Summer internship report BHARAT ELECTRONICS LTD

36
TRAINING REPORT SIX WEEKS INDUSTRIAL TRAINING AT “BHARAT ELECTRONICS LIMITED, GHAZIABAD” In Partial Fulfilment of the degree of Bachelor of Technology In MECHANICAL ENGINEERING LOVELY PROFESSIONAL UNIVERSITY, PUNJAB SCHOOL OF MECHANICAL ENGINEERING Under the Guidance of MR.ARVIND KUMAR SUBMITTED BY: NAME: VIVEK TYAGI REG. NO.11104344 M1106 BTECH (M.E)

Transcript of Summer internship report BHARAT ELECTRONICS LTD

Page 1: Summer internship report BHARAT ELECTRONICS LTD

TRAINING REPORT

SIX WEEKS INDUSTRIAL TRAINING

AT

“BHARAT ELECTRONICS LIMITED, GHAZIABAD”

In Partial Fulfilment of the degree of

Bachelor of Technology

In

MECHANICAL ENGINEERING

LOVELY PROFESSIONAL UNIVERSITY, PUNJAB

SCHOOL OF MECHANICAL ENGINEERING

Under the Guidance of

MR.ARVIND KUMAR

SUBMITTED BY:

NAME: VIVEK TYAGI

REG. NO.11104344

M1106

BTECH (M.E)

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ACKNOWLEDGEMENT

I am highly grateful to Bharat Electronics Limited Ghaziabad, one of the leading defence

organizations of the nation, for providing me an opportunity to undertake six weeks training

at their manufacturing premises at Ghaziabad, Uttar Pradesh. It was a great learning

experience as I was introduced to various aspects of the working of the organization, the

latest state of the art technologies & machines used in the manufacturing processes. It was

wonderful to see the company striving hard to keep up the national security at par with the

rest of the world. I would like to express my sincerest gratitude towards Mr.Yogendra Kumar

Sara swat (MANAGER) and Mr.Ravindra Kumar (DGM FABRICATION) for their regular

support and guidance that helped me in successful completion of my six weeks training. At

the end I would like to thank all the staff members of BEL, Ghaziabad who made this training

a rich learning experience.

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PREFACE

With the on-going revolution mechanical engineering where innovations are taking at the

blink of eye, it is impossible to keep the pace with the emerging trends. Excellence is an

attitude that whole of human race is born with. It is the environment that makes sure that

whether the result of this attitude is visible or otherwise. A well planned, properly executed

and evaluated industrial training helps a lot including a professional attitude. It provides a

linkage b/w the student and industry to develop an awareness of industrial approach to

problem solving, based on broad understanding of process and mode of operation of

organization.

During this period, the student gets the real experience for working in the actual industry

environment. Most of the theoretical knowledge that has been gained during the course of

their studies is put to test here. Apart from this the student gets an opportunity to learn the

latest technology, which is immensely helps in them in building their carrier.

I had an opportunity to have a real experience on many ventures, which increased my sphere

of knowledge to great extent. I got a chance to learn many new technologies and was also

interfaced to many instruments.

And all this credit goes to organization Bharat Electronics Ltd.

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ABOUT

BHARAT ELECTRONICS LIMITED

(BEL)

After Independence India had many responsibilities from basic necessity to telecomm &

defence equipment so after adoption of its constitution in 1950, the government was seized

with the plans to lay the foundation of a strong, self-sufficient Modern India. On the

industrial announced in the year 1952. It was recognized that in certain core sectors

infrastructure facilities require huge investments, which cannot be met by private sector and

as such, the idea of Public Sector Enterprise (PSE) was mooted. Under this a Professional

Electronics company in India incorporated that was front, industrial policy resolution (IPR)

was BHARAT ELECTRONICS LIMITED.

BEL was established in 1954 as a Public Sector Enterprise under the administrative

control of Ministry of Defence as the fountain head to manufacture and supply electronics

components and equipment. BEL, with a noteworthy history of pioneering achievements, has

met the requirements of state-of –art professional electronic equipment for Defence,

broadcasting, Civil Defence and telecommunications as well as the component requirement

of entertainment and medical X-ray industry. Over the years, BEL has grown to a multi-

product, multi-unit and technology driven company with track record of a profit earning PSU.

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BEL was born to meet the growing needs of Indian Defence services for electronic

systems. Employing the best engineering talent available in the country, BEL has progressed

manufacturing state-of-the-art products I n the field of Defence Electronics like

Communications including encryption, Radars and strategic components.

Over the years, BEL has diversified to meet the needs of civilian customers as well

and has provided products and network solutions on turnkey basis to customers in India and

abroad.

