HINDUSTAN MACHINE TOOLS LIMITED.doc

In-Plant Training Report 2015-16

1. HINDUSTAN MACHINE TOOLS LIMITED

By the end of the Second World War the government of India was confronted by a big

problem of disposing the colossal war waste. Ultimately a committee was constituted to

inquire into the possibilities. The committee report of 1948 proposed the establishment of a

Govt. owned machine tool industry. This was expected to fulfill two aspects. The first was

being utilization of Rs. 4000 Million worth of metallic waste. The second was the

incorporation of a state owned manufacturing facility. The result was the birth of the

HINDUSTAN MACHINE TOOLS LIMITED, which diversified in due course of time to the

present stature of the multi product industrial giant HMY Ltd. The HMT Ltd. Was started as

a single factory to produce Tool Room Lathes at Bangalore in collaboration with M/S

Oerlikon of Switzerland in 1953, with a capacity to manufacture around 400 machines per

year. Since then different collaboration, continued in house R&D and tremendous marketing

efforts brought HMT, to present status.

The growth of HMT Ltd. was characterized by the forward and backward integration

of technology and product diversification. Thus the company that started with manufacturing

and selling lathes expanded its machine tools product range to evolve as the ultimate solution

in metal cutting. The product diversification efforts took the company to the business of

watches in 1976, Food processing Machinery in 1980, CNC System in 1986, Ball Screw in

1986 and reconditioning in 1990.

The multiproduct activities made HMT Ltd. Changes its identity as HINDUSTAN

MACHINE TOOLS LTD.

Today, HMT Ltd. Has 16 manufacturing units with 22 product divisions, spread

through the length and breadth of INDIA. ASUBSIDIARY Vise, HMT (international) Ltd.

undertakes the exports of the company. They are also export agents for several other Indian

Companies.

HMT Ltd. Was restructured in 1992 to facilities better administration of the

multiproduct business groups was established.

Dept.of Mechanical Engg 1 AWH PTC


Machine Tools Business Group, to concentrate on the metal cutting machines.

Industrial Machinery Business Group, to deal with printing Machines, Die casting and

plastics injection molding machines, Food processing machines and metal forming

machines.

Agricultural Business Group to concentrate on Tractors • Engineering components

Business Group to deal with casting and Ball Screws • Consumer products Business

Group to deal with watches and lamps. In addition to this business group the company

owns three subsidiaries as follows:-



2. ORGANIZATION CHART

TOP EXECUTIVES



3. HMT MACHINE TOOLS LIMITED:-

The HMT MACHINE TOOLS LIMITED is engaged in the manufacture

and marketing of General Purpose Machine Tools, Special Purpose Machine Tools,

Computer Machines, Metal Forming Presses, Die Casting and Plastic injection Molding

Machines, Ferrous Casting.

1.1.1HMT MACHINES TOOLS UNITS:-

1. HMT machine tools ltd Bangalore

2. HMT machine tools ltd Hyderabad

3. HMT machine tools ltd kalamassery

4. HMT machine tools ltd pinjore

5. HMT machine tools ltd Ajmer

6. Praga machine tools ltd Hyderabad

KALAMASSERY:-

CNC Turning Centers

Turn Mill Centre

Flexible turning Cell

Centre Lathe

Offset Printing Machines

Paper Cutting Machine.



4. PRODUCTION PLANNING

4.1 INTRODUCTION

The production planning department is the most vital link between product design and

production department. The production planning department provides the necessary facilities

and technical now-how for the manufacture of the product. Production requires the organized

utilization of natural resources men money material and machine. The role of production

planning department MTK is as shown below. Production planning department compares the

following sections.

Production preplanning and planning estimation- PPP and PPE

Production planning ordering and PPS-PPO and FPC

4.2 OBJECTIVE OF PRODUCTION PLANNING

In any business organization production activities must be related to market demands

as indicated by continuous stream of customer orders. Objective of production planning

department ensure that annual production planning is achieved is-an economic manner.

