Dite Industrial Visit

8/16/2019 Dite Industrial Visit

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REPORT ON INDUSTRIALVISIT TO DITE, WAZIRPUR

Date of Visit: 4 th March, 2015

Date of Submission: 28 th May, 2015

Gurkirat Singh Gi

!24"M#"1$

M#%&'1

M%'21(, #ractica )raining

)eacher *ncharge: Mr+ #ra ee- .hanna(i)


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ACKNOWLEDGEMENTI would like to take this opportunity to acknowledge the administration of mycollege Netaji Subhas Institute of Technology for providing the required facilitiesand the environment without which this trip would not have been a success.Secondly, I would like to specially thank my .!.". "r. Sachin #aheshwari andmy professor #r. $radeep %hanna for their whole hearted e&ort in organi'ingthe trip and the support and guidance given by them in the enlightening thelearning process.

I am also very thankful to the concerned authorities at "elhi Institute of Tool(ngineering, )a'irpur for specially taking out time for us and getting usacquainted with both the conventional as well as modern processes in the *eldof manufacturing.

(ii)


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CONTENTS+. INT !"- TI!N/. 01!-T "IT(2. #0 IN(S 0N" $ ! (SS(S 0T "IT(

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2.


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undertaken as part of subject #0>/+@ $ractical Training of the course of #anufacturing $rocesses and 0utomation (ngineering, : th Semester. The reporttalks about the various processes the students observed under the guidance of concerned authority and faculty at "IT( and their various applications intodayAs world. It was a learning curve of di&erent sorts for the students as wecould identify better with the theory part of our course courtesy the visit to"IT(.

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2. ABOUT D.I.T.E


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3. PROCESSES AND MACHINES AT DITE The students of #$0(>+ were divided into two halves at "IT( and then underthe guidance of the eDpert faculty were shown the various process andmachines being put to use in the workshop of "IT(. The eDperts made sure thatall the students could gather information about the minute details of the

machines being shown were open to any kind of doubts being put forward byus. It was quite an interactive eDperience for all of us. The variousmachinesJprocesses shown to us at "IT( wereK

+. Surface 4rinding/. #illing2. (lectron "ischarge #achining:. ;ig 4rinding


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3.1 SURFACE GRINDINGSu f!"e g in#ing is used to produce a smooth *nish on Lat surfaces. It is awidely used *nishing process in which a spinning abrasive wheel covered inrough particles B grinding wheel C cuts chips of metallic or non>metallicsubstance from a work piece, making a face of it Lat or smooth. It is done to

give them a more re*ned look or to attain a desired surface for a functionalpurpose.

The surface grinder is composed of an abrasive wheel, a work holding deviceknown as a chuck , and a reciprocating or rotary table. The chuck holds thematerial in place while it is being worked on. It can do this one of twowaysK ferromagnetic pieces are held in place by a magnetic chuck, while non>ferromagnetic and non>metallic pieces are held in place by vacuum ormechanical means.

3actors to consider in surface grinding are the material of the grinding wheeland the material of the piece being worked on. 0 grinding wheel is speci*ed bythe abrasive material, grit si'e, bonding material, grade, structure etc. Typicalworkpiece materials include cast iron and mild steel. These two materials donMttend to clog the grinding wheel while being processed. !ther materials arealuminum, stainless steel, brass and some plastics.

The grinding wheel is not limited to a cylindrical shape and can have a myriadof options that are useful in transferring di&erent geometries to the objectbeing worked on. Straight wheels can be dressed by the operator to producecustom geometries. )hen surface grinding an object, one must keep in mindthat the shape of the wheel will be transferred to the material of the object likea mirror image .

3.1.1 EQUIPMENT

The machine tool used in the process of Surface 4rinding is called Surface4rinder and provides precision to a critical si'e or surface *nish. The typicalprecision of a surface grinder is ?.??/mm.