With the Research & Development efforts, its engineers have fructified it into a

world-class organization. The company has a unique position in India of having dealt with all

the generations of electronic component and equipment. Having started with a HF receiver in

collaboration with T-CSF of France, the company‟s equipment designs have had a long

voyage through the hybrid, solid-state discrete component to the state-of-art integrated circuit

technology. In the component arena also, the company established its own electron

valve manufacturing facility. It moved on to semiconductors with the manufacture of

germanium and silicon devices and then to manufacture of Integrated circuits. To keep in

pace with the component and equipment technology, its manufacturing and product assurance

facilities have also undergone sea change. The design groups have CADD‟s facility, the

manufacturing has CNC machines and a Mass Manufacture Facility, and QC checks are

performed with multi-dimensional profile measurement machines. Automatic testing

machines, environmental labs to check extreme weather and other operational conditions are

there. All these facilities have been established to meet the stringent requirements of MIL

grade systems.

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Product mix of the company are spread over the entire electromagnetic (EM)

spectrum ranging from tiny audio frequency semiconductor to huge radar systems and X-ray

tubes on the upper edge of the spectrum. Its manufacturing units have special focus towards

the product ranges like Defence Communications, Radars, Optical & Opto-electronics,

Telecommunications, Sound and Vision broadcasting, Electronic components, etc.

Besides manufacturing and supply of a wide variety of products, BEL offers a variety

of services like Telecom and Radar Systems Consultancy, Contract Manufacturing,

Calibration of test& measuring instruments, etc. At the moment, the company is installing

MSSR radar at important airports under the modernization of airports plan of National

Airport Authority (NAA).

BEL has nurtured and built a strong in-house R&D base by absorbing technologies

from more than 50 leading companies worldwide and DRDO labs for a wide range of

products. A team of more than 800 engineers is working in R&D. Each unit has its own R&D

Division to bring out new products to the production lines. Central Research Laboratory

(CRL) at Bangalore and Ghaziabad works as independent agency to undertake contemporary

design work on state-of-art and futuristic technologies. About 70% of BEL„s products are of

in-house design.

Probably one of the first project of its nature in India and Asia. BEL has won a

number of national and international awards for Import Substitution, Productivity, Quality,

Safety etc.

Today, BEL has set up impressive infrastructure spread in 9 locations with 29-

production division and manufacturing facilities in their ISO-9001/9002

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BEL was amongst the first Indian companies to manufacture computer parts and peripherals

under arrangement with International Computers India Limited (ICIL) in 1970‟s. BEL

assembled a limited number of 1901 systems under the arrangement with ICIL. However,

following Government‟s decision to restrict the computer manufacture to ECIL, BEL could

not progress in its computer manufacturing plans. As many of its equipment were

microprocessor based, the company continued to develop computers based application, both

hardware and software. Most of its software requirements are in real time. EMCCA, software

intensive naval ships control and command system is certified production units around the

country. They are –Bangalore, Ghaziabad, Pune, Taloja (Maharashtra), Hyderabad,

Panchkula (Haryana), Chennai, Machilipathnam (A.P.) and Kotdwara (U.P.)

BEL has won a number of national and international awards for Import Substitution,

Productivity, Quality, Safety Standardization etc. BEL was ranked no.1 in the field of

Electronics and 46th

overall among the top 1000 private and public sector undertakings in

India by the Business Standard in its special supplement "The BS 1000 (1997-98)". This

organization also stands on number 7th

position in the best 100 public and private companies

according to the "electronic for u" in 2002. BEL was listed 3rd

among the Mini Ratna‟s

(category II) by the Government of India, 49th

among Asia's top 100 Electronic Companies

by the Electronic Business Asia and within the top 100 worldwide Defence Companies by the

Defence News, USA.

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VARIOUS UNITS

Its corporate office is at Bangalore. Bangalore complex is the BEL‟s first and largest unit and

it accounts for two-thirds of both the company‟s turnover and manpower. This unit‟s product

range covers over 300 Defence and Civilian products. Ghaziabad is the second largest unit of

BEL and it specializes in radars, communication equipments & microwave-components.

In total BEL has got 9 units. These are distributed in all over the India as:

BANGALORE (Corporate Office)

GHAZIABAD

PANCHKULA

MACHILIPATNAM

PUNE

HYDERABAD

CHENNAI

KOTDWARA

TALOJA

Besides, there are two Central Research Laboratories (CRL) located at Bangalore and

Ghaziabad, to address futuristic technologies of interest to BEL.

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Bangalore (Karnataka)

BEL started its production activities in Bangalore in 1954 with 400W high frequency

(HF) transmitter and communication receiver for the Army

The Unit has now diversified into manufacturing of electronic products for the

civilian customers such as DOT, VSNL, AIR and Doordarshan, Meteorological Dept.,

ISRO, Police, Civil Aviation, and Railways. As an aid to Electorate, the unit has

developed Electronic Voting Machines that are produced at its Mass Manufacturing

Facility (MMF).

