TRAINING REPORT

AT

AK AUTOMATICS, ROHTAK

“Submission of training report in the partial fulfillment of the

requirement for the award of degree of [Link].”

On

“MANUFACTURING PROCESS”

Submitted By: - Submitted To:-

Mohit Verma Mr. Rishi Raj
23D/MEL/908
B Tech. [ME] 7th Semester
Page 2 of 43
 ACKNOWLEDGEMENT

I would like to thank [Link] { Senior Manager (H.R) } who helped me in carrying out this
project study, acting as the guiding spirit behind the compiling of this report and putting
tremendo us effort from his side to assist me as much as possible.

I am also equally grateful to AK Automatics and Sh. LALIT KUMAR (Senior Executive H.R) or
his valuable suggestions and encouragement given to me from time to time.

I am also thankful to all EXECUTIVES OF DOCUMENTATION CENTRE, AK Automatics for

their time, and co-operation and helping attitude towards me, which made me complete this
project.

Mohit Verma

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 PREFACE

As an integral part of Bachelor of technology ([Link]) course, a student has to

undergo a Nine weeks of the real construction world. Fulfilling this course
curriculum, the project was under taken at AK AUTOMATICS [Link].

The project work has been undertaken to analyze the industry in India in the
liberalized economy with particular reference to AK AUTOMATICS.

The following report will drive the reader an insight in to the inter plant
manufacturing system based on standard production. The comparative analyze will
enable to analyze trend of performance and present the picture of operation of AK
Automatics in pre – liberalization.

The report present a frame work (in liberalized environment) for the trend of
production performance of the company, the change in the performance, the
various factors leading to these changes, the expenditure on raw material, operating
cost, production etc.

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 CONTENTS

CHAPTER- 1: ABOUT THE COMPANY Pg. No -

 Vision 6
 Mission 7
 Specialized 7
 Products 8
 Infrastructure 9
 Customers 10

CHAPTER -2: ABOUT THE DEPARTMENT

 Manufacturing processes 11
 Machining processes 12
 Conventional process 12~24
 Non-Conventional process 24~28
 Measuring tools 28~30

CHAPTER- 3: TASKSPERFORMED
 Geometric Dimensioning and Tolerance 31
 Surface Roughness and Symbols 32
 Engineering Drawing 33~39
 Assembly section 40

CHAPTER- 4: OUTCOMES
 Specific outcome 41
 Conclusion 42
 Reference 43

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CHAPTER 1: ABOUT THE COMPANY:-

AK Automatics is engaged in the manufacturing vertical. The industries we serve include, but
are not limited to, the Construction, Aerospace, Automobile and Hydraulic Industries.

They have experienced and energetic team of professionals with a nothing's too difficult
philosophy. The company is keen to make its mark in the manufacturing Industry by providing
100% results.

They achieved name by Manufacturing Expertise, State-of-the-Art Machine, wide range of

Materials & Services, Exceptional Quality Control. With a proven understanding of the design,
technology and manufacturing process, we create solutions that provide our customers with a
competitive advantage.

 Vision

Their vision is to continuously provide 100% customer satisfaction bysupplying quality products
on time delivery with promised lowest cost. As they are unique they state their vision in three
verticals.

To Customers:

• 100%satisfaction. Prime Quality.

• On time Delivery.

To Vendors:

• Permanent Orders Last long Relationship.

• On Time Payment.

To Employees:

• To make our people wealth.

• To make our people Skilful.
• Respecting Diversity.

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  Mission

Their business is dedicated to providing superior products and services to their customers. They
believe their customers are the most important part of their business now and in the future.

AK Automatics Committed:

To Customers:

• Unmatched quality, and support to every customer.

To Vendors:

• Foster the relationships with our vendors.

To Employees:

• We foster an open, collaborative culture where dedication, Passion, ideas second to none.

 Specialized In:-

• Designing of jigs and fixture.

• Manufacturing manual and robotic welding jigs and Fixtures.
• Aero space components.
• Construction machines.
• Hydraulic and pneumatic cylinders.

