
of technology and its transfer through development of research, and manufacturing and
repairing of import alternative equipment to ensure uninterrupted industrial production.

Location: Bangladesh Industrial & Technical Assistance Center (BITAC), 116 (kha),
Tejgaon Industrial Area, Dhaka-1208.

Departments Of BITAC:
➢ Industrial Engineering Division
➢ Production Control Division
➢ Heat Treatment & Mold Section
➢ Foundry & Pattern Shop
➢ Machine Tool Shop
➢ CNC Shop
➢ Welding and Fabrication Section & Inspection Section
➢ Machine Maintenance. & Automobile Section
➢ Tool and Technology Institute
.

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Industrial engineering division (IED)
IED stands for the Industrial Engineering Division. IED's key focus is on its customers.
First, they visit BITAC and meet with the IED division when a party or customer (people, a
government agency, a nonprofit organization, or a company) wants to create a job.
Sometimes BITAC is unable to complete every task for a job. In that case, a quotation form
is given to the party, and the process is completed at any outside retailer. The cost of the job
or product is then roughly estimated by IED using the sketch, sample, and quantity of the
products. The total cost is made up of the following expenses: material costs, casting costs
(if necessary), matching costs (depreciation expenses, electricity costs, worker salaries),
overhead expenses (which account for 25% of total costs and are ultimately paid to
Bangladesh Bank), emergency expenses (which are typically 10% of total costs), packing
expenses (if necessary), and transportation expenses (if necessary).

If the party does not select a material, IED determines the material's required strength based
on its planned application and then selects the material with the requisite qualities.
After totaling all expenses, 1.25 is added to the total. It is the estimated total cost necessary
to get the desired result. It is typically multiplied to provide leeway for the party's bargaining
and for added advantage. IED estimates the total cost of the job and then provides the party
with a quote. If the other party agrees, the party issues a work order to the IED. For a
government company or institution, the entire cost might be paid once the project is
finished. However, 50% of the total cost should be paid to a factory or organization that is
not government-owned right away.
The work order and quotation form are eventually sent by IED to PCD via a task file.

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Figure: Cost estimation by IED

_____________________

Signature of the Instructor

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Production control division (PCD)
Our designated area focused on the Production Control Device (PCD), which involves
overseeing job documentation from the initiation of job booking to the successful delivery to
customers. In the IED division, the initial step involves estimating job costs, and then the plan
is forwarded to PCD. PCD is responsible for completing the remaining paperwork, including
communication with workshops and customers, to ensure a smooth process from job
estimation to final delivery.
The Production Control Division (PCD) primarily concentrates on six key areas: 1. Planning
operations, 2. Managing the supply of raw materials, 3. Overseeing the production process, 4.
Consolidating diverse reports, 5. Ensuring quality control and successful job delivery, and 6.
Handling the collection of bills.

1. Planning Operations:
• Initiate job booking and assess requirements.
• Plan the production schedule.
2. Managing Raw Material Supply:
• Identify required raw materials.
• Coordinate procurement for timely delivery to production sites.
3. Overseeing Production Process:
• Monitor production progress.
• Communicate with workshops and address issues.
4. Consolidating Diverse Reports:
• Collect data from various stages of production.
• Analyze and compile comprehensive reports.
5. Ensuring Quality Control and Job Delivery:
• Implement quality checks throughout production.
• Ensure products meet specified standards.
• Coordinate successful job delivery to customers.
6. Handling Bill Collection:
• Generate invoices based on job completion.
• Coordinate with finance for billing.
• Follow up on payments to ensure timely collection.

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Figure: Material Requisition.

Figure: Quotation

_____________________

Signature of the Instructor

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Foundry and Pattern shop:
Each group visited the pattern and foundry shop on their assigned date. There was kept
proximity between pattern and foundry shop as they might be used in a sequence to
accomplish a particular-type product order.
Learning outcomes of this shop are described below:

Pattern shop:
Pattern is the same replica of the object about to be made through casting. Patterns are made
based on the product design before molding.
Mainly in the pattern shop, there are used 2 types of material for making pattern:

1. Wood: Gamari wood is used for making patterns of wood.

Figure: Gamari wood

2. Metal: Aluminum is used for metal patterns, as it is corrosion-resistant and flexible
for machining.

Figure: Metal Pattern

Machines that were used for pattern making in pattern shop:

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1) Wood turning lathe: This machine is used for wood turning.

Figure: Wood turning machine

2) Meter saw: This machine is used for cutting.

Figure: Meter saw

3) Drill machine: This machine is used for making holes.

Figure: Drill machine

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4) Mortiser Machine: This machine is used for generating groove

Figure: Mortiser Machine

5) Disc sander: This machine is used for surface finishing.

Figure: Disc sander machine

6) Circular saw: It is used for parting according to the required size.

Figure: Circular saw

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Hand tools used in Pattern shop:

1. Measuring tape 9. Outside calipers

2. Pencil 10. Inside calipers

3. Eraser 11. Wooden clamp

4. Scriber 12. C- clamp

5. Hand saw 13. Punch

6. Hand planer 14. T square

7. Scissor 15. Chisel

8. Hammer

Fig 9: Hand Tools

Foundry:
Foundries are facilities that produce metal castings and offer casting-related services. A
foundry is a factory where metal is melted and cast into new shapes.
Foundry technology involves molding, melting, and casting of parts; that is, producing
castings by filling the prepared molds with molten metal alloys (mostly aluminum). In
BITAC casting materials are mostly cast iron, stainless steel, mild steel, aluminum etc.
In metalworking, casting involves pouring liquid metal into a mold, which contains a hollow
cavity of the desired shape and then allowing it to cool and solidify. The solidified part is also
known as a casting, which is ejected or broken out of the mold to complete the process.
Mainly two types of casting are used here:
1. Sand Casting
2. Die Casting
Sand casting: Sand casting is used in case of customized or very low rate production.
Firstly, we need to prepare the sands.
Sand Mixer: It is a vital piece of equipment in sand casting, responsible for uniformly
mixing sand, binders, additives, and water to create the molding sand.

