INTERNSHIP REPORT

Submitted By: Hisbah Fatimah

Submitted To: POFIT

Reg #: FA21-BME-027

Program: BS (Mechanical Engineering)

Duration: 26 July 2024 – 22 Aug 2024

COMSATS University Islamabad,Wah Campus

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 TABLE OF CONTENTS

INTRODUCTION. ............................................................................................................................................................................................ 4

PAKISTAN ORDNANCE FACTORIES. ................................................................................................................................................................. 4

WEAPONS FACTORY. ..................................................................................................................................................................................... 5

C-24 PRESS & WELDING SHOP.........................................................................................................................................................................6

C-23 BARREL & AUTOMATICS SHOP. ............................................................................................................................................................ 12

SINGLE AUTO SECTION. ..................................................................................................................................................................... 12

MULTIPLE AUTO SECTION.................................................................................................................................................................. 13

BARREL SECTION. ...............................................................................................................................................................................15

C-22 MACHINING SHOP. ............................................................................................................................................................................... 17

GROUP A ................................................................................................................................................................................................ 21

GROUP B. ...............................................................................................................................................................................................23

GROUP C. ...............................................................................................................................................................................................26

GROUP D. ............................................................................................................................................................................................... 27

GROUP E................................................................................................................................................................................................. 29

C-21 HEAT TREATMENT SHOP. ........................................................................................................................................................................ 31

HEAT TREATMENT ............................................................................................................................................................................ 31

SURFACE TREATMENT.......................................................................................................................................................................35

B-22 CNC SHOP. ............................................................................................................................................................................................. 40

B-20 ASSEMBLY SHOP. .................................................................................................................................................................................... 44

MG3 SECTION................................................................................................................................................................................... 44

G3A3 & MP5 SECTION....................................................................................................................................................................... 45

IDA................................................................................................................................................................................................... 47

C-26 PLASTIC SHOP. ....................................................................................................................................................................................... 48

SUGGESTION. ................................................................................................................................................................................................. 49

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 INTRODUCTION

The Pakistan Ordnance Factories (reporting name: POF) is a major firearm, defense contractor, and
military corporation headquartered in Wah Cantt, Punjab, Pakistan. It is "the largest defense industrial
Complex under the Ministry of Defense Production, producing conventional arms & ammo to
international standards. POF Board headquarter is at Wah Cantt.

PAKISTAN ORDNANCE FACTORIES

HISTORY

In 1894, this project was launched by the British and it was named as Weapon Repairing Factory.
Keep in mind that this was not the name of just the weapon factory, but it was the name of the whole
setup.

In 1951, President Sikander Mirza and Prime Minister of the time Khawaja Nazimuddin approved the
modification in the name from Weapons Repairing Factory to Pakistan Ordnance Factories (POFs).

WEAPONS FACTORY

INTRODUCTION
Weapons Factory of Pakistan Ordnance Factories is the biggest industrial complex in Pakistan. The
demands are mainly from the armed forces but in some cases other domestic dealers have contacted
POF for weapon supplying.

The weapons factory manufactures parts of a weapon, machining of the parts, finishing of the parts, fitting
or assembly of the weapon and proof testing of the weapon in a closed and safe environment.

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SECTIONS & SHOPS
There are many sections in Weapons Factory, but the major sections related to our concern are:
 C-26 (Plastic Shop)
 C-25 (Store)
 C-24 (Press and Welding Shop)
 C-23 (Barrel & Automatics Shop)
 C-22 (Machining Shop)
 C-21 (Heat Treatment Shop)
 C-20 (Woodworks Shop)
 B-22 (CNC Shop)
 B-20 (Assembly Shop)
 Tool Room Weapon (TRW)

WEAPONS

Some of the weapons being manufactured in weapons factory are listed below.
 G3A3
 MG3
 MP5 A2
 MP5 P3
 POF Eye
 DMR
 .308 Win Sportier
 SMG PK1 > POF-4 Pistol
 POF-5 Pistol
 LSR

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 C-24 (Press & Welding Shop)

Introduction

A Press and Welding Shop in a weapons factory is a specialized manufacturing unit where various metal
components for weapons are fabricated, shaped and assembled.

The press shop is equipped with heavy machinery such as power presses, hydraulic presses, and stamping machines.
These machines are used to cut, shape, and form metal sheets into precise components used for weapon manufacturing.
The process involves operations like blanking, punching, bending, and drawing, which are critical in producing parts with
high accuracy and strength.

The welding shop is dedicated to joining metal components together using various welding techniques such as MIG, TIG,
spot welding, and arc welding. This shop ensures that different parts of the weapons, such as barrels, frames, and other
assemblies, are securely and precisely joined to meet strict safety and durability standards.

Press Machine
A press machine works by applying a controlled force to shape, cut, or mold metal into desired forms using a die. It operates
through mechanical, hydraulic, or pneumatic means, enabling precise shaping of metal sheets. We need press machines to
efficiently produce consistent, high-accuracy parts for weapon. They are essential for mass production, reducing labor costs, and
ensuring uniformity in the components produced.