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PRODUCTS:-

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LIST OF MACHINERIES:-

1. D.R.O. Milling (LAGUN): MNTR, ISO 40, Bed Length

1000mmX400mmX350mm.
2. LATHE (Rajkot): Medium Duty, SOB-300mm.
3. CO2WeldingM/C:250A
4. CNC Turning Centre: LOKESH TL-20 OD 200mm (Max), Length
400mm (max).
5. Micrometric Cylindrical Grinding M/C: OD 350mm (Max), Length
1000mm (Max) ID 200mm (Max. Approx), Dia. 16mm (min).
6. Gear Hobbing. M/C:(Upto8Modules) Future Project.

LIST OF INSTRUMENTS:-

1. Vernier (Analog):0-300mm,LC0.02mm
2. VernierHeightGauge:0-300mm,LC0.02mm
3. Plunger Dial Gauge(Mitutoyo):0-10mm,0.01mm, 0.001mmOD
4. Micrometer:0-25mm,25-50mm,50-75mm,75-100mm,100-125mm,125-150mm,150-
175mm,175-200mm,200-225mm,225-250mm,250-275mm,275-300mm
5. Bore Gauge:18-300mm
6. Bevel Protractor, Radius Gauge, Calipers, Pitch Gauge Etc.

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CUSTOMERS:-

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CHAPTER 2: ABOUT THE DEPARTMENT

2.1 Manufacturing Processes

Manufacturing is the backbone of any industrialized nation. Manufacturing and technical staff in
industry must know the various manufacturing processes, materials being processed, tools and
equipments for manufacturing different components or products with optimal process plan using
proper precautions and specified safety rules to avoid accidents. Beside above, all kinds of the
future engineers must know the basic requirements of workshop activities in term of man,
machine, material, methods, money and other infrastructure facilities needed to be positioned
properly for optimal shop layouts or plant layout and other support services effectively adjusted
or located in the industry or plant within a well-planned manufacturing organization.

The complete understanding of basic manufacturing processes and workshop technology is

highly difficult for anyone to claim expertise over it. The study deals with several aspects of
workshops practices also for imparting the basic working knowledge of the different engineering
materials, tools, equipments, manufacturing processes, basic concepts of electro- mechanical
controls of machine tools, production criteria’s, characteristics and uses of various testing
instruments and measuring or inspecting devices for checking components or products
manufactured in various manufacturing shops in an industrial environment. It also describes and
demonstrates the use of different hand tools (measuring, marking, holding and supporting tools,
cutting etc.), equipments, machinery and various methods of manufacturing that facilitate
shaping or forming the different existing raw materials into suitable usable forms. It deals with
the study of industrial environment which involves the practical knowledge in the area of ferrous
and non-ferrous materials, their properties and uses. It should provide the knowledge of basic
workshop processes namely bench work and fitting, sheet metal, carpentry, pattern making,
mould making, foundry, smithy, forging, metal working and heat treatment, welding, fastening,
machine shop, surface finishing and coatings, assembling inspection and quality control. It
emphasizes on basic knowledge regarding composition, properties and uses of different raw
materials, various production processes, replacement of or improvement over a large number of
old processes, new and compact designs, better accuracy in dimensions, quicker methods of
production, better surface finishes, more alternatives to the existing materials and tooling
systems, automatic and numerical control systems, higher mechanization and greater output.

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2.2 Machining Processes

Machining is a process in which a piece of raw material is cut into a desired final shape and size
by a controlled material-removal process. There are two types of machining Process.

 Conventional Machining Process

 Non-Conventional Machining Process

2.2.1 Conventional Machining Process

It is nothing but the process in which the material is removed by the direct contact between tool
and work piece. The energy is utilized to rotate either work piece or tool, and the cutting tool
should be harder than work piece.

 Lathe
 Drilling Machine
 Milling Machine
 Grinding Machine

[Link] Lathe

A lathe is a machine which is used for shaping wood & metals (ferrous and non-ferrous),
phosphorous bronze, copper, nylon etc.

Fig.2.1: LATHE (Rajkot): MediumDuty,SOB-300mm

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Operations in lathe

 Facing:-

Facing is used to make a flat surface at the end of the work piece. The work part should
be rotating and the implied feed should be radial.

 Contour turning:-

In this operation of lathe machine the tool is not fed in a straight path. Instead the tool
follows a contour. A contoured form is created in the turned part.

 Form turning:-

In this method a special shaped tool is used. The tool is inserted radially.

