Royal College of Engineering and Technology

Chiramanangad P.O, Akkikavu Rd, Chiramanangad, Kerala 680604

Department of Mechanical Engineering

INTERNSHIP REPORT
 Aknowledgement
We would like to express our sincere gratitude to all those who supported us during the
course of internship.
We extend our gratitude to the Management, Royal college of Engineering and
Technology for giving us the opportunity to carry out the internship program.
We also express our deep gratitude to Dr. Suresh Venugopal, Principal, Royal college of
Engineering and Technology for all the encouragement and support provided for the
program.
We are deeply thankful to SIDCO Tool Room and Training Centre, Olavanna,
Kozhikode for Providing us with the opportunity to undertake this internship and gain
valuable experience. We are especially grateful to all the mentors for their guidance,
support and encouragement throughout our time at the organization.
We are deeply obliged to Dr. Shanavas S, HOD Mechanical Engineering Department,
Royal college of Engineering and Technology, for his continuous encouragement and
Support.
 Preface
Industrial training is an essential component of the [Link] Mechanical Engineering
curriculum under APJ Abdul Kalam Technological University (KTU). It provides
students with an opportunity to bridge the gap between classroom learning and practical
industrial applications by exposing them to real manufacturing environments and
professional engineering practices.
As a part of the curriculum, we successfully completed a 14-day industrial internship
at SIDCO Tool Room and Training Centre, Olavanna, Kozhikode. The training
enabled us to observe various manufacturing processes, machine tools, CNC machining,
quality control procedures, tool room operations, maintenance practices, and workplace
safety standards. It also provided valuable insight into the functioning of a modern
manufacturing organization.
This report presents a comprehensive account of the knowledge and experience gained
during the internship. It includes an overview of the organization, details of the
departments visited, machines and manufacturing processes studied, observations made
during the training, and the skills acquired throughout the internship period.
The internship has significantly enhanced our practical knowledge, technical
understanding, and professional awareness. We believe that the experience gained
through this industrial training will serve as a strong foundation for our future academic
pursuits and engineering careers.
 Abstract
This report presents the details and outcomes of a 14-day industrial internship carried
out at SIDCO Tool Room and Training Centre, Olavanna, Kozhikode, as part of the
[Link] Mechanical Engineering curriculum under APJ Abdul Kalam Technological
University (KTU). The primary objective of the internship was to provide practical
exposure to modern manufacturing techniques, industrial work practices, and the
operation of various machine tools used in engineering industries.
During the training period, an understanding was gained of the organizational structure,
tool room activities, manufacturing processes, and quality control practices followed at
the centre. Practical exposure was obtained in conventional machining operations such
as turning, milling, drilling, grinding, and shaping, as well as modern manufacturing
technologies including CNC turning, CNC milling, Electrical Discharge Machining
(EDM), Wire-Cut EDM, and Computer-Aided Design and Manufacturing (CAD/CAM).
The internship also provided insight into die and mould manufacturing, precision
measurement, heat treatment processes, machine maintenance, and industrial safety
practices.
This report summarizes the observations made during the internship, the departments
visited, the machines and equipment studied, and the manufacturing processes observed.
The training helped bridge the gap between theoretical concepts learned in the
classroom and their practical application in industry. It enhanced technical knowledge,
problem-solving ability, professional ethics, and understanding of industrial standards
and manufacturing practices.
Overall, the industrial internship was a valuable learning experience that strengthened
practical engineering skills and provided a better understanding of the working
environment in a modern tool room and manufacturing industry, thereby contributing to
the professional development of a Mechanical Engineering student.
CHAPTER 1
Introduction to Industrial Internship
1.1 Introduction
Industrial internship is an essential component of engineering education that provides
students with practical exposure to industrial environments and real-world engineering
practices. It enables students to understand how theoretical concepts learned in the
classroom are applied in manufacturing industries and helps bridge the gap between
academic knowledge and practical implementation.
The training was carried out at SIDCO Tool Room and Training Centre, Olavanna,
Kozhikode, a government organization engaged in precision manufacturing, tool room
services, CNC machining, die and mould manufacturing, technical training, and quality
inspection. The centre plays an important role in supporting small and medium-scale
industries by providing high-quality manufacturing solutions and technical expertise.
During the training, various departments and manufacturing facilities were visited to
understand the complete production process. Exposure was gained to conventional
machining operations, CNC machining, tool room activities, quality inspection, material
handling, maintenance practices, and industrial safety procedures. The functioning of
different machines, production planning methods, and quality assurance systems was
also observed.
The internship provided valuable insight into the working of a small-scale
manufacturing industry. It helped in understanding how workshop space is organized for
efficient production, how machines are selected and arranged according to
manufacturing requirements, how raw materials are stored and handled, and how
finished products are inspected before delivery. The training also highlighted the
importance of coordination among engineers, supervisors, technicians, and machine
operators in maintaining productivity and product quality.
Practical exposure to precision measuring instruments, CAD/CAM software,
engineering drawings, production documentation, and industrial work culture enhanced
technical understanding and strengthened professional skills. The experience provided a
better appreciation of the knowledge, discipline, teamwork, and continuous learning
required to work effectively in the manufacturing sector.

1.2 Objectives of the Industrial Internship

The objectives of the industrial internship were:
• To understand the working environment of a manufacturing industry.
• To observe the organizational structure and workflow of a tool room.
 • To study conventional and CNC machining processes.
• To understand the manufacture of precision components, dies, moulds, and tools.
• To learn material selection, storage, and handling practices.
• To study quality control methods and inspection procedures.
• To gain knowledge of precision measuring instruments and their applications.
• To understand the use of CAD/CAM software in design and manufacturing.
• To observe preventive maintenance and machine safety practices.
• To understand production planning and workflow management.
• To improve technical knowledge, practical skills, communication, and
teamwork.
• To develop an understanding of the professional responsibilities of a Mechanical
Engineer.