4.3 FUNCTIONS AND RESPONSIBILITY OF PLANNING PERSONNEL

1. Processing of design document received for corresponding products

2. Implementation of design alternation

3. Coordinating activity related to alteration requests received from other departments

4. Coordinating all activities related to computerization PPP function

5. Coordination with foundry for the manufacture or alteration of patterns



4.4 FUNCTIONS AND RESPONSIBILITY OF PPC PERSONNEL

1. Estimation of standard time for all manufacturing or assembly operation

2. Identified in operation layouts assembly list of operations

3. Attending shop complaints regarding standard time

4. Authorization for special time in job cards.



5. QUALITY CONTROL

INTRODUCTION

Quality control in it's simplest term refer to control of quality during manufacturing

both quality. Control and inspector are envisaged to assure the quality is entire area of any

production process inspection is determine function. When the control because effective the

need of inspection decreases. Hence quality control determines the causes of variation in the

characteristics of production and gives solution by which there variations can be controlled. It

is economical in it's purpose objective in it's procedure dynamic in it's operation and helpful

need treatment

OBJECTIVE The total quality management department series measurable quality objective for every

year. These objectives ensure that the requirement of products not only identified and met but

also consulter wide and improved. The measurable objectives are taking it's to considering

the followings *To reduce internal losses due to scrap rejection and reworks To reduce

external losses due to science cost To maximize the customer satisfaction 3.3 PURPOSE

To ensure in coming items or raw material being used directly indirectly are not

supplied for manufacturing and product without inspection or verification for it's

conformance to specified standard

To ensure the casting products in the foundry need specified standards

To ensure the components and assembled units during various stages of it's progress

are inspected or tested and the details documented

To ensure major components at various manufacturing process are inspected and

design recorded in the reagent documents.



INTERACTIVE GRAPHIC SYSTEM IN COMPUTER AIDED PART

PROGRAMMING



6. HIGH TECHNOLOGY CENTRE

INTRODUCTION The most important section in the manufacturing department is the High Technology

Centre (HTC).This is the prestigious manufacturing section of HMT .in this section, there are

five CNC machines

1. VMC (Vertical Machining Centre)

2. HMC (Horizontal Machining Centre)

3. HM.4 (Horizontal Machining Centre with 4 axis)

4. VTC.1 (Vertical Machining Centre with automatic tool changer)

5. VTC.2 (Vertical Machining Centre with automatic tool centre)

All these machines are working with the help of CNC control. Controlling a machine

tool by means of a prepared program which consists of blocks or series of numbers is known

numerical control or NC.An NC machine tool system contains a machine tool itself.

DEFINITION Computer Numerical Control(CNC) is one which the functions and motions of a

machine tool are controlled by means of a prepared program containing coded alpha numeric

data.

APPLICATIONS The applications of CNC include both for machine tool as well as non-machine tool

areas. In the machine tool category CNC is widely used for the, drill press, milling machine,

grinding unit, laser, sheet metal press working machine, tube bending machine etc. Highly

automated machine tools such as turning centre and machining centre which change the

cutting tools automatically under CNC control have been developed.



PATTERN SHOP A pattern is defined as anything used for an important is called mould in the sand

mould when filled with molten material on solidifying forms a reproduction of pattern and is

known as mould. It’s slightly longer in size then casting. as the first stage in preparing the

casting the pattern of casting prepared at pattern shop with either of the material as its given

below.

WOOD;-Wood is most commonly used pattern material as its cheap, easily available can also

easy to joint and fabricate

METALS;-Metals have advantage of that they do not wrap, very accurate and have high

strength. But shaping is slightly difficult and it's also subjected to rusting and the cost is high

PLASTICS;-The most common example is gypsum cement prepare cannot easily done and it

does not need skilled labors

THERMOCOAL;-Single use pattern are made using thermo coal in the process of casting a

pattern of casting of pattern is repair of the object to be cast used to prepare the cavity into

which molten material will poured during the casting process. the pattern made to incorporate

suitable shrinkage allowance depending or material followed heat transfer considerate.

Pattern making is skilled technique that was highly indulgent.