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 Figure: Sand Mixer
CO2 Process: It is a chemically bonded sand process used in sand casting for making molds
and cores. It utilizes sodium silicate (Na2SiO3) as the binder, which is activated by carbon
dioxide (CO2) gas.
Mixture Percentage:

Ingredients Cast iron M.S., S.S, Cu and Al

Sand 90% 92%
Na2SiO3 7% 6%
Coal Dust 1.5 0%
Sawdust 1.5% 2%
Applications: Critical machine parts.
Molasses process: It is a simple and inexpensive method of strengthening the surface of sand
molds in sand casting. It involves mixing molasses with water and spraying it onto the
surface of the mold.
Mixture Percentage:
Ingredients Cast iron M.S., S.S, Cu and Al
Sand 93% 93%
Na2SiO3 5% 5%
Sawdust 1% 2%
Coal Dust 1% 0
Applications: Showpieces
Die casting: die casting is used in case of repeated production . Molds are made generally by
CNC , Conventional Machining
Machines involved:

For metal casting there are a number of machines that can be used. In BITAC they use the
following machines for metal casting:
Cupola Furnace: This furnace is used for melting a large amount of metal (above 500 kg).Its
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capacity is 500 to 1000kg .It is used for melting cast iron. Its maximum temperature is
3000°c of above.

Figure: Cupola furnace

Core oven: It is used to heat the mold cavity, so that large portion of moisture can be

removed. It is necessary to remove that moisture because this moisture can cause crack or
defect in final job.

Figure: Core oven

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Induction Furnace: It has a hydraulic lifting system to pour the molten metal into the
crucible. The maximum temperature is 2600°C (as per their use). Capacity 300kg.

Figure: Induction furnace

Pit crucible furnace: Maximum temperature is 1400°C and capacity is 100 kg.

Figure: Crucible furnace

Tilting furnace: Maximum temperature is 1400°C and capacity is 300 kg.

Figure: Tilting furnace

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Ladle: These are used to handle molten metal.

Figure: Ladle

_____________________

Signature of the Instructor

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Welding & Fabrication Section:
There were five different kinds of machinery in the Welding & Fabrication Section based on
their intended applications.
Sheering Machine: (a) Sheet Sheering Machine (b) Combined Sheering Machine
Rolling Machine: (a) Power Rolling Machine
Bending Machine: (a) Power Bending Machine
Drilling Machine: (a) Column Drilling Machine (b) Radial Drilling Machine
Welding Machine: (a) Arc Welding (b) TIG Welding (c) Gas Welding (d) MIG Welding (e)
Submerged Arc Welding (f) Gas cutting (g) Plasma cutting

Fabrication Section
Combined Shearing Machine:

Figure: Combined Shearing Machine

Function: Merges shearing and press brake functions.

Purpose: Efficient angle cutting and shaping of sheet metal and plates, hole making, and
punching.
Working Procedure:
Material Preparation: Select the sheet metal and ensure it is flat and debris-free.
Setting Parameters: Adjust the machine settings based on the desired cut width, thickness,
and shearing angle.
Positioning Material: Place the sheet metal on the work table and position it accurately
according to the cutting line.
Operating the Machine: Engage the lever or activate the foot pedal to initiate the cutting
action. The upper blade descends, applying force onto the sheet metal, resulting in a clean
and precise cut.
Removing the Material: Once the cut is complete, carefully remove the sheet metal and
dispose of any scrap material.

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Sheet Shearing Machine:

Figure: Sheet Shearing Machine

Function: Guillotine shears for cutting sheet metal or plates.

Purpose: Precise cutting of various sheet materials.

Working Procedure:
Material Preparation: Select the sheet metal and ensure it is flat and debris-free.
Setting Back Gauge: Adjust the back gauge to the desired cutting length.
Positioning Material: Place the sheet metal on the worktable and align it with the back
gauge.
Operating the Machine: Engage the lever or activate the foot pedal to initiate the cutting
action. The upper blade descends, cutting the sheet metal to the predetermined length.
Removing the Material: Once the cut is complete, carefully remove the sheet metal and
dispose of any scrap material.

Power Rolling Machine:

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 Figure: Power Rolling Machine

Function: Shapes metal with V-shaped rollers.

Purpose: Reduces thickness, ensures uniformity, and creates specific patterns.
Working Procedure:
Material Preparation: Select the sheet metal and ensure it is flat and free from wrinkles or
creases.
Setting Parameters: Adjust the machine settings based on the desired bend radius and sheet
thickness.
Positioning Material: Place the sheet metal on the rollers and align it to the bending line.
Operating the Machine: Engage the motor and activate the rollers to start the bending
process. Apply consistent pressure and monitor the bending progress.
Removing the Material: After achieving the desired bend, stop the motor and carefully
remove the bent sheet metal.

Power Bending Machine (Press Brake)

Figure: Power Bending Machine

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Function: Bends sheet metal using a bed, ram, and punch.
Purpose: Common in metal fabrication for bending sheets and plates.

Working Procedure:
Material Preparation: Select the sheet metal and ensure it is flat and free from wrinkles or
creases.
Setting Parameters: Adjust the machine settings based on the desired bending angle and
sheet thickness.
Positioning Material: Place the sheet metal on the die and align it with the bend line.
Operating the Machine: Engage the motor and activate the ram to press the sheet metal
against the die, creating the desired bend.
Removing the Material: Once the bend is complete, stop the motor and carefully remove the
bent sheet metal.

Bench Drilling Machine:

Figure: Bench Drilling Machine

Functions: Create holes in various materials.

Purposes: Column for stationary drilling
Working Procedure:
Material Preparation: Select the material and ensure it is securely clamped or positioned on
the worktable.
Selecting Drill Bit: Choose the appropriate drill bit based on the desired hole size and
material type.
Adjusting Settings: Set the drill speed and depth based on the material type and hole depth.
Operating the Machine: Securely hold the drill and engage the motor. Lower the drill bit
slowly and steadily into the material until the desired depth is reached.
Removing the Drill Bit: Once the drilling is complete, release the motor and slowly pull the
drill bit out of the hole.
Radial Drilling Machine
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 Fig: Radial Drilling Machine

Functions: Create holes in various materials.

