INDUSTRIAL TRAINING ATINDUSTRIAL TRAINING AT Opto Electronics FactoryOpto Electronics Factory,,

DehradunDehradun

PRESENTED BY:PRESENTED BY: SAURABH PASBOLASAURABH PASBOLA

ME IIME II

OVERVIEWOVERVIEW History of Opto Electronics FactoryHistory of Opto Electronics Factory Main Components of Factory Main Components of Factory Lathe Lathe Working principle of latheWorking principle of lathe Parts of latheParts of lathe Machines in Turning ShopMachines in Turning Shop Operation in Turning ShopOperation in Turning Shop Lathe AccessoriesLathe Accessories Introduction of CNCIntroduction of CNC Programming language in CNCProgramming language in CNC Advantages and Disadvantages of CNCAdvantages and Disadvantages of CNC Coolants and LubricationCoolants and Lubrication Characteristics of cutting fluids Characteristics of cutting fluids

History of Opto Electronics FactoryHistory of Opto Electronics Factory

Opto Electronics Factory (OLF)Opto Electronics Factory (OLF) established in 1988 is established in 1988 is the most advanced Opto Electronics Instruments the most advanced Opto Electronics Instruments manufacturing unit of the manufacturing unit of the Ordnance Factory BoardOrdnance Factory Board under the Ministry of Defense, Govt. of India, under the Ministry of Defense, Govt. of India,

situated in situated in lush green,lush green, hilly Dehradun hilly Dehradun valley. valley.

        A wide range of world class Optics and Opto A wide range of world class Optics and Opto Electronics Instruments and Laser based sighting Electronics Instruments and Laser based sighting systems are manufactured specifically, to meet the systems are manufactured specifically, to meet the requirements of Military, Para-Military and Security requirements of Military, Para-Military and Security Forces.Forces.

        The design of these systems is based on State of The design of these systems is based on State of

Art Technology provided by foreign collaborators as Art Technology provided by foreign collaborators as well as indigenous research and development. These well as indigenous research and development. These Vision instruments enable the forces to see, operate Vision instruments enable the forces to see, operate and fight in and fight in day/nightday/night and adverse climatic and adverse climatic conditionsconditions

OLFOLF is amongst a few manufacturing units in the is amongst a few manufacturing units in the world, which has the facilities to manufacture high world, which has the facilities to manufacture high precision Laser Range Finder with its Fire Control precision Laser Range Finder with its Fire Control System for AFVs, right from the component level to System for AFVs, right from the component level to the final instrument and its testing and integration, the final instrument and its testing and integration, under one roof. under one roof.

        OLFOLF products meet the most desirable quality products meet the most desirable quality performance levels and latest International Quality performance levels and latest International Quality Standards through its adherence to the Quality Standards through its adherence to the Quality Management Systems laid down by the ISO and the Management Systems laid down by the ISO and the calibration services a per NABL.calibration services a per NABL.

  The key elements of The key elements of OLFOLF’s success and recognition ’s success and recognition as the most advanced Opto Electronics production as the most advanced Opto Electronics production unit are :unit are :

1.Its State of the Art Technology.1.Its State of the Art Technology. 2.A highly skilled and motivated work force.2.A highly skilled and motivated work force.         3.A clean environment up to class 100 in the 3.A clean environment up to class 100 in the

manufacturing process areas. manufacturing process areas.        4.Emphasis on stage to stage quality control 4.Emphasis on stage to stage quality control

measures. measures.

Main Components of FactoryMain Components of Factory

In The Factory various components are:In The Factory various components are:

1. AJEYA TANK (T-72)1. AJEYA TANK (T-72)

2. SARTH TANK (BMP-2) 2. SARTH TANK (BMP-2)

3. BHISMA TANK (T-90) 3. BHISMA TANK (T-90)

AJEYA TANK (T-72)AJEYA TANK (T-72) Laser range finder (TPDK-1)Laser range finder (TPDK-1) Site periscope, gunner sight (TPN-3)Site periscope, gunner sight (TPN-3) Site periscope, commander sight (TKN-3)Site periscope, commander sight (TKN-3) Site periscope, driver site (TVNE-4)Site periscope, driver site (TVNE-4) Temperature regulator (RST27-4M)Temperature regulator (RST27-4M) The complete AJEYA TANK (T-27) is assembled at Chennai.The complete AJEYA TANK (T-27) is assembled at Chennai.

