IGTR report

MSME TOOL ROOM INDO GERMAN TOOL ROOM, AURANGABAD

(A Govt. of India Society, Ministry of MSME) ISO 9001:2000 & ISO 14001:2004 ORGANISATION

INDO GERMEN TOOL ROOM (IGTR) is a Government authorized Training center undertaken by Ministry Of MSME(Micro Small Medium Enterprise).

It is ISO Standrad Institute (ISO 9001:2000 & ISO 14001:2004).It is also accredited By NABL Production and training center.

It is established in 1990 in Aurangabaad. It also provide training programmes and courses like (Auto-CAD,

Catia,Ansys Hypermesh , Delcam,Nastran and CNC programing and Tool Design etc.) for students .

IGTR is strongly belief in TQM Philosophy.High precision equipments like CNC Co-ordinate Measuring machine,Electronic Height master,profile Projector and tool maker’s microscope ensures through checking of equipments and Components.In addition trial of the tools are taken on Mechanical press and injection moulding machine.


ISO-14001:2004ISO-14001:2004ISO-9001:2000ISO-9001:2000


TOTAL PLOT AREA 51878 sq. meters

TOTAL BUILT UP AREA 17430 sq. meters

SANCTIONED ELECTRIC POWER 1500 KVA

CAPTIVE POWER GENERATION 2X320 KVA

COMPRESSED AIR SUPPLY

OVERHEAD & UNDERGROUND WATER RESERVOIRS

CENTRAL AIR CONDITIONING UNIT

CLEAN AND DUST FREE ENVIRONMENT

ADMINISTRATION

TRAINING

PRODUCTION

RESIDENTIAL COMPLEX

CANTEEN

INTERNATIONAL HOSTEL

BOYS HOSTEL

GIRLS HOSTEL

COMMUNITY CENTER

AUDITORIUM

INFRASTRUCTURE AT GLANCEINFRASTRUCTURE AT GLANCE


CANTEENCANTEENAUDITORIUMAUDITORIUMHOSTELHOSTEL

ADMINISTRATIONADMINISTRATION PRODUCTIONPRODUCTION TRAININGTRAINING

INFRASTRUCTURE AT GLANCEINFRASTRUCTURE AT GLANCE

Aurangabad is a historical city located near the world famous Ajanta and Ellora Caves. Aurangabad is well connected by Road, Rail, Air with rest of the country.


CONVENTIONAL MACHINES

LATHE – 30 NOS.

MILLING – 30 NOS.

GRINDING – 10 NOS.

EDM – 01 NO.

OTHERS(SHAPER,DRILLING,H.GRINDERS, ETC) – 40 NOS.

CNC MACHINES

LATHE – 07 NOS.

MILLING – 14 NOS.

EDM – 06 NOS.

WIRE CUT - 06 NOS.

RESOURCESRESOURCES


CADAUTO CAD - 2008MECHANICAL DESK TOP - 2008AUTO CAD INVENTOR - 9.0SOLIDWORKS – 9.0MASTERCAM - X3DELCAM - 9.0CATIA - V5R19PRO – E - WILD FIRE 4UNIGRAPHICS - NX6

CAMMASTERCAM - X3DELCAM - 9.0CATIA - V5R19PRO – E - WILD FIRE 4UNIGRAPHICS - NX6CNC PROG.& MCHINING (MTS)

CAEANSYS XHYPERMESHCOSMOSMOLDFLOWPRO MECHANICA WF-4

RESOURCESRESOURCES


CAD / CAM LABS 15 NOS.

CNC PROGRAMMING LABS 03

NOS.

CNC MACHINING LABS 06 NOS.

HYDRAULICS / PNEUMATICS LAB 01

NO.

COMPUTER HARDWARE MAINT. LABS 04

NOS.

CALIBERATION LAB 01

NO.

INSPECTION & Q. A. LAB 01

NO.