Ghaziabad (Uttar Pradesh)

The second largest Unit at Ghaziabad was set up in 1974 to manufacture special types

of Radars for the Air Defence Ground Environment Systems (Plan ADGES).

The Unit's product range included Static and Mobile Radars, Troposcatter equipment,

professional grade Antennae and Microwave components.

PUNE:

Image convertor, image intensifier,

X-ray tubes

Batteries

Electro-optics

MACHLIPATNAM:

Optical & optoelectronic equipment like binoculars, microscopes Medical Electronics

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NAVI MUMBAI

Glass shells for black & white TV picture tubes

Shelters for Electronic Equipment

Train Actuated Warning System

Electronic Equipment Assembly

PANCHKULA

This unit manufactures only tactical communication equipment like VHF, UHF

transceivers etc.

KOTDWARA:

This is a unit in Garhwal district of Uttaranchal. This unit manufactures radio relay,

multiplex equipments & exchanges etc.

CHENNAI:

Tank related electronic equipments

Optical fire control systems

HYDERABAD:

This is another unit of BEL which manufactures electronic warfare equipment.

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CORPORATE MOTTO, MISSION AND OBECTIVES

The passionate pursuit of excellence at BEL is reflected in repulsion with its customers that

can be described in its motto, mission and objectives

CORPORATE MOTTO: “QUALITY, TECHNOLOGY AND INNOVATION”

CORPORATE MISSION: To be the market leader in Defence Electronics

and in other chosen fields and products.

CORPORATE OBJECTIVES:

(a) To become a customer-driven company supplying quality products at

competitive prices at the expected time and providing excellent customer

support.

(b) To achieve growth in the operations commensurate with the growth of

professional electronics industry in the country.

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(c) To generate internal resources for financing the investments required for

modernization, expansion and growth for ensuring a fair return to the investor.

(d) In order to meet the Nation's strategic needs, to strive for self-reliance by

indigenization of materials and components.

(e) To retain the technological leadership of the company in Defence and other

chosen fields of electronics through in-house.

(f) Research and Development as well as through collaboration/co-operation with

Defence/National Research Laboratories, International Companies,

Universities and Academic institutions.

(g) To progressively increase overseas sales of its products and services.

(h) To create an organizational culture which encourages members of the

organization to realize their full potential through continuous learning on the

job and through other HRD initiatives.

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QUALITY OBJECTIVES:

(a) Effective and Efficient design and development process, considering the

present and future needs of customers.

(b) Enhanced customer satisfaction by on-time delivery of defect free products

and effective life cycle support.

(c) Continual up gradation and utilization of infrastructure and human resources.

(d) Mutually beneficial alliances with suppliers.

e) Continual improvement of processes through innovation, technology and

knowledge management.

MAIN PRODUCT OF BEL GHAZIABAD ROHINI RADAR

Low level Light Weight 3D Radar - ROHINI: ROHINI is a multifaceted ground based S-

Band 3D Low Level Light Weight Surveillance Radar for deployment in diverse terrains like

plains, deserts, mountain tops and high altitude regions. Rohini detects and tracks

heterogeneous air targets, including helicopters, fighters and UAVs at low and medium

altitudes. The radar can scan the valley. It provides accurate range, azimuth and height

information for each target with electronically steerable multi-beam technology in elevation.

The radar sweeps 360° in azimuth and 30° in elevation to provide air space awareness. Semi -

distributed active aperture radar uses advanced VLSI and high-speed digital technologies like

high efficiency T/R modules, DDS, digital receiver and programmable signal processor to

provide 3D air space awareness with high accuracy, resolution and reliability.

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Bharat Electronics Ltd., (BEL), a premier Professional Electronics Company of India, has

established and nurtured a strong in-house R&D base over the years to emerge and remain as

a market leader in the chosen areas of business in professional electronics. Each of the nine

manufacturing units of BEL is having its own in-house R&D Division to develop new

products in its field of operations.

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AREAS OF R&D ACTIVITY

Main areas of R&D activities at BEL include development of Military Radars, Naval

Systems, Military Communication Products, Electronic Warfare Systems,

Telecommunication products, Sound and Vision Broadcasting Equipment and Systems, Opto

Electronic Products, and Electronic Components. CRL performs the dual role of carrying out

blue sky research for the development of future technologies and supporting the D&E

Divisions of BEL's nine units with state-of-the-art core technology solutions in areas like

Embedded Computers and applications, Radar Signal Processing, VLSI designs, RF &

Microwave Communication Technologies, Software modules etc.