The machine consists of a table that traverses both longitudinally and acrossthe face of the wheel. The longitudinal feed is usually powered by hydraulics, as


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may the cross feed, however any miDture of hand, electrical or hydraulic maybe used depending on the ultimate usage of the machine Bi.e., production,workshop, costC. The grinding wheel rotates in the spindle head and is alsoadjustable for height, by any of the methods described previously. #odernsurface grinders are semi>automated, depth of cut and spark>out may be presetas to the number of passes and, once set up, the machining process requiresvery little operator intervention.

"epending on the work piece material, the work is generally held by the use of a magnetic chuck. This may be either an electromagnetic chuck, or a manuallyoperated, permanent magnet type chuck.

The machine has provision for the application of coolant as well as theeDtraction of metal dust Bmetal and grinding particlesC.

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The si'e of the grinding wheel was 2??mm, the abrasive material on thegrinding wheel was 0luminium !Dide B0l / ! 2C, a magnetic chuck was used andthe coolant contained cooling oil and water in the ratio of +KE.


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The di&erent types of Surface 4rinding areK

• ori'ontal>spindle BperipheralC surface grinders• 7ertical>spindle Bwheel>faceC grinders• "isc grinders and double>disc grinders

3.1.2 APPLICATIONS

0s eDplained earlier, surface grinders are used to produce Lat, angular andirregular surfaces. Surface grinding is often used to sharpen material or blades,

produce Lat stock, or grind large surfaces. It is also used in abrasive machining,abrasive planing, automatic grinding, back grinding, and ball grinding,deburring, dimensioning, sharpening, honing, and rubbing applications.


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3.2 MILLING$illing is the machining process of using rotary cutters to removematerial from a work piece advancing Bor feeding C in a direction at an anglewith the aDis of the tool. It covers a wide variety of di&erent operations andmachines, on scales from small individual parts to large, heavy>duty gangmilling operations. It is one of the most commonly used processes in industryand machine shops today for machining parts to precise si'es and shapes.

#illing can be done with a wide range of machine tools . The original class of machine tools for milling was the %illing %!"hine Boften called a %ill C. 0fterthe advent of computer numerical control B N C , milling machines evolvedinto %!"hining "ente s Bmilling machines with automatic tool changers, toolmaga'ines or carousels, N control, coolant systems, and enclosuresC,generally classi*ed as &e ti"!l %!"hining "ente s BV$Cs C and ho i'ont!l%!"hining "ente s B($Cs C.

The milling cutter is a rotary cutting tool , often with multiple cutting points. 0sopposed to drilling , where the tool is advanced along its rotation aDis, thecutter in milling is usually moved perpendicular to its aDis so that cuttingoccurs on the circumference of the cutter. 0s the milling cutter enters the workpiece, the cutting edges BLutes or teethC of the tool repeatedly cut into and eDitfrom the material, shaving o& chips from the work piece with each pass. Thecutting action is shear deformationO material is pushed o& the work piece intiny clumps that hang together to a greater or lesser eDtent Bdepending on the

materialC to form chips. This makes metal cutting somewhat di&erent fromslicing softer materials with a blade .

The milling process removes material by performing many separate, small cuts. This is accomplished by using a cutter with many teeth, spinning the cutter at


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A++li"!tions K Turret mills are only practical as long as the machine remainsrelatively small. 0s machine si'e increasesA, moving the knee up and downrequires considerable e&ort and it also becomes di cult to reach the quill feedhandle Bif equippedC. Therefore, larger milling machines are usually of the bedtype.

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3.2.1.2 HORIZONTAL MILL

0 hori'ontal mill has the cutters are mounted on a hori'ontal arbor across thetable. #any hori'ontal mills also feature a built>in rotary table that allowsmilling at various anglesO this feature is called a universal table . )hile endmillsand the other types of tools available to a vertical mill may be used in a

hori'ontal mill, their real advantage lies in arbor>mounted cutters, called sideand face mills, which have a cross section rather like a circular saw, but aregenerally wider and smaller in diameter. 1ecause the cutters have goodsupport from the arbor and have a larger cross>sectional area than an end mill,quite heavy cuts can be taken enabling rapid material removal rates .

