Presentation on Practical Training taken at
HMT Machine Tools Ltd., Ajmer.
Siddharth BhatnagarB2-147
12ESKME417
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Company Profile
• HMT Machine Tools Ltd. was Incorporated in 1953 by Govt. of India as a Machine Tool Manufacturing Company.
• Established for the purpose of making India self-reliant in manufacture of precision Grinding Machines.
• Over the years diversified into Watches, Tractors, Printing Machines, Metal Forming Presses, Die Casting, Machinery, CNC System & Bearings.
• HMT comprises 6 subsidiaries under the ambit of a holding co., which also manages the tractors business directly.
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Company Profile (Ajmer Unit)
• HMT Machine Tools Limited, Ajmer was established as Machine Tools Corporation of India Ltd. In 1967.
• It was established in collaboration with Skoda Exports Ltd., Czechoslovakia and subsequently with WMW & GDR, East Germany.
• Ajmer unit was merged with HMT Ltd. in 1975 & from April 1, 2000 it became a unit of HMT Machine Tools Ltd., a wholly owned subsidiary of HMT Ltd, a GoI undertaking.
• The unit is situated over 178 Acres of Land, out of which 62 acres are for factory campus & 116 acres for township.
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Awards
• National Productivity Award, in Machine Tools category for the year 1986-87.
• National Award for R & D efforts in Mechanical Engineering Sector in1990.
• HMT Ajmer was the first unit to receive ISO-9001 Certification in Rajasthan and second in HMT Units in the country.
• Conferred upon CMTI-Trust award for the best innovative design of the year.
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Vision & Mission
Vision
To be the World's largest and most admired CNC Grinder Manufacturing Company.
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Vision & Mission
Corporate Mission
• To establish ourselves as one of the world’s premiere companies in the engineering field having strong international competitiveness.
• To achieve market leadership in India through ensuring customer satisfaction by supplying internationally competitive products & services at most affordable prices.
• To achieve sustained growth in the earnings of the group on behalf of shareholders.
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Workplace Management
Workplace Management is carried out via 5-S tool:
• Shitsuke: Discipline.• Seiketsu: Standardization.• Seiso: Cleanliness.• Seiton: Neatness.• Seiri: Organisation.
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Departments of the Company
Major Departments of the Company are:
• Manufacturing.• Assembly.• Foundry.• Maintenance.• Inspection.• Human Resources.
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Manufacturing & Assembly
• HMT Ajmer’s manufacturing environment is highly advanced; this department looks after utilizing the latest production techniques in all phases of Manufacturing & Assembly.
• The assembly of machines is done in stages, such as sub assembly, group assembly and final assembly of individual components.
• The major sub departments associated with Manufacturing are: MM Shop, Rounds, Tool Room & HDM Shop.
• The major sub departments associated with Assembly are: GDS, GCS, GTC & Electrical Assembly.
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Manufacturing & Assembly
The different sections associated with the Manufacturing & Assembly Department are:
• Spindle Section• Turret Section• Round Section• Gearing Section • Non Round Section• Sheet Metals Section
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Manufacturing & Assembly
The different Operations performed at the Manufacturing & Assembly Department are:
• Marking.• Vertical Milling.• Drilling.• Fitting.• Grinding.
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Foundry
• Foundry produces Metal Castings and it’s the Initiation process in the whole Fabrication of the Machines and their components.
• Metals are cast into shapes by melting them into a liquid, pouring the metal in a mold, and removing the mold material or casting after the metal has solidified as it cools.
• The most common metals processed are Aluminum and Cast Iron other metals, such as Bronze, Brass, Steel, Magnesium, and Zinc, are also used to produce castings.
• Parts of desired shapes and sizes can be formed.
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Foundry
Pattern Making
• Patterns provide the exterior (mould) or interior (core) shape of the finished casting and are produced in wood, metal or resin for use in sand mould and core making.
• Patterns are usually made in two halves.• It is a direct duplication, pattern very closely conforms to the
shape and size of the desired casting, except for a few variations due to the necessary allowances.
• Wood, Metal, Thermo-col, Rubber & Epoxy resins are the commonly used Patterns.
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Foundry
Sand Mould & Core Making
• Sand casting is the most common production technique, especially for ferrous castings.
• Sand is mixed with clay and water or with chemical binders and then packed or rammed around the pattern to form a mould half.
• The two halves are joined together to make the mould - a rigid cavity that provides the required shape for the casting.
• The finished cores, which can be solid or hollow, are inserted into the mould to provide the internal cavities of the casting.
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Foundry
Metal Melting
• Molten metal is prepared in a variety of furnaces, the choice of which is determined by the quality, quantity and requirement.
• Electric Induction Furnaces are the most common type used for batch melting of ferrous, copper and super alloys.
• This method involves the use of an electrical current surrounding a crucible that holds the metal charge.
• Furnace sizes range from < 100 kg up to 15 Tonnes.
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Foundry
Metal Melting
Specifications of 1.5 Tonne Furnace
• Line Voltage : 11000 Volts• Primary Voltage : 440 Volts• Power Voltage : 440 KW• Power Rating : 5 KA• Melting Power : 1 Tonne per Hour• Frequency : 50 Hz• Lining Thickness : 95 mm• Power Factor : 0.9
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Foundry
Other Foundry Processes
• Casting & Separation.• Removal of Runners & Risers. • Finishing.• Sand Recovery & Reclamation.
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Major Achievements
• Development of 8 axes CNC Crank Shaft Journal & Pin Grinding Machine as Import Substitution.
• CNC Heavy Duty Internal Grinding machine model GI400(SPM) for grinding carbide bush ID up to 400mm with diamond grinding wheel.
• CNC Heavy Duty Vertical spindle reciprocating table surface grinding machine for grinding locomotive equalizer beams.
• CNC Centre-less grinding machine for grinding bearing race dia. up to 300 mm as import substitution.
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Customers
• Automotive Sector: Bajaj Auto, Ford India, Hyundai Motors, Ashok Leyland.
• General Engineering: Videocon, Godrej, TI Diamonds, Voltas, Indian Railways.
• Defense: Kanpur Ordnance Factory, HAL, Jabalpur Vehicle Factory, Nuclear Fuel Complex.
• Bearing Industries: NEI Bearings, Timken India, NRB Bearings, KCI Bearings.
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