 Taper turning: -

Like contour turning the tool is not fed parallel to the axis of rotation of the work part.
The tool is fed at an angle. This turning operation gives a conical and taper cylindrical
shape.

 Cut off or Parting:-

In parting operation the tool is fed radially and the end part of the work piece is cut off.

 Boring: -

A single point tool head is fed linearly to the end of the work piece (on the inside
diameter).

 Threading:-

A pointed tool is used at the outside surface of the work piece with linear feed to create a
thread.

 Drilling:-

Drilling and reaming is done by feeding the lathe tool along the axis of the rotating job

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 part.

 Knurling:-

It is a metal forming method which creates a regular cross hatched pattern. It is not a
machining process. It does not involve any cutting of the metal.

 Grooving:-

The term grooving usually applies to a process of forming a narrow cavity of a certain
depth, on a cylinder, cone, or a face of the part.

Tolerance achieved in lathe: 100 microns (0.1mm)

Average roughness value can be achieve in lathe 1.6 above

Turning operations cannot be done after heat treatment. Can be done by using certain special tips
up to certain extent of 35-40Hrc.

Types of tool material used in lathe

 Carbide
 High speed steel (HSS)
 Diamond

Types of Lathe Machine

 Speed Lathe/ Wood Lathe

 Engine lathe
 Tool room lathe
 Capstan lathe and turret lathe
 Special purpose lathe
 Wheel lathe
 Automatic lathe
 CNC lathe
 Crank shaft lathe
 Vertical lathe

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[Link](a) CNC Turning

 Turning done by programming according to the desired shapes in drawing

 Its preferred over conventional when there is complex shapes in turning which cannot be
achieved in conventional.

Fig.2.2: CNC Turning Centre:Z-MatTL-20OD200mm(Max), Length 400mm(max)

Advantages of CNC Machine

CNC Machines have following advantages –

 CNC machines can be used continuously 24×7 throughout the year and only need to be
switched off for occasional maintenance.
 Less skilled/trained people can operate CNC machines unlike manual lathes / milling
machines etc. which need skilled engineers.
 Time saving when compared to conventional turning
 Normally used for batch or mass productions
 Modern design software allows the designer to simulate the manufacture of his/her idea.
There is no need to make a prototype or a model. This saves time and money.

Tolerance achieved in CNC Machines: up to 10 microns (0.01mm)

Average roughness value can be achieved is 0.8.

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[Link] Drilling Machine

Drilling is an operation of producing a cylindrical hole of required diameter and depth by

removing metal by the rotating edges of a drill

Fig.2.3:DRO Drilling Machine

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Operations Performed in Drilling Machine

Drilling:-

Drilling is the operation of producing a cylindrical hole of required diameter and depth by
removing metal by the rotating edge of a cutting tool called drill.

Reaming:-

Reaming is an accurate way of sizing and finishing a hole which has been previously drilled by a
multi-point cutting tool known as reamer.

Boring:-

Boring is the operation enlarging the diameter of the previously made hole.

Counter boring:-

Process of enlarging a drilled hole along part of the length of the hole by drilling with a greater
diameter.

Countersinking:-

Countersinking is the operation of making a cone shaped enlargement at the starting of the hole.
The included angle of the conical surface may be in the range of 45° to 90°

Spot Facing:-

Spot facing is the operation of smoothing and squaring the surface around a hole. It is done to
provide proper seating for a nut or the head of a screw.

Tapping

Tapping is the operation of cutting internal threads by means of a cutting tool called ‘tap’

Tolerance achieved in Drilling Machine : 100 microns (0.1mm) in drill bits

: 20 microns (0.02) in reamers.

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Types of drilling Machine:-

1. Portable drilling machine (or) Hand drilling machine

2. Sensitive drilling machine (or) Bench drilling machine

3. Upright drilling machine

4. Radial drilling machine

5. Gang drilling machine

6. Multiple spindle drilling machine

7. Deep hole drilling machine

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[Link] Milling Machine

Milling is the process of machining using rotary cutters to remove material by advancing a
cutter into work piece

Fig.2.4: MillingMachine

Operations performed in Milling Machine:-

 Plain milling: As the name implies, this operation used to get plain surface. In this
milling, the cutting tool axis is parallel to the machining surface or the face of the
machining surface.
 End milling: In this operation, the cutting tool axis is perpendicular to the machining
surface or the face of the machining surface. It is used to perform pocket milling, small
slotting operations
 Gang milling: In this operation more than one milling cutters which are in different
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 shapes and size are used for machining. To get the desire shape in one pass.