A++li"!tions - sed to mill grooves and slots. $lain mills are used to shape Latsurfaces. Several cutters may be ganged together on the arbor to mill acompleD shape of slots and planes. Special cutters can also cut grooves, bevels,

radii, or indeed any section desired. It is also easier to cut gears on a hori'ontalmill. Some hori'ontal milling machines are equipped with a power>take>o& provision on the table. This allows the table feed to be synchroni'ed to a rotary*Dture, enabling the milling of spiral features such as hypoid gears.


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3.3 ELECTRON DISCHARGE MACHININGEle"t i"!l #is"h! ge %!"hining BED$ C, sometimes also referred to as s+! ) %!"hining , s+! ) e o#ing , *u ning , #ie sin)ing , -i e *u ning or -i ee osion , is a manufacturing process whereby a desired shape is obtained usingelectrical discharges BsparksC. #aterial is removed from the workpiece by aseries of rapidly recurring current discharges between two electrodes ,separated by a dielectric liquid and subject to an electric voltage . !ne of theelectrodes is called the tool>electrode, or simply the PtoolP or PelectrodeP, whilethe other is called the workpiece>electrode, or PworkpieceP.

)hen the distance between the two electrodes is reduced, the intensity of the electric *eld in the volume between the electrodes becomes greater thanthe strength of the dielectric Bat least in some pointBsCC, which breaks, allowingcurrent to Low between the two electrodes. This phenomenon is the same asthe breakdown of a capacitor BcondenserC Bsee also breakdown voltage C. 0s aresult, material is removed from both electrodes. !nce the current stops Bor is


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stopped, depending on the type of generatorC, new liquid dielectric is usuallyconveyed into the inter>electrode volume, enabling the solid particles BdebrisCto be carried away and the insulating properties of the dielectric to be restored.

0dding new liquid dielectric in the inter>electrode volume is commonly referredto as PLushingP. 0lso, after a current Low, the di&erence of potential betweenthe electrodes is restored to what it was before the breakdown, so that a new

liquid dielectric breakdown can occur.

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3.3.1 EQUIPMENT/TYPES

There are two types of ("# machining, sinker ("# and )ire ("#

. .1.1 Sin)e ED$

Sinker ("#, also called cavity type ("# or volume ("#, consists of anelectrode and workpiece submerged in an insulating liquid such as, moretypically, oil or, less frequently, other dielectric Luids. The electrode andworkpiece are connected to a suitable power supply. The power supplygenerates an electrical potential between the two parts. 0s the electrode

approaches the workpiece, dielectric breakdown occurs in the Luid, forming aplasma channel, and a small spark jumps.

These sparks usually strike one at a time, because it is very unlikely thatdi&erent locations in the inter>electrode space have the identical local electrical


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characteristics which would enable a spark to occur simultaneously in all suchlocations. These sparks happen in huge numbers at seemingly randomlocations between the electrode and the workpiece. 0s the base metal iseroded, and the spark gap subsequently increased, the electrode is loweredautomatically by the machine so that the process can continue uninterrupted.Several hundred thousand sparks occur per second, with the actual duty cyclecarefully controlled by the setup parameters.

A""#i$%&i' * -sed when the shape required is di cult to machine from theconventional machines. The shape of electrode is the generally the one werequire.

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. .1./ Wi e ED$

In wire electrical discharge machining B)("#C, also known as wire-cut EDM and wire cutting , a thin single>strand metal wire, usually brass , is fedthrough the workpiece, submerged in a tank of dielectric Luid, typicallydeioni'ed water. The wire, which is constantly fed from a spool, is held betweenupper and lower diamond guides.

The guides, usually N >controlled, move in the x H y plane. !n most machines,the upper guide can also move independently in the z Hu Hv aDis, giving rise tothe ability to cut tapered and transitioning shapes Bcircle on the bottom, squareat the top for eDampleC. The upper guide can control aDis movements in x H y Hu H


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3.5 IN-ECTION MOULDINGIn0e"tion %oul#ing is a manufacturing process for producing parts byinjecting material into a mould. Injection moulding can be performed with ahost of materials, including metals, glasses , elastomers , confections, and mostcommonly thermoplastic and thermosetting polymers. #aterial for the part isfed into a heated barrel, miDed, and forced into a mould cavity, where it coolsand hardens to the con*guration of the cavity. 0fter a product is designed,usually by an industrial designer or an engineer , moulds are made by a mouldmaker Bor toolmakerC from metal, usually either steel or aluminum ,and precision>machined to form the features of the desired part.