In sand casting pattern is usually of wood where as it may be metal or other material in

pressure of centrifugal casting. The pattern making also decide where the space respect to the

pattern parts object which have holes or depression. Material will not flow sometime pattern

may also accommodate chills, solid piece of final material to make rapid cooling resisting in

mastinsticness during in high neighborhood of chill

SAND MAKING PROCEDURE

The procedure of making a typical sand molding start by placing a button board, first

either the molding plate form on the floor making the surface when the drag molding flask is

kept upside down on the bottom board acting with the drag part of pattern at the centre of the

board. These should be enough clearance between the pattern and the walls of the flask. Rest

of the drug flask is completely filled with backup sand and uniformly rammed to compact the

sand and after the ramming out the excess sand in flask is completely suspend using a flat bar

to lead of flask edge. The finished drag flask is near rolled out to the bottom board expose the

pattern using stick. The edge of sand around is replaced and cope with the help of pattern is

replaced. Out the drag pattern changing with the help of the pins dry parting sand sprinkled

all over on the drag on the pattern.



The space pin for making the replaced passage is located at the small distance to form

the pattern also a riser pin of required is kept at an appropriate place and freshly prepared

molding sand similar to that of the drag along with backing sand is sprinkled. The sand

thoroughly removed excess sand shaped and holes are made all over in the copy as in the

drag. Now the cope and the drag pattern holes are withdrawn by using the draw spikes and

rapping the pattern all around to slightly enlarge the mould cavity that the mould wall are not

spilled by withdrawing pattern.

MOULDING PROCEDURE

The pig iron, msscrap, carbon, and other constitute materials are melted in electric arc

furnace. The molten metal is drawn into a ladder and transported casing all over head. The

molten metal is poured into the mould cavity which designed

FORGING It's the operation of where the metal is heated and then the force is applied to

manipulate the metal in such a way that the required final shape is obtained. Forging is

generally a hot working operation though cold forging is used sometimes

FETLING The complete process of cleaning of casting called fetling.it involves the removal of

cores gate,riscus cleaning of the casting surface and chipping of any of un-necessary

projections on the surface the dry sand covers can be removed simply by remaking of with

iron bar By means of core vibrator or by means of hydro-blasting. The method depend upon



the size completely and core material used in gates and raisers can be removed by

hammering, chipping, obsessive cut off or big flames or cutting removal of gates and results

can be simplified by providing a reduced by metal sultan at the casting joint for brittle

material such as gray cast iron in the gates. Lab easily be broken by hitting with hammer for

steel and other similar materials saving with any metal cutting saw like hacksaw or band be

more

FOUNDRY PATTERN



7. M T K SMALL PARTS

INTRODUCTION M T K Small parts is a separate division of HMT Kalamassery which manufacture and

produces small parts related with lathe and CNC's M T K Small parts can be decided into

following all departments on the basis of effective cost calculation manufacturing process etc.

1. Non Round Section 5.Lead screw 2. CNC Turning 6.Accessories 3. Round Section 7.

Spindles 4. Gears 8. Turrets 10.2 NON ROUND SECTION

This section mainly consists of milling operation of the non round parts of lathe. In the

milling machine key leg clamping is used to hold the which is the work piecc.There are 2

types of milling machines. Vertical milling machine 2. Horizontal milling machine

GEARS



Gears are usually used to transmitting power from one shaft to anotlier.Gears necessary

be lathe to proper adding, turning, facing and holding shaping are various spaces usually

involved in gear manufacture. Shaping is more accurate and usually used for production

of gears its move economic. After holding process the gear should undergo grinding for

square finish gears are produced by gear shaping mach

ACCESSORIES

1. Accessories as the tool and equipment used in lathe the operation. They have the tools

which are general operation. They have the tools which are provided with lithe and

intrude tools for lathe and CNC'S and also checks 4 gears and 3 gears . Check is a

device which is used to holds work piece.

2. TURRETS: It produced by using dies. Turret refers to a set of arrangement. It’s used to

several buoyancy which can be inspect and low speed in necessary for threading the

turret. The proper preparation of turret is necessary. The coolant usually used in

satisfied.

3. Features : • Rotary and reciprocating motion • Shearing actions used • Honing

operation is limited to very few number of industries



BORING MACHINE They are used to mill drill bore and cut threads curing rotating tool, usually a cutter,

driller or milling head. Boring machine is used for drill closed and open opening is solid

materials boring, reaming, threading. Boring machine include vertical boring mill and

horizontal boring machine mill. Boring operation is to enlarge and finish hole.