1.3 Importance of Industrial Training

Industrial training provides engineering students with the opportunity to understand the
functioning of manufacturing industries beyond classroom learning. It develops
technical competence, professional confidence, and awareness of industrial standards,
enabling students to become better prepared for engineering careers.
One of the most valuable outcomes of the training was understanding how a small-scale
engineering industry is organized and managed efficiently. The training provided
practical knowledge about workshop planning, machine layout, production flow,
material movement, and the effective utilization of available space to improve
productivity.
It also offered an understanding of:
• Workshop layout and efficient utilization of floor space.
• Selection and operation of conventional and CNC machine tools.
• Roles and responsibilities of engineers, supervisors, technicians, and machine
operators.
• Storage, handling, identification, and movement of engineering materials.
• Production planning and process sequencing.
• Quality inspection using precision measuring instruments.
• Preparation and interpretation of engineering drawings.
• Use of CAD/CAM software in manufacturing.
• Maintenance of machines and equipment.
• Industrial safety practices and the use of personal protective equipment (PPE).
• Documentation and quality assurance procedures followed in manufacturing
industries.
The training demonstrated that successful engineering practice requires not only sound
technical knowledge but also discipline, teamwork, communication skills, problem-
solving ability, time management, and a commitment to quality. It also emphasized the
importance of continuous learning to keep pace with advancements in manufacturing
technology.
Overall, industrial training provides an excellent opportunity to understand industrial
expectations, improve practical skills, and develop the confidence required to perform
effectively as a future Mechanical Engineer.
CHAPTER 2
About Kerala SIDCO and SIDCO Tool
Room Cum Training Centre, Olavanna
2.1 Kerala Small Industries Development Corporation
(SIDCO)
The Kerala Small Industries Development Corporation Limited (SIDCO) is a
Government of Kerala undertaking established in 1975 with the objective of promoting
and developing Micro, Small, and Medium Enterprises (MSMEs) across the state. Since
its establishment, SIDCO has been providing infrastructure, technical assistance,
marketing support, raw material supply, and common facility services to strengthen the
small-scale industrial sector in Kerala.
SIDCO plays a significant role in the industrial development of the state by establishing
and managing industrial estates, mini industrial estates, industrial parks, production
units, and training centres. Through these facilities, the corporation supports
entrepreneurs, government organizations, and manufacturing industries by providing
quality products, engineering services, and technical expertise.
The corporation currently operates nine production units located across Kerala. These
units undertake manufacturing activities, precision engineering, fabrication, furniture
production, and technical services. The major customers include Government
Departments, Public Sector Undertakings (PSUs), Government and Quasi-Government
organizations, ISRO, VSSC, HAL, BrahMos Aerospace, and various MSMEs.
SIDCO also functions as a Common Facility Centre (CFC) by providing access to
advanced machinery and manufacturing facilities for MSMEs that may not be able to
invest in expensive equipment. This initiative enables small industries to improve
product quality, increase productivity, and remain competitive in the manufacturing
sector.
During the financial year 2023–2024, SIDCO's Production Division achieved a
production turnover of approximately ₹22.08 crore, reflecting its contribution to the
industrial and manufacturing sector in Kerala.

2.2 Vision
To be the leader of choice for the sustainable growth of Micro, Small and Medium
Enterprises (MSMEs).
2.3 Mission
The mission of SIDCO is to promote industrial development by:
• Providing modern industrial infrastructure.
• Supporting MSMEs through technical and manufacturing services.
• Supplying quality engineering products and raw materials.
• Offering common facility centres with advanced machinery.
• Developing skilled manpower through technical training programmes.
• Encouraging innovation, entrepreneurship, and sustainable industrial growth.

2.4 Production Units of SIDCO

SIDCO's production units are classified into three major categories based on their
functions.

1. High Precision Machining Centres

These centres undertake precision machining and manufacture high-accuracy
engineering products for aerospace, defence, and industrial applications.
The major high-precision machining centres are:
• SIDCO Tool Room Cum Training Centre, Olavanna, Kozhikode
• Government Instrument Workshop, Pappanamcode, Thiruvananthapuram
• SIDCO Tools, Umayanalloor, Kollam
These units manufacture:
• Precision engineering components
• Aerospace components
• Injection moulds
• Blow moulds
• Rubber moulds
• Pressure die-casting dies
• Jigs and fixtures
• Cutting tools
• Gauges
• Special-purpose precision machining jobs
2. Steel Furniture and Fabrication Centres
These production units undertake fabrication works and manufacture engineering
products for industrial and public-sector applications.
Major units include:
• Pressure Die Casting Unit, Pappanamcode
• SIDCO Service Workshop, Ollur
• SIDCO Straw Board Factory, Parumala
Products manufactured include:
• Steel furniture
• Laboratory equipment
• Hospital furniture
• Kitchen equipment
• Water purifiers
• High mast and mini mast poles
• LED street lights
• Stainless steel water tanks
• Play equipment
• Fitness equipment
• Modular kitchen systems
• Cleaning equipment

3. Wooden Furniture Manufacturing Centres

SIDCO operates specialized furniture manufacturing units with more than four decades
of experience in producing high-quality furniture.
Major units are:
• Woodworking Unit, Pappanamcode
• Wood Workshop, Kollakadavu
• Government Wood Workshop, Kozhikode
These units manufacture:
• Office furniture
• Hospital furniture
 • Laboratory furniture
• Household furniture
• Computer furniture
• Wooden doors and windows
• Aluminium fabrication products
• Interior furnishing products

2.5 SIDCO Tool Room Cum Training Centre,

Olavanna
The SIDCO Tool Room Cum Training Centre (TRTC), Olavanna, is one of the High
Precision Machining Centres operated by Kerala SIDCO. It was established to provide
advanced manufacturing facilities, precision engineering services, and technical training
for engineering students, industries, and MSMEs.
The centre is equipped with modern conventional and CNC machine tools capable of
manufacturing precision engineering products with high dimensional accuracy. It
undertakes the manufacture of aerospace components, precision mechanical assemblies,
moulds, dies, jigs, fixtures, gauges, and other specialized engineering products.
Apart from manufacturing activities, the centre provides industrial training to
engineering students, diploma students, ITI trainees, and industrial personnel, helping
them acquire practical knowledge of modern manufacturing technologies and industrial
work practices.

