INTERNSHIP REPORT

ON

ACE DESIGNERS
SUBMITTED BY

PAVAN R SRUJAN MS
SHASHANK S YESHWANTH KN

UNDER THE GUIDANCE OF

Mr.Anil Kumar.PR Mr.Purushotam

Internship Cordinator HR
Sapthagiri Collage of Engineering ACE Designers

DEPARTMENT OF MECHANICAL ENGINEERING

SAPTHAGIRI COLLEGE OF ENGINEERING
(Accredited by NAAC with an “A” grade)
(An ISO 9001:2015 & ISO 14001:2015 Certified Institution)
(Affiliated to VTU, Belagavi and approved by AICTE, New Delhi)
4/5, Chikkasandra, Hesarghatta Main Road, Bengaluru-560057
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 ACKNOWLEDGEMENT
• The satisfaction and euphoria that accompany the completion of any
task would be incomplete without the mention of the people who made
it possible, whose constant guidance and encouragement ground my
efforts with success.

• I consider it a privilege to express my gratitude and respect to all

those who guided me in the completionof the internship. I thank
• Dr. H RAMAKRISHNA, Principal, Sapthagiri College of Engineering,
for the encouragement and facilities provided to carry out this work
successfully.

• With deep gratitude and pleasure, I express my sincere and

cordial thanks to the dynamic guide, Mr.Purushotam [HR], Peenya
for his cheerful guidance and continuous encouragement
throughout the course of the internship.

• It’s a great privilege to place on record my deep gratitude to

Dr. Tulsidas.D, HOD of Mechanical Engineering, for his continuous
support and advice.

• I would like to express my hearty gratitude to my internship

coordinator and guide, Prof. Anil Kumar P R, Assistant Professor,
Department of Mechanical Engineering, for his timely advice and
regular assistance throughout the work.

• I thank all the teaching and non-teaching faculty members who have
helped me directly or indirectly.Finally, I also thank my family and
friends for their cooperation and motivation to complete this
successfull 2
internship

successfull 2
 CONTENT

• Abstract

• Introduction

• Mission, Vision and Features

• Operation Performed

• Skills and experience acquired

• Conclusion

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 INTRODUCTION
About Company

Ace Designers, led by 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 over 50000
square meters, its manufacturing plants, located in Bangalore, India, are
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 designs 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

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.

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, South East Asia, Japan and Australia.

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 MISSION, VISION AND FEATURES

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 Organisation enabled by Vibrant Inspired People achieving
Accelerated Growth

MISSION

Locally Inspired & Globally Admired organization driven by processes,

fuelled by innovation to achieve 2026 Crores by 2026

FEATURES

Area of 50,000 sq. mt.

State of the art Innovation center housing R&D, Design and IT
High quality plant & machinery for in-house manufacturing of key
components
Assembly of machines on conveyor lines for volume production
Current plant capacity of 5000 machines annually

CERTIFICATIONS

Ace Designers Ltd has setup management systems as per ISO 9001:2015 &
ISO 14001:2015 standards and is certified by TÜV NORD CERT GmbH.

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 ACE BRANDS

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 DEPARTMENTS

CMD (COMPONENT MANUFACTURING DIVISION)

• SMD (SHEET METAL DIVISION)

• LASER CUTTING
• WELDING
• PAINTING AND POWDER COATING
• PCD (PANNEL COOLING DIVISION)
• TELESCOPIC COVER ASSEMBLY

SECTION CNC MACHINE ASSEMBLY

• CNC BAY 1-4

• TOOL ROOM
• SPECIAL PURPOSE DEVELOPMENT MACHINES
• HYDRAULICS DIVISION
• METROLOGY
• SPINDLE ASSEMBLY

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 OPERATIONS PERFORMED
1. Facing
Face turning is the process used to cut a flat surface perpendicular to the
workpiece’s rotational axis.
The tool is mounted into a tool holder that rests on the carriage of the
lathe.
facing tool will feed perpendicularly across the rotational axis of the part.

2. Turning
The CNC machine turning operation refers to removing material from the
outer diameter of the workpiece. Turning can either be performed parallel
to the rotational axis of the part or at an angle to create a tapered part.

3. Drilling
If a hole is required on the rotational axis of the part, a drill is used. In more
advanced turning centers, a hole can be drilled in almost any orientation
and is not limited to the central
axis.

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4. Boring
After a hole has been drilled it may be necessary to enlarge it. The easiest
way to do this is through a boring operation where the cutting tool is fed
into an existing hole and removes material from the inner wall of the
hole.

5. Threading
Threading is the process of cutting threads into a hole or over the outer
diameter of a workpiece.

6. Grooving or Parting
Grooving is typically used to create features like O-ring or circlip
grooves and contouring operations. A grooving tool is sometimes also
called a parting-off tool and is used to remove the completed part
from the workpiece stock.

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7. Knurling
Knurling produces a diamond pattern into the outer diameter of a part.
This pattern is not produced by cutting, but rather the knurling tool
compresses the material into the desired pattern. Knurling is most
often used to add grips onto a part.

8. TAPER TURNING
Taper turning produces a ramp transition between the two surfaces with
different diameters due to the angled motion between the workpiece and
a cutting tool.

9. CONTOUR TURNING
In contour turning operation, the cutting tool axially follows the path with a
predefined geometry.
Multiple passes of a contouring tool are necessary to create desired
contours in the workpiece.