RESOURCE AND INVESTMENT

BEL's R&D Units have state-of-the-art R&D infrastructure, facilities, and manpower

with relevant technical expertise for product development. There are about 1000 engineers

working in BEL on various D&E projects. BEL spends around 5 % of company turnover for

the year on R&D every year. HRD Divisions of BEL take adequate initiatives for the all-

round development and expertise up gradation of R&D human resources. State of the art

infrastructures, test equipment, computers & workstations, Software packages etc. are

augmented every year for the R&D divisions. BEL R&D Units are recognized by the

Department of Scientific & Industrial Research under the Ministry of Science & Technology,

Govt. of India.

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CUSTOMER PROFILE

PRODUCTS AND SERVICES CUSTOMERS

DEFENCE COMMUNICTION INDIAN DEFENCE SERVICES,PARA-MILITARY

FORCES

RADAR AND SONARS INDIAN DEFECE SERVICE,CIVIL

AVIATION,METEOROLOGICL DEPARTMAENT

,SPACE DEPARTMENT

TELECOMMUNICATION DEPARTMENT OF

TELECOMMUNICATION,PARAMILITARY

ORCES ,POWER SECTOR,OIL

INDUSTRY,RAILWAYS

BROADCASTING EQUIPMENTS AND

STUDO SYSTEM

ALL INDIA RADIO,DOORDARSHAN

ELECTRONIC VOTING MACHINE ELECTION COMMISSION OF INDIA

SOLAR PRODUCT AND SYSTEMS INDIVIDUALS,PRIVATE AND GOVERNMENT

ORGANISATIONS

TURNKEY SYSTEMS,E-GOVERNANCE

NETWORKS

POLICE,STATE GOVERNMENTS,PUBLIC

SECTOR UNDERTAKING

COMPONENTS TV BROADCASTERS,INSTRUMENTATION

NDUSRTY,SWITCHING

INDUSTRY,ENTERTAINMENT

INDUSTRY,TELEPHONE INDUSTRY

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DEPARTMENTS & FUNCTIONS

BEL Ghaziabad has different divisions which are further divided into departments-

1. D&E (Development and Engineering)

This is a division which is further divided into departments. They are:

D&E (DEVELOPMENT & ENGINEERING) – It is to design the project, make the

modifications to prepare design and related documents.

D&E CRYPTO – It is for designing of secure communication.

TIC (Technical Information Centre) – TIC is a library for designing purpose.

DRA OFFICE - It is the Drawing office.

STDS (STANDARDS) –These are the standards for Drafting, Design manure, Quality

standards.

2. MFG (MANUFACTURING):

WA (WORK ASSEMBLY) – There are different types of work assembly i.e. PCB

assembly, Module assembly, Final assembly.

WF (WORK FABRICATION) – It is the department for the mechanical work.

AMF (ADVANCED MANUFACTURING FACILITIES) – Advanced machines are

used in the manufacturing of the projects as SMT (Surface Mounted Technology), it is

an automatic system to mount the item on the PCB.

PE (PRODUCTION ENGINEERING) – It is for the installation of the new

machinery.

PPC (PRODUCTION, PLANNING and CONTROL) – In this the work is planned.

SC (SUB CONTRACT)

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3. MM (MATERIAL MANAGEMENT):

It is the management of the materials.

PUR (PURCHASE DEPARTMENT) - This department purchases the materials.

ISM (INTEGRATED STORE MANAGEMENT)

HS (HOLDING STORE) – It has different bins that holds items after inspection.

IGS (INCOMING GOODS STORE)

MC (MATERIAL CONTROL)

4.MKTG / PA (MARKETING / PRODUCT ASSURANCE):

MKTG (Marketing Division)

Sales – It is to prepare ESO equipment source order.

FGS (FINISH GOODS STORE) – After finishing the project it is sent to FGS for

final packing.

TL (Technical Literature) – It is the booklet with the project having instructions.

PR (PUBLIC RELATION) –It is the relation with the customers.

TESTING – Products are tested by different tests

C TEST (CIPHER TEST) - It is the test for the secrecy.

PS (PRODUCT SUPPORT) – It is done after sale services.

SELF CERT (SELF CERTIFICATION) – It is the department which visits the place

where work is going on.

5. QA (QUALITY ASSURANCE):

It deals with the quality of the material.

INSP(WA) {INSPECTION IN WORK ASSEMBLY)

INSP(WF) {INSPECTION IN WORK FABRICATION)

R&E (RELIABILITY & EVALUATION) - The materials are checked before giving

it to customers.

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6. P&S (PLANT AND SERVICES):

It is the department for providing the services to company. Services are water supply,

electrical supply, transport, horticulture.

7. HR & A (HUMAN RESOURCES & ADMINISTRATION):

PERSON. (PERSONNEL) – In this department the recruitment of employees is done.

ESTD. (ESTABLISHMENT) – It is to use manpower in different areas.

MEDICAL – Medical facilities are also available.