2.6 Services of SIDCO Tool Room Cum Training

Centre
The major services offered by the centre include:
• Precision machining of engineering components
• Manufacture of aerospace components
• CNC turning and CNC milling operations
• Design and manufacture of injection moulds
• Blow mould manufacturing
• Rubber mould manufacturing
• Pressure die-casting dies
• Jigs and fixtures
 • Cutting tools
• Precision gauges
• Reverse engineering and prototype development
• CAD/CAM support for manufacturing
• Industrial training and skill development

2.7 Major Clients

SIDCO Tool Room Cum Training Centre has established itself as a trusted
manufacturing partner for several prestigious organizations. Its major clients include:
• Indian Space Research Organisation (ISRO)
• Vikram Sarabhai Space Centre (VSSC)
• Hindustan Aeronautics Limited (HAL)
• BrahMos Aerospace
• Bharat Earth Movers Limited (BEML)
• Government Departments
• Public Sector Undertakings (PSUs)
• Government and Quasi-Government Organizations
• Micro, Small and Medium Enterprises (MSMEs)

2.8 Achievements of SIDCO Tool Room Cum Training

Centre
The Tool Room has achieved several important milestones in precision manufacturing
and aerospace component production.
Some of its notable achievements are:
• Signed two Rate Contract Agreements with ISRO in 2014 and 2015, which
continue to be extended.
• Successfully executed several critical precision machining jobs for ISRO.
• Participated in prestigious ISRO projects such as the Reusable Launch Vehicle
Technology Demonstrator (RLV-TD) programme.
• Contributed to the Human Space Flight Programme (Gaganyaan) by
manufacturing precision pyro-system hardware.
 • Manufactured precision mechanical systems and control actuation components
for launch vehicles.
• Successfully supplied Pyro Devices and Control Actuation Systems for various
ISRO programmes.
• Approved as a regular vendor of Vikram Sarabhai Space Centre (VSSC) for
precision mechanical systems.
• Recently approved as a vendor of Hindustan Aeronautics Limited (HAL),
expanding opportunities in the aerospace and defence manufacturing sector.
These achievements demonstrate the technical capability, quality standards, and
reliability of the SIDCO Tool Room Cum Training Centre in executing high-precision
engineering projects for India's leading aerospace and defence organizations.
3.2 Departments and Sections Visited
During the industrial internship at SIDCO Tool Room Cum Training Centre,
Olavanna, we visited various sections of the organization to understand the complete
manufacturing process. Each section performs a specific function and works together to
ensure the production of high-quality precision components.

3.2.1 Office Section

The Office Section is responsible for the overall administration of the organization.
Activities such as customer communication, order processing, production planning,
documentation, accounts, and coordination between different departments are carried
out here.

3.2.2 Conventional Machining Section

This section houses conventional machine tools such as centre lathes, universal
milling machines, vertical turret milling machines, band saw machines, tapping
machines, and surface grinding machines. These machines are used for general
machining operations, prototype work, repair jobs, and machining operations that do not
require CNC technology.

3.2.3 CNC Machining Section

The CNC Machining Section is the main production area of the tool room. It is
equipped with advanced CNC Vertical Machining Centres (VMCs), CNC Horizontal
Machining Centres (HMCs), CNC Lathe Machines, Five-Axis Machining Centres,
and Turn-Mill Centres. These machines are used to manufacture high-precision
components for aerospace, defence, and other engineering applications with high
accuracy and repeatability.

3.2.4 EDM and Design Section

The EDM Section contains Wire EDM, CNC Wire EDM, ZNC EDM, and EDM
Drilling Machines, which are used to machine complex shapes and hardened materials.
Adjacent to this section is the Design Section, where engineers prepare component
models and CNC programs using DELCAM CAD/CAM software. The design team
develops machining programs and tool paths based on customer drawings before
production begins.

3.2.5 Quality Control Section

The Quality Control (QC) Section ensures that manufactured components meet the
required dimensions and quality standards. The section is equipped with advanced
inspection instruments, including Coordinate Measuring Machines (CMMs), digital
height gauges, micrometers, vernier calipers, and other precision measuring
instruments. Both in-process and final inspections are carried out before dispatch.
3.2.6 Store Section
The Store Section is responsible for receiving, storing, and issuing raw materials,
cutting tools, consumables, and safety equipment required for production. It also
maintains inventory records and ensures proper material identification and storage.
Personal protective equipment (PPE), such as gloves required for processes like Liquid
Penetrant Inspection (LPI), is issued from this section. After final inspection, finished
products are properly packed, documented, and dispatched to customers from the stores.