Purposes: Radial for flexibility in drilling large and deep holes.
Working Procedure:
Material Preparation: Select the material and ensure it is securely clamped or positioned on
the worktable.
Selecting Drill Bit: Choose the appropriate drill bit based on the desired hole size and
material type.
Adjusting Settings: Set the drill speed and depth based on the material type and hole depth.
Positioning the Arm: Move the radial arm to the desired drilling location and adjust the
height for accurate positioning.
Operating the Machine: Securely hold the drill and engage the motor. Lower the drill bit
slowly and steadily into the material until the desired depth is reached.
Removing the Drill Bit: Once the drilling is complete, release the motor and slowly pull the
drill bit out of the hole.

Welding Process
Welding is a fabrication process that joins materials, usually metals or thermoplastics, by
using high heat to melt the parts together and allowing them to cool, causing fusion. This
process can be applied to various materials and thicknesses, making it a versatile and widely
used technique.

Types of Welding:
Arc welding: Uses an electric arc to generate heat.
TIG welding: Uses a non-consumable tungsten electrode and an inert gas for shielding.
MIG welding: Uses a consumable wire electrode and an inert gas for shielding.
Submerged arc welding: Uses a covered electrode and flux to protect the weld pool.
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Gas cutting: Uses a flame to melt and oxidize metal, creating a cut.
Plasma cutting: Uses a high-temperature plasma arc to cut through metal.

Applications:
1. Manufacturing
2. Construction
3. Repair and maintenance
4. Automotive industry
5. Aerospace industry
6. Shipbuilding etc.

Arc Welding:

Figure: Arc Welding

Arc welding is a straightforward process for joining metals. First, we clean the metal surfaces
to get rid of any dirt or rust. Then, we pick the right welding electrode based on the metal
we're working with. Adjusting the machine settings comes next—this includes things like
amperage, voltage, and wire feed speed.

To start welding, we strike an arc by touching the electrode to the metal and quickly pulling it
away, creating a spark. As we move the welding tool along the joint, the melted metal from
the electrode fills the gap, creating a strong bond. We keep feeding the electrode continuously
to make sure the weld is strong and complete.

Once we finish welding, we let the metal cool down naturally and clean off any leftover bits.
Arc welding is great for many tasks, like building structures, ships, heavy equipment, and
cars. It's a bit of an art that takes practice, but it's powerful and versatile for various metal
projects.

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TIG (Tungsten Inert Gas) Welding:

Figure: TIG Welding

Tungsten Inert Gas (TIG) welding, a method synonymous with precision, demands
meticulous preparation. Surfaces must be impeccably clean, devoid of rust, dirt, and grease.
The choice of a tungsten electrode, tailored to the metal type and desired weld characteristics,
is critical. Adjusting the flow rate of the inert gas, typically argon, ensures proper shielding
during welding.

Arc initiation involves a deliberate scratch of the tungsten electrode against the workpiece.
During welding, a delicate dance unfolds: one hand holds the torch, positioning the tungsten
electrode close to the joint, while the other skillfully feeds filler metal into the weld pool.
Maintaining a consistent distance ensures optimal heat input and weld quality. TIG welding
excels in delivering high-quality welds with minimal spatter and distortion, offering precise
control over the weld pool. Its versatility spans various metals, including aluminum, stainless
steel, and titanium, making it suitable for applications in industries such as aerospace,
automotive, chemical processing, food and beverage, medical devices, and nuclear power.
While slower than some methods, TIG welding's craftsmanship demands skill and training,
with specialized equipment contributing to its efficacy in producing superior welds.

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Gas Welding:

Figure: Gas Welding

Gas welding, characterized by its versatile working procedure, stands out as a portable and
cost-effective method applicable to various welding tasks. The process begins with
meticulous preparation, ensuring the cleanliness of metal surfaces and selecting suitable
welding nozzles. Flame settings are adjusted for optimal heat intensity, and gas flow rates for
oxygen and fuel gas, typically acetylene, are calibrated.

Initiating the flame involves lighting the torch and adjusting it to achieve a neutral flame,
crucial for optimal welding results. During welding, the flame is directed onto the joint,
preheating both sides of the metal. The filler metal is melted with the flame and directed into
the joint to fuse the metal pieces. Consistency in flame size and position is maintained
throughout the welding process.

Upon completion, the welded joint is allowed to cool naturally. Gas welding offers distinct
benefits, including portability, versatility, and relatively low costs compared to other welding
processes. It proves applicable not only to welding but also to cutting and brazing tasks.
However, it comes with limitations such as lower welding speed and productivity, requiring
good hand-eye coordination and skill to achieve consistent results. Additionally, it can
produce more spatter and fumes.

Gas welding finds its niche in repair and maintenance work, showcasing its adaptability in
addressing a spectrum of metalworking needs.

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MIG (Metal Inert Gas) Welding:

Figure: MIG Welding

MIG Welding, an acronym for Metal Inert Gas Welding, is characterized by a straightforward
working procedure, rendering it a widely employed and adaptable welding technique. The
process begins with meticulous preparation, ensuring the cleanliness of metal surfaces and
the selection of appropriate welding wire based on metal type. Machine settings for
amperage, voltage, and wire feed speed are calibrated for optimal performance.

Arc initiation involves touching the wire tip to the workpiece, swiftly creating a spark and
establishing the arc. During welding, the torch is held in proximity to the joint, allowing the
automatic feeding of the wire into the arc. This wire melts and fills the weld pool. A
consistent travel speed is maintained, and the torch is maneuvered along the joint to control
the weld path.

Upon completion, the welded joint is allowed to cool naturally, and any spatter is
subsequently cleaned off. MIG welding offers notable benefits such as high productivity, a
rapid deposition rate, and ease of learning compared to TIG welding. It proves versatile,
suitable for various metals and thicknesses. However, it does have limitations, producing
more spatter than TIG welding, requiring shielding gas to prevent contamination, and being
less suitable for very thin sheet metal.

In applications ranging from the automotive industry to shipbuilding, construction, and

manufacturing, MIG welding stands out as a preferred method for its efficiency and
versatility.

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Submerged Arc Welding (SAW):

Figure: SAW Welding

Submerged Arc Welding (SAW) is a highly efficient welding process characterized by a

systematic working procedure. The preparation phase involves meticulous cleaning and joint
edge preparation, ensuring a precise fit-up. Flux material is strategically placed on the joint
edges, and machine settings for amperage, voltage, and travel speed are adjusted.