LABORATORIESLABORATORIES


Hartford-HB2150SGWorking Range = X 2100, Y1500, Z 800

Deckel – Maho DMC 100 VWorking Range = X 1000, Y 800, Z 550 MM

Deckel – Maho DMC 70 V Hi-dynWorking Range = X 700, Y 550, Z 500 MM

Deckel – Maho DMC 70 VWorking Range = X 700, Y 550, Z 500 MM

HAAS VF2SS ( 3 nos.) Working Range X = 762, Y = 406, Z 508 MM

Makino V-33 Working Range = X 600, Y 400, Z 350 MM

Deckel – Maho 70 V Hi-dyn

HAAS VF2SS

A] CNC Machining Centre:A] CNC Machining Centre: RESOURCESRESOURCES


Mikron-UME 710 Working Range = X 710, Y 630, Z 500 MM

Mikron-WF 52DWorking Range = X 710, Y 560, Z 500 MM

Makino V-33

Charmilles Robofil 300

B] CNC Milling Machines :B] CNC Milling Machines :




Electronica Ultracut S1

Electronica Ecocut (2 nos.)

RESOURCESRESOURCES

C] CNC Wire Cut C] CNC Wire Cut


CMMCMM

Carl-Zeiss – PrismoRange 700 X 900 X 500 MM

Brown & Sharp- Hexagon Globel Range 500 X 700 X 500 MM

Hauser B-3 DR

Jig BoringJig Boring

Hauser B-3 DR Working Range = X 400, Y 250, Z 450 MM

Carl-Zeiss – Prismo

RESOURCESRESOURCES


Mechanical PressMechanical Press - 125 T. (ZEULENRODA)

Hydraulic PressHydraulic Press - 63 T. (DUNKES)

Injection Moulding M/cInjection Moulding M/c - 100 T. (BATTENFELD)

Injection Moulding M/cInjection Moulding M/c - 250 T. (L&T DEMAG)

100 T. (BATTENFELD) 125 T. (ZEULENRODA)

RESOURCESRESOURCES


Training

Design, Development & Tool Manufacturing

ACTIVITIESACTIVITIES


TOOLING SOLUTIONSTOOLING SOLUTIONS


DESIGN, DEVELOPMENT & MANUFACTURINGDESIGN, DEVELOPMENT & MANUFACTURING

PLASTIC MOULDS

PRESS TOOLS

DIE CASTING DIES

SPECIAL PURPOSE MACHINES

JIGS & FIXTURES

GAUGES

REVERSE ENGINEERING

PRODUCT DEVELOPMENT


REVERSE ENGINEERING

SURFACE & 3D SOLID MODELING

PRODUCT DEVELOPMENT

TOOL DESIGN & MANUFACTURING

CNC PROGRAMING & MACHINING

ASSEMBLY & TRY-OUTS

JOB WORK (WIRE CUT, JIG BORING, CNC

MACHINING, GRINDING ETC.)

MACHINING OF HIGH PRECISION

COMPONENTS (BATCH PRODUCTION)

CMM INSPECTION & CALIBRATION ETC.

PROJECTS UNDERTAKEN :PROJECTS UNDERTAKEN :


DESIGN & MFG. OF PRESS TOOLS IN THE AREAS OF AUTOMOBILE, DESIGN & MFG. OF PRESS TOOLS IN THE AREAS OF AUTOMOBILE,

ELECTRICALS, COSUMER AND HOME APPLIANCESELECTRICALS, COSUMER AND HOME APPLIANCES

CLUTCH PARTS

BRAKE SYSTEM

GASKETS

KITCHEN SINKS

BEARING CASE

RETAINER BUMPER

ELECTRICAL PARTS ETC.

EXPERTISE IN PRESS TOOLSEXPERTISE IN PRESS TOOLS


DESIGN & MFG. OF MOULDS IN THE AREAS OF AUTOMOBILE, DESIGN & MFG. OF MOULDS IN THE AREAS OF AUTOMOBILE,

HOME APPLIANCES, ELECTRICALS & MEDICAL EQUIPMENTHOME APPLIANCES, ELECTRICALS & MEDICAL EQUIPMENT

MCBs FOR SWTICH GEARS

LID & BASE

BEARING

SCISSOR

HANDLE

GEAR BOX FOR WASHING MACHINE

EXPERTISE IN MOULDSEXPERTISE IN MOULDS


Enclosure Base(Controller Box)

Terminal Shroud(Switchgear)

Neutral Shroud(Switchgear)