3.2.7 Manufacturing Workflow

The manufacturing process followed at SIDCO Tool Room Cum Training Centre can be
summarized as follows:
Customer Order → Design & CAD/CAM Programming → Material Issue from
Store → Machining (Conventional/CNC/EDM) → Quality Inspection → Packing
→ Dispatch
This systematic workflow helps ensure that every component is manufactured according
to customer specifications while maintaining high standards of quality and timely
delivery.
Materials Used and Their Applications
The manufacturing facility undertakes precision machining of a variety of engineering
materials based on customer specifications and the functional requirements of the final
product. Material selection is carried out by considering properties such as strength,
weight, hardness, wear resistance, corrosion resistance, and machinability. The most
commonly machined materials observed during the training were aluminium alloys and
titanium alloys, along with various grades of steel and non-ferrous metals.
Aluminium Alloys:
Aluminium alloys are extensively used because of their low density, excellent
machinability, high strength-to-weight ratio, and corrosion resistance. These properties
make them suitable for lightweight precision components, tooling, fixtures, and
aerospace applications.
Titanium Alloys:
Titanium alloys possess high mechanical strength, low density, outstanding corrosion
resistance, and excellent performance at elevated temperatures. These materials are
widely used for manufacturing precision components requiring high reliability and long
service life.
Tool Steel:
Tool steels are characterized by high hardness, wear resistance, and toughness. They are
commonly used in the manufacture of dies, moulds, cutting tools, gauges, punches, and
other tooling applications.
Stainless Steel:
Stainless steel provides excellent corrosion resistance, durability, and mechanical
strength. It is used for precision engineering components, industrial equipment, fixtures,
and parts operating under corrosive conditions.
Mild Steel:
Mild steel offers good machinability, weldability, and adequate strength for general
engineering applications. It is commonly used for machine parts, fabricated structures,
fixtures, and prototype components.
Copper and Brass:
Copper and brass are selected for applications requiring high electrical and thermal
conductivity, together with good machinability. These materials are widely used in
electrical components, precision fittings, bushes, and connectors.
The selection of suitable engineering materials plays a vital role in ensuring the required
mechanical properties, dimensional accuracy, durability, and overall performance of the
manufactured components.
4.1 Conventional Machines
Conventional machines are manually operated machine tools used for machining,
shaping, cutting, threading, and finishing engineering materials. Although CNC
machines are widely used for precision manufacturing, conventional machines remain
important for prototype development, repair work, maintenance, and simple machining
operations.

4.1.1 Centre Lathe Machine

Working Principle

A lathe machine operates on the principle that the workpiece rotates while the cutting
tool remains stationary or moves linearly. Material is removed from the rotating
workpiece by the cutting tool to produce the desired shape and dimensions.

Applications

• Turning cylindrical components

• Facing operations
• Thread cutting
• Knurling
• Drilling and boring
• Taper turning
• Repair and maintenance work

4.1.2 Universal Milling Machine

Working Principle

A milling machine removes material using a rotating multi-point cutting tool while
the workpiece is securely clamped on the machine table. The table can be moved in
different directions to perform various machining operations.

Applications

• Flat surface machining

• Slot and keyway cutting
• Gear cutting
• Profile machining
 • Angular machining
• Production of machine components

4.1.3 Vertical Ram Turret Milling Machine

Working Principle

The Vertical Ram Turret Milling Machine is a versatile milling machine in which the
spindle is mounted vertically. The turret and ram allow the spindle to be positioned at
different angles and locations, enabling machining from various directions without
repositioning the workpiece.

Applications

• Precision milling
• Drilling and boring
• Slot milling
• Face milling
• Prototype machining
• Tool room applications

4.1.4 Tapping Machine

Working Principle

A tapping machine is used to produce internal threads inside pre-drilled holes by

rotating a tap into the workpiece. The machine ensures accurate thread formation while
maintaining proper alignment.

Applications

• Internal thread cutting

• Manufacturing threaded holes
• Assembly components
• Production of machine parts
• Tool room operations
4.1.5 Heavy Duty Double Column Band Saw
Working Principle

A band saw uses a continuous loop of toothed metal blade running over two wheels to
cut metal stock. The workpiece is clamped while the moving blade performs the cutting
operation.

Applications

• Cutting raw material to required length

• Cutting bars, rods, pipes, and blocks
• Preparing workpieces before machining
• Production and fabrication work
These conventional machines are mainly used for material preparation, prototype
development, repair work, and general machining operations before or after precision
CNC machining.

4.2 CNC Machines

Computer Numerical Control (CNC) machines are automated machine tools controlled
by computer programs. They are capable of producing complex and high-precision
components with excellent dimensional accuracy, repeatability, and surface finish. CNC
technology minimizes human error, reduces production time, and improves
manufacturing efficiency. The manufacturing facility is equipped with several advanced
CNC machines for precision machining applications.

4.2.1 CNC Lathe Machine

Working Principle

A CNC lathe operates by rotating the workpiece while the cutting tool moves along
programmed paths to remove material. The machine performs turning operations
automatically according to the CNC program.

Applications

• Turning cylindrical components

• Facing and taper turning
• Thread cutting
• Grooving
 • Boring
• Precision shaft manufacturing

4.2.2 CNC Vertical Machining Centre (VMC)

Working Principle

A Vertical Machining Centre has a vertically mounted spindle that rotates the cutting
tool while the workpiece is clamped on the machine table. Material is removed by
programmed movements along the X, Y, and Z axes.

Applications

• Face milling
• Slot milling
• Pocket milling
• Drilling
• Tapping
• Contour machining
• Precision component manufacturing

4.2.3 CNC Horizontal Machining Centre (HMC)

Working Principle

In a Horizontal Machining Centre, the spindle is mounted horizontally. The workpiece

is fixed on a pallet, allowing machining on multiple faces with improved chip removal
and reduced setup time.

Applications

• Multi-face machining
• Heavy-duty milling
• Large precision components
• Batch production
• Aerospace and automotive components
4.2.4 CNC Five-Axis Vertical Machining Centre
Working Principle

A Five-Axis Machining Centre allows simultaneous movement along the X, Y, and Z

linear axes together with two rotary axes. This enables machining of complex
components from multiple directions in a single setup.

Applications

• Aerospace components
• Complex moulds and dies
• Turbine blades
• Medical implants
• Precision engineering components

4.2.5 CNC Vertical Machining Centre with 4+1 Axis

Rotary Tilting Table
Working Principle

This machine combines the three linear axes with a rotary tilting table. The workpiece
can be indexed or tilted to different angles, allowing machining on multiple faces
without repeated repositioning.