 Straddle milling: In this operation, two or more parallel vertical surface machined in a
single pass. In this milling the work piece is situated between the two cutters which can
machined the surface vertically.
 Slotting: In this operation slots are cut by a cutter on the work piece. The slots are in
various shapes like circular, rectangular etc. and sizes according to the requirement.
 Angular milling: In this operation, surfaces which are at an angle to the axis of the
cutter, is machined by the rotary cutter.

Tolerance achieved in milling machine: 100 microns

Types if Milling Machines

1. Column and knee type milling machine

 Vertical milling machine

 Horizontal milling machine
 Universal milling machine

2. Fixed bed milling machine

 Simplex milling machine

 Duplex milling machine
 Triplex milling machine

3. Planner milling machine

4. Special milling machine

 Tracer milling machine

 CNC milling machine.

Average roughness value that can be achieved is 0000 and it’s above

Tolerance can be achieved is – (+ or - 0.1mm) .

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[Link](a) CNC Milling Machine

 Machine will operates on predefined program according to the desired shape

 Types – Horizontal and Vertical Milling Machine
 Types based on axis – 3Axis, 4Axis, 5Axis
 Complex shapes can be achieved which cannot achieved in conventional
 Flatness can be achieved up to 0.01mm(10 microns)
 Average Roughness value – 0.8
 Tolerance that can be achieve is -0.01mm(10 microns)
 VMC(Vertical milling Centre)
 Here Spindle is placed vertical y (perpendicular) to the job
 Horizontal milling centre
 Spindle is placed horizontal
 Normally the industries uses the 3Axis Machine.

[Link] Grinding Machine

[Link](a) Surface Grinding

 Grinding is an abrasive machining process that uses a grinding wheel as the cutting tool
 The Grinding wheel is made up of abrasive particles
 Surface grinding is used to produce a smooth finish on flat surfaces

Types of surface grinding machines are

1. Horizontal spindle and reciprocating table:-

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2. Vertical spindle and reciprocating table

3. Horizontal spindle and rotary table

4. Vertical spindle and rotary table

Average roughness can be achieved in this process is 0.3 and above

Tolerance can be achieved is 0.002mm (2 microns)

Flatness can be achieve is 0.002mm (2 microns)

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[Link](b) CYLINDRICAL GRINDING

This machine is used to grind external cylindrical surface and inner cylindrical surface

Types of Cylindrical grinding machine :-

1. Plain centre type cylindrical

2. Universal cylindrical surface grinder

3. Centre less cylindrical surface grinder

Grinding Machine

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 Schematic representation of Universal cylindrical surface grinder

 Normally in industries Universal cylindrical surface grinder are used due to its flexibility
fl
when compared to other two
 The Average Roughness value can be achieved 0.3-0.8
0.3
 Maximum tolerance that can be achieved in the machine is 0.002mm
 The grinding surfaces may be straight, tapered, steps, or ID grinding
 Centre less cylindrical surface grinder used, when the job can’t hold between the
2centres, and when concentricity is not required

[Link].(c) CENTRELESS GRINDING

Centrerless grinding

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2.2.2 Non-conventional Machining process

Non-conventional machining process is a special type of machining process in which there is no

direct contact between the tool and the work piece.

Types of Non-traditional Machining

 Ultrasonic Machining (USM)

 Water-Jet Machining & Abrasive-Jet Machining
 Chemical Machining
 Electrochemical Machining (ECM)
 Electrical-Discharge Machining (EDM)
 High-Energy-Beam Machining –Laser-beam machining (LBM) –Electron-beam
machining (EBM)

Why Non-traditional Machining?

 Situations where traditional machining processes are unsatisfactory or uneconomical:

 Work piece material is too hard, strong, or tough.
 Work piece is too flexible to resist cutting forces or too difficult to clamp.
 Part shape is very complex with internal or external profiles or small holes.
 Requirements for surface finish and tolerances are very high
 Temperature rise or residual stresses are undesirable or unacceptable

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[Link] Water Jet Machining (WJM)

WJM is a form of micro erosion. It works by forcing a large volume of water through a
small orifice in the nozzle. The extreme pressure of the accelerated water particles contacts
a small area of the work piece and acts like a saw and cuts a narrow groove in the
material.