FEATURES Work piece one commonly H04 moles in diameter

Control system can lie computer cased

Bottom cooling of the bores are done through a hollow passage way t

Horizontal and vertical movement

Hand operation knurled socket attached to hand stock drive motor

High surface finish

GRINDING MACHINE



Grinding machine is used to fresh work piece that must shows. Accuracy of shape and

dimension. It consists of

➢ a bed with a fracture to guide and hold the work piece

➢ Power divine grinding wheel spinning at required speed

➢ Surface grinding work piece moved back and forth under the grinding wheel 1E4

DRILLING MACHINE This machine is used to drill, mainly rotation and movement of the

rail. Drill bit is damped manually or automatically and speed of movement and rotation are

varied. Features : o Electromagnetic damping provide for drill head and arm sleeve o

Machine drilling capacity is 80mm/100mm o Massive and rigid construction o Precious depth

release o Electric motor AC/400V



8. HEAVY PARTSHeavy parts section in HMT includes milling planning, drilling, boring etc. operations.

Pants of lathes like tide, head stock, tailstock etc. are machined here.

PLANE MILLING Plane milling is the process of production of plane, flat, horizontal

surface parallel to the crisis of the rotation of a plane cutter Features : DC motor Rack &

pinion arrangements used Length up to 13 meters used.

PLANO MILLING MACHINE Plano milling machine is widely used in precise shaping of

methods of various processes such as slot cutting, routing, welding & turning in many

industry.

Features: Precise dimension

Easy to install

High operation efficiency

Hydraulic press is used

Various lengths of 1.5m, lm & 3m are used.



9. CNC ASSEMBLY

Ever increasing demands the need for accuracy, scrub reduction have pushed for

development in the field of machining and manufacture. All this have led to the invention and

improvement of CNC machines which can undoubtedly be learned as one of the milestones

of the century. A part from rocketing the productions sky high CNC machines have made it

possible to machine up to an accuracy of micron to a modest one of the growing popularity of

CNC machines can also be attainted to repeatability of CNC part programs and reached skill

demands of labors.

HMT machine tools Kalamassery is famous for its world class CNC turning centre. It

was in the late 80's that HMT machine tools Ltd. Kalamassery stared the production of the

CNC turning centers. The earlier models of machines and liniment and numeric control

system and MCU (machine control unit) whereas the new generation CNC machine of the

unit was (fame/sins) control system.

The assembly of CNC turning centers can be divided into:

1. Group assembly

2. Pre-final assembly

3. Final assembly



ELEMENTS OF A CNC

A CNC system consist of three basic components

1. Part program

2. Machine control unit (MCU)

3. Machine tool (lathe, drillpress, milling machine etc...)

Part program:-Part program is a detailed set of commands to be followed by the

machine tool. Each command specifies a position in the car tension coordinate

system(x, y, z) or motion (work place travel or cutting tool travel),machining

parameters and on/off function.

Machine control unit (MCU):-It is a micro computer that stores the program and

executes the commands into actions by the machine tool. The MCU consist of two

main units the data processing unit (DPU) and control loops unit(CLU).

Machine tool:-It could be one of the following:- Lathe, milling machine,

laser,plasma,coordinate measuring machine etc.

POINT TO POINT SYSTEM

Point To Point System is those that move the tool or the work place from one point to

another and then the tool performs the required task



CONTINOUS PATH SYSTEM (Straight cut & contouring system)

These systems provide continuous path such that tool can perform while they are

moving, enabling the system to generate angular surfaces, two dimensional cut or three

dimensional contours. Example is a milling machine.

GROUP ASSEMBLY

This is the place where Assembly of the headstock, tailstock, turret, indexingunit,

power stock turret fixing, etc. is done. The parts required for the assembly are produced by

various units and kept in store .As per requirement by the assembly unit, the stores issues the

required components for the assembly of the products. After assembly of each part they are

set to an extensive test and are passed on to pre-final assembly only after the inspection

department certify on it. The most commonly used method is the use of curvier coupling. It

has two gears like parts. One of them has a convex surface and other a concave surface for

firm contact. Another method is to use hydraulic pressure about 4Mpa for clamping. When

the pressure is released the turret is unclamped and ready for indexing.

PRE-FINAL ASSEMBLY The pre-final assembly is the section where the assemblies

of various components of the CNC like headstock takes place to the lathe bed. The

head is moved from the heavy parts store to the pre-assembly directly upon the

request.