CRECHE

CANTEEN

WELFARE

8. F&A (FINANCE & ACCOUNT):

FINANCE - Department for the sanction of money.

PAYROLL – It is the salary of the employees.

BUDGET – It is made for one year.

ACCOUNTS – It is the record of the money.

AUDIT – Survey of the systems.

9.IS / MS (INFORMATION SYSTEMS):

MRP - All Production Related work related to assy,stores, purchase etc.

PAYROLL - Related to Salary.

FINANCE - Concerned with ledgers, sub-sidary ledgers, General ledger etc.

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10. QM (QUALITY MANAGEMENT):

ISO (INTERNATIONAL STANDARDS ORGANISATION) – It is to sell our

products in the international market.

6 SIGMA – It is the statistical Technique for maintaining Quality.

TES (TEST EQUIPMENT AND SUPPORT) – Calibration or measuring of

instruments.

IGI (INCOMING GOODS INSPECTION)

QCC (QUALITY CONTROL CIRCLE) – In this department there is a group of

employees who discuss the problems, find out its solution and present it to manager.

PRODUCTION MANAGEMENT AND CONTROL

Production Management also called operations management, planning and control of

industrial processes to ensure that they move smoothly at the required level. Techniques of

production management are employed in service as well as in manufacturing industries. It is a

responsibility similar in level and scope to other specialties such as marketing or human

resource and financial management. In manufacturing operations, production management

includes responsibility for product and process design, planning and control issues involving

capacity and quality, and organization and supervision of the workforce.

The production manager must plan and control the process of production so that it moves

smoothly at the required level of output while meeting cost and quality objectives. Process

control has two purposes: first, to ensure that operations are performed according to plan, and

second, to continuously monitor and evaluate the production plan to see if modifications can

be devised to better meet cost, quality, delivery, flexibility, or other objectives.

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WHAT INDUSTRIAL PRODUCTION MANAGER DO :

Review operations and confer with technical or administrative staff to resolve

production or processing problems.

Review processing schedules or production orders to make decisions concerning

inventory requirements, staffing requirements, work procedures, or duty assignments,

considering budgetary limitations and time constraints.

Hire, train, evaluate, or discharge staff or resolve personnel grievances.

Coordinate or recommend procedures for facility or equipment maintenance or

modification, including the replacement of machines.

Prepare and maintain production reports or personnel records.

Maintain current knowledge of the quality control field, relying on current literature

pertaining to materials use, technological advances, or statistical studies.

This sub-department forms the most important section among the others present because it

forms the ‗backbone„. Right from the beginning till the end of the production of a particular

set, the responsibility lies in the hands of this section, it mainly performs three functions

namely:-

Scheduling

Launching

Control

The market section takes the order from the customer and gives the equipment stock order to

PPC. The management servicing department prepares the work order and gives it to PPC.

Now PPC makes the list of each component involved in product. This is called

―Scheduling‖.

Next function that comes is launched PPC prepares shop order and engineering documents

such as drawings. This function is called ―Launching‖.

Now comes material control. Here the PPC keeps track of production i.e. the purchase

requisition is given to purchase department and sub-contact department. The purchase now

comes to the IGS (Inwards Goods Section) where it is tested in IGI. The pieces that are

okayed are then stored in holding stores.

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INDUSTRIAL ENGINEERING DEPARTMENT

INDUSTRIAL ENGINEERING MANAGER RESPONSIBILITIES AND

DUTIES

Analyse and evaluate efficient working of all projects and administer all processes and

methods according to required supply standards and systems.

Assist to organize and approve all labour and supply cost annually and prepare reports to

measure all labour performance.

Analyse all product costs and assist to reduce all negative variance on same and prepare

strategies to reduce labour and wastage in all engineering projects.

Assist Industrial Engineering department to design business plans and develop salary for all

employees and prepare all required reports on weekly and monthly basis and manage all

communication with production management.

Develop salary model budgets for all industrial engineering processes and provide support to

all world class manufacturing facilities and analyse all waste elimination plans and develop

appropriate factory flow analysis on processes.

Maintain and update knowledge for all manufacturing engineering processes and design all

processes for manpower and associate program and monitor all productivity and ensure

compliance to all safety standards.

Evaluate and perform investigation on all variances for all planned and actual results for

industrial processes and maintain track of all information and ensure integrity of all results

for processes.

Supervise reporting processes on everyday basis and manage everyday activities and ensure

adherence to all fiscal budgets and prepare strategic models.

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MACHINE SHOP AND ANTTENA FABRICATION

BHARAT ELECTRONCS LIMITED

THE STUDY OF CNC MACHINE IN MACHINE SHOP

Automation or automatic control is the use of various control systems for operating

equipment such as machinery, processes in factories, boilers and heat treating ovens,

switching in telephone networks, steering and stabilization of ships, aircraft and other

applications with minimal or reduced human intervention. Some processes have been

completely automated.