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 MAJOR MACHINES

DOOSAN SK

STANDARD SPECIFICATIONS

X - Travel 1020 mm
Y - Travel 540 mm
Z - Travel 530 mm
Table Length 1200 mm
Table Width 540 mm
Length 5300 mm
Width 3400 mm
Height 3000 mm
Weight 7000 kg

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 MAZAK FH

STANDARD SPECIFICATIONS
Axis X 1050 mm
Axis Y 800 mm
Axis Z 825 mm
Rotary table (4th axis) no
CNC Mazatrol M-Plus
Table length 630 mm
Table width 630 mm
Max. part weight 1500 kg
Number of tool pockets 80
Spindle taper CAT 50
Max. spindle speed10000
rpm
Spindle motor power 30 kW
Length x width x height 6770.0 × 3380.0 × 3225.0
Weight 17000 kg

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 DIXI 200

STANDARD SPECIFICATIONS
Swing Over Bed 500mm
Std. Turning Dia. 250mm
Max. Turning Dia.* 320mm
Max. Turning Length* 320mm
X-Axis Travel (Cross) 175mm
Z-Axis Travel (Longitudinal) 320mm
Rapid Feed (X & Z Axis) 24/24mm/min
Spindle Motor Power - Siemens 9.8/7.5kw
Spindle Motor Power - Fanuc 7.5 / 5.5kw
Spindle Speed Range 50-4000rpm
Spindle Bore 55mm
Spindle Nose A25
Max. Bar Capacity 44mm
No. of Station 8
Max. Boring Bar Dia. 40mm
Tool Size (Cross Sectional) 25 x 25mm

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 STARRAG
STANDARD SPECIFICATIONS
Number of axes 3-axis
Spindle orientation vertical
Spindle mount HSK A-63, HSK-80-A
Number of tool stations 24 tools
Other characteristics high-speed, high-productivity, high-
precision, high-rigidity
X travel,100 mm, 1,600 mm
(43 in, 63 in)
Y travel400 mm(16 in) STANDARD
Z travel400 mm(16 in)
SPECIFICATIONS
Rotational speed18,000 rpm
(113,097 rad.min-1)
Power28 kW(38.07 hp)
Work feed X-axis62,000 mm/min(41 in/s)

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 QUALITY AND INSPECTION

INSTRUMENTS

CMM MACHINE

Vernier Caliper

Polar projecter

Screw Gauge

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 Tasks Performed

1. Operation Monitoring-Watching gauges, dials or other

indicators to make sure a machine is working properly.
2. Writing the standard operating procedure(SOP) of the
manufacturing process in the shop floor and in assembly.
3. Writing the specifications of CNC machine and also various
parameters to be considered while machining a part.
4. Quality Control and Testing: Ensuring that products meet
quality standards through inspections, tests, and certifications.
5. Maintenance and Repair Services: Providing maintenance
services for industrial equipment and machinery, as well as
offering repair solutions for damaged or malfunctioning parts.

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 SKILLS LEARNT

1. Reading Comprehension - Understanding written sentences,

paragraphs and symbols in work related drawings and
documents.

2. Systems Analysis - Determining how a system should work

and how changes in conditions, operations, and the
environment will affect outcomes.

3. Feeding and altering the program to an CNC machine through

the interface.

4. Handling of special gauges used to check the taper angle,

checking the run-out of an spindle using the Dial gauge.

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 DISCIPLINE AND BEHAVIOUR LEARNT

1. Following the instructions of higher authorities.

2. Team work and follow the standard operating procedures

3. Time management.

4. Safety measures to be taken while operating a machine.

5. Punctuality and efforts in completing the assigned task.

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 SUMMARY

1. On the whole, this internship was a useful experience. I

have gained new knowledge, skills and met many new
people. achieved several of our learning goals, we got
insight into professional practice.

2. Got the knowledge about the type of CNC machines

available in the industry like vertical axis, horizontal axis, 5
axis CNC machines, CNC milling centres and universal
grinding machines etc.

3. Got an insight of handling a CNC machine and also various

parameters to be considered while machining a
part.

4. The internship was also good to find out what my

strengths and weaknesses are. This helped me to define
what skills and knowledge I have to improve in the coming
time.

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 SAPTHAGIRI COLLEGE OF ENGINEERING

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 PRODUCTS

Engine Valve Ball Pin

Brake Disc Cam Shaft

Compressor Housing
Crank

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Transmission Gear Transmission Shaft

Self Lubricating Bush Spherical Bearings

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 CONCLUSION

Our Internship at “ACE DESIGNERS” has considerably increased our

knowledge of activities performed by an industrial organization. We
were provided the opportunity to observe all the activities on the shop
floor and we were able to relate most of the activities to our subjects.
This provided us with a visual experience, due to which many topics and
concepts have been etched in our mind.We were exposed to an
industrial atmosphere and this helped us bridge the gap between
theoretical and practical learning. We learnt in detail how to plan and
schedule production according to customer requirement and resources
available.
Through detailed drawings we were able to identify the bottleneck
processes and reduce cycle time. We also learnt the working of CNC
Machines and the various other types of machines. Real world
problems have to be tackled using basic tools of quality which find out
the cause quickly and save time and energy. The most important take
home message is the customer value should always be kept in mind for
the successful running of an organization in the midscompetition.

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