Applications

• Angular machining
• Multi-sided components
• Mould manufacturing
• Fixture manufacturing
• Precision machining

4.2.6 CNC High Precision Turn-Mill Centre

Working Principle

A Turn-Mill Centre combines CNC turning and CNC milling operations in a single
machine. The workpiece rotates for turning operations, while driven tools perform
milling, drilling, and tapping without transferring the component to another machine.
Applications

• Complex precision components

• Shafts with milled features
• Aerospace components
• High-accuracy engineering parts
• Reduced setup and machining time

Advantages of CNC Machines

• High dimensional accuracy
• Excellent repeatability
• Ability to machine complex geometries
• Reduced production time
• Improved surface finish
• Higher productivity
• Reduced manual intervention
• Consistent product quality
• Suitable for mass production and precision manufacturing
The advanced CNC machines available in the manufacturing facility enable the
production of high-quality precision components used in aerospace, defence, tooling,
and other engineering applications.
4.3 Die and Mould Manufacturing
The manufacturing facility specializes in the design and manufacture of precision dies,
moulds, jigs, fixtures, gauges, and aerospace components. These products are
manufactured according to customer drawings using advanced machining techniques to
achieve high dimensional accuracy, surface finish, and reliability.

4.3.1 Injection Mould

Injection moulds are precision tools used for producing plastic components by injecting
molten plastic into a mould cavity under high pressure. After cooling and solidification,
the finished product is ejected from the mould.
Applications:
• Plastic automotive components
• Electrical and electronic parts
• Household products
• Medical devices
• Industrial plastic components

4.3.2 Blow Mould

Blow moulds are used to manufacture hollow plastic products. In this process, heated
plastic is inflated inside the mould cavity using compressed air until it takes the required
shape.
Applications:
• Plastic bottles
• Containers
• Fuel tanks
• Storage cans
• Industrial packaging products

4.3.3 Press Die

A press die is a precision tool used in press machines for shaping, cutting, bending,
punching, or forming sheet metal into the required shape. Press dies ensure high
production rates with consistent quality.
Applications:
 • Sheet metal components
• Automotive parts
• Electrical enclosures
• Metal brackets
• Precision press components

4.3.4 Jigs
A jig is a work-holding device that accurately locates the workpiece and guides the
cutting tool during machining. It improves machining accuracy and reduces production
time.
Applications:
• Drilling operations
• Repetitive machining
• Mass production
• Precision hole positioning

4.3.5 Fixtures
A fixture is a device used to securely hold and locate the workpiece during machining.
Unlike a jig, it does not guide the cutting tool but ensures stability and repeatability.
Applications:
• Milling operations
• Turning operations
• Grinding
• Welding
• CNC machining

4.3.6 Gauges
Gauges are precision inspection tools used to verify the dimensions and tolerances of
manufactured components. They help ensure that products meet specified quality
standards.
Applications:
• Dimensional inspection
 • Quality control
• Go/No-Go inspection
• Production verification

4.3.7 Aerospace Components

The manufacturing facility also produces high-precision aerospace components that
require extremely close tolerances and stringent quality control. These components are
manufactured using advanced machining processes and undergo detailed inspection
before delivery.
Applications:
• Launch vehicle systems
• Precision mechanical assemblies
• Control system components
• Aerospace tooling
• Defence and space engineering applications
The manufacture of these precision products requires careful material selection,
accurate machining, rigorous quality inspection, and strict adherence to engineering
specifications to ensure reliable performance in demanding industrial and aerospace
applications.
4.4 Electrical Discharge Machining
(EDM) Technologies
Electrical Discharge Machining (EDM) is a non-traditional machining process used to
machine electrically conductive materials. In this process, material is removed by a
series of controlled electrical sparks generated between the tool electrode and the
workpiece while both are immersed in a dielectric fluid. Since there is no direct contact
between the tool and the workpiece, EDM is capable of machining hard materials and
complex shapes with high accuracy.

4.4.1 Wire EDM

Principle

Wire EDM uses a continuously moving thin wire, usually made of brass or coated wire,
as the electrode. Electrical sparks generated between the wire and the workpiece remove
material accurately along the programmed path. The dielectric fluid continuously cools
the workpiece and flushes away the eroded particles.

Advantages

• High dimensional accuracy

• Excellent surface finish
• Can machine hardened materials
• No cutting forces on the workpiece
• Suitable for intricate profiles and narrow slots
• Produces burr-free components

Applications

• Precision dies and moulds

• Punches and tooling
• Aerospace components
• Precision engineering parts
• Jigs and fixtures
• Complex profile machining
4.4.2 ZNC EDM (Sinker EDM)
Principle

ZNC (Z-axis Numerical Control) EDM uses a specially shaped electrode made of
copper or graphite. The electrode gradually moves towards the workpiece, and
controlled electrical discharges erode the material to produce the required cavity or
shape. The process is commonly used where conventional cutting tools cannot reach.

Advantages

• Produces complex cavities and intricate shapes

• Machines very hard materials with ease
• High dimensional accuracy
• Good surface finish
• No mechanical cutting forces
• Suitable for deep cavities and sharp internal corners

Applications

• Injection moulds
• Die-casting dies
• Forging dies
• Precision cavities
• Tool and die manufacturing
• Prototype components

4.4.3 EDM Drilling

Principle

EDM Drilling, also known as hole drilling EDM, uses a rotating tubular electrode to
produce small and deep holes through spark erosion. Dielectric fluid flows through the
electrode to remove debris and cool the machining zone.