1) Pneumatic Press
A pneumatic press uses compressed air to generate force, driving a piston that moves a ram to perform tasks like
punching, bending, or forming. It's fast and efficient, suitable for light to medium-duty operations, and offers easy control
and adjustment.

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 2) Hand Press
A hand press operates manually, using a lever or screw mechanism to apply force. It's ideal for small-scale, low-force
applications like assembly, stamping, or riveting, where precision and control are more important than speed.

3) Hydraulic Press

A hydraulic press uses a hydraulic cylinder filled with fluid to generate high force, pushing a ram to shape or
cut materials. It's powerful, capable of handling heavy-duty operations, and provides consistent pressure
throughout the process.

4) Eccentric Press
An eccentric press uses a rotating eccentric cam to convert rotary motion into linear motion, driving the ram up and down.
It's commonly used for stamping, punching, and forming, offering high speed and precision in operations.

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 5) Frictional Press
A friction press operates using a flywheel and friction discs to generate force, which is transferred to the ram. It’s
typically used for tasks like forging and coining, where high impact force is needed for short-duration operations.

Material Used in C-24 Shop

Type of Operation
The main types of operations perform in C-24 shops are:

 Blanking

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  Bending
 Shaving

 Trimming
 Stamping
 Folding
 Embossing
 Forming
 Blocking

Different Components Manufacture in C-24

 FS Holder
 Loading Handle
 Magazine (G3A3 & MP5)
 Safety Pin
 Receiver (G3A3 & MP5)
 LL Housing
 Front Sight
 Magazine Catch
 Pistol Grip
 Trigger Housing
 Bearing plate
 Clip spring tension
 Back plate
 Lining
 Magazine floor plate

 Follower (G3A3 & MP5)

 Scribers tube
 Safety Catch
 Trigger
 Trigger Guard

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Front Sight Holder
[Link]. Operation Tool/Fixture Gauge
1 Cut off at least Special jaws Vernier caliper
73-0.25mm 101.3-101.55 V2
(unilateral)

2 Rough Round stamping tool Vernier caliper

stamping 1013-101-55W1

3 Finish Round stamping tool Vernier caliper

stamping 1013-101-55W2
(round)

4 Finish Round stamping tool Vernier caliper

stamping 1013-101-55W3
(simple)

5 Trim outer Round stamping tool Vernier caliper

form 1013-101-55W5

6 Piercing Round stamping tool Vernier caliper

1013-101-55W4

Welding
Welding is a process that joins two or more metal parts by melting the base materials and adding a filler material to
form a strong joint upon cooling. It involves intense heat, often generated by an electric arc, gas flame, or laser. Welding creates
a permanent bond between the metals, ensuring structural integrity. It's widely used in weapon manufacturing. Proper technique
and equipment are crucial to achieving a durable and defect-free weld.

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 1) Arc Welding

Arc welding uses an electric arc between an electrode and the workpiece to generate intense heat, melting the
metals to create a strong joint. The process can be manual and it’s suitable for various metals. It often requires a
filler material to fill gaps and strengthen the weld. Common types include Shielded Metal Arc Welding
(SMAW) and Gas Metal Arc Welding (GMAW).

2) Spot Welding
Spot welding is a resistance welding process where two overlapping metal sheets are joined by applying electrical current
and pressure at specific points. This creates localized heat that melts and fuses the metal at the contact points. It’s
commonly used in weapon manufacturing and sheet metal fabrication for creating strong, quick welds.

3) MIG Welding
MIG (Metal Inert Gas) welding is a type of arc welding where a continuous wire electrode is fed through a welding gun,
and an inert gas shield protects the weld pool from contamination. It’s known for its speed and ease of use, making it
suitable for thin to medium-thick materials. MIG welding is also used in C-24 shop.

4) Seam Welding
Seam welding is a resistance welding process that joins overlapping sheets of metal by applying pressure and passing an
electric current through the entire seam. The continuous weld is created by rotating electrodes that move along the seam.
It’s used for creating Scribers tube

5) Projection Welding
Projection welding is a form of resistance welding where specific areas of the metal parts are locally heated and joined
through projections or dimples. This process is ideal for welding parts with complex geometries and is used in high-
volume production for joining small metal components, like fasteners and fittings.

6) Gas Welding

Gas welding, or oxy-fuel welding, uses a flame produced by burning oxygen and a fuel gas (usually acetylene) to melt and
join metals. It’s often used for welding thin materials and precision work. The process requires a filler rod, which is
melted to form the weld. Gas welding is versatile and commonly used in repair and artistic applications.

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 C-23 (Barrel & Automatic Shop)
This is the Weapon Factory's most important and crucial shop since the C-23 workshop is where the most
crucial part of a rifle or gun is made. For the bulk manufacture of smaller components like locking pins and the
like, there are also automatic rods filling machines that are driven by a cam.

Single Auto Section

In this section all machines have single spindle that are operate through cam. Multiple tools are used there to achieve
desired targets.