 Pros : no need for predrilled holes, no heat, no work piece deflection (hence
suitable for flexible materials), minimal burr, environmentally friendly.
 Cons : limited to material with naturally occurring small cracks or softer material.
 Applications:

- Mostly used to cut lower strength materials such as wood, plastics, rubber, paper,
leather, composite, etc.
- Food preparation
- Good for materials that cannot withstand high temperatures of other methods for
stress distortion or metallurgical reasons.

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[Link] Electrical Discharge Machining (EDM)

 EDM is one of the most accurate while quite affordable manufacturing processes.
 Principle - Electrical discharge machining process works on the basic principle of
spark generation and metal removed by spark erosion.
 The EDM system consists of a shaped tool or wire electrode.
 The part is connected to a power supply to create a potential difference
between the work piece and the tool.
 When the potential difference is sufficiently high, a transient spark discharges
through the fluid, removing a very small amount of metal from the work
piece.

The dielectric fluid:-

i. Acts as an insulator until the potential is sufficiently high,

ii. Acts as a flushing medium, and
iii. Provides a cooling medium.

Types of EDM
1. Sparking
2. Wire Cutting or Wire EDM

[Link](a)Sparking

 Tool used for sparking is COPPER

 Copper is used because it is highly conductive material
 Tolerance can be achieved is 0.001mm
 Sparking is used when the material has to remove up to particular depth in the job.

The above picture is for sparking.

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[Link](b)Wire Cutting Machine

 Type of wire used in process is BRASS

 Diameter of the wire is 0.25mm – 0.3mm
 Tolerance can be achieved is 0.001mm
 Average roughness value can we get is 0.8
 Wire cutting is used to cut the material only when the wire is allowed to pass
through the job

Above picture is for wire cutting EDM

2.3 Measuring tools used in Manufacturing Process

1. Vernier caliper
2. Micrometer
3. Dial gauge
4. Bore gauge
5. Vernier height gauge
6. Try square

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Vernier caliper

Vernier calipers have both a fixed main scale and a moving vernier scale.

Micrometer

A micrometer, sometimes known as a micrometer screw gauge, is a device incorporating a

calibrated screw widely used for accurate measurement of components in mechanical
engineering and machining as well as most mechanical trades, along with other metrological
instruments such as dial, vernier, and digital calipers.

Dial gauge

 A gauge consisting of a circular graduated dial and a pointer actuated by a member

that contact with the part being calibrated.
 Dial indicators are one of the primary measuring tools used in precision engine
building.

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  They are typically used to measure deck clearances, crankshaft thrust and
straightness, lifter travel and other measurements that involve the distance between
two surfaces or small amounts of component travel.

Bore Gauge

A bore gauge is a collective term for the tools that are unique to the process of accurately
measuring hole

Vernier height gauge

A height gauge is a measuring device used for determining the height of objects, and for
marking of items to be worked on Height gauges may also be used to measure the height of an
object by using the underside of the scriber as the datum.

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CHAPTER 3: TASKS PERFORMED

3.1 Geometric Dimensioning and Tolerance

Geometric Dimensioning and Tolerance (GD&T) is a language of symbols and standards

designed and used by engineers and manufacturers to describe a product and facilitate
communication between entities working together to produce something

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3.2 Surface Roughness and Symbols

Surface roughness often shortened to roughness, is a component of surface texture. Roughness

plays an important role in determining how a real object will interact with its environment.
Roughness is often a good predictor of the performance of a mechanical component, since
irregularities on the surface may form nucleation sites for cracks or corrosion. On the other hand,
roughness may promote adhesion.

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3.3 Engineering Drawing

An engineering drawing is a type of technical drawing that is used to convey information about
an object. A common use is to specify the geometry necessary for the construction of a
component and is called a detail drawing. Usually, a number of drawings are necessary to
completely specify even a simple component. The drawings are linked together by a master
drawing or assembly drawing which gives the drawing numbers of the subsequent detailed
components, quantities required, construction materials and possibly 3D images that can be used
to locate individual items. Although mostly consisting of pictographic representations,
abbreviations and symbols are used for brevity and additional textual explanations may also be
provided to convey the necessary information.