There are more than hundred machines in each department of Bharat Electronics Limited

which are operated my computer and some are also manually operated.

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1) CNC Lathe machine:

CNC: Computer Numerical Control

A numerical control, or “NC”, system controls many machine functions and movements

which were traditionally performed by skilled machinists.

•Numerical control developed out of the need to meet the requirements of high production

rates, uniformity and consistent part quality.

•Programmed instructions are converted into output signals which in turn control machine

operations such as spindle speeds, tool selection, tool movement, and cutting fluid f low.

•The most basic function of any CNC machine is automatic precise, and consistent motion

control.

•Rather than applying completely mechanical devices to motion as is required on most

conventional machine tool machines allow motion control in a revolutionary manner

•All forms of CNC equipment have two or more direction motion, called axes. These axes

can be precisely and automatically positioned along their lengths of travel.

•The two most common axis types are linear (driven along straight path) and rotary (driven

along a circular path).

CNC Lathe

Automated version of a manual lathe.

Programmed to change tools automatically.

Used for turning and boring wood, metal and plastic.

Controlled by G and M codes.

These are number values and co-ordinates.

Each number or code is assigned to a particular operation.

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2) CNC MILLING MACHINE

CNC milling is a specific form of computer numerical controlled (CNC) machining. Milling

itself is a machining process similar to both drilling and cutting, and able to achieve many of

the operations performed by cutting and drilling machines. Like drilling, milling uses a

rotating cylindrical cutting tool. However, the cutter in a milling machine is able to move

along multiple axes, and can create a variety of shapes, slots and holes. In addition, the work-

piece is often moved across the milling tool in different directions, unlike the single axis

motion of a drill.

CNC milling devices are the most widely used type of CNC machine. Typically, they are

grouped by the number of axes on which they operate, which are labelled with various letters.

X and Y designate horizontal movement of the work-piece (forward-and-back and side-to-

side on a flat plane). Z represents vertical, or up-and-down, movement, while W represents

diagonal movement across a vertical plane. Most machines offer from 3 to 5 axes, providing

performance along at least the X, Y and Z axes. Advanced machines, such as 5-axis milling

centres, require CAM programming for optimal performance due to the incredibly complex

geometries involved in the machining process. These devices are extremely useful because

they are able to produce shapes that would be nearly impossible using manual tooling

methods. Most CNC milling machines also integrate a device for pumping cutting fluid to the

cutting tool during machining.

Computer numeric controlled machining centres are used to produce a wide range of

components, and tooling costs involved have continued to become more affordable. In

general, large production runs requiring relatively simple designs are better served by other

methods, although CNC machining can now accommodate a wide range of manufacturing

needs. CNC milling centres are ideal solutions to everything ranging from prototyping and

short-run production of complex parts to the fabrication of unique precision components.

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3) CNC DRILLING MACHINE:

Computer Numerical Control (CNC) Drilling is commonly implemented for mass production.

The drilling machine, however, is often a multi- function machining centre that also mills and

sometimes turns. The largest time sink for CNC drilling is with tool changes, so for speed,

variation of hole diameters should be minimized. The fastest machines for drilling varying

hole sizes have multiple spindles in turrets with drills of varying diameters already mounted

for drilling. The appropriate drill is brought into position through movement of the turret, so

that bits do not need to be removed and replaced.

A variety of semi-automated drilling machines are also used. An example is a simple drill

press which, on command, drills a hole of a set depth into a part set up beneath it.

4) TURRET PUNCH (NC) MODEL: PEGA 30 40 50

MODEL SPECIFICATION

PRESS CAPACITY 30 TON

MAXIMUM TRANSVERSE (MM) 1000X11270

MAXIMUM SHEET SIZE (MM) 1000X2540

SHEET THICKNESS (AL) 6.35

STROKE/MIN 350

MAXIMUM FEED SPEED (M/MIN) 50

TURRET SPEED (RPM) 30

NUMBER OF STATION 56

AUTO INDEXING 2

ACCURACY +-0.1

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A typical CNC turret punch has a choice of up to 60 tools in a "turret" that can be rotated to

bring any tool to the punching position. A simple shape (e.g., a square, circle, or hexagon) is

cut directly from the sheet. A complex shape can be cut out by making many square or

rounded cuts around the perimeter. As a press tool requires a matching punch and die set,

there are two corresponding turrets, above and below the bed, for punch and die. These two

turrets must rotate in precise synchronisation and with their alignment carefully maintained.

Several punches of identical shape may be used in the turret, each one turned to a different

angle, as there is usually no feature to rotate the sheet work piece relative to the tool.