Advantages

• Produces very small diameter holes

• Capable of drilling deep holes
 • Machines hardened materials
• High accuracy
• No tool breakage due to cutting forces
• Suitable for difficult-to-machine materials

Applications

• Start holes for Wire EDM

• Cooling holes in moulds and dies
• Aerospace components
• Turbine blades
• Precision engineering components
• Medical and electronic components

Advantages of EDM Technology

• Can machine hardened steels, titanium, carbide, and other difficult-to-machine
materials.
• Produces intricate shapes and complex geometries with high precision.
• No direct contact between the tool and workpiece, eliminating cutting forces.
• Excellent dimensional accuracy and surface finish.
• Burr-free machining with minimal distortion.
• Suitable for manufacturing precision dies, moulds, aerospace components, and
tooling.
EDM technology plays an important role in modern precision manufacturing because it
enables the production of components that are difficult or impossible to machine using
conventional machining processes.
4.5 Grinding and Heat Treatment
Grinding and heat treatment are important manufacturing processes used to improve the
dimensional accuracy, surface finish, hardness, and mechanical properties of
engineering components. During the industrial training, surface grinding and cylindrical
grinding operations were observed, and the purpose of common heat treatment
processes was studied.

4.5.1 Surface Grinding

Working Principle

Surface grinding is a finishing process in which a rotating abrasive grinding wheel

removes a small amount of material from the surface of a workpiece. The workpiece is
usually held on a magnetic chuck while the grinding wheel moves over the surface to
produce a smooth and accurate finish.

Applications

• Finishing flat surfaces

• Achieving close dimensional tolerances
• Improving surface finish
• Finishing machine parts, dies, and moulds
• Preparing surfaces before assembly

4.5.2 Cylindrical Grinding

Working Principle

Cylindrical grinding is used to finish the external surface of cylindrical components.

The workpiece rotates between centres or in a chuck while the grinding wheel rotates at
high speed and removes a small amount of material to obtain the required diameter and
surface finish.

Applications

• Finishing shafts and rollers

• Precision cylindrical components
• Bearing seats
• Spindles
 • Machine tool components

4.5.3 Heat Treatment

Heat treatment is a controlled process of heating and cooling metals to modify their
mechanical properties without changing their shape. It is commonly used to improve
hardness, strength, toughness, and relieve internal stresses.

Hardening

Hardening is carried out by heating the material above its critical temperature and then
rapidly cooling it, usually in water, oil, or another suitable quenching medium. This
process increases the hardness and wear resistance of the material.
Applications:
• Cutting tools
• Dies and moulds
• Gears
• Machine components subjected to wear

Tempering

Tempering is performed after hardening by reheating the hardened material to a lower

temperature and then allowing it to cool. This process reduces brittleness while
improving toughness and ductility.
Applications:
• Machine tools
• Shafts
• Springs
• Automotive and aerospace components

Stress Relieving

Stress relieving is a heat treatment process used to remove internal stresses developed
during machining, welding, casting, or forming. The component is heated to a moderate
temperature and cooled slowly to minimize distortion and improve dimensional
stability.
Applications:
• Welded structures
 • Precision machined components
• Dies and moulds
• Large fabricated parts
Grinding and heat treatment together play an important role in producing precision
engineering components with the required dimensional accuracy, surface quality,
hardness, and service life.
4.6 CAD/CAM Department
The CAD/CAM Department is responsible for converting customer requirements and
engineering drawings into digital models and CNC machining programs. It acts as the
link between product design and manufacturing, ensuring that components are produced
accurately and efficiently. During the training, the activities carried out in this
department, including engineering drawing interpretation, CAD modelling, CAM
programming, and CNC code generation, were studied.

4.6.1 Engineering Drawing

Engineering drawings provide complete information about a component, including its
dimensions, tolerances, material specifications, surface finish, and machining
requirements. They serve as the primary means of communication between the design,
production, and inspection departments.
Applications:
• Product design and development
• Manufacturing planning
• Quality inspection
• Assembly and production documentation

4.6.2 AutoCAD
AutoCAD is a Computer-Aided Design (CAD) software used to prepare accurate two-
dimensional (2D) engineering drawings and basic three-dimensional (3D) models. It
improves drawing accuracy, simplifies modifications, and reduces design time.
Applications:
• 2D drafting
• Engineering layouts
• Component detailing
• Technical documentation

4.6.3 DELCAM Software

DELCAM is an advanced CAD/CAM software package used for designing
components, creating tool paths, and programming CNC machines. The software
supports complex machining operations and accepts standard CAD file formats such as
IGES (IGS) and STEP (STP).
Applications:
• Component design
• Tool path generation
• CNC machining simulation
• Manufacturing process planning

4.6.4 CAD Modelling

CAD modelling is the process of creating accurate three-dimensional digital models of
engineering components. These models help designers visualize the product, verify
dimensions, and identify possible design issues before manufacturing.
Applications:
• Product development
• Die and mould design
• Assembly verification
• Engineering analysis

4.6.5 CAM Programming

Computer-Aided Manufacturing (CAM) programming uses CAD models to generate
machining tool paths and machining parameters for CNC machines. The software
determines cutting sequences, tool movements, spindle speeds, feed rates, and
machining operations.
Applications:
• CNC milling
• CNC turning
• Multi-axis machining
• Tool path optimization
• Production planning

4.6.6 CNC Code Generation

After CAM programming, the software generates CNC part programs in the form of G-
codes and M-codes. These programs provide instructions to the CNC machine,
specifying tool movements, spindle speed, feed rate, coolant operation, and machining
sequence. The generated code is verified before being transferred to the machine for
production.
Applications:
• Automated machining
• Precision component manufacturing
• Multi-axis machining
• Repeatable production
• Reduction of machining errors
The CAD/CAM Department plays a vital role in modern manufacturing by improving
design accuracy, reducing production time, minimizing material wastage, and ensuring
the efficient manufacture of high-precision engineering components.
4.7 Quality Control and Metrology
Quality Control (QC) is an essential part of the manufacturing process that ensures
every component meets the specified dimensions, tolerances, and quality standards
before delivery. The Quality Control Department carries out incoming, in-process, and
final inspections using precision measuring instruments. During the training, various
metrology instruments and inspection methods used for precision manufacturing were
studied.