HOT RUNNER MOULD FOR ENCLOSURE, BOSS STREAMLINE

INJECTION MOULD FOR NEUTRAL SHROUD

INJECTION MOULD FOR TERMINAL SHROUD

DESIGN & MFG. OF MOULDS IN THE AREAS OF AUTOMOBILE, DESIGN & MFG. OF MOULDS IN THE AREAS OF AUTOMOBILE,

HOME APPLIANCES, ELECTRICALS & MEDICAL EQUIPMENTHOME APPLIANCES, ELECTRICALS & MEDICAL EQUIPMENT

EXPERTISE IN MOULDSEXPERTISE IN MOULDS


DESIGN & MFG. OF DIE CASTING DIES IN THE AREAS OF DESIGN & MFG. OF DIE CASTING DIES IN THE AREAS OF

AUTOMOBILESAUTOMOBILES

FOUR WHEELER WHEEL RIM DIES

TWO WHEELER WHEEL RIM DIES

2 WHEELER CLUTCH SYSTEM DIES

(WHEEL CLUTCH, HUB & HOUSING)

CARBURETORS

EXPERTISE IN DIE CASTING DIESEXPERTISE IN DIE CASTING DIES


TOOLINGS MANUFACTURED

CATEGORY NOS.

Press Tools 561

Moulds 242

Die Casting Dies 303

Jigs, Fixtures & Gauges 562

Job Work 40617

As there are many products produced in production dept.

My Area of Work is “HOW TO PREPARE THE MOULD AND THEIR PRODUCTS”.

So Let us Know About Moulding

INTRODUCTION: Molding or moulding is the process of manufacturing

by shaping meltable raw material using a rigid frame or model called a pattern.

A mold or mould is a hollowed-out block that is filled with a liquid like plastic, glass, metal, or ceramic raw materials. The liquid hardens or sets inside the mold, adopting its shape. A mold is the counterpart to a cast. The manufacturer who makes the molds is called the moldmaker. A release agent is typically used to make removal of the hardened/set substance from the mold easier. Typical uses for molded plastics include molded furniture, molded household goods, molded cases, and structural materials.

Injection moulding Blow molding Compaction or sintering Compression molding Expandable bead molding Extrusion molding Foam molding

This process uses Metal as its raw material. The mold is usually made of metal. The raw material is heated in a heating chamber and then forced or injected into the mold. The material is allowed to cool and solidify in the mold chamber. This type of molding leaves parting lines and sprue lines. Parting lines are the marks left on the final object where the parts of the object meet. Sprue is the part of the mold through which the raw material is injected into the mold. Some part of the material solidifies in the sprue hole, which has to be broken off, leaving marks on the final product.

STEP 1 CLAMPING - the moving and fixed platens of the

injection moulding machine holds the mould tool together under pressure.

STEP 2 INJECTION - the molten plastic or the metal that has

been melted from pellet form in the barrel of the moulding machine is injected under pressure into the mould.

STEP 3 DWELLING - after the molten plastic has been

injected into the mould pressure is applied to ensure all cavities are filled.

STEP 4 COOLING - the plastic parts are then allowed to

solidify in the mould.

STEP 5 OPENING - the moving platen moves away from the

fixed platen separating the mould tool. STEP 6 EJECTION - rods, a plate or air blast then aids ejection

of the completed plastic moulding from the injection mould tool.

The length of time from closing the mould to ejecting the finished plastic moulding is the cycle.

Simple shapes to reduce tooling cost• No undercuts, etc.

Draft angle to remove part• In some cases, small angles (1/4) will do• Problem for gears

Even wall thickness Minimum wall thickness ~ 0.025 in Avoid sharp corners Hide weld lines

• Holes may be molded 2/3 of the way through the wall only, with final drilling to eliminate weld lines


SUB CENTRESSUB CENTRES

MSME-TR – MSME DI CAD/CAM Training Centre Swargate, Shankarshet Road, Near PMT Workshop, Pune – 411 037 Phone: (020) 24440861 Fax : (020) 24440862 Email: [email protected]

MSME DI – MSME-TR CAD/CAM Training Centre Saki Naka, Kurla – Andheri Road, Mumbai – 400 072. Phone : (022) 28576090, 28573091, Fax No. (022)28570663Email: [email protected]

PUNE

MSME-TR - MSME DI CAD/CAM Training Centre‘C’ Block C.G.O.Complex, Seminary HillsNagpur : 440 006, Email: [email protected] 0712-6450688, 2513095, Fax: 0712-2511985

NAGPUR

MUMBAI

In this institute I learned lot of thing practically but as related to my theory concept.

I understood how design is going to relate manufacturing .

I saw how to behave in company or institute like this.

And thankful for those persons who helped me lot.

IGTR report

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