The process of producing engineering drawings is often referred to as technical drawing or

drafting. Drawings typically contain multiple views of a component, although additional scratch
views may be added of details for further explanation. Only the information that is a requirement
is typically specified. Key information such as dimensions is usually only specified in one place
on a drawing, avoiding redundancy and the possibility of inconsistency. Suitable tolerances are
given for critical dimensions to allow the component to be manufactured and function. More
detailed production drawings may be produced based on the information given in an engineering
drawing. Drawings have an information box or title block containing who drew the drawing, who
approved it, units of dimensions, meaning of views, the title of the drawing and the drawing
number.

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 Engineering Drawing

One of the best ways to communicate one's ideas is through some form of picture or drawing.
This is especially true for the engineer. The purpose of this guide is to give you the basics of
engineering sketching and drawing.

We will treat "sketching" and "drawing" as one. "Sketching" generally means freehand
drawing. "Drawing" usually means using drawing instruments, from compasses to computers
to bring precision to the drawings.

This is just an introduction. Don't worry about understanding every detail right now - just get a
general feel for the language of graphics.

We hope you like the object in Figure, because you'll be seeing a lot of it. Before we get started
on any technical drawings, let's get a good look at this strange block from several angles.

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 A Machined Block.

Isometric Drawing

The representation of the object in figure 3.2 is called an isometric drawing. This is one of a
family of three-dimensional views called pictorial drawings. In an isometric drawing, the
object's vertical lines are drawn vertically, and the horizontal lines in the width and depth
planes are shown at 30 degrees to the horizontal. When drawn under these guidelines, the lines
parallel to these three axes are at their true (scale) lengths. Lines that are not parallel to these
axes will not be of their true length.

Figure3.2 –An Isometric Drawing.

Any engineering drawing should show everything: a complete understanding of the object should
be possible from the drawing. If the isometric drawing can show all details and all dimensions on
one drawing, it is ideal. One can pack a great deal of information into an isometric drawing.
However, if the object in figure 3.2 had a hole on the back side, it would not be visible using a
single isometric drawing. In order to get a more complete view of the object, an orthographic
projection may be used.

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Orthographic or Multi view Drawing

Imagine that you have an object suspended by transparent threads inside a glass box, as in figure
3.3

Figure3.3-The block suspended in a glass box.

Then draw the object on each of three faces as seen from that direction. Unfold the box (figure
3.4) and you have the three views. We call this an "orthographic" or "multi view" drawing

Figure3.4- The creation of an orthographic multi view drawing.

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 Figure3.5- A multi view drawing and its explanation.

Which views should one choose for a multi view drawing? The views that reveal every detail
about the object. Three views are not always necessary; we need only as many views as are
required to describe the object fully. For example, some objects need only two views, while
others need four. The circular object in figure 3.6 requires only two views

Figure3.6- An object needing only two orthogonal views

Dimensioning

Figure3.7- An isometric view with dimensions

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 We have "dimensioned" the object in the isometric drawing in figure 3.7. As a general
guideline to dimensioning, try to think that you would make an object and dimension it in the
most useful way. Put in exactly as many dimensions as are necessary for the craftsperson to
make it -no more, no less. Do not put in redundant dimensions. Not only will these clutter the
drawing, but if "tolerances" or accuracy levels have been included, the redundant dimensions
often lead to conflicts when the tolerance allowances can be added in different ways.

Repeatedly measuring from one point to another will lead to inaccuracies. It is often better to
measure from one end to various points. This gives the dimensions a reference standard. It is
helpful to choose the placement of the dimension in the order in which a machinist would create
the part. This convention may take some experience.

Sectioning

There are many times when the interior details of an object cannot be seen from the outside
(figure 3.8).

Figure3.8- An isometric drawing that does not show all details

We can get around this by pretending to cut the object on a plane and showing the "sectional
view". The sectional view is applicable to objects like engine blocks, where the interior details
are intricate and would be very difficult to understand through the use of "hidden" lines (hidden
lines are, by convention, dotted) on an orthographic or isometric drawing.