4.7.1 Coordinate Measuring Machine (CMM)

Working Principle

A Coordinate Measuring Machine (CMM) measures the dimensions of a component by

using a precision probe to collect coordinate points on its surface. The measured data
are compared with the CAD model or engineering drawing to verify dimensional
accuracy.

Applications

• Dimensional inspection of precision components

• Inspection of dies and moulds
• Aerospace components
• Geometric tolerance verification
• Final quality inspection

4.7.2 Vernier Caliper

Working Principle

A Vernier caliper measures external, internal, and depth dimensions using a main scale
and a Vernier scale. The difference between the two scales provides accurate
measurements.

Applications

• External diameter measurement

• Internal diameter measurement
• Depth measurement
• General dimensional inspection
4.7.3 Micrometer
Working Principle

A micrometer measures small dimensions using a precision screw mechanism. Rotation

of the thimble moves the spindle linearly, allowing highly accurate measurement.

Applications

• Shaft diameter measurement

• Thickness measurement
• Precision inspection
• Tool and component measurement

4.7.4 Height Gauge

Working Principle

A height gauge is used on a surface plate to measure or mark the height of a component
from a reference surface. It consists of a vertical scale with a movable measuring slider.

Applications

• Height measurement
• Layout marking
• Inspection of machined components
• Precision measurement

4.7.5 Dial Indicator

Working Principle

A dial indicator measures small linear displacements using a spring-loaded plunger

connected to a pointer on a graduated dial. It is mainly used to detect deviations from
the required position or alignment.

Applications

• Runout measurement
• Flatness inspection
• Alignment checking
 • Machine setup
• Concentricity inspection

4.7.6 Surface Roughness Testing

Working Principle

Surface roughness testing is carried out using a surface roughness tester that moves a
stylus over the machined surface. The instrument records the surface profile and
calculates the roughness value, commonly expressed as Ra.

Applications

• Surface finish evaluation

• Quality control of machined parts
• Inspection of precision components
• Verification of customer specifications

4.7.7 Inspection Methods

The Quality Control Department follows systematic inspection procedures throughout
the manufacturing process to ensure product quality.

Incoming Inspection

Raw materials and purchased items are inspected before they are accepted for
production.

In-Process Inspection

Components are inspected during machining to verify dimensions and prevent

manufacturing errors.

Final Inspection

After machining is completed, each component undergoes final dimensional and visual
inspection to ensure compliance with engineering drawings and customer specifications
before dispatch.
Quality control and metrology play a vital role in precision manufacturing by ensuring
dimensional accuracy, maintaining product quality, reducing defects, and improving
customer satisfaction.
CHAPTER 5
Daily Internship Activities
Day 1
The internship commenced with the completion of registration and other official
formalities. A safety briefing and orientation session were conducted, followed by a
general introduction to the organization and its manufacturing activities. The layout of
the tool room and the major departments were explained.

Day 2
A detailed visit to the Conventional Machining, CNC Machining, EDM, CAD/CAM,
Quality Control, and Stores sections was conducted. The functions of each department,
the responsibilities of technical staff, and the general work culture of a precision tool
room were explained. The working principle of the profile comparator and its role in
inspection were also demonstrated.

Day 3
Training was provided in the Conventional Machining Section. The operation of the
heavy-duty band saw machine for cutting raw materials was demonstrated, and
assistance was provided during material cutting. The working principle and basic
operations of the conventional centre lathe, including turning and facing operations,
were also studied.

Day 4
The functioning of conventional milling machines, CNC Vertical Machining Centres
(VMC), and Horizontal Machining Centres (HMC) was studied. The basic concepts of
CNC programming, including G-codes and M-codes, machine coordinates, and
machining sequences, were introduced.

Day 5
The operation of the tapping machine and thread-cutting process was explained. An
introduction to Liquid Penetrant Inspection (LPI) was provided, including the
procedure, safety precautions, and the use of Personal Protective Equipment (PPE).
Under supervision, Liquid Penetrant Inspection was performed on finished components
to identify surface defects.

Day 6
The working of CNC lathe machines was studied in detail. The machining sequence,
work holding methods, cutting tools, and CNC program execution were explained.
Basic G-code and M-code commands used in CNC turning operations were discussed.
Day 7
Further exposure to CNC lathe operations was provided. Various turning operations and
machining cycles were observed, and discussions were held on programming concepts,
dimensional accuracy, and machining parameters. Assigned Liquid Penetrant Inspection
activities were also carried out.

Day 8
The Electrical Discharge Machining (EDM) section was visited. The working principles
and applications of Wire EDM, ZNC EDM, and EDM Drilling machines were
demonstrated. Their importance in machining complex and hardened components was
explained.

Day 9
The CAD/CAM Department was visited to study engineering drawings, CAD
modelling, CAM programming, tool path generation, and CNC code generation using
DELCAM software. The relationship between design and CNC machining was
explained. Assigned Liquid Penetrant Inspection work was also carried out.

Day 10
Further study of EDM machining processes and CAD/CAM programming was
undertaken. Demonstrations of machining operations using generated CNC programs
were observed, followed by supervised Liquid Penetrant Inspection of completed
components.

Day 11
Training continued in the Conventional Milling Section, where different milling
operations and machine settings were studied. The Stores and Inventory Section was
also visited to understand inventory management, material identification, storage
procedures, and the operation of the power lift used for material handling.

Day 12
Activities in the Stores Section continued with material handling and inventory
management. Assistance was provided in organizing engineering materials and handling
workpieces using the power lift under supervision. Assigned Liquid Penetrant
Inspection work was also completed.