Main Machines
Single Auto Index 12
Main points about this machine are given below:

 Index 12 indicate that maximum diameter of 12mm rod can insert here in this machine.
 This is operated mainly by three cams such as front, rear and 3 rd.
 Total five tools can operate in this machine.
 As the operation change the lead cam also change accordingly.

Single Auto Index 25

Main points about this machine are given below:

 Index 25 indicate that maximum diameter of 25mm rod can insert here in this machine.
 This machine can hold 7 tools at a time as well as 1 stopper.
 Cam function is of prime importance here.

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Single Head Turning Machine (Auto)
Main points about this machine are given below:

 Lead screw is use to operate this machine and perform different operation.

 Tools remain static, rod feed and components manufacture.

 Maximum length of rod insert here is approximately 9m.

Main Components
Some of main components in this section are given below:

 Eye bolt

 Head sleeve

 Hammer pin

 Axial pin ejector

Multi Auto Section

In this division, cam-operated automatic machines are used to produce numerous small components in large
quantities.

Main Machines
 Six Spindle Automatic Lathe
Main points about this machine are given below:

 This machine is use to make small components such as locking pin grip that are used in G3.

 The rod diameter that insert in this machine is in range of 6 to 20mm.

 The operation we can perform here are facing, drilling, turning, Central drill, undercut, rough turning, chamfering,
finish turning and parting etc.

 Eight Spindle Automatic Lathe

Main points about this machine are given below:

 This machine can handle maximum diameter rod of 40mm.

 Bolt head of MP5 manufacture here on this machine. Bolt head have outer diameter 25.2mm and inner diameter

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 of 10.2mm.

 Mild steel workpiece is cut by high speed steel tool.

 Six Spindle Pneumatic System

Main points about this machine are given below:

 Pneumatic system is control by collet.

 Through four rollers the rod insert in machine.
 Locking part of MP5 and G3 manufacture here on this machine.

 Profile Milling Machine

Main points about this machine are given below:

 In this machine tool and workpiece rotate in same direction.

 Approximately 30 Bar hydraulic pressure apply on job clamp.
 Locking piece mostly manufacture here on this machine.
 Here first milling perform using 5 tip, T milling by 11 tips and 3 rd milling means 30 degree angle using 3 tips.
 Tips are made up of tungsten carbide.

Manufacturing of Bolt head Carrier (G3A3)

We insert the mild steel rod of diameter 39.8mm and multi spindle automatic lathe reduce the outer diameter to 38.6 mm
while inner one is about 11.05 mm. This machine takes 86sec to complete it one operation.

STEP

 Central Drill

 10mm drill clockwise

 6mm drill front side chamfer

 Milling (cavity)

 Internal facing

 Front side facing

 Back side chamfer

 11mm drill

 Finish turning

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  Boring and chamfering

 10mm cavity

 Half parting tool

 Reamer finish hole (11mm)

 Parting

Barrel Section
This section of C-23 handles the entire barrel production process, from a long, solid rod to a fully functional barrel that is
ready for inspection.
Whole list of different guns barrel and their length are given below:

Guns Barrel Length (mm)

LSR 661
DMR 560
MG3 530
G3 Wing Supporter 520.7
G3A3 450
BW20 406.4
CW39 406.4
SMG 147.7

Manufacturing Process of Barrel

As we know that straight-shooting tube, which is often composed of stiff, high-strength metal, is what allows a high-
pressure gas to expand quickly and restrict itself, allowing a projectile to fire out of the front end quickly.
Some the main steps of barrel manufacturing are given below:

 Rod Parting
Initially, the rod is divided into sections based on the specifications (417mm).

 Facing & Chamfering

At this point the separated rod's two sides are chamfered and faced with 1 mm.

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  Drilling

Drilling is done on the rod throughout. (7.73 mm Drill Bit). It can take up to 35–40 minutes to complete this operation.

 Coning

With a 30% angle, coning is completed on both sides using a conning cutter.

 Rough turning (R1)

Rough turning (R1) results in a 2mm Dia reduction. There are now 26 mm of diameter left.

 Semifinal turning

R2 rough turning results in another 2 mm Dia reduction. There are now 24 mm of diameter left.

 Penciling

The pencil form on the muzzle side has a 5mm length.

 Finish turning

Inner Dia is decreased in Finish turning. The pencil's current diameter is 15.9 mm, and the remaining diameter is 23 mm.

 Grinding

A grinding machine reduces its diameter by 0.3 mm during the grinding stage. 22.70 mm is the remaining diameter.

 Holding Diameter for hammering

After the holding diameter is made, get the barrel ready using the gauges. (15.9 mm is the pencil side).

 Draw bore

Using a dowel and offset holes in the mortise and tenon to draw the joint together, draw boring is a technique that
strengthens a mortise and tenon joint. There is an Internal Process in accordance with reaming with complete side at this
point.