The welding process commences as an automatic welding head lowers the electrode onto the
joint, initiating the arc beneath the protective flux layer. As the welding head traverses the
joint, it melts the metal and deposits molten metal from the electrode. Crucially, the flux
covers the arc and weld pool, shielding them from atmospheric contamination.

Upon completion of the welding operation, the slag formed by the flux is removed. The
benefits of SAW include high productivity and deposition rates, deep penetration capabilities,
and the ability to produce high-quality welds, especially suitable for welding thick plates and
large structures.

However, SAW comes with its limitations, requiring complex and expensive equipment. It
may not be suitable for all materials or welding positions, necessitating a skilled operator to
set up and monitor the process. Widely applied in heavy equipment manufacturing,
shipbuilding, offshore structures, and pressure vessel fabrication, SAW stands as a versatile
method for robust welding applications.

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Gas Cutting:

Figure: Gas Cutting

Gas cutting follows a straightforward procedure, starting with the preparation of the metal
workpiece by marking the cutting line and adjusting the gas pressure and flow rate for the
cutting torch. The addition of an appropriate cutting tip precedes the preheating phase, where
the flame is directed onto the cutting line. Once the metal reaches ignition temperature, the
cutting process initiates. During cutting, the torch flame, enriched with oxygen, oxidizes the
molten metal, creating a kerf. Maintaining a constant speed and torch angle ensures a precise
cut. Post-cutting, allowing the metal to cool is the concluding step. The method offers
advantages in its simplicity, cost-effectiveness, and versatility for various cutting thicknesses
and shapes. Despite its benefits, it does exhibit limitations such as lower cut quality compared
to plasma cutting, slower cutting speed for thicker materials, and a requirement for operator
skill to consistently achieve desired results. Common applications include scrap cutting,
demolition, and repair and maintenance tasks.

Plasma Cutting:

Figure: Plasma Cutting

Plasma cutting involves a meticulous process starting with the preparation of the metal

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workpiece by marking the cutting line and configuring the gas pressure and flow for the
plasma torch. The arc is initiated using the torch trigger, forming a high-temperature ionized
gas stream. As the plasma torch traverses the cutting line, the metal is melted and vaporized,
ensuring a clean and precise cut. The procedure concludes with allowing the cut metal to
cool. This method offers notable benefits, including high-cut quality and speed, along with
the ability to achieve precision in cutting complex shapes.

Inspection Section

Inspection, a crucial aspect of the evaluation process, involves a thorough examination of

materials, components, or products to ensure they meet specified standards. In our inspection
process report, we categorized tools into hand tools (e.g., screwdrivers, hammers) and
machine tools (e.g., lathe machines, milling machines). Precision measurement tools,
accurate to 1/10000 of the actual value, included outside micrometers, inside micrometers,
depth micrometers, ball-to-ball micrometers, and screw gauges for bearing measurements.

Non-precision tools, like vernier calipers and steel rulers, were also employed. The vernier
caliper, comprising outside jaws, inside jaws, main scale, vernier scale, and a lock screw,
played a crucial role. Practical exercises on a job piece were conducted to determine its
length and the diameter of different sections, ensuring a comprehensive inspection process.

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Figure: Inspection of a Job

_____________________

Signature of the Instructor

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Machine (Light) Shop
Light machine shop performs operations on light jobs. In light machine shop we do turning,
milling, facing, grinding, drilling etc. Light machine shop consists of the following machines:
1) Lathe Machine:
The lathe is one of the most important machines in any workshop. The initial objective of
using a lathe was to remove material. In BITAC there are 23 pieces of lathe machine in the
light machine shop. There have some types:
a) Capstan lathe machine – It is also called production lathe because it holds 6 jobs at a
time and cutting comparatively. Less time is required in making the desired shape of a job.
Maximum 8 tools used in this lathe. It has no extra lead screw but it can cut thread.
b) Centre lathe machine – The center lathe machine is used to turn and cut metal. A
few of the common operations are facing, straight turning, taper turning, thread cutting,
parting, necking, knurling, and forming. There are two types of center lathe machines –
BECO CL 250, BECO CL 160.
c) Copying lathe machine – It is a very important type of lathe machine because it can
copy the design. Here the lead and pitch are the same. It’s step 0.25, 0.5, 0.75,1 inch. It can
carry about 1-ton weight.

Figure: Lathe machine

2) Gear Hobbing Machine: It is used to manufacture different types of gear.

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 Figure: Gear hobbing machine

3) Grinding Machine:
To smooth the outer surface of any job we do perform grinding operation. In light machine
shop we see wheel grinding machine.

Figure: Grinding machine

4) Milling Machine:
The milling machine is a type of machine which removes the material from the work piece by
feeding the work past a rotating multipoint cutter. The metal removal rate is higher very high
as the cutter has a high speed and many cutting edges.
It is the most important machine in the tool room as nearly all the operations can be
performed on it with high accuracy. MRR (Material Removal Rate) can be further increased

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by increasing the number of teeth on the cutter.

Figure: Milling Machine

The following Operation is performed by the Milling Machine:

1. Plain or Slab Milling Operation
2. UP and DOWN Milling Operation
3. Face Milling Operation
4. End Milling Operation
5. Gang Milling Operation
6. Straddle Milling Operation
7. Groove Milling Operation
8. Gear Milling Operation
9. Side Milling Operation and
10. T-Slot Milling Operation

Shaper Section:
There are two types of shaper machine-
I. Vertical shaper machine or slotting machine – The vertical shaper machine is
vertically positioned. The work is done in this order. It is mostly employed for
finishing. The table is immovable. Internal gear cutting is another application for it. It
is employed to create worm gears and keyways.
II. Hydraulic shaper machine – The work is fixed here, and the ram goes back and forth.
It is used for cutting metal.

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Jig Section:

In the BITAC Jig section, two types of jig machines are available. Those are –

a) Jig boring machine – Boring is done with a jig boring machine. This machine is unable

to cut through hard metal. This machine allows for 100% precise centre-to-centre boring.

Additionally, the diameter is always exact. Drilling can only go down 0.3 millimetres.

The millimetre Jig boring machine has an accuracy of 0.001 mm, and the inch Jig boring

machine has a precision of 0.0001 inch.

b) Jig grinding machine – Both hard and soft metals can be used to operate it. The most

exact grinding is done with it. used for grinding that is most precise.