Day 13
The Quality Control and Metrology Section was visited. The operation of the
Coordinate Measuring Machine (CMM), Vernier calipers, micrometers, height gauges,
dial indicators, and other measuring instruments was demonstrated. Various inspection
procedures followed for precision components were explained.
Day 14
On the final day, assistance was provided in measuring the dimensions of raw materials
and workpieces before machining. Material dimensions were verified and approximate
material requirements were estimated based on engineering drawings. The internship
concluded with an interaction with the technical staff, clarification of doubts, and a
review of the knowledge gained during the training.
CHAPTER 6
Skills Acquired, Industrial Exposure,
Learning Outcomes, Challenges Faced
and Suggestions
6.1 Skills Acquired
The industrial internship provided an opportunity to develop both technical knowledge
and professional skills related to modern manufacturing. The major skills acquired
during the training include:
• Basic understanding of precision manufacturing processes.
• Knowledge of conventional and CNC machining operations.
• Familiarity with CAD/CAM applications and CNC programming concepts.
• Understanding of EDM technologies and grinding processes.
• Basic knowledge of engineering materials and their industrial applications.
• Exposure to precision measuring instruments and quality inspection methods.
• Improved ability to interpret engineering drawings and manufacturing
workflows.
• Awareness of industrial safety practices and workplace discipline.

6.2 Industrial Exposure

The internship offered practical exposure to the functioning of a precision
manufacturing facility. It helped in understanding how different departments work
together to transform customer requirements into finished products. The exposure
included:
• Organization of a modern tool room.
• Production planning and manufacturing workflow.
• Advanced machining technologies.
• Quality assurance and metrology practices.
• Material handling and inventory management.
• Industrial work culture and teamwork.
6.3 Learning Outcomes
The internship bridged the gap between classroom learning and industrial practice. The
major learning outcomes are:
• Understanding the complete manufacturing process from design to dispatch.
• Learning the applications of CNC machining and EDM in precision
manufacturing.
• Gaining knowledge of dies, moulds, jigs, fixtures, and gauges.
• Understanding the importance of quality control and dimensional inspection.
• Appreciating the role of CAD/CAM in modern manufacturing.
• Developing awareness of industrial standards, productivity, and quality
requirements.
• Understanding the importance of safety, documentation, and systematic
workflow in industry.

6.4 Challenges Faced

Although the internship was highly informative, a few challenges were encountered
during the training:
• Understanding the operation of advanced CNC and EDM machines within the
limited training period.
• Familiarizing with technical terminology and industrial documentation.
• Limited opportunity for hands-on operation of high-precision machines due to
safety and operational restrictions.
• Understanding complex manufacturing processes and quality standards within a
short duration.
These challenges were addressed through demonstrations, discussions with engineers,
and continuous observation of industrial practices.

6.5 Suggestions
Based on the experience gained during the internship, the following suggestions are
offered:
• Increase the duration of industrial internships to allow more practical exposure.
• Include more hands-on sessions under the supervision of experienced engineers.
 • Conduct technical demonstrations on CNC programming, CAD/CAM software,
and quality inspection methods.
• Organize interactive sessions on industrial standards, quality management, and
modern manufacturing technologies.
• Encourage regular interaction between students and industry professionals to
enhance practical knowledge and career awareness.
Overall, the internship was highly beneficial in improving technical knowledge,
industrial awareness, and professional confidence. It provided valuable insight into
precision manufacturing practices and highlighted the importance of modern
technologies in the mechanical engineering industry.
Practical Activities Performed During the Internship
In addition to observing various manufacturing processes, we were given the
opportunity to participate in several shop-floor activities under the supervision of
experienced technical staff. These practical activities helped us understand industrial
procedures, safety practices, and quality requirements.
• Assisted in Liquid Penetrant Inspection (LPI) for detecting surface defects in
machined components. During the inspection, appropriate Personal Protective
Equipment (PPE), including protective gloves, was used while handling
penetrant, cleaner, and developer chemicals.
• Performed dimensional measurement of long bars and raw materials using
measuring instruments to verify dimensions before machining.
• Assisted in the handling and lifting of metal bars, blocks, and cubical
workpieces for material movement between the stores, machining sections, and
inspection areas while following safe material handling practices.
• Participated in cleaning metal chips and swarf generated during machining
operations to maintain machine cleanliness, improve workplace safety, and
ensure smooth production.
• Observed the preparation of workpieces before machining, including material
identification, marking, and loading for machining operations.
• Assisted in maintaining cleanliness and proper organization of the work area in
accordance with good industrial housekeeping practices.
These practical activities provided valuable exposure to industrial working conditions
and improved our understanding of manufacturing operations, quality inspection,
material handling, workplace safety, and shop-floor discipline.
CHAPTER 7
Conclusion
The industrial internship provided valuable exposure to the working environment of a
modern precision manufacturing facility. It helped in understanding the practical aspects
of manufacturing, quality control, production planning, and industrial management that
complement the theoretical knowledge gained during the [Link] Mechanical
Engineering programme.
During the internship, various manufacturing departments were visited and the
operation of conventional machines, CNC machining centres, EDM technologies,
grinding machines, CAD/CAM systems, and metrology equipment was studied. The
workflow from design and material selection to machining, inspection, and dispatch
provided a clear understanding of industrial production practices.
The internship also emphasized the importance of engineering drawings, precision
machining, quality assurance, workplace safety, teamwork, and professional discipline.
The exposure to modern manufacturing technologies and industrial practices enhanced
technical knowledge and provided valuable insight into the requirements of the
manufacturing and aerospace industries.
Overall, the internship was a highly beneficial learning experience that strengthened
practical skills, improved industrial awareness, and increased confidence in applying
engineering concepts to real-world manufacturing processes. The knowledge and
experience gained during this training will be valuable for future academic studies and
professional career development.