A Centre of Excellence for Grinding Solutions

PRACTICAL TRAINING REPORT

FROM 24th May 2012 TO 25th June 2012

Submitted By:

AJAY KUMAR SAMARIYA

(GLOBLE INSTITUTE OF TECHNOLOGY)

IV year (MECHANICAL)

ACKNOWLEDGEMENT

We feel profound happiness in forwarding this industrial training report as an image of sincere

efforts. It is almost in evitable to ensure indebt ness to all who generously helped by sharing their

valuable experience & devoting their precious time with us, without whom this industrial

training report would never have been accomplished.

I am highly indebted to HMT TRAINING INCHARGE for providing us with the

opportunity of industrial training such reputed and leading industry where we were not only

trained in technical aspects but also on human grounds. We also thanks to the staff of the

industry who, throughout the visit guided us their valuable guidance is indeed praiseworthy in

the entire process.

AJAY KUMAR SAMARIYA

B.Tech , Final Year , ME

PREFACE

Engineering student gets theoretical knowledge only through their books.

Only theoretical Knowledge is not sufficient for absolute mastery in any field. Theoretical

knowledge given in our book is not of much use without knowing its practical implementation. It

has been experienced that theoretical knowledge is volatile in nature; however practical

knowledge makes solid foundation in our mind.

To accomplish this aspect the Rajasthan Technical University has included Industrial training for

the student of degree in the ending of VI semester. We accomplished our Industrial training on

24th

May 2012 to 25th

June 2012 succeeding chapters give details about what we have learnt

from the prestigious Organization.

CONTENTS:-

Introduction

HMT at a glance

Different departments of HMT

HMT Grinding Solutions

Cylindrical grinding machines

Important parts

Applications

Major customers

Major achievements in last five years

Chapter-1 INTRODUTION

When India achieved independence in 1947, there was hardly any industrial base

in the country. Right form the prior H.M.T. has played an important role in providing the

much needed industrial base as well as a launching pad for the growth & development of

the country.

HMT was conceived by the Government of India in 1949, and was incorporated

in 1953, with the objective of producing a limited range of machine tools, required for

building an industrial edifice for the country.

HMT Limited was established in 1953 in technical collaboration with M/s

Orleikon of Switzerland. Over the years, new products have been added to its

manufacturing range. It has technical collaboration with over 30 leading International

Engineering Companies for manufacture of various products HMT’s diversified product

range includes Machine Tools, Watches, Tractors, Printing Machine Press, Di-Casting

and Plastic Injection, Moulding Machines, Food Processing Machinery, CNC Systems,

Bal Screws etc.

This Unit was established as Machine Tool Corporation of India limited in

January 1964 keeping in view the Government Policy of differing new industries in under

developed areas of the country and achieving self reliance in production of Grinding

Machine Tools which were imported.

This Unit was started 1970-71 with a production of Rs. 8.64 Lack faces with

difficulty in procurement of quality Machine Tool Casings a captive Foundry Plant was

installed in 193 with a capital of about Rs.2 Crore.

This Unit was subsequently merged with HMT Ltd. On 1st April 1975 as sixth

Machine Tool Plant with this merger; the Unit got backup support of HMT. The basic

plant was established with the collaboration of the Czechoslovakian firms, M/s Skoda

Export, Praha and German firm WMW, then in East Germany.

1.1 HMT AT A GLANCE

Date of Registration 11-01-1967

Commencement of Production 1970-71

Merger with HMT 1-04-1975

Capital Employed (as on 1.4.2007) 201 Lacs.

Land Area –Total 178 Acres

Plant Foundry 62 Acres

Township 116 Acres

Covered Area (Plant) 31848 Sq. M.

No. of Quarters 136

Power Required 4.00 Lacs Units/Month

No. of Employees (as on 01.04.2011) 381

No. of Machines 250

ISO-9001 Certified 1994

Unit situated area 178 acres

[62 acres : For factory campus

166 acres : for township

136 quarters : for housing its employees]

Cost of Machines working in the unit 6 Lacs up to 1 CR.60 Lacs

No. Of machine shops 180

Working shifts 4

[‘A’ shift - (6.00am to 2.00pm)

‘B’ shift - (2.00pm to 10.00pm)

‘C’ shift - (10.00pm to 8.00am)

1.2 DIFFERENT DEPARTMENTS OF HMT

1.2.1 Human Resource Department:

Headed by Joint General Manager (HRM) this department is setup with an aim of

conservation and proper utilization of human resources and is also responsible for

maintaining the cordial relations between employees and management. The other important

functions of this department are performance appraisal and different welfare activities for

the employee.

1.2.2 Foundry Department:

Headed by JGM Foundry. This department is administratively under HMT Ajmer,\

but functionally under executive director.

