1. Govt. Engineering College Bikaner (An Autonomous Institution of Govt. of Rajasthan) A PRESENTATIONON VOCATIONAL TRAINING AT INDO DANISH TOOL ROOM , JAMSHEDPUR By : By Dept. of Mechanical Engineering Gaurav Gunjan B. Tech. (Final Year) Dept. of Mechanical Engineering1

2. ABOUT IDTR:- Indo Danish Tool Room, Jamshedpur was established in 1991 by Government of India under the assistance of Govt. of Denmark. Their main objective is to provide consistent, reliable, quality service for industrial growth based on its trained, skilled and innovative manpower capabilities backed by the state of the art tool room facilities and provide trained manpower (through long & short term training). They undertake Design and Manufacturing of Jigs, Fixtures, Gauges, Die Casting Dies, Press Tooling and Plastic Moulds for the Automobile and Engineering Sectors and machining of precision components. MSME Tool Room and Training Centre, Jamshedpur (IDTR) is a Government of India Society, Under Ministry of MSME

3. To impart long-term and short-term training to youngsters in the fieldof Tool & Die making course with the latest technologies (and otherallied Engineering trades) both for freshers and personnel alreadyengaged in this field.To provide Consultancy Services primarily to Small scale Units in thefield of Tool Engineering aimed at improving the productivity of theSmall Scale UnitsTo design and manufacture Moulds, Tools, Dies, Jigs Fixtures etc ofhigh precision quality.To provides common facility services in precision machining / heattreatment and other technical engineering know-how in tooling toSmall Scale Industries in the Country.

4. DEPARTMENTS:-Design & Manufacturing:Design and manufacture of precision dies and tools, moulds, jigs & fixtures,gauges etc. and their appropriate use and maintenance.Tool manufacturing using latest technology.Tool related innovations for improved product design using Rapid PrototypingTechnology.Precision machining and Heat Treatment.Consultancy & Others:Product & Process Development.Productivity/ Quality improvement.Training Program/Course curriculum development for training institutes.Execution of Turn-key projects.Vacuum Heat Treatment.Productivity/ Quality improvement.Inspection and calibration facilities.

5. Partners:-SIEMENSIDTR offers following training program in collaboration withSIEMENS:--CNC COMMISSIONING & MAINTENANCE.AC SERVO DRIVE COMMISSIONING & MAINTENANCE.CNC PROGRAMMING & OPERATION (SinuTrain).IGNOU, New DelhiIDTR offers Certificate Course on Motorcycle Service andRepairing in collaboration with IGNOU and Hero-Honda.

6. CustomersOur Valued Customers are:TATA MOTORS, Jamshedpur. JMT LIMITED, Jamshedpur.TATA MOTORS, Pune. LUCAS TVS, CHENNAI.Tata Cummins, Jamshedpur. NIKUNJ, MUMBAI.TTL, Jamshedpur. MARUTI UDYAG LIMITED, CHENNAI.TELCON, Jamshedpur. HIGHCO ENGINEERS, Jamshedpur.TELCON, Kharagpur RAMAKRISHNA FORGE LIMITED, Jamshedpur.IAL Jamshedpur. JINDAL STEEL & POWER LIMITED, RAIPUR.Makino India Pvt Ltd. Bengaluru. CTM India Ltd.TIMKEN CHENNAI. Cross Manufacturing Pvt.Ltd. Jamshedpur.CAPARO Jamshedpur. Steel Strips Wheels Ltd. Jamshedpur.VIP NASIK. Rasandik Engineering, Delhi.ARVIND ENGINEERING KOLKATA. MINDA Industries Ltd. Gurgaaon.HINDUSTHAN MOTORS KOLKATA. Metalsa, Jamshedpur.ENDURENCE ENG.LTD. TVS Lucas, Chennai.SONA GROUP CHENNAI. Bharat Heavy Engineering Ltd.ARUN MOULD,MUMBAI. Delhi Metro Rail Corporation.HVTL, Jamshedpur. McNally Bharat Engineering Company Ltd. JOST ,Jamshedpur.

7. CNCMACHINES

8. Computer Numerical Control (CNC) The idea of computer numerical control is to position a computer right at the machine tool.The introduction of CNC machines radically changed the manufacturing industry. Curves are as easy to cut as straight lines complex 3-D structures are relatively easy toproduce, and the number of machining steps that required human action have been dramatically reduced.

9. Advantages:-Reduces tooling costsReduces layout timeIncreases machine and tool lifeReduces storage problemsLess setup timeReduces actual machining time Allows rapid designchanges in part Less jigs and fixtures are neededAvoids human errorsComplex geometry is produced as cheaply as simpleones

10. 10Hardware Configuration of CNC Mechanical Engineering Ken YoussefiMachine Department Machine Control Unit (MCU) the brain of the NC machine. The Data Processing Unit (DPU) reads the part program. The Control Loop Unit (CLU) controls the machine tool operation.