FINAL ASSEMBLY The lathe is brought from the pre-final assembly the various

electrical components required for the functioning are installed. The electrical drives,

systems and special accessories like tools, studyrests, etc. are imported The main

suppliers are Siemens and Franc. The stabilizer unit and coverer belt are also

assembled during this stage. The various functional groups are explained briefly as

follows:

BED Most of CNC turning centers of HMT is of slant bed type. There are many

reasons behind such a design. A few can be listed as: • reduced thermal growth: The

thermal growth during machining can be considerably reduced by using slant beds. •

Chip removal becomes easier when it comes to slant beds. • Loading/Unloading

become much less tedious in slant bed machines.

HEAD STOCK: Unlike the head stock of conventional lathes, the CNC do not have

speed shift gears incorporated. Two types of pulleys are used to transfer power from

the main motor to spindle. Tapered pulleys and keyed pulleys. Moreover two types of

belts are used: V-belts and parallel belts. The main spindle has also an encoder which



acts as to the fee back servomotor so that the required speed is attained. All spindles

are stabilized (Starting from low speed the speed of the spindle is gradually increased

to its maximum rated speed) and then put on the test run before mounting on the

machine. Manufacturing the spindles free of vibrations is critical to maintain accuracy

in machining and for life of the entire unit.

DRIVES: The machine contains three servomotors. One for main spindles, one for

saddle Travers over the bed and the third one for cross slide/turret movement across

the saddle. The driving unit and are directly controlled by the computer while on run.

SADDLE: Saddle is that portion which carries the turret and slides over the bed. The

saddle actually is fixed to the ball nut. The ball screw mounted on bearing is powered

by a servomotor. As the screw rotates, the nut moves causing the turret and hence the

cutting tool to move in the axial direction (Z).

TURRET: Turret is that part of a CNC machine that holds various tools and positions

the required form to perform the cutting. The sequence of operations that takes place

during indexing is given below:

i. Unclamping: The turret male part unclamps from the curvy coupling. This actuated by a

piston cylinder arrangement enclosed within the turret housing. ii. Rotation: The hydraulic

motor is actuated by means of a direction control valve solenoid valves (DCV).This rotation

is fed back to the controller by another encoder. This rotation is takes place in the direction of

shortest possible angle. iii. Creep: As the turret reaches the desired angle an opposite flow is

given to motor so as to reduce the speed of rotation. iv. Clamping: once the desired position

is attained the turret clamps back to the coupling and ready for machining.

TAILSTOCK The tail stock of a CNC machine is highly advanced. Instead of rotating a

rotating centre is used to reduce heat generation. The tail stock body is used to reduce heat

generation. The tail stock Body is moved by means of a special hook-like mechanism

provided at the end of the saddle. The tail stock is clamped to the guide way by the plunger in

and plunger out operations and movement are only possible if the plunger is executed.

HYDRAULLIC SYSTEMS Many of the critical operations of the CNC machines,

including fool proof set-up are hydraulic systems owing their flexibility and controllability.

The major hydraulic systems are described below: i. Head stock: As explained above the

work piece is clamped by means of a piston cylinder arrangement. ii. Tail stock: the tail stock

cylinder is also controlled valves. The plunger too is hydraulically Controlled. iii. Turret: As

above mentioned the turret clamping /unclamping, indexing, creeping and all are controlled



hydraulically. iv. Gearbox: The gear shifts in CNC machines are actuated by hydraulic

systems. The levers are shifted when the piston inside the cylinder pushes them.

LUBRICATION SYSTEM

Ensuring sufficient lubrication for the rotating as well as sliding parts are essential to

maintain smooth running for the machine as well as to reduce vibrations heat generations and

errors. The lubrication pipes are made of copper pipes and flow is controlled by metering

cartridges.

LUBRICATION SYSTEM

Ensuring sufficient lubrication for the rotating as well as sliding parts are essential to

maintain smooth running for the machine as well as to reduce vibrations heat generations and

errors. The lubrication pipes are made of copper pipes and flow is controlled by metering

cartridges.

OTHER SYSTEMS

Chip conveyor for removal chips inside the machine.