$arts to be injection moulded must be very carefully designed to facilitate themoulding processO the material used for the part, the desired shape andfeatures of the part, the material of the mould, and the properties of themoulding machine must all be taken into account. The versatility of injectionmoulding is facilitated by this breadth of design considerations and possibilities.

Injection moulding uses a ram or screw>type plunger to force molten plasticmaterial into a mould cavityO this solidi*es into a shape that has conformed tothe contour of the mould. It is most commonly used to processboth thermoplastic and thermosetting polymers , with the former beingconsiderably more proli*c in terms of annual material volumes processed.

)ith injection moulding, granular plastic is fed by gravity from a hopper into aheated barrel. 0s the granules are slowly moved forward by a screw>typeplunger, the plastic is forced into a heated chamber, where it is melted. 0s theplunger advances, the melted plastic is forced through a no''le that restsagainst the mould, allowing it to enter the mould cavity through a gate andrunner system. The mould remains cold so the plastic solidi*es almost as soonas the mould is *lled.


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3.5.1 EQUIPMENT

Injection moulding machines consist of a material hopper, an injection ram orscrew>type plunger, and a heating unit. 0lso known as presses, they hold themoulds in which the components are shaped. $resses are rated by tonnage,

which eDpresses the amount of clamping force that the machine can eDert. Thisforce keeps the mould closed during the injection process. Tonnage can varyfrom less than < tons to over @,??? tons, with the higher *gures used incomparatively few manufacturing operations. The total clamp force needed isdetermined by the projected area of the part being moulded. If the plasticmaterial is very sti&, it will require more injection pressure to *ll the mould, andthus more clamp tonnage to hold the mould closed. $oul# or #ie are thecommon terms used to describe the tool used to produce plastic parts in

moulding. The mould consists of two primary components, the injection mould B0 plateCand the ejector mould B1 plateC. These components are also referred toas moulder and mouldmaker. $lastic resin enters the mould througha sprue or gate in the injection mouldO the sprue bushing is to seal tightlyagainst the no''le of the injection barrel of the moulding machine and to allowmolten plastic to Low from the barrel into the mould, also known as the cavity.

The sprue bushing directs the molten plastic to the cavity images throughchannels that are machined into the faces of the 0 and 1 plates. Thesechannels allow plastic to run along them, so they are referred to as


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runners. The molten plastic Lows through the runner and enters one or morespeciali'ed gates and into the cavity geometry to form the desired part.

3.5.2 APPLICATIONS

Injection moulding is used to create many things such as wirespools, packaging , bottle caps, automotive parts and components, 4ameboys,pocket combs, some musical instruments Band parts of themC, one>piece chairsand small tables, storage containers, mechanical parts Bincluding gearsC, andmost other plastic products available today. Injection moulding is the mostcommon modern method of manufacturing partsO it is ideal for producing highvolumes of the same object.

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3.6 LATHE MACHINE0 l!the is a machine tool which rotates the workpiece on its aDis to performvarious operations such as cutting , sanding , knurling , drilling ,or deformation , facing , turning , with tools that are applied to the workpiece tocreate an object which has symmetry about an aDis of rotation . Since a varietyof machining operations can be done on it due to its versatility, it is often calledas the mother machine.

6athes are used in woodturning , metalworking , metal spinning , thermal

spraying , parts reclamation, and glass>working. 6athes can be used toshape pottery , the best>known design being the potterMs wheel . #ost suitablyequipped metalworking lathes can also be used to produce most solids of revolution , plane surfaces and screw threads or helices . !rnamental lathes canproduce three>dimensional solids of incredible compleDity. The workpiece is


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usually held in place by either one or two centers , at least one of which cantypically be moved hori'ontally to accommodate varying workpiece lengths.!ther work>holding methods include clamping the work about the aDis of rotation using a chuck or collet , or to a faceplate , using clamps or dogs .