11. NUMERICAL DATA (NC CODE) NUMERICALMANUFACTURING CONTROLLER OPERATOR Drive Control PROCESSED PART MACHINE UNIT 11

12. HOW CNC WORKS:- Controlled by G and M codes. These are number values and co-ordinates. Each number or code is assigned to a particular operation. Typed in manually to CAD by machine operators. G&M codes are automatically generated by the computer software.

13. ELECTRICAL DISCHARGE MACHINE - EDMDie-sinking EDM systems, the electrode (cutting tool) and workpiece are held bythe machine tool. The power supply controls the electrical discharges andmovement of the electrode in relation to the workpiece. During operation theworkpiece is submerged in a bath of dielectric fluid (electrically nonconducting).(Die-Sinking EDM is also called Sinker, Ram-Type, Conventional, Plunge orVertical EDM)MECHANICAL ENGINEERING DEPARTMENT Ken Youssefi 13

14. EDM DIE-SINKING (PLUNGE) During normal operation the electrode never touches the workpiece but is separated by a small spark gap. The electrode (plunger) can be a complex shape, and can be moved in X, Y, and Z axes, as well as rotated, enabling more complex shapes with accuracy better than one mil. The spark discharges are pulsed on and off at a high frequency cycle and can repeat 250,000 times per second. Each discharge melts or vaporizes a small area of the workpiece surface. The amount of material removed from the workpiece with each pulse is directly proportional to the energy it contains. Plunge EDM is best used in tool and die manufacturing, or creating extremely accurate molds for injection- molding plastic parts.

15. EDMThe EDM process can be used on any material that isan electrical conductorThe EDM process does not involve mechanicalenergy, therefore, materials with high hardness andstrength can easily be machined. Applications include producing die cavity for large components, deep small holes, complicated internal cavities

16. EDM DIE-SINKING (PLUNGE) During normal operation the electrode never touches the workpiece but is separated by a small spark gap. The electrode (plunger) can be a complex shape, and can be moved in X, Y, and Z axes, as well as rotated, enabling more complex shapes with accuracy better than one mil. The spark discharges are pulsed on and off at a high frequency cycle and can repeat 250,000 times per second. Each discharge melts or vaporizes a small area of the workpiece surface. The amount of material removed from the workpiece with each pulse is directly proportional to the energy it contains. Plunge EDM is best used in tool and die manufacturing, or creating extremely accurate molds for injection- molding plastic parts.

17. FLOW OF COMPUTER-AIDEDCNC PROCESSING Develop or obtain the 3D geometric model of the part, using CAD. Decide which machining operations and cutter-path directions are required (computer assisted). Choose the tooling required (computer assisted). Run CAM software to generate the CNC part program. Verify and edit program. Download the part program to the appropriate machine. Verify the program on the actual machine and edit if necessary. Run the program and produce the part.

18. CNC MACHINESMachining Centers, equipped with automatic tool changers, arecapable of changing 90 or more tools. Can perform milling, drilling,tapping, boring on many faces. MECHANICAL ENGINEERING DEPARTMENT Ken Youssefi 18

19. TOOLS:-- Most are made from high speed steel (HSS), tungsten carbide or ceramics. Tools are designed to direct waste away from the material. Some tools need coolant such as oil to protect the tool and work.

20. TOOL PATHS, CUTTINGAND PLOTTING MOTIONS Tool paths describes the route the cutting tool takes. Motion can be described as point to point, straight cutting or contouring. Speeds are the rate at which the tool operates e.g. rpm. Feeds are the rate at which the cutting tool and work piece move in relation to each other. Feeds and speeds are determined by cutting depth, material and quality of finish needed. e.g. harder materials need slower feeds and speeds. Rouging cuts remove larger amounts of material than finishing cuts. Rapid traversing allows the tool or work piece to move rapidly when no machining is taking place.

21. CNC Programming Basics Each letter address relates to a specific machine function. G and M letter addresses are two of the most common. A G letter specifies certain machine preparations such as inch or metric modes, or absolutes versus incremental modes. A M letter specifies miscellaneous machine functions and work like on/off switches for coolant flow, tool changing, or spindle rotation. Other letter addresses are used to direct a wide variety of other machine commands.

22. Conventional milling machines Vertical Milling machine architecture

23. BASIC CNC PRINCIPLES Using a vertical mill machining center as an example, there are typically three linear axes of motion. Each is given an alphabetic designation or address. The machine table motion side to side is called the X axis. Table movement in and out is the Y axis, while head movement up and down the column is the Z axis.

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