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  Honing

A workpiece's shape, dimensional accuracy, and surface quality can all be enhanced by honing, a bonded-grain cutting
technique that maintains continuous surface contact with the tool. Generally speaking, precise machining (such as
grinding) is completed before honing. at this point. The barrel is finished with roughing, semi-roughing, and grinding in
accordance with gauges.

 Hammering/Forging

To work on the interior bore and plug size, as well as to increase length and decrease diameter, cold forging is necessary.
The length is expanded by 100mm here.

 Parting

Excess length cut out here.

 Coning

Once more, coning at a 30-degree angle on both sides of the barrel.

 CNC Turning

To prepare the profile turning in accordance with the designs, CNC turning is used in this process.

 Parting

Once again extended length is cut out.

 Block Setting/ Straightening

Once more, block setting is carried out, which entails straightening the barrel in accordance with gauges. This is necessary
because, as previously mentioned, various operations are carried out on the barrel, which may cause a small disturbance in
its straightness.

 Chamber Reaming (R)

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The chamber reamer is placed into a barrel's bore and kept still while the barrel is rotated (usually using a lathe). The
chamber that can hold a particular cartridge is created as the reamer gradually removes material. Rough Chamber
Reaming is completed initially. (7.62 x 51 mm).

 Chamber Reaming (F)

Once more, the chamber reamer is placed into the barrel's bore and kept there while the barrel is rotated (usually using a
lathe). The chamber that can hold a particular cartridge is left behind after the reamer gradually removes material.
Final Chamber Reaming is completed at this point. (7.62 x 51 mm).

 Breaching Dia Grinding

In this operation, grinding is done (the diameter is lowered from 22.35 to 22.043 mm).

 Grooving

By turning a workpiece, a thin cut known as a "groove" is made. The width of a cutting instrument determines the size of
the cut. Wider grooves require several tool passes to be machined.

 Middle Dia Grinding

Grinding is the process of compressing anything into tiny pieces or powder. Grinding is completed at this point, where the
diameter is lowered from 16.8 to 16.5 mm.

 Muzzle Diameter Grinding

In this operation, grinding is done (the diameter is lowered from 16.3 to 16 mm).

 Parting and Serration

The length that was exceeded is removed, leaving a 450mm finish length. Following splitting, the process of serration is
completed; the result is a row of sharp, tooth-like projections or a saw-like look. There are numerous tiny points of contact
between a serrated cutting edge and the substance being cut.

 Mapping

By dissecting the manufacturing process into manageable components, mapping makes it simple to identify areas in need
of improvement.
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  Honing

Once more, the barrel is finished in this stage using gauges and roughing, semi-roughing, and grinding.

 Threading

A grinding machine is used to grind threads using specifically prepared grinding wheels that fit the thread shape.
Typically, the procedure is employed to create precise threads or threads in hard materials.

 Lapping

Lapping is the name given to a machining technique in which two surfaces are machined or manually rubbed together
using a certain kind of abrasive. Chemical mechanical polishing, or CMP, is commonly used in this procedure for
materials such as silicon, glass, metal, plastic, etc.

 Q/A Inspection

QA inspections verify that processes and goods live up to expectations regarding quality. QA inspections aid in finding
weaknesses and irregularities in the process. They are essential to resolving problems, advancing continuously, and
upholding compliance.

 IDA Inspection

IDA collaborates closely to guarantee that the greatest number of manufacturing details are recorded and
communicated to the product's final design. This helps IDA's Manufacturing Group in a number of ways, such
as evaluating upcoming new parts, protocols, and testing techniques that should be implemented and
guaranteeing that the right procedures are followed to coordinate with the planning and construction of the
Products.

Main Machine

Some most common machines that are used there are given below:

 Drilling Machine

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 CNC Turning Machine

 Grinding Machine

 Honing Machine

 Robotic Forging Machine

 Threading Machine

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 C-22 (Machining Shop)
As name indicate that all kind of machining operations done in this shop. Machining is a manufacturing process in which
material is removed from a workpiece to shape or finish it into a desired form. This is typically done by cutting, grinding,
drilling, or other processes that involve the use of tools and machines. Machining can produce precise dimensions and
smooth finishes, making it a key method for producing parts and components in industries such as automotive, aerospace,
and manufacturing. Common machining processes include turning, milling, and drilling. This is of great importance in the
weapon factory.

Group A
This group is a long cycle group where limited components are machined. In this group major components machining take
place, such as bolt head (G3A3, MP5), bolt head carrier, locking piece, spring gauge etc.

Machining Process of Bolt Head

Machining process of bolt head carrier consist of different stages.

Stage 1 to 4:

Stage 1 to 4 completed in C-23 shop and then sent to C-22 for additional stages.

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Stage 5:

 Grinding is completed
 Length grows to 47.30
 Diameter turns to 21.30

Stage 6:

 7.6mm Right hand drill

 7.96mm reamer
 Broaching
 Finish broach
 Surface grinding

Stage 7:

 Rough slotting
 Finish slotting
 Slotting (curves)
 Drilling
 Milling
 Deburring
 Gauges

Stage 8:

 Milling 5mm cutter

 Deburr
 Milling
 T-slot Cutting
 Angle (Degree)
 Turbo (Deburr)

Stage 9 to 11:
 Job move to CNC shop for further machining

Stage 12:
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  Adjust to gauges

 Engraving

Main Machine
 Drilling

 Horizontal Milling Machine

 Vertical Milling Machine

 Lathe Machine

 Copy Lathe

 Grinding

Group B
In this group small components machining take place, such as extractor, ejector, hammer, trigger etc.