SARTH TANK (BMP-2)SARTH TANK (BMP-2) Gunner site (BPK-24)Gunner site (BPK-24) Site periscope commander site (TKN-3B)Site periscope commander site (TKN-3B) Driver site (TVNE-1PA)Driver site (TVNE-1PA) Power supply unit (VT6-26E)Power supply unit (VT6-26E) OBSERVATION DEVICEOBSERVATION DEVICE IP3-3IP3-3 TNPU-170TNPU-170 PNP-3508PNP-3508 TNPT-1TNPT-1 PROTECTIVE GLASSPROTECTIVE GLASS SE-2PSE-2P SE-1SE-1 GLASS TEMPERATURE REGULATORGLASS TEMPERATURE REGULATOR RTS27-1mRTS27-1m The SARTH TANK (BMP-2) is assembled at Hyderabad The SARTH TANK (BMP-2) is assembled at Hyderabad

BHISMA TANK (T-90)BHISMA TANK (T-90)

Sight 1G46 (Gunner sight)Sight 1G46 (Gunner sight) Power unitPower unit Control consoleControl console Ballistic combater BV1Ballistic combater BV1 Automatic control unit 9S5Automatic control unit 9S5 Tilt sensorTilt sensor Wind sensorWind sensor Blockbg29-45 (commander sight)Blockbg29-45 (commander sight) The BHISMA TANK (T-90) instruments are manufactured in The BHISMA TANK (T-90) instruments are manufactured in

OLF Factory Dehradun.OLF Factory Dehradun.

LATHELATHE A center/engine lathe is one of the oldest and perhaps most A center/engine lathe is one of the oldest and perhaps most

important machine tools ever developed.important machine tools ever developed.

The job is to be machined is rotated (turned) and the The job is to be machined is rotated (turned) and the cutting tool is moved relative to the job. That is why, the cutting tool is moved relative to the job. That is why, the lathes are also called “Turning machines”.lathes are also called “Turning machines”.

The first lathe machine that was ever developed was the The first lathe machine that was ever developed was the two-person lathe machine which was designed by the two-person lathe machine which was designed by the Egyptians in about 1300 BC. Primarily, there are two things Egyptians in about 1300 BC. Primarily, there are two things that are achieved in this lathe machine set-up. The first is that are achieved in this lathe machine set-up. The first is the turning of the wood working piece manually by a rope; the turning of the wood working piece manually by a rope; and the second is the cutting of shapes in the wood by the and the second is the cutting of shapes in the wood by the use of a sharp tool. As civilizations progressed, there have use of a sharp tool. As civilizations progressed, there have been constant modifications and improvements over the been constant modifications and improvements over the original two-person lathe machine, most importantly on the original two-person lathe machine, most importantly on the production of the rotary motion.production of the rotary motion.

WORKING PRINCIPLE OF LATHEWORKING PRINCIPLE OF LATHE

In lathe, the work piece is held in a chuck or between In lathe, the work piece is held in a chuck or between centers and rotated about its axis at a uniform speed.centers and rotated about its axis at a uniform speed.

The cutting tool held in tool post is fed into the work piece The cutting tool held in tool post is fed into the work piece for desired depth and in desired direction.for desired depth and in desired direction.

Since there exists a relative motion between the work piece Since there exists a relative motion between the work piece and the cutting tool, therefore the material is removed in and the cutting tool, therefore the material is removed in the form of chips and the desired shape is obtained.the form of chips and the desired shape is obtained.