Cabinet cooling set up to keep the electronic circuits and optimum temperature

Oil refrigeration unit for cooling and control temperature of oil inside the power pack.

Power supply system to provide constant voltage to the pump and servomotors.

The MCVC supplied by the control system manufacture.

AXIS ALIGNMENT Axis alignment is done on every machine produced at HMT. But for CNC machine it

is of slightly higher importance, because the accuracy of machine is determined by this

process. This is different from those done on conventional lathes produced in that slight

errors beyond allowable values are compensated for the control system.



10. NH/NL ASSEMBLY

Assembly is the process of collaboration of all component part of a lathe to form a

lathe. It involves three step of assembly: 1)-pre assembly 2)-group assembly 3)-final

assembly

SCRAPING

Removal of high points to get quality contact or bearing for getting a smooth surface

for good battling. It is a manual process. The following parts are scraped by scrapes.

1. Saddle 2.keepers 3.cross slide 5. apron split nut

4. Legs

6. Tail stock base

7. Component slide 8.accessories

SADDLE ASSEMBLY

a) Oil grooving:-for lubrication purposes, some grooves are provided on the saddle

b) Distribution assembly Oil piping:- for reducing friction the oil distribution Properly

c) Cross feed assembly.

FEED BOX ASSEMBLY &INSPECTION

It consist of size shaft pre assembled with gears .It consist of feed rode ,control shaft, lead

screw. It 's steps are friction cone assembly

APRONE ASSEMBLY

a)-pre assembly

b)-group assembly

C-split nut lead screw engagement

d)-reciprocating pump and lubrication

e)-feed drive transmission to cross slide and longitudinal movement on bed



HYDRAULICS

-Lapping: - It is the process done by scribing the metal part with mixture of silicon carbide

and kerosene -Pump assembly and inspection -Pipe bending -Valve body assembly -

Distribute assembly -Piping on to machine

TAIL STOCK —ASSEMBLY

-Sleeve clamping -Roller assembly =Top and clamping assembly

SWIVEL ASSEMBLY

HEAD STOCK ASSMBLY

Headstock pre assembly -Saddle balancing and pulley balancing -Break assembly -

Clutch assembly -Lubrication distributes -Dial assembly -Head stock control

assembly -Head stock group assembly

HEAD STOCK INSPECTION

Checking noise level -Checking main spindle -Head stock lubrication

FINAL ASSEMBLY

Front work on to bed

Spindle apron assembly -Feed box assembly -Lead screw, friction cone, control rod

and bearing assembly -Support assembly -Rack assembly

TOP WORK ON HEAD:-

Head stock permeating -Tail stock assembly -Cross slide assembly -swivel assembly

and it's reading

QUADRENT BOX ASSEMBLY

Pick of gears with different gear ratios can be fitted at quadrant For feeds as per the

requirement and at key is used to shear it high load occur

MAJOR MOUTING

Pulley motored.

MACHINES

Surface grinding -Taper grinding -Turning lathe -Milling machine

VARIENTS OF NH/NL ASSEMBLY

Bed length wise-1,1.5,2,3....etc -Gap bed straight bed -Hardness -Centre height(nh

22,nh26,nh 32) -Head stock (A2-6,A2-8) -Motor speed(high/low)

PROTECTING ASSEMBLY

Front cover -Name plate -Chip tray -Wiper -Splash guards -Hydraulic tank assembly



11. CONCLUSION

The machine tool industry is experiencing both evolutionary and revolutionary

change .Key components such as spindles and motors are improving incrementally while

researches propose radical new designs for bearing and machine tool configuration. HMT is

the leading machine tool manufacturing company in India. The company has to face tough

competition from various companies. Even in the midst of tough competition from giants it

still has a unique reputation of being the producer of a quality product. Even though the

product has goodwill and good demand, the record shows that the company is running on

loss. There are many factors, which contributes to the loss of the company.

1 it was a wonderful experience for all of us having our first industrial HMT-Machine tools

Ltd.

2. Realized the experience of team work.

3. Get the knowledge of a production company.

4. Get the knowledge of working of machinery in the company.

5. Get the little knowledge of CNC machine working. 6 Good experience of the production of

machine tools.


HINDUSTAN MACHINE TOOLS LIMITED.doc

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