Machining Process of Extractor

The operations that are performing for machining of extractor are given below:

 Parting

 Deburr

 Chamfer (45 degree milling)

 Deburr (Linisher Machine)

 By using special purpose rotary milling machine cut T-slot, End Milling and twist drill of 4.5mm

 Deburr

 Use special purpose rotary milling machine

 Inspection

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  Hardening (C-21)

Machining Process of Ejector (MP5, G3A3)

The operations that are performing for machining of ejector are given below:

 Blanking (Sheet having thickness of 250mm)

 Straightness

 Milling for maintaining width and height (Side and Face Cutter)

 14° chamfer 1.4mm

 Deburring

 C-21 (Hardening)

 Triple angle grinding (Finish)

 Gauges check

 Phosphating

 Final Gauge check

Machining Process of Hammer

Hammer hit the fire pin when trigger is pressed. The operations that are performing for machining of ejector are given
below:

 To B&G for Forging

 C-21 for Annealing
 Drilling (5.9mm)
 Finished Reamer (Dia 6.03mm)
 Rough Mill Lower Form
 Finish Milling Lower Form
 Rough Milling Front Form
 Finished Milling Front Form

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  Mill Radius of 10mm. Circular Milling Both sides
 Mill Excess (Dia 26x6 Both sides)
 Mill Excess (Dia 24.2 Both sides)
 Mill Lower Form (DIM 11.05)
 Saw Front slot
 Saw Rear Notch
 Deburring
 Mill Chamfer
 For Tumbling
 Mill Rear Notches
 Mill Front Notches
 Deburring and Chamfer Edges
 Drill and Counter Bore
 Surface Grinding 1" and 2nd side
 Counter sinking both sides
 After Heat treatment Honing
 C-21 for Heat Treatment
 Quality Assurance
 For Phosphating
 Finish Grinding
 Grind Front Notch
 Grind Rear Notch
 C-21 for Polishing
 Final Pass

 Adjust To Gauges

Main Machines
The main machines uses there are:

 Vertical Milling Machines

 Horizontal Milling Machines
 Threading Machines
 Knurling Machines
 Slotting Machines
 NC Turning Machines

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  Circular Milling Machines
 Surface Grinding Machines
 Drilling Machines
 Engraving Machines

Group C
Due to the variety of grinding operations that occur there, Group C is referred to as the Grinding group. Grinding is a
machining process that removes material from a workpiece using an abrasive wheel. The process is used to achieve a
smooth surface finish, precise dimensions, or specific shapes. It is ideal for hard materials and is commonly used in
manufacturing for finishing metal parts. Grinding ensures high accuracy and fine surface texture.

As there are different kind of grinding so this group is sub divided accordingly.

 Cylindrical Grinding
Cylindrical grinding is a process used to shape the external surface of cylindrical workpieces. The workpiece
rotates around its axis while a grinding wheel moves along its surface, removing material to achieve a smooth finish or
precise diameter. It is typically used for producing round parts, such as shafts or rods, with tight tolerances. The process
can be performed between centers or with the workpiece held in a chuck.

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  Centerless Grinding
Centerless grinding is a machining process that removes material from the external surface of a workpiece without
using centers to hold it in place. The workpiece is supported by a blade and rotated between a high-speed grinding wheel
and a slower regulating wheel. This method is efficient for producing cylindrical parts with consistent diameters and is
ideal for mass production of small, slender parts like pins or bars.

 Surface Grinding
Surface grinding is a process used to produce flat, smooth surfaces on a workpiece. The grinding wheel moves over
the surface of the workpiece, removing small amounts of material to achieve a precise, flat finish. This process is
commonly used for finishing large, flat components such as plates or mold bases. Surface grinding ensures high accuracy
and fine surface texture, often as a final step in the manufacturing process.

Important Components
Some of the components that grind in this group are given below:

 Front Sight

 FS Holder

 MG3 Equipment Lock

 Firing Pin

 Loading Lever Housing

 Disconnector (CW39, BW20)

 Sighting Disk

 Recoil Spring Tube

 Locking Roller

Group D
Group D, which produces a wide variety of springs for the Pakistani military, is regarded as the center of the armament
manufacturing. Other than springs, its main component is the bayonet.

Spring
A spring is a mechanical device that stores and releases energy by deforming under load and returning to its original shape
when the load is removed. Springs are typically made from elastic materials, such as steel, and can be designed in various

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forms, such as coils, leaves, or spirals. They are used in a wide range of applications, including absorbing shock,
maintaining tension, and storing mechanical energy in devices.

Follower Spring

 Follower Springs are used in the magazines.