PARTS OF LATHEPARTS OF LATHE

BEDBED It is the base or foundation of the Lathe.It is the base or foundation of the Lathe. It is heavy rigid casting made in one piece.It is heavy rigid casting made in one piece. It holds or supports or parts of the lathe.It holds or supports or parts of the lathe. It is made of grey cast iron , nodular cast iron or high It is made of grey cast iron , nodular cast iron or high

strength, wear resistant cast ironstrength, wear resistant cast iron

HEADSTOCKHEADSTOCK It is permanently fastened to the innerways at the left hand It is permanently fastened to the innerways at the left hand

end of the bed.end of the bed. It serves to support the spindle and driving arrangements.It serves to support the spindle and driving arrangements. All receive their power through headstock.All receive their power through headstock.

TAILSTOCKTAILSTOCK It is situated at right hand end of the bed.It is situated at right hand end of the bed. It is used for supporting right end of work.It is used for supporting right end of work. It is also used for holding and feeding the tools such as It is also used for holding and feeding the tools such as

drills, reamers, taps etc.drills, reamers, taps etc.

CARRIAGECARRIAGE The carriage controls and supports the cutting tool.The carriage controls and supports the cutting tool. The carriage has the following five major parts:The carriage has the following five major parts: (i) Saddle: It is a H-shaped casting fitted over the bed. It (i) Saddle: It is a H-shaped casting fitted over the bed. It

moves along the guideways.moves along the guideways. (ii) Cross-slide: It carries the compound slide and the tool (ii) Cross-slide: It carries the compound slide and the tool

post; can be moved by power or hand.post; can be moved by power or hand. (iii) Compound rest: It is marked in degrees; used during (iii) Compound rest: It is marked in degrees; used during

taper turning to set the tool for angular cuts.taper turning to set the tool for angular cuts. (iv) Tool Post: The tool is clamped on the tool post.(iv) Tool Post: The tool is clamped on the tool post. (v) Apron: It is attached to the saddle and hangs in front of (v) Apron: It is attached to the saddle and hangs in front of

the bed. It has gears, levers and clutches for moving the the bed. It has gears, levers and clutches for moving the carriage with the lead screw for thread cutting.carriage with the lead screw for thread cutting.

FEED MECHANISM FEED MECHANISM It is employed for imparting various feeds It is employed for imparting various feeds

(longitudinal, cross and angular) to the cutting (longitudinal, cross and angular) to the cutting tool.tool.

It consists of feed reverse lever, tumbler It consists of feed reverse lever, tumbler reversing mechanism, change gears, feed gear reversing mechanism, change gears, feed gear box, quick change gear box, lead screw, feed rod, box, quick change gear box, lead screw, feed rod, apron mechanism and half nut mechanism. apron mechanism and half nut mechanism.

MACHINES IN TURNING SHOPMACHINES IN TURNING SHOP

SCHAUBLIN 150SCHAUBLIN 150

SCHAUBLIN 125SCHAUBLIN 125

SCHAUBLIN 102SCHAUBLIN 102

LB17LB17

NH 22NH 22

DIFFERENT OPERATION IN DIFFERENT OPERATION IN TURNING SHOPTURNING SHOP

FACINGFACING – Facing is an operation of machining the ends of a – Facing is an operation of machining the ends of a work piece to produce a flat surface square with the axis.work piece to produce a flat surface square with the axis.

PLANE TURNING PLANE TURNING It is an operation for removing excess It is an operation for removing excess material from the surface of the cylindrical work piece material from the surface of the cylindrical work piece

TAPER TURNINGTAPER TURNING – A taper may be defined as the increase – A taper may be defined as the increase or decrease in diameter of a piece of work measured along or decrease in diameter of a piece of work measured along

its length.its length.

Methods of Taper Turning- Methods of Taper Turning-

(i) By setting over tailstock center(i) By setting over tailstock center

(ii) By swiveling the compound rest(ii) By swiveling the compound rest

(iii) By using taper turning attachment(iii) By using taper turning attachment

4-4-DRILLINGDRILLING – It is an operation of producing a – It is an operation of producing a

Cylindrical hole in a work piece by the rotating cutting edge Cylindrical hole in a work piece by the rotating cutting edge of cutter known as drill.of cutter known as drill.