1.2.2.1 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.

1.2.2.2 Sand mould and 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, as shown in Fig.

6 below.

Variations on this technique include the use of plaster in place of sand and the recently

invented Patternless process (CDC 2000), where the mould is machined directly out

of a sand block without the need for a pattern.

Cores are produced by blowing, ramming or in heated processes, investing sand into a

core box. The finished cores, which can be solid or hollow, are inserted into the mould

to provide the internal cavities of the casting before the mould halves are joined. Sand

cores are also widely used in diecasting, where permanent metal moulds are employed.

1.2.2.3 Metal melting

Molten metal is prepared in a variety of furnaces, the choice of which is determined by

the quality, quantity and throughput required.

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.

For production of super alloys and titanium, melting may be undertaken in a vacuum

chamber to prevent oxidation

1.2.2.4 Casting and separation

Molten metal is poured into moulds using various types of ladles, or in high volume

production, automated pouring furnaces. Metal is poured into the “runner” (a channel into

the mould cavity) until the runner bush is full. The “riser” provides an additional

reservoir of feed metal to counteract the shrinkage that occurs as the casting begins to

cool.

When the metal has cooled sufficiently for the casting to hold its shape, it is separated

from the mould by mechanical or manual methods. Where sand moulds are used, the

process is often referred to as shakeout or knockout, and large amounts of dust may be

generated

1.2.2.4 Removal of runners and risers

After casting, these extraneous pieces of metal are removed and often collected for re-

melting. In ferrous castings and larger non-ferrous castings, they may be removed by

knocking off, sawing or cutting using an arc air or oxy-propane torch. In die-castings,

they are often snapped off manually.

1.2.2.5 Finishing

A range of finishing processes is usually undertaken. These include:

♦ cleaning to remove residual sand, oxides and surface scale, often by shot or tumble

blasting;

♦ heat treatment, including annealing, tempering, normalising and quenching (in

water or oil) to

enhance mechanical properties;

♦ removal of excess metal or surface blemishes, (e.g., flash resulting from incomplete

mould

closure or burrs left from riser cut-off), by grinding, sawing or arc air (oxy-propane

cutting);

♦ rectification of defects by welding;

♦ machining;

♦ non destructive testing to check for defects;

♦ priming, painting or application of a rust preventative coating.

1.2.2.6 Sand recovery and reclamation

The industry recycles a large proportion of mould and core making sand internally for

re-use. This involves processing to remove tramp metal and returns the sand to a

condition that enables it to beused again for mould or core production

1.2.3 Manufacturing and Assembly Department:

Headed by JGM (manufacturing). HMT Ajmer’s manufacturing environment is highly

advanced; this department also looks after utilizing only the latest production

techniques in all phases of manufacturing maintenance. This assembly of machine is

done stages, much as sub assembly. Group assembly and final assembly of individual

components. There subassemblies after inspection pass on group assembly, which

consists of head stock assembly, saddle, gearbox, tail stock assemblies etc. this group

then reaches to the final assembly to be fitted on the bed. Electrical are also inter faced

and the machine is ready for final testing and printing of plant and equipment.

1.2.4 Service & Inspection Department:

Headed by DGM. This department is responsible for inspection & Servicing of the

M/C’s. This department is concerned with the inspection of various components and

machines being manufactured. The inspection is carried out in various stages, beginning

from the inspection of individual components at different stages of manufacturing

followed by the inspection of the whole machine while included final runs etc.

Inspection of incoming material is also handled.

1.2.5 Materials Department:

Headed by JGM. It is responsible for all kinds of purchases made by unit. This

department also maintains a Central store and looks after appropriate levels.

1.2.6 Planning Department:

Headed by JGM(EQ). The main functions of the planning department are as under: -

Time calculations for each operation. Job card booking of workers in shifts.

To prepare monthly progress reports for the production activities carried out in shop.

To calculate manpower and machines available, accordingly new machines are ordered

and component.

Counting of products and components.

Prepare machines and sectional layouts

1.2.7 Design Department:

Headed by JGM. Its functions are: -

Design & development of products.

Vendor development for new items.

Drawing of component, group assembly, special assembly etc. along with master part

list (BOM) for machines.

Deciding the type of material required for each component grade such as casting alloy

etc.

Testing & trials of machines.

Marketing of special purpose machine.

1.2.8 Finance Department:

Headed by AGM Finance. The functions of this department include maintenance of all

accounts of the Company. The balance sheet is finally prepared which is sent to the

head office for the preparation of combined balance sheet. The costing section of this

dept. is responsible for the computing of each product of that the selling price may be

determined accordingly.