_____________________

Signature of the Instructor

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Heat Treatment and Mould
Heat Treatment
Heat Treatment is a controlled process of applying heat to a material, typically a metal or
alloy, to alter its physical and sometimes chemical properties. This is done by heating the
material to a specific temperature, holding it at that temperature for a certain amount of time,
and then cooling it at a specific rate. The specific temperature, holding time, and cooling rate
all depend on the desired outcome of the heat treatment.
In the Heat Treatment section, we were introduced to hit treatment machines, Rockwell
hardness tester, some parts which are being hit treated and the raw materials which are used
for carburizing. According to the shop instructor, there are seven steps involved in the heat
treatment process.
1. Metal test

7. Heating the furnace

6. Soaking

5. Cooling

4. Hardness test

3. Tempering

2. Again, Hardness test

Description:
At the start of the heat treatment process the material is inspected by grinding wheel spark
test. A grinding wheel spark test is a traditional method for identifying the general
classification of ferrous materials (mainly steels) by analyzing the sparks produced when the
material is rubbed against a grinding wheel. It's a simple, quick, and relatively inexpensive
test. After that the furnace is heated to the desired temperature according to the requirements.
There were two types of furnaces in the workshop:
- Semi-muffle fire box furnace (for hardening, carburizing, and annealing)
- Electric super heating furnace (for hardening)
Once the target temperature is reached, the material is held at that temperature for a specific
duration called the soak time. This allows the heat to penetrate the material uniformly and

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ensures consistent properties throughout. Then the job is entered into the furnace. If
necessary, carburizing is performed. It is a heat treatment process where carbon is added to
the surface of low-carbon steel at high temperatures (typically 850-950°C). This increases the
hardness, wear resistance, and fatigue strength of the steel without affecting the softer, ductile
core. Carburizing components are:
Wood coal (fine powder): 58%
Stone coal(fine powder): 25%
Barium carbonate (BaCO₃): 15%
Sodium carbonate (Na₂CO₃): 2 %
After that cooling and then hardening test is performed with a conventional Rockwell
hardness testing machine. There are 3 types of cooling process- air cooling, oil cooling and
water cooling. The cooling step is crucial for hardening the material. The material is quickly
immersed in a quenching medium like water, oil, or air, trapping the carbon atoms in a
metastable state, which significantly increases hardness and strength.

Figure: semi-muffle furnace Figure: Wood coal Figure: Rockwell hardness

testing machine

Figure: Oil cooler Figure: Barium carbonate

Mould
In this section we have visited different types of machine tool which are mainly used for
pantographs, mainly two types of pantographs
- Engrave
- Ambush

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Figure: Pantograph copy milling machine 10:1

 Figure: EDM Machine Figure: Universal Milling Machine

Figure: Pantograph copy milling machine 1:1 Figure: Surface grinding machine

Figure: Hydraulic Press Machine Figure: Center Lathe Machine

_____________________

Signature of the Instructor

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Machine maintenance & Automobile Section
Our assigned focus area was the Machine Maintenance section at BITAC, where we delved
into two primary types of maintenance: Preventive and Breakdown Maintenance, specifically
tailored for the machines within BITAC. Additionally, we explored Routine Maintenance, a
crucial aspect of our study.

During our exploration, we concentrated on Routine Maintenance, examining various gears

that undergo significant stress during operations. We identified three types of gears: straight
gear, helical gear (with left-hand and right-hand variations), and three types of bevel gears—
straight, helical, and spiral. Notably, the load capacity varies among these types, with spiral
bevel gears having the highest load capacity. We also learned about the module, which refers
to the teeth-to-teeth distance in gears, and pitch, which denotes the thread-to-thread distance
in screws.

Figure : Different Machine Parts in Maintenance Shop

Preventive Maintenance:
Preventive maintenance involves scheduled inspections, tasks, and repairs designed to
preempt equipment failures. The primary objective is to detect and address potential issues
early, thereby minimizing breakdowns. This proactive approach extends equipment lifespan,
enhances reliability, and reduces overall maintenance costs. Activities under preventive
maintenance encompass routine inspections, lubrication, parts replacement, and system
testing.

Breakdown Maintenance:
Breakdown maintenance, also known as reactive or corrective maintenance, focuses on
addressing issues after equipment failure. This approach entails swiftly fixing equipment to
restore functionality. While less cost-effective than preventive maintenance, it may be applied
to less critical equipment where preventive measures outweigh occasional breakdown costs.

Routine Maintenance:
Routine maintenance comprises regular, planned activities to ensure equipment operates
smoothly and prevent unexpected failures. Scheduled at predetermined intervals, routine
maintenance involves simple, recurring tasks to sustain equipment performance. It includes
visual inspections, lubrication, cleaning, tightening, calibration, and testing.

Inspections: Regular visual checks to identify wear, damage, or abnormalities.

Lubrication: Applying lubricants to reduce friction and prevent premature wear.

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Cleaning: Removing contaminants affecting equipment performance.
Tightening: Ensuring fasteners are secure to maintain equipment integrity.
Calibration: Adjusting settings for accuracy and efficiency.
Testing: Conducting basic tests to verify equipment operates within specified parameters.

Routine maintenance is a proactive approach, cost-effective in catching potential issues early,

contributing to equipment reliability and operational efficiency. BITAC integrates routine
maintenance into broader management programs, complementing other strategies like
preventive and predictive maintenance.

_____________________

Signature of the Instructor

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CNC (Computer Numerical Control)
Today we visited the CNC shop as per our assigned schedule. CNC stands for Computer
Numerical Control, a manufacturing technique that automates the regulation, movement, and
precision of machine tools by utilizing preprogrammed computer software embedded within
the tools. This method is applicable to various intricate machinery such as grinders, lathes,
mills, and CNC routers. It replaces the limitations of manual control, where operators
manually guide machine tools using levers, buttons, and wheels. While a CNC system may
outwardly resemble standard computer components, the specialized software programs and
consoles used in CNC machining set it apart from other computational forms. We have
learned about CNC, how CNC machines are different from traditional machines, how to give
instructions to CNC machines, how to operate CNC machines, operations of different CNC
machines and their components and 3D printing machines.