5-5-REAMINGREAMING – Reaming is an operation done after drilling to – Reaming is an operation done after drilling to

get high surface finish and dimensional accuracyget high surface finish and dimensional accuracy. .

6-6-BoringBoring – It is an operation of enlarging and turning a hole – It is an operation of enlarging and turning a hole produced by drilling.produced by drilling.

7-7-THREADINGTHREADING - It is an operation of cutting helical grooves - It is an operation of cutting helical grooves on cylindrical surface of work piece.on cylindrical surface of work piece.

KNURLNGKNURLNG – It is an operation of embossing a diamond – It is an operation of embossing a diamond

shaped pattern on the surface of work pieceshaped pattern on the surface of work piece..

Introduction of CNC MachiningIntroduction of CNC Machining CNC Machining is a process used in the manufacturing CNC Machining is a process used in the manufacturing

sector that involves the use of computers to control sector that involves the use of computers to control machine tools. Tools that can be controlled in this manner machine tools. Tools that can be controlled in this manner include lathes, mills, routers and grinders. The CNC in CNC include lathes, mills, routers and grinders. The CNC in CNC Machining stands for Computer Numerical Control.Machining stands for Computer Numerical Control.

Under CNC Machining, machine tools function through Under CNC Machining, machine tools function through numerical control. numerical control.

A computer program is customized for an object and the A computer program is customized for an object and the machines are programmed with CNC machining language machines are programmed with CNC machining language (called G-code) that essentially controls all features like (called G-code) that essentially controls all features like feed rate, coordination, location and speeds. feed rate, coordination, location and speeds.

With CNC machining, the computer can control exact With CNC machining, the computer can control exact positioning and velocity.positioning and velocity.

CNC machining is used in manufacturing both metal and CNC machining is used in manufacturing both metal and plastic parts.plastic parts.

PROGRAMING LANGUGE IN PROGRAMING LANGUGE IN CNC MACHINECNC MACHINE

G-CODE:G-CODE:

In fundamental terms, G-code is a language in which In fundamental terms, G-code is a language in which people tell computerized people tell computerized machine toolsmachine tools what to make what to make and how to make it. and how to make it.

The "how" is defined by instructions on where to The "how" is defined by instructions on where to move to, how fast to move, and through what path move to, how fast to move, and through what path to move. to move.

The most common situation is that, within a The most common situation is that, within a machine toolmachine tool, a , a cutting toolcutting tool is moved according to these is moved according to these instructions through a toolpath, cutting away excess instructions through a toolpath, cutting away excess material to leave only the finished workpiece.material to leave only the finished workpiece.

But the same concept also extends to noncutting But the same concept also extends to noncutting tools, such as forming or burnishing tools; to tools, such as forming or burnishing tools; to additiveadditive methods; and to measuring probes that validate the methods; and to measuring probes that validate the results.results.

Some G-Codes are as followsSome G-Codes are as follows:: G00: Positioning (rapid transverse)G00: Positioning (rapid transverse) G01: Linear interpolation (cutting feed)G01: Linear interpolation (cutting feed) G02: Circular interpolation CW or helical interpolation CWG02: Circular interpolation CW or helical interpolation CW G04: Dwell, Exact stopG04: Dwell, Exact stop G17: Xp Yp plane sectionG17: Xp Yp plane section G18: Zp Xp plane sectionG18: Zp Xp plane section G19: Yp Zp plane sectionG19: Yp Zp plane section G21: Input in mmG21: Input in mm G33: ThreadingG33: Threading G40: Cutter Compensation cancel G40: Cutter Compensation cancel

G43: Tool length compensationG43: Tool length compensation G54: Workpiece coordinate system 1 selectionG54: Workpiece coordinate system 1 selection G80: Canned cycle stopG80: Canned cycle stop G81: Drilling cycle or spot boring cycleG81: Drilling cycle or spot boring cycle G68: Coordinate system rotation mode onG68: Coordinate system rotation mode on G85: Boring cycleG85: Boring cycle G95: feed/rev.G95: feed/rev.