1.2.9 Sales Department:

is headed by JGM(Sales). This dept. is divided into 3 sections viz. Sales, Spares and

Reconditioning. These functions of sales sections are the execution of sales order and to

bid for contracts through tenders. The function of service section is to provide after

sales & also looks after customer’s complaints and supply of spares.

1.2.10 Security Department:

This is headed by Junior Security officer. Main function of this dept. is preventions of

theft, sabotage and maintenance of industrial security within the HMT compound

including Township.

1.2.11. Quality Assurance Department:

Dy. General Manager heads this department. This department also looks after the

feedback received from marketing division so as to make improvement accordingly

1.3 HMT Grinding Solutions:-

CNC Cylindrical Grinding Machines

Small / Medium / Heavy duty

Cam shaft Grinder

Crank shaft Grinder (Medium & Heavy Duty)

CNC Centreless grinding Machines

CNC Double Disc Grinding Machines

CNC Internal Grinding Machines

CNC Surface Grinding Machines

CNC Turning Centre

CNC Training Machines

1.3.1 CYLINDRICAL GRINDING MACHINES

1.3.1.1 K 130 CH -130/150, CD- 300/500/800/1000 (ANUBHAV)

MACHINE FEATURES

Bed made of high tensile strength cast iron, heavily ribbed for better vibration damping

and shock absorption.

Precision, widely placed V & flat guideways for table with continuous automatic

lubrication. Turcite lining for G17.

Grinding wheel head spindle runs in a high precision hydrodynamic bearing.

Higher powered wheel head for production model for high rate of stock removal.

Spindle is nitrided and super finished for reliability and life.

Precision, V & Flat guideways with turcite for infeed slide for better damping & higher

repeatability.

Automatic infeed at table reversal for traverse grinding operation.

Auto plunge grinding cycle consisting of rapid approach, coarse feed, fine feed, spark out

and rapid retraction.

Single piece robust construction with long guided sleeve for better rigidity of tailstock.

Independent drive for internal grinding attachment.

Single push button control cycle.

1.3.1.2 G 17 CH- 175/225, CD- 800. 120 (APURVA)

MACHINE FEATURES

Infeed and table guideways lined with turcite B

Two axes CNC controlled external cylindrical grinding machine with Siemens / Fanuc

CNC System

Both axes are driven by preloaded ball screw and servo motor

Linear and circular interpolation

Machine system Metric or Inch

Input system Metric or Inch

Position measuring system - incremental encoders

Variable pulse weighing

One machine home position per axis

Data input and output during machining

Manual data input via key board

Backlash compensation in each axis

U-MODEL:

With Internal grinding machine

Swiveling wheel head

Work head with rotating spindle with antifriction bearing

Wheel head motor power is 4KW

P-MODEL:

Fixed wheel head

Work head with nonrotating spindle

Wheel head motor power is 5.5KW

1.3.1.2 CGM-175 CNC

\

1.3.1.3 CGM -225 CNC AH

1.3.1.4 CNC CYLINDRICAL GRINDING MACHINE

Offers economic solution for cylindrical grinding applications and angular head grinding

applications.

Can be used for grinding of crankshaft journals in automatic cycle with auto positioning.

Inprocess gauge (optional) controls the finished size

DIFFERENT PARTS

ANGULAR WHEEL HEAD

TAIL STOCK

INPROCESS GAUGE

HYDRAULIC AND COOLANT SYSTEM

CONTROL PANEL

WHEEL HEAD DRIVE

TOUCH PROBE

PNEUMATICS FOR INPROCESS GAUGE

1.3.1.5 Cylindrical Grinding machine at a glance

1.3.1.3CYLINDRICAL GRINDING APPLICATIONS

1. Component : Syringe Needle

Material : Stainless Steel Tube

Hardness : 35 – 40 HRC

Grinding Allowance : 0.8 mm

(sharpening)

No. of setups : One

Achievable Accuracies:

Surface Finish : 0.2 µRa

Production Rate : 15,000 pcs/hr

Loading & Unloading : Manual

2. Component : Collar Bush

Material : Case Hardening Steel

Hardness : 60 – 62 HRC

Grinding Allowance : 0.3 mm on dia.