Imagine slicing the object in the middle (figure 3.9):

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 Figure3.9-" Sectioning" an object

Figure3.10- Sectioned isometric and orthogonal views.

Take away the front half (figure 3.10) and what you have is a full section view (figure 3.11).

Figure 3.11 - Sectioned isometric and orthogonal views.

The cross-section looks like figure 3.11 when it is viewed from straight ahead.

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Drawing Tools:-

To prepare a drawing, one can use manual drafting instruments (figure 3.12) or computer-aided
drafting or design, or CAD. The basic drawing standards and conventions are the same
regardless of what design tool you use to make the drawings. In learning drafting, we will
approach it from the perspective of manual drafting. If the drawing is made without either
instruments or CAD, it is called a freehand sketch.

Figure 3.12 - Drawing Tools

"Assembly" Drawing

An isometric view of an "assembled" pillow-block bearing system is shown in figure 3.13. It

corresponds closely to what you actually see when viewing the object from a particular angle.
We cannot tell what the inside of the part looks like from this view.

We can also show isometric views of the pillow-block being taken apart or "disassembled"
(figure 3.14). This allows you to see the inner components of the bearing system. Isometric
drawings can show overall arrangement clearly, but not the details and the dimensions.

Figure 3.13 - Pillow-block (Freehand sketch)

Page 40 of 43
CHAPTER 4: OUTCOMES

4.1 Specific Outcomes

The whole internship was a great learning experience. I was able to learn the following from
each department,

1. Turning/CNC Turning Department:- First the introduction to the whole department and the
process that take place were explained. Different Machines were shown; the working and
features of the machines were explained. During our stay we were able to observe the facing,
turning, and taper turning process. Major takeaway from the department is the skill of
understanding the part drawing.

2. Milling/CNC Milling Department: - Introduction to the department facility, there were

several types of machines available such as two axis, three axis and five axis machine. During
our stay we were able to observer the milling process of rectangular slab that is changing shape
from rectangular to hexagon cross section, here we were exposed to Siemens machine and its
programming.

3. Wire EDM Department: - Introduction to the department facility, the machines available
over there. We were exposed to the process of sparking and wire EDM process, the process of
cutting blanks of titanium spacers was taking place. The advantages of the machine over the
traditional machining. We also learned the types of cutting wire which were used in EDM
process.

4. Planning Department:- In this department we were exposed to the procedure carried out in
planning of a product manufacturing. Also we learnt about the series of steps involved in
planning and we got to know about how the process plan is created. We were exposed to how the
planning department is interconnected with other departments of manufacturing.

5. Other learning:- In this Internship I got to know about how organization works. The different
departments which helps the organization to run easier. The works/tasks carried out by each
department and how they are each connected to one other. The wholes process of the
organization. Also I learned the discipline that has to be maintained in the organization and
also the safety precautions that must be taken within the organization.

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6. Non-technical outcome:-

 Interpersonal skills such as social skills and coping with authority

 Organizational skills such as personal organization and the ability to order and prioritise
 Analytical skills such as the ability to exercise judgement, managing time or problem
solving
 Personal skills such as insight, motivation, confidence, reliability and health awareness.

4.2 Conclusion

On the whole, this internship was a useful experience. We have gained new knowledge,
skills and met many new people. We achieved several of our learning goals. We got insight into
professional practices currently advocated in the industry. We learned the different facets of
working within a well-established industry. Related to our study we learned more about the
manufacturing, assembly and testing of the various products. Furthermore we have
experienced that it is of importance that education is objective and that we have to be aware of
the industrial aspects of the topics we study. This internship program was not one sided, but it
was a way of sharing knowledge, ideas and opinions.

The internship was also good to find out what our strengths and weaknesses are.
This helped us to define what skills and knowledge we have to improve in the coming time. We
can confidently assert that the knowledge we gained through this internship is sufficient to
contribute towards our future endeavors. At last this internship has given us new insight and
motivation to pursue a career in core mechanical department.

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Reference

 [Link]
machinep40202001/
 [Link]
andmanufacturing-i-spring-2009/related-resources/drawing_and_sketching/
 [Link]
 [Link]
m
 [Link]
management/processplanning/procedure-of-process-planning-7-steps-
industries/9424
 [Link]

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