 They are manufactured on the wire bending machine.
 Initial Wire Diameter 1.6mm Initial Wire Length 1188mm
 Final visible length 318mm (after bending)
 45 mm length at the inner bends
 52mm side/small rectangular side length

Blade Bayonet
First of all, straight bar is given and then it is turned into a bayonet

 Top Milling Cut

 Grip Mitting Straight Cut
 Slot on both sides
 Radius the length edges
 Cope sharpening
 Remaining Milling on the handle/grip
 45-degree angle

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  Both sides Grinding 25
 Deburring
 Roll Milling Front side view (16mm)
 2nd Roll milling side view (5mm)
 Radius of the handle bottom
 Hole Drill at the bottom

 Assembly of Plastic Grip and blade, using cross piece, clip chord and block catch retailer.

Group E
The components of MG3 are primarily related to Group E of C-22. Approximately seventy-five MG3 components are
produced in this category.

Main Machines

Some of the major machines of this section are:

 Vertical Milling Machines
 Horizontal Milling Machines
 Form Milling Machine
 Surface Grinding Machines
 Form Cutters
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 Profile Cutting Machines
 Slotting Machines
 Drilling Machines

IMPORTANT COMPONENTS

There are more than 100 components are prepared in this group but some major components are listed below:
 Curved Piece
 Bow of Curved Piece
 Cross Piece
 Bolt Housing
 Feed Tray and Cover
 MG3 Bolt head
 Bolt Head Carrier
 Pictionary Rail DMR
 Pressure Plate MG3
 Catch Cocking Slide
 Bushing Sleeve
 Transport Lever Welded
 Cover Riveted

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 C-21 (Heat Treatment Shop)

Introduction

As indicate from shop name that heat treatment of various components is done here. As we know that heat
treatment is a controlled process used to alter the physical and sometimes chemical properties of a material, typically
metals or alloys. The process involves heating the material to a specific temperature, holding it at that temperature for a
certain period, and then cooling it at a controlled rate. Heat treatment is used to improve various properties of the
material, such as hardness, strength, ductility, toughness, or resistance to wear and corrosion. Common heat treatment
processes include annealing, quenching, tempering, and case hardening.

HEAT TREATMENT
In this part of shop all the process related to heat treatment along with carbonization perform here. In weapon factory
major metals use here are:

 Mild steel
 Spring steel

Mild steel contain carbon less than 0.3%. So it is very important to carbonize it first in order to increase its strength.
While in spring steel carbon content is already very high so we direct hard it. If we try to carbonize it and then harden it
than its will get brittle.

Process of heat treatment

Process of heat treatment includes:

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  Annealing
 Hardening
 Quenching
 Tempering

1) Annealing

This process involves heating the material to a specific temperature and then slowly cooling it, usually in a furnace.
Annealing softens the material, relieves internal stresses, and improves its ductility, making it easier to work with.

For annealing we use these furnaces:

 Pit type annealing furnace

 Annealing brazing furnace

Pit type annealing furnace

This furnace consists of many electrical elements the components mostly made here are:

 Recoil boost
 Rear cover N
 FS holder
 Buffer housing
 Locking piece MG3

Annealing brazing furnace

This furnace is dual function here brazing is also done along with annealing. It is conveyor type furnace and speed of
conveyor is 5m/h. the range of temperature is 680 to 850℃.

2) Quenching

In quenching, the material is heated to a high temperature and then rapidly cooled by immersing it in a quenching
medium like water, oil, or air. These rapid cooling increases the hardness and strength of the material but can make it
brittle.

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 3) Tempering

After quenching, tempering is done by reheating the material to a lower temperature and then cooling it slowly.
Tempering reduces the brittleness imparted by quenching while maintaining most of the material's hardness, resulting in a
more balanced combination of strength and toughness.

4) Carburization (case hardening)

In this shop, we perform case depth of approximately 0.1mm to 0.85mm.

 SOLID CARBURIZATION

For solid carburization Pack carburization furnace or chamber furnace is use here in weapon factory. In this furnace a box
is place that is filled with charcoal and components that are to be carburize. The ratio of charcoal is 1:10 which indicate
1% unused charcoal add with 10% used. Than we place box inside furnace for about 2 to 7 hours at 910℃ and allow
upper surface of component to case hard.

 LIQUID CARBURIZATION

For liquid carburization C3, C5 and GS540 use in cyanide bath. The temperature here is usually about 910℃. We place a
component here for about 10 to 150 minutes. Through liquid carburization we can increase case depth in range 0.1 to 0.7
mm. After salt bath we quench components in AS140 chemical for hardening and after air cooling we wash it.

 GAS CARBURIZATION

For gas carburization here use gas carburizing furnace or sealed quench furnace. Nitrogen gas, methanol and acetone are
used for case hardening. The temperature provides is in range of 840 to 910℃. We place components for 25 to 40 minute
in furnace. This process will increase case depth in range of 0.1 to 0.2 mm.