LIST OF DIFFERENT VARIABLES LIST OF DIFFERENT VARIABLES USED WITH G-CODEUSED WITH G-CODE

G- Preparatory codeG- Preparatory code X- Absolute or incremental position of X-axisX- Absolute or incremental position of X-axis Y- Absolute or incremental position of Y-axisY- Absolute or incremental position of Y-axis Z- Absolute or incremental position of Z-axisZ- Absolute or incremental position of Z-axis A- Rotational axis around X axisA- Rotational axis around X axis B- Rotational axis around Y axisB- Rotational axis around Y axis C- Rotational axis around Z axisC- Rotational axis around Z axis U- Incremental axis parallel to X axisU- Incremental axis parallel to X axis V- Incremental axis parallel to Y axisV- Incremental axis parallel to Y axis W- Incremental axis parallel to Z axisW- Incremental axis parallel to Z axis M- Action code or Machine codeM- Action code or Machine code F- Defines feed rate for toolF- Defines feed rate for tool S- Defines speed of spindleS- Defines speed of spindle N- Line no. in programN- Line no. in program R- Define size of arc radiusR- Define size of arc radius P- Defines dwell time or variables in canned cycleP- Defines dwell time or variables in canned cycle T- Tool selectionT- Tool selection

M-CODEM-CODE M00: Program stopM00: Program stop M01: Optional stopM01: Optional stop M02: Program endM02: Program end M03: Spindle rotation CWM03: Spindle rotation CW M04: Spindle rotation CCWM04: Spindle rotation CCW M05: Spindle stopM05: Spindle stop M06: Tool changeM06: Tool change M07: Coolant ‘ON’ (flood)M07: Coolant ‘ON’ (flood) M08: Coolant ‘ON’ (mist)M08: Coolant ‘ON’ (mist) M09: All coolant ‘OFF’M09: All coolant ‘OFF’ M10: Rotary table unclampM10: Rotary table unclamp M11: Rotary table clampM11: Rotary table clamp M19: Spindle orientationM19: Spindle orientation M30: Program end and rewindM30: Program end and rewind

COOLANTS AND LUBRICANTSCOOLANTS AND LUBRICANTS

In all metal working operations in workshops, the use of In all metal working operations in workshops, the use of metal working fluids is indispensable. These fluids are given metal working fluids is indispensable. These fluids are given various names viz, coolants, lubricants and cutting various names viz, coolants, lubricants and cutting compounds and cutting fluids, according to their use.compounds and cutting fluids, according to their use.

The metal working fluids usually performs the following The metal working fluids usually performs the following functions: functions:

1.Increases the tool life and produces better finish by 1.Increases the tool life and produces better finish by carrying away the heat generated during metal working.carrying away the heat generated during metal working.

2. Minimizes the friction between the mating surfaces and 2. Minimizes the friction between the mating surfaces and thus prevents rise in temperature.thus prevents rise in temperature.

3. Protects the finished surface from corrosion. 3. Protects the finished surface from corrosion. 4. Drives away the chips, scale and dirt etc. from between 4. Drives away the chips, scale and dirt etc. from between

the working or mating surfaces.the working or mating surfaces.

CHARACTERISTICS OF CHARACTERISTICS OF CUTTING FLUIDSCUTTING FLUIDS

It should provide sufficient lubrication between the tool and It should provide sufficient lubrication between the tool and work and the tool and chips so as to minimize tool wear and work and the tool and chips so as to minimize tool wear and reduce power consumption.reduce power consumption.

It must carry away the heat generated during the process It must carry away the heat generated during the process and thus cool the tool and workpiece both.and thus cool the tool and workpiece both.

Its flash point should be high.Its flash point should be high. It should be able to impart antiwelding properties.It should be able to impart antiwelding properties. It should not discolor the finished work surface.It should not discolor the finished work surface. It should be non-poisonous and should not cause skin It should be non-poisonous and should not cause skin

irritation.irritation. It should carry such constituents which will prevent the It should carry such constituents which will prevent the

finished work surface and the tool from being rusted and finished work surface and the tool from being rusted and corroded.corroded.

THANK YOU…THANK YOU…