5) SHOT BLASTING MACHINING

Shot Blasting is a surface treatment process using high velocity steel abrasive. Shot blasting

is method through which it is possible to obtain excellent cleaning and surface preparation for

secondary finishing operations.

Shot blasting is commonly used for:

• The cleaning of iron, steel, non-cast parts, forgings, etc.

• Mechanical cleaning of sheets, rods, coils, wire, etc.

• Shot peening to alter mechanical properties (increasing resistance to fatigue for springs,

gears, etc.)

• Preparing surfaces to be painted, coated, etc.

Other than these there are also many machines that are manually operated since the cost of

one RADAR is too much therefore the machining are done by specialised workers only under

the antenna fabrication department and machine shop.

The welding section uses variety of welding technique for the manufacturing of RADAR

parts and also for assembling them as per the requirement.

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FABRICATION DEPARTMENT IN BEL

Metal fabrication is the building of metal structures by cutting, bending, and assembling

processes:

Cutting is doneby sawing, shearing, or chiselling (all with manual and powered variants);

torching with hand-held torches (such as torches or plasma torches); and via numerical

control (CNC) cutters (using a laser, mill bits, torch, or water jet).

Bending is done by hammering (manual or powered) or via press brakes and similar

tools. Modern metal fabricators utilize press brakes to either coin or air-bend metal sheet

into form. CNC-controlled back gauges utilize hard stops to position cut parts in order to

place bend lines in the correct position. Off-line programing software now makes

programing the CNC-controlled press brakes seamless and very efficient.

Assembling (joining of the pieces) is done by welding, binding

with adhesives, riveting, threaded fasteners, or even yet more bending in the form of a

crimped seam. Structural steel and sheet metal are the usual starting materials for

fabrication, along with the welding wire, flux, and fasteners that will join the cut pieces.

As with other manufacturing processes, both human labour and automation are

commonly used. The product resulting from fabrication may be called a fabrication.

Shops that specialize in this type of metal work are called fab shops. The end products of

other common types of metalworking, such as machining, metal stamping, forging,

and casting, may be similar in shape and function, but those processes are not classified

as fabrication.

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Fabrication comprises or overlaps with various metalworking specialties:

Fabrication shops and machine shops have overlapping capabilities, but fabrication shops

generally concentrate on metal preparation and assembly as described above. By

comparison, machine shops also cut metal, but they are more concerned with the

machining of parts on machine tools. Firms that encompass both fab work and machining

are also common.

Blacksmithing has always involved fabrication, although it was not always called by that

name.

The products produced by welders, which are often referred to as weldments, are an

example of fabrication.

Boilermakers originally specialized in boilers, leading to their trade's name, but the term

as used today has a broader meaning.

Similarly, millwrights originally specialized in setting up grain mills and saw mills, but

today they may be called upon for a broad range of fabrication work.

Ironworkers, also known as steel erectors, also engage in fabrication. Often the

fabrications for structural work begin as prefabricated segments in a fab shop, then are

moved to the site by truck, rail, or barge, and finally are installed by erectors.

METAL FABRICATION

Metal fabrication is a value added process that involves the construction of machines and

structures from various raw materials. A fab shop will bid on a job, usually based on

the engineering drawings, and if awarded the contract will build the product. Large fab shops

will employ a multitude of value added processes in one plant or facility including welding,

cutting, forming and machining. These large fab shops offer additional value to their

customers by limiting the need for purchasing personnel to locate multiple vendors for

different services. Metal fabrication jobs usually start with shop drawings including precise

measurements then move to the fabrication stage and finally to the installation of the final

project

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Cutting

The raw material has to be cut to size. This is done with a variety of tools.

The most common way to cut material is by Shearing (metalworking);

Special band saws designed for cutting metal have hardened blades and a feed mechanism for

even cutting. Abrasive cut-off saws, also known as chop saws, are similar to mitre saws but

with a steel cutting abrasive disk. Cutting torchescan cut very large sections of steel with little

effort.

Forming

Forming is a process of material deformation. Forming is typically applied to metals. To

define the process, a raw material piece is formed by applying force to an object. The force

must be great enough to change the shape of the object from its initial shape. The process of

forming can be controlled with the use of tools such as punches or dies. Machinery can also

be used to regulate force magnitude and direction. Proper design and use of tools with

machinery creates a repeatable form which can be used to create products for many

industries, including jewellery, aerospace, automotive, etc.

Machining

Machining is a trade, in and of itself, although Fab shops will generally entail a limited

machining capability including; metal lathes, mills, magnetic based drills along with other

portable metal working tools.

Welding

Welding is the main focus of steel fabrication. The formed and machined parts will be

assembled and tack welded into place then re-checked for accuracy. A fixture may be used to

locate parts for welding if multiple weldments have been ordered.