The Basic Principles of CNC: From Design to Machined Part

1. Design in CAD (SolidWorks):

The first step in the CNC process is to create a digital 3D model of the part using
CAD software. Popular options include SolidWorks, CATIA, and Autodesk Inventor.
These programs provide tools for drawing, sketching, extruding, and manipulating
geometry to create precise representations of the desired part.

2. Transfer to CAM (MasterCam):

Once the design is finalized in CAD, it needs to be transferred to CAM software.
Programs like MasterCam, Fusion 360, and HSMWorks specialize in interpreting the
design and generating the necessary instructions for the CNC machine. This process
involves defining the tools, cutting paths, and machining parameters to achieve the
desired results.

3. Generate G-Code:
Based on the information provided in CAM, the software generates G-code, a
programming language specifically designed for CNC machines. G-code consists of a
series of commands that tell the machine where to move, how fast to move, and what
tool to use at each point. The complexity of the G-code depends on the complexity of
the part and the desired machining operations.

4. Machine Selection:
The final step before machining is selecting the appropriate CNC machine for the job.
Different types of CNC machines are available, each with its own strengths and
limitations. Common choices include:
• CNC mills: These machines use rotating cutting tools to remove material from
a solid workpiece. They are ideal for creating complex geometries and intricate
features.
• CNC lathes: These machines rotate the workpiece while a stationary cutting
tool removes material. They are best suited for creating cylindrical or round parts.

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 Once the machine is selected, the G-code is uploaded and the machining process begins.
The CNC machine automatically follows the instructions in the G-code, precisely cutting
and shaping the material into the desired part.

Considerations for CNC Machining:

CNC machining is a complex process requiring careful consideration of various factors to
achieve the desired results. Here are some key considerations:
1. Axis:
The number of axes a CNC machine possesses determines its versatility and
available machining options. Common options include:
a. 2-axis: These machines are limited to linear movements in the X and Y
directions. They are suitable for simple 2D parts.
b. 3-axis: Adding the Z-axis allows for added depth and the ability to
create 3D parts. This is the most common configuration for CNC mills.
c. 4-axis and 5-axis: These machines offer additional rotational
capabilities, enabling them to work on all five sides of a part without
manual repositioning. They are ideal for complex geometries and intricate
features.
2. Tool Changer:
The number of tools a machine can hold in its tool changer affects its
flexibility and efficiency. More tools allow for performing various machining
operations without manual intervention, increasing productivity. Typical tool
changers hold 12 to 18 tools, but some advanced machines can accommodate
significantly more.
3. Spindle Speed:
The spindle speed determines how fast the cutting tool rotates. Higher speeds
are generally desirable for machining softer materials, while slower speeds are
better suited for harder materials. Maximum spindle speeds range from a few
thousand RPM to 12,000 RPM or even higher for specialized machines.
4. Retract:
The retract function allows the cutting tool to move up and away from the
workpiece between cuts. This prevents the tool from damaging the finished
surface and ensures smooth toolpath transitions. It should be rapid.
5. Cutting Patterns:
CNC machines can execute various cutting patterns to remove material from
the workpiece efficiently. Common patterns include:
a. Parallel: Straight cuts made side-by-side, ideal for flat surfaces.
b. Zig-zag: Back-and-forth cuts that minimize tool wear and are suitable
for curved surfaces.
c. Raster: Similar to parallel but with overlapping cuts for smoother
finishes.
d. Spiral: Circular cuts that offer high efficiency and good chip removal.
6. Overlap:
Overlap refers to the amount of material removed during subsequent cuts. This
helps ensure smooth transitions and avoids leaving ridges or imperfections on
the finished part.
7. Plunge Rate:

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 The plunge rate is the speed at which the cutting tool enters the work piece. It
is crucial to set the plunge rate correctly to prevent tool breakage and ensure
smooth cutting. Normally in CNC lathe and milling it hit outside the job
boundary, so it doesn’t create any damage.
8. Work Offset:
The work offset defines the relationship between the machine's coordinate
system and the actual location of the workpiece. Setting the correct work
offset ensures that the cutting tool paths are positioned accurately relative to
the part.
9. Tool Offset:
The tool offset compensates for the difference between the programmed
toolpath and the actual size and shape of the cutting tool. This ensures that the
final part dimensions are accurate.
10. Round Edge/Ball Mill Tools:
For applications requiring smooth finishes and no sharp edges, ball mill tools
are used. These tools have a rounded cutting surface that creates a gentle
radius on the machined part.
11. Positioning:
CNC machines can be programmed to move the cutting tool using either
absolute or incremental positioning.
a. Absolute positioning: The machine moves the tool to a
specific, predefined location regardless of its previous position.
b. Incremental positioning: The machine moves the tool relative to its
current position by a specified amount.
12. Material properties:
Different materials require different cutting tools, speeds, and feeds.
13. Surface finish:
The desired surface finish of the final part will influence the selection of cutting
tools and machining parameters.
14. Cooling and lubrication:
Using coolant and lubrication helps to improve tool life, part quality, and overall
process efficiency.
By carefully considering these factors, manufacturers can optimize their CNC machining
process for efficiency, accuracy, and quality.
3 types of machines in CNC shop:
1. CNC Milling Machine: The CNC Milling Machines, namely CM1, VF1,
and VF5, have distinct features. All the machines were bought from HAAS
company. The difference among them is bed size. CM1 and VF5 operate with 4
axes, while VF1 has 3 axes. Vertical machining is carried out on a Vertical
Machining Center (VMC) with a vertically oriented spindle.

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 Figure: HAAS-VF1, VF5, VMC

The spindle allows tools to move straight down, providing no side motion. The machine has
two main movement axes for the table (X and Y) and an additional axis for indexing motion
when cutting threads. Origin detection can be done manually or automatically, where manual
systems use work and tool offsets, and automatic systems employ probe and receiver sensors.
Designing is done using SOLIDWORKS, and coding is executed with MASTERCAM. The
spindle has a maximum RPM of 10,000, and continuous coolant supply is maintained during
operation.