High Frequency Furnace:

This is most important type of furnace use for induction hardening. Main thing about this furnace is that only desired
portion is hard only, not whole part or [Link] is totally electrically operated. The step down transformer reduces the
voltage and the tube at end contains water for cooling purpose.

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Hardness Testers:

There are three main type of testers:

 Rockwell Hardness Tester

 Vicker Hardness Tester
 Brinell hardness Tester

1) Rockwell Hardness Tester

The Rockwell hardness tester measures the hardness of materials by determining the depth of penetration of an
indenter under a large load compared to a preliminary load. The test uses different scales, such as A, B, or C, depending
on the material being tested and the indenter type. A diamond cone or hardened steel ball is typically used as the indenter.
The Rockwell test is quick and straightforward, making it widely used in manufacturing environments for metals, alloys,
and plastics. The hardness value is directly read from the machine, where a smaller indentation depth indicates a harder
material, providing a Rockwell hardness number (HR).

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 2) Brinell Hardness Tester

The Brinell hardness tester works by pressing a hard, spherical indenter, usually 10 mm in diameter, into the surface
of a material under a specified load, typically ranging from 500 to 3000 kgf. After applying the load for a set time, the
diameter of the resulting indentation is measured. The Brinell hardness number (BHN) is then calculated using a formula
that accounts for the load and the indentation diameter. This method is particularly useful for testing materials with a
coarse or uneven grain structure, like cast iron or forgings, providing an average hardness value over a larger surface area.

3) Vickers Hardness Tester

The Vickers hardness tester employs a diamond pyramid indenter with a square base and an angle of 136 degrees
between opposite faces. The indenter is pressed into the material's surface under a precisely controlled load, which can
range from a few grams to several kilograms. After the load is removed, the diagonal lengths of the resulting indentation
are measured using a microscope. The Vickers hardness number (VHN) is calculated by dividing the applied load by the
surface area of the indentation. The Vickers test is versatile and can be used for all types of materials, providing a high
degree of accuracy and repeatability, especially for thin materials and coatings.

SURFACE TREATMENT
Surface treatment is a process applied to the exterior of a material to enhance its surface properties, such as wear
resistance, corrosion resistance, or appearance, without altering the underlying material's core characteristics.
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Classification of surface treatment

Major processes include in surface treatment are:

 Anodizing
 Shot Blasting
 Degreasing
 Phosphating
 bluing
 Painting

1) Anodizing
All components cannot paint some required anodizing to secure their surface. In anodizing tank two cathode plates are
present that are made up of lead while component to be anodize act as anode. The electrolyte use for this process is dilute
sulphuric acid. When electricity supply particle from cathode start moving toward anode and they change the chemical
properties of upper layer of components. We can check it, if it is anodize properly by connecting it to ohmmeter. If this
meter indicate infinite resistance it mean it is completely anodize. After anodizing we wash it in fresh water and if
required than apply paint or dye color.

2) Shot Blasting

Shot blasting is an industrial process used to clean, strengthen (peen), or polish metal surfaces. It involves propelling a
stream of abrasive material (often called "shot") at high velocity against the surface of a material. The abrasive material
can be steel balls, steel grit, copper slag, aluminum oxide, or other types of abrasive particles. But mostly shot that use in
weapon factory is steel pieces.

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Purpose of Shot Blasting:

 Surface Cleaning: It removes rust, scale, paint, or other contaminants from the surface of metal parts,
preparing them for further processing like welding, painting, or coating.
 Surface Preparation: It roughens the surface to improve the adhesion of coatings, paints, or other
finishes applied afterward.
 Surface Strengthening (Peening): Shot blasting can induce compressive stresses on the surface of
metal parts, which helps in increasing their fatigue strength and reducing the chances of stress -corrosion
cracking.
 Surface Finishing: It can also be used to polish or matte the surface, depending on the desired finish.
 Deburring: It removes burrs, sharp edges, and other surface imperfections from metal parts, improving
their functionality and appearance.

3) Degreasing

It is a very crucial process to remove oil and grease from component and make it ready for other important procedures. in
degreasing tank we use trichloroethylene chemical for achieving our goal. This chemical is present in bottom and on some
height we have a tray over which component that’s degreasing are required are placed. When electrical element present in
the base of tank get ON and temperature of tank reaches 80℃ this trichloroethylene convert into vapor form and remove
all oil, dirt and grease particles from components. This process holds a lot of importance in surface treatment.

4) Phosphating

All the steps of phosphating are given below:

 After unloading of components, firstly we move it toward degreasing tank to remove oil or grease if present.
 Second step is to place components in phosphating tank that is 15 min process. There we use bonder 95 chemical
and temperature is in range of 95 to 98℃. Here the layer of single coat is approximately 0.005mm.
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  After phosphating we wash components in hot water.
 Fourth step is to place components in pickling tank where concentration of sulphuric acid is 10% while water is
90%.
 We again wash components in deionized water
 If we have to create double coat of phosphate on component than we again move it to phosphating tank. We place
it there for about 20 to 30 sec and thickness of this layer is 0.01mm.
 We wash it again in clean water.
 If we want to paint component than after washing we have dry it completely in drier tank but if we don’t want
paint than we have to oil it.