The welder then completes welding per the engineering drawings, if welding is detailed, or

per his own judgment if no welding details are provided.

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Special precautions may be needed to prevent warping of the weldment due to heat. These

may include re-designing the weldment to use less weld, welding in a staggered fashion,

using a stout fixture, covering the weldment in sand during cooling, and straightening

operations after welding.

Straightening of warped steel weldments is done with an Oxy-acetylene torch and is

somewhat of an art. Heat is selectively applied to the steel in a slow, linear sweep. The steel

will have a net contraction, upon cooling, in the direction of the sweep. A highly skilled

welder can remove significant warpage using this technique.

Steel weldments are occasionally annealed in a low temperature oven to relieve residual

stresses. Such weldments, particularly those employed for engine blocks, may be line-bored

after heat treatment.

The various machines that are used in the FABRICATION DEPARTMENT OF BEL are:

Shearing machine

Plate levelling machine

Bending machine

Bench Hydraulic press

Fine coordinate Drilling machine

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MATERIAL HANDLING EQUIPMENTS USED IN BEL

• Material Handling is defined as the movement, storage, protection and control of

materials throughout the manufacturing and distribution process including their

consumption and disposal.

• Material handling equipment includes:

• Transport equipment

• Storage systems

• Unitizing equipment

• Identification and tracking systems

1) Industrial Trucks

2) Fork lift rider Trucks 3) Mono rails 4) Crane 5) Towing tractors

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WORK AND MAINTENANCE DEPARTMENT IN BEL

Maintenance Engineering is the discipline and profession of

applying engineering concepts to the optimization of equipment, procedures, and

budgets to achieve better maintainability, reliability, and availability of equipment.

Maintenance engineering is increasing in importance due to rising amounts of

equipment, systems, machineries and infrastructure. Since the Industrial Revolution,

devices, equipment, machinery and structures have grown increasingly complex,

requiring a host of personnel, vocations and related systems needed to maintain them.

A Maintenance Engineer should possess significant knowledge

of statistics, probability and logistics, and additionally in the fundamentals of the

operation of the equipment and machinery he or she is responsible for.

A Maintenance Engineer shall also possess high interpersonal, communication,

management skills and ability to make quick decisions.

MAINTENANCE TYPES

Preventive maintenance, where equipment is maintained before break down occurs.

This type of maintenance has many different variations and is subject of various

researches to determine best and most efficient way to maintain equipment. Recent

studies have shown that Preventive maintenance is effective in preventing age related

failures of the equipment. For random failure patterns which amount to 80% of the

failure patterns, condition monitoring proves to be effective.

Operational maintenance, where equipment is maintained in using.

Corrective maintenance, where equipment is maintained after break down. This

maintenance is often most expensive because worn equipment can damage other parts

and cause multiple damages.

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Preventive maintenance is maintenance performed in an attempt to avoid failures,

unnecessary production loss and safety violations.

Corrective maintenance is probably the most commonly used approach, but it is easy to see

its limitations. When equipment fails, it often leads to downtime in production. In most cases,

this is costly business. Also, if the equipment needs to be replaced, the cost of replacing it

alone can be substantial. It is also important to consider health, safety and environment (HSE)

issues related to malfunctioning equipment.

Corrective maintenance can be defined as the maintenance which is required when an item

has failed or worn out, to bring it back to working order.

Corrective maintenance is carried out on all items where the consequences of failure or

wearing out are not significant and the cost of this maintenance is much greater

than preventive maintenance.

Corrective maintenance is the program focused on the regular task that will maintain all the

critical machinery and the system in optimum operating conditions. The major objectives of

the program are to

1. Eliminating breakdown

2. Eliminating deviation

3. Eliminating unnecessary repairs

4. Optimize all the critical planned system

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RESULTS & CONCLUSION

The industrial training at B.E.L. has given me an exposure of the activities of a defence unit.

This being a large organization deals with wide spectrum of technologies.

During my training in B.E.L, I came to know about working of different types of CNC or

manually operated machines .The industrial‟s environment and the working culture of

industry. The six weeks of summer training at BEL, GZB unit generated a lot more interest in

my subject.

It made me more aware of the scope of Mechanical Engineering. It has also made me

appreciative of an industrial work environment.

Undergoing training on the indoor substation has helped me integrate conceptual knowledge

with real life application. I was fortunate to have personal guidance from experienced

professionals who took been interest in explaining the working details of various equipment.

I feel that without this opportunity, my own understanding of this subject and also the

motivation to acquire more knowledge would have remained incomplete.

Well, regarding future scope I think my training has given me enough motivation and an

exposure that I will try to join defence services or get linked up with the defence of the

country.

“To know the technical know-how, industrial training is the best way to move forward.”

Page 36: Summer internship report BHARAT ELECTRONICS LTD