Figure: HAAS-CM1 Taper Milling Machine

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 3. CNC Turret Milling Machine: This 4-axis machine holds tools in a turret
holder, featuring 12 tools, including 2 live tools. An emergency stop button is
utilized for design and parameter changes, safety concerns, and coolant/grease
supply. The chuck has rotational movement only, while the tool holder has 3-axis
motion. The spindle reaches a maximum speed of 4,000 RPM, and the tool
operates at a maximum speed of 3,400 RPM. Both the chuck and tailstock are
hydraulically operated.

Figure: HAAS Turn milling machine

4. 3D Printer: Operating on the principle of additive manufacturing, a 3D

printer constructs objects layer by layer from a digital design. Key components
include the extruder, responsible for melting and depositing printing material
(plastic) onto the heated build platform.

Figure: 3D Printer (Plastic Fed, Smooth finish) with prototype

The control system interprets the 3D model and coordinates movements using motors and
belts in the X, Y, and Z axes. Filament or resin serves as the raw material, and some printers
incorporate a cooling system, such as fans, to solidify the printed material.

_____________________

Signature of the Instructor

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TTI(Tool and technology institute)
We have been also assigned to TTI (Tool and technology institute) in our training program. It
was founded to create light engineering products, such as vehicle parts. This institute
conducts a wide range of research in collaboration with other institutions in the same field.
We mostly observe contemporary CNC machining in this institute. "Computer Numerical
Control" is referred to as CNC. Three different CNC machine types were on display here.
They are a 5-axis machine, a CNC milling machine, and a CNC lathe machine. All of the
machines are produced by "HAAS AUTOMATION," the biggest manufacturer of machine
tools in the US and one of the biggest producers of CNC equipment worldwide.

CNC Five Axis Machine (UMC-750):

This device's model number is UMC-750. In TTI, there is only one option. This machine can
be used for milling and turning operations. For multi-sided and complex products, 5-axis
machining is an efficient way to shorten setup times and improve accuracy. The Haas UMC
Series universal machining centers are reasonably priced options for simultaneous 3-plus-two
machining and 5-axis machining. With a 500 mm diameter platter, standard T-slots, and a
precision pilot bore, the UMC-750 has an integrated dual-axis trunnion table that offers
adaptability. The trunnion offers 360 degrees of rotation, plus +120 and -35 degrees of tilt,
for excellent tool clearance and high part capacity. This machine doesn't currently have any
operators working on it.

Figure: UMC-750 CNC Machine.

CNC Milling Machine (VF-2, VF-4, VF-6):

All CNC milling machines at BITAC have model names that begin with "VF." Gene Haas,
the firm's founder, added "F-1" to formally mark it as the "Very First One" of the company.
The "V" in the model’s name stands for vertical, an industry-standard designation for a
vertical mill. There are five machines in total, but only three of each type, in TTI. They
consist of the VF-2 (2 units), VF-4 (2 units), and VF-6 (1 unit). These are divided into groups
based on the machine's capacity. All the machines work on the X, Y, and Z axes to complete
the task.

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 I. VF-2: The job's maximum allowable weight is 1500 kg. The tool is held in place with
VT-40.
II. VF-4 is identical to VF-2.
III. VF-6: Maximum allowed weight of the job is 4000kg. VT-50 is used for holding the
tools These machines are used to produce facing boring, slotting, cutting, grooving.

Figure: VF-6 CNC Machine.

Figure: VF-2 CNC Machine.

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 Figure: VF-4 CNC Machine.

CNC Lathe Machine:

All CNC lathe machines at BITAC have model names that begin with ST. High setup
flexibility, exceptional stiffness, and high thermal stability are all features of the HAAS ST
Series high-performance turning centres. In their class, these machines provide the highest
value and performance for the money. There are two different varieties and a total of three
machines accessible at TTI. Al machines carry out the work along two axes, like X and Z.
The ST 10 and 3T 20 machine models are two examples. One tool-post on these machines
can accommodate 12 different kinds of cutting tools. Without pausing the machine, several
operations can be carried out. These machines' operations are comparable to conventional
ones but more precise than the old ones.

Figure: ST-10 CNC Machine.

CNC Grinder Machine:

In CNC Unit 2, There are CNC grinder machine, Electro Discharge Machine (EDM), EDM
Wire Cutting, Coordinate Measurement Machine (CMM), 7 axis Machine. CNC grinder

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machines are of 3 types: Internal, External & Surface. A CNC (Computer Numerical Control)
grinding machine is a precision machining tool that uses computerized controls and rotating
abrasive wheels to remove material from a workpiece. The primary purpose of a CNC
grinding machine is to achieve high levels of precision and surface finish in the machining
process.

Figure: Internal-Surface Grinding Machine

Figure: External-Surface Grinding Machine

Electro Discharge Machine:

Electrical Discharge Machining (EDM) represents an unconventional approach to
manufacturing, employing a sequence of electrical discharges to selectively erode material
from a workpiece. Specifically designed for the machining of intricate and robust shapes that
prove challenging or unfeasible with conventional methods, EDM relies on the generation of
sparks between an electrode and the submerged workpiece, immersed in a dielectric fluid.
This fluid plays a dual role: serving as an insulator between the electrode and workpiece
during non-spark intervals and efficiently sweeping away debris resulting from the spark. The
spark's heat melts and vaporizes a minute amount of material from the workpiece, and the
molten residue is carried away by the dielectric fluid. This cyclic process continues until the
workpiece attains the desired shape. EDM excels in machining hard and brittle materials that
pose difficulties for traditional methods, producing intricate shapes with precision.
Furthermore, it yields a high-quality surface finish, making it a relatively swift and efficient
machining process.

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 Figure: Electro Discharge Machine

EDM Wire Cutting Machine:

The EDM Wire Cutting Machine is a precision cutting apparatus that utilizes a wire
electrode, typically copper-coated, to perform accurate cuts. The process involves the use of
oil or distilled water as a cooling fluid. Also known as wire electrical discharge machining
(Wire EDM), this non-contact subtractive manufacturing technique is adept at cutting
intricate shapes in a workpiece. The workpiece is immersed in a tank filled with dielectric
fluid, such as oil or water. The wire electrode, threaded through the workpiece, establishes a
high voltage between itself and the workpiece, creating sparks that melt or vaporize a small
amount of material. The molten residue is then efficiently removed by the dielectric fluid.
Continuous movement of the wire electrode relative to the workpiece ensures a seamless cut.
Crucial cutting parameters like voltage, current, and feed rate are precisely controlled by a
CNC controller to achieve the desired shape. Wire EDM boasts several advantages over
traditional machining methods, including its ability to handle hard and brittle materials like
hardened steel and titanium, machine complex shapes that would be challenging with
conventional methods, produce high-quality surface finishes, and operate as a relatively fast
and efficient machining process.

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 Figure: EDM Wire Cutting Machine

Coordinate Measurement Machine (CMM):

CMM machine has a scanner that can scan a 3D object and make a SolidWorks file.
Coordinate Measuring Machine (CMM) is a machine used to measure the geometric
dimensions of a workpiece. It consists of a three-axis measuring probe that is controlled by a
computer. The probe is used to touch the surface of the workpiece at a series of points, and
the computer calculates the coordinates of each point. The CMM probe is mounted on a
carriage that can move in three axes: X, Y, and Z. The carriage is controlled by a computer,
which directs the probe to touch the surface of the workpiece at a series of points. The
computer then calculates the coordinates of each point by measuring the distance between the
probe and the reference point. The reference point can be a fixed point on the CMM or a
point on the workpiece that has been previously measured. The computer uses the coordinates
of the measured points to create a three-dimensional model of the workpiece. CMMs have
several advantages over other types of measurement devices, including-
Accuracy: CMMs can measure with very high accuracy, typically to within a few
micrometers.
Precision: CMMs can measure very small features with high precision.
Speed: CMMs can measure a workpiece quickly, typically in a matter of minutes.
Versatility: CMMs can be used to measure a wide variety of geometric features.

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 Figure: Coordinate Measurement Machine (CMM)

Tool Making Machine:

It is a 7-axis machine. It is only used for cutting different tools. A 7-axis tool making
machine is a type of CNC machine that uses 7 axes of motion to machine tools and dies. This
allows to produce complex shapes and features that would be difficult or impossible to
machine with a 3-axis machine. The 7 axes of motion on a 7-axis tool making machine are:
X-axis: longitudinal movement
Y-axis: transverse movement
Z-axis: vertical movement
A-axis: rotational movement around the X-axis
B-axis: rotational movement around the Y-axis
C-axis: rotational movement around the Z-axis
U-axis: additional rotational movement around an axis perpendicular to the X-Y-Z plane.
The 7 axes of motion are controlled by a CNC controller, which directs the tool to move in a
specific way to machine the desired shape into the workpiece. The CNC controller also
controls the speed and feed rate of the tool. 7-axis tool making machines are used to machine
a variety of tools and dies, including: Milling cutters, Turning tools, Drill bits, Broaches,
Form cutters, Blanking dies, Piercing dies, Extruding dies, Stamping dies. 7-axis tool making
machines are also used to machine complex shapes in molds and other parts. 7-axis tool
making machines have a number of advantages over 3-axis machines, including: They can
machine complex shapes and features that would be difficult or impossible to machine with a
3-axis machine. They are more versatile and can be used to machine a wider variety of parts.
They produce higher quality parts with tighter tolerances. They are more efficient and can
produce parts faster than 3-axis machines.

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Figure: Tool Making Machine

_____________________

Signature of the Instructor

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Conclusion:
Our industrial training at the Bangladesh Industrial and Technical Assistance Center
(BITAC) was a multifaceted journey, immersing us in the intricacies of various critical
domains within the industrial landscape. As Industrial and Production Engineering students,
the exposure to diverse facets such as Welding and Fabrication, Machine Maintenance,
Machine Tools shop, CNC shop, Tool and Technology Institute, Heat treatment and
Moulding, Foundry and Pattern, Production Control Division, and Industrial Engineering
Division has been nothing short of enlightening. The Welding and Fabrication segment
provided us with an up-close understanding of the precision and skill required to meld
different materials into functional structures. Witnessing the intricate dance of machinery in
the Machine Maintenance and Tools shop underscored the significance of regular upkeep for
ensuring seamless production processes. The CNC shop opened a window into the world of
computer-controlled machining, showcasing the synergy between cutting-edge technology
and manufacturing precision. The Tool and Technology Institute emerged as a hub of
innovation, where we delved into the latest advancements shaping the industrial landscape.
Heat treatment and Moulding offered insights into the transformative processes that materials
undergo to meet specific industrial requirements, emphasizing the role of temperature and
precision in achieving desired outcomes.

The Foundry and Pattern division unfolded the art and science behind casting and shaping
raw materials into molds, illuminating the craftsmanship involved in creating intricate
components. Navigating through the Production Control Division, we gained a profound
understanding of the orchestration required to synchronize various elements of the production
process seamlessly. This experience was complemented by our engagement with the
Industrial Engineering Division, where we witnessed the application of systematic
approaches to optimize efficiency, productivity, and resource utilization within an industrial
setting. The significance of this industrial training extended beyond the technical aspects,
reaching into the realm of professional development. Engaging with seasoned professionals at
BITAC provided us with invaluable mentorship and real-world insights. The collaborative
atmosphere fostered a dynamic exchange of ideas, enabling us to bridge the gap between
academic knowledge and practical application. Our journey at BITAC was not merely a
passive observation of processes but a hands-on experience that encouraged active
participation. We were afforded the opportunity to apply theoretical concepts in a tangible
setting, honing our problem-solving skills and adaptability. The practical challenges
encountered in each division became platforms for learning, pushing us to think critically and
innovatively to overcome obstacles.

The holistic exposure to BITAC's diverse divisions enabled us to connect the dots between
different stages of the industrial lifecycle. It provided a comprehensive perspective on the
interdependence of various processes and departments, reinforcing the idea that successful
industrial engineering requires a holistic approach. This immersive experience laid a solid
foundation for us as aspiring Industrial and Production Engineers, enhancing our ability to
contribute meaningfully to the dynamic and evolving field. In retrospect, our industrial
training at BITAC was not just a chapter in our academic journey; it was a transformative
experience that sculpted our understanding of industrial operations.
It equipped us with technical prowess, problem-solving acumen, and a nuanced appreciation
for the collaborative nature of industrial processes. As we transition from students to
professionals, the lessons learned at BITAC will undoubtedly resonate in our approach to
industrial and production engineering, serving as a guiding beacon in our future endeavors.

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