3.6.1 EQUIPMENTS/PARTS

0 lathe may or may not have legs which sit on the Loor and elevate the lathebed to a working height. 0 lathe may be small and sit on a workbench or table,and not require a stand. 0lmost all lathes have a bed, which is Balmost alwaysCa hori'ontal beam. 0t one end of the bed Balmost always the left, as theoperator faces the latheC is a headstock. The headstock contains high>precisionspinning bearings. otating within the bearings is a hori'ontal aDle, with an aDisparallel to the bed, called the spindle . Spindles are often hollow, and have

eDterior threads andJor an interior #orse taper on the PinboardP Bi.e., facing tothe right J towards the bedC by which work>holding accessories may be mountedto the spindle. Spindles may also have eDterior threads andJor an interior taperat their PoutboardP Bi.e., facing away from the bedC end, andJor may have ahand>wheel or other accessory mechanism on their outboard end. Spindles arepowered, and impart motion to the workpiece. In addition to the spindle and itsbearings, the headstock often contains parts to convert the motor speed intovarious spindle speeds . The counterpoint to the headstock is the tailstock,sometimes referred to as the loose head, as it can be positioned at anyconvenient point on the bed by sliding it to the required area. The tail>stockcontains a barrel which does not rotate, but can slide in and out parallel to theaDis of the bed, and directly in line with the headstock spindle. The barrel ishollow, and usually contains a taper to facilitate the gripping of various type oftooling. Its most common uses are to hold a hardened steel center, which isused to support long thin shafts while turning, or to hold drill bits for drillingaDial holes in the work piece. #etalworking lathes have a carriage Bcomprising asaddle and apronC topped with a cross>slide, which is a Lat piece that sitscrosswise on the bed, and can be cranked at right angles to the bed. Sittingatop the cross slide is usually another slide called a compound rest, whichprovides / additional aDes of motion, rotary and linear. 0top that sits a toolpost,which holds a cutting tool which removes material from the workpiece. Theremay or may not be a leadscrew , which moves the cross>slide along the bed.

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3.6.2 APPLICATIONS

0s mentioned earlier, lathes are used while making furniture, pottery,machine parts, and a variety of other products individuals use every day. 0lathe uses a secure aDis to spin the materials being worked on while anoperator uses a variety of tools, including their hands, in some cases, to


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work the material. This way the craftsperson can more easily form itemsthat range from tables, to trophies, to bowls, and more.

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,. CONCLUSION


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The visit to "elhi Institute of Tool (ngineering, )a'irpur for the students wasa learning eDperience as students got the hands>on eDperience of some of the very important manufacturing processes. Not only the knowledge of themachining processes was gained, but the applications, the safety measureswhich come along with every machine were made known to the studentstoo.

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5. REFERENCES


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!. htt+ 22en.-i)i+e#i!.o g2-i)i2L!the

*. htt+ 22en.-i)i+e#i!.o g2-i)i2In0e"tion3%oul#ing

". htt+ 22#ite.#elhigo&t.ni".in2in#e4.!s+

#. htt+ 22en.-i)i+e#i!.o g2-i)i2ED$

e. htt+ 22en.-i)i+e#i!.o g2-i)i2Su f!"e3g in#ing

f. $!nuf!"tu ing P o"esses !n# Auto%!tion P o"esses, D. RS P! %!

g. htt+ 22---.!%e i"!n%!"hinetools."o%2

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http://en.wikipedia.org/wiki/Lathehttp://en.wikipedia.org/wiki/Injection_mouldinghttp://dite.delhigovt.nic.in/index.asphttp://en.wikipedia.org/wiki/EDMhttp://en.wikipedia.org/wiki/Surface_grindinghttp://www.americanmachinetools.com/http://en.wikipedia.org/wiki/Injection_mouldinghttp://dite.delhigovt.nic.in/index.asphttp://en.wikipedia.org/wiki/EDMhttp://en.wikipedia.org/wiki/Surface_grindinghttp://www.americanmachinetools.com/http://en.wikipedia.org/wiki/Lathe

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