No. of setups : One

Achievable Accuracies:

Size Tolerance : 63.66 h5 & 75.5 h5

Circularity : 0.003

Surface Finish : 0.4 µRa on OD

0.6 µRa on face

Production Rate : 60 pcs. /hr

Loading & Unloading : Manual

3. Component : Crank shaft

Material : Grey cast iron

Hardness : 170 -210 HB

Grinding Allowance : 0.1 mm on Face

No. of setups : One

Achievable Accuracies:

Surface Finish : 0.8 - 1.6 µRa

Face runout : 0.035 mm

Production Rate : 60 pcs / hr

4. Component : Bearing Inner Race

Material : Bearing Steel

Hardness : 60 – 62 HRC

Grinding Allowance : 0.3 mm

No. of Grinding setups : One

Achievable Accuracies:

Size Tolerance : + 0.008

Circularity : 0.003

Cylindricity : 0.005

Surface Finish : 0.4 µRa

Production Rate : 40

Loading & Unloading : Manual

5. Component : Fan Shaft

Material : M 5

Grinding Allowance : 0.3 mm

No. of Grinding setups : One

Achievable Accuracies:

Size Tolerance : IT 7 w/o In- process Gauge

IT 5/ IT 6 with in-process Gauge

Circularity : 0.002

Cylindricity : 0.005

Surface Finish : 0.4 – 0.8 µRa

Production Rate : 90 pcs / hr

6. Component : Crank shaft

Material : Grey cast iron

Hardness : 170 - 210 HRB

Grinding Allowance : 0.3 mm

No. of Grinding setups : One

Achievable Accuracies:

Size Tolerance : 0.007

Circularity : 0.0025

Surface Finish : 0.35 µRa

Production Rate : 70 Pcs/ hr

7 Component :Bearing Inner race

Material : Bearing Steel

Hardness : 60 - 62 HRC

Grinding Allowance : 0.3 mm on OD

0.1 mm on face

No. of Grinding setups : One

Achievable Accuracies:

Size Tolerance : IT 7

Circularity : 0.003 – 0.004

Surface Finish : 0.4 µRa on OD

0.6 µRa on face

Production Rate : 50 pcs/hr

Major customers:-

Automobile Sector:-

Bajaj Auto

Ashok Leyland

Hero Honda

Honda, Thailand

Honda Motorcycles & Scooters India Ltd.

Mahindra & Mahindra

TELCO

Maruti

Premier Automobiles

Escorts Ltd,

HMT Tractors

Punjab Tractor

Ford India

LML

Hyundai Motors

TV

Auto- Ancillary:-

Kirloskar Toyada textile machinery

Shriram Piston & Rings

Munjal Showa

Gabriel India Ltd.

Mushashi Auto Products

Escorts

MICO

Bajaj Motors

Cooper Metals

International Tractors

Greaves Cotton Ltd.

SRMT

Sona Steering

Pricol

Kalyani Brakes

TATA Yutaka

Automax Industries (Omax Auto)

General Engineering:-

TI Diamonds

AUDCO

Assam Carbon Ltd.

BPL

Videocon

Voltas

Godrej

Kirloskar Copeland

Himson Textiles

Bearing Industries:-

Timken India

HMT Bearing

SKF Bearing

NRB Bearings

KCI Bearings

NEI

Defence:-

Ordnance Factory Ambernath, Khamaria, Ambajari, Katni, Kanpur

V.F & GCF Jabalpur,

MSF Ishapore

Nuclear Fuel Complex (NFC)

H.V.F. Avadi

A.H.Q

Base Repair Depot (BRD)

HAL

Army Base Workshops (ABW)

MAJOR ACHIEVEMENTS IN LAST FIVE YEARS (IN HOUSE DEVELOPMENT)

Development of 8 axes CNC CRANK SHAFT JOURNAL AND PIN GRINDING MACHINE as Import Substitution.

CNC Centreless grinding machine for grinding bearing race dia. upto 300 mm as import substitution.

CNC Heavy Duty Vertical spindle reciprocating table surface grinding machine for grinding locomotive equalizer beams to M/s.CLW, Chittaranjan.

CNC Heavy Duty Cylindrical grinding machine with 3000kg weight capacity, swing 840mm & ABC 3000mm . Highest value order executed in history of MTA as import substitution at a price of Rs.330 lakhs for BHEL Haridwar.

CNC Heavy Duty Internal Grinding machine model GI400(SPM) for grinding carbide bush ID up to 400mm with diamond grinding wheel for M/S Flow Serve, Chennai.

CNC Heavy Duty Double Disc Grinding machine with Shot Gun Type Feeder for Grinding both faces of Large bearing races as import substitution for M/s Timken, Jamshedpur.

Robotics loading and un loading of con rods on CNC double disc grinding machine to M/s.Mushashi Auto, Gurgaon.

PLANS FOR 2012-13

Particulars ACTUAL ESTIMATE GROWTH(%)/ PLAN FOR

2010-11 2011-12 VARIATION 2012-13

Value in ` Lakhs

Production 1945 2836 46 4000

Sales (I) 2162 2624 21 3942

Sales (X) 47 77 64 58

Sales (T) 2209 2701 22 4000

Gross Margin (PBDIT) -505 116 +621 L 657

Opening Pending Orders 4013 5434 +1421 L 5434

No. of employees 381 332 (-) 49 -

Thank you

HMT Machine Tools

Limited,AJMER