5) Bluing

It is more expensive process as compare to phosphating. All the steps of phosphating are given below:

 Firstly we place components in soda water and wash them properly.

 Second step is again to wash components in fresh water.
 Third step is to place components in Negrovate V2 where temperature range is from 140 to 145℃. this is a
chemical that perform bluing.
 After removing it from this chemical, component’s surface become more smooth and shining. Than we place it in
cold water and then hot water.
 At end we place component in oil that is basically dichromal oil and after oiling it is now final.

6) Painting
There are two method of painting use in C-21 shop:

 Manual Painting
 Auto Electrostatic Spray Painting

 Auto Electrostatic Spray Painting working principle:

Auto electrostatic spray painting works by atomizing paint into fine droplets and charging them with a high voltage.
The object to be painted is grounded, creating an electrostatic field. The charged paint particles are attracted to the
grounded surface, ensuring uniform coverage, even on complex shapes. The electrostatic attraction minimizes overspray,

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increasing paint transfer efficiency. As the paint wraps around the object, it forms a consistent coating. After application,
the painted item is cured in an oven, hardening the paint and resulting in a durable, high-quality finish. This method is
efficient and reduces paint waste.

 Specification

Main specification of spray paint is:

 Length of conveyor = 80m

 Speed of conveyor = 1m/min
 Cycle time = 80min
 Rotation of disc = 18500/min
 Air Pressure = 2Bar
 Electrostatic Generator = 50KV
 Components in one shift = 600 – 800

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 B-22 (CNC Shop)
This shop was established in 1984 and all its machinery and tools are German. This is very important shop as it deals with
the performance of most critical operations on the components of the weapons. A CNC (Computer Numerical Control)
machine is a computerized manufacturing tool that uses pre-programmed software to control the movement of machinery
and tools. CNC machines can perform precise cutting, drilling, milling, and other operations on various materials such as
metal, plastic, and wood. The use of computer control allows for high precision, repeatability, and the ability to produce
complex shapes that would be difficult to achieve manually.

Main Machines

Mainly milling and turning NC and CNC machines are present in this shop.
 NC Milling Machine
 NC Grinding Machine
 CNC Turning Machines
 NC Slot Cutting Machine
 CNC milling machine (VBZ 630L, 3 Axis)
 CNC machine (Citizen E-32)
 CNC milling machine (VBZ 630L, 5 Axis)
 CNC milling machine (STEINEL BZ-20)
 Electric discharge machine (wire cut)

1) CNC milling machine (VBZ 630L, 3 Axis)

 The component that is machined here is 'Bolt head carrier of G3A3'.

 It also has three component axis with:

 X-table range 630 mm

 Y-table range=400 mm
 Z-table range 450 mm

 Computer that is used is GSK 251.

 It has a tool capacity of 20 tools.
 Spindle speed is about 30-4500 RPM.
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  It has accuracy of 0.001 mm.
 Data is input through manually or by USB.
 Number of tools used = 07.
 Number of gauges 07.
 Production of components in a single shift = 18

2) CNC milling machine (VBZ 630L, 5 Axis)

The name of component that is machined is 'curved piece MG-3'. It also five
component axis with:
X- table range = 630 mm
Y-table range = 400 mm
Z-table range = 450 mm
A&B-table range = 180 Degree

 Computer that is used is GSK 251.

 It has a tool capacity of 20 tools.
 Spindle speed is about 30-4000 RPM.
 It has accuracy of 0.001 mm.
 Data is input through manually or by USB.

1st Setting operation:

> Number of tools used 11 (left) 06 (right).
> Number of gauges: 32.
> Production of components in a single shift: 06.

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2nd Setting operation:
> Number of tools used 04 (left) + 03 (right).
> Number of gauges: 09.
> Production of components in a single shift: 16.

3) CNC machine (Citizen E-32)

The name of component that is machined is 'Eccentric MG-3'.
 Function performed is turning.
 Range of RPM is 0-4000.
 Range of feed is 0-200.
 Accuracy is of 0.001 mm.
 Time consumed for 1 component=35.
 Total production per day = 12.
 Total production per day 18 with overtime

4) EDM Wire Cut

Wire Cut Electric Discharge Machining (Wire EDM) is a precision machining process that uses electrical discharges
(sparks) to cut through conductive materials. For this machine Bob CAD-CAM is use for program properly. Here's how it
works:

1. Wire as Electrode
A thin, electrically charged wire (typically made of brass or copper) acts as the cutting tool. This wire does not touch the
workpiece but is instead positioned close enough to create an electrical discharge.

2. Workpiece Setup
The workpiece, which must be electrically conductive, is submerged in a dielectric fluid (usually deionized water). This
fluid helps to cool the workpiece, flush away debris, and act as an insulator until the discharge occurs.

3. Electrical Discharges
A voltage is applied between the wire and the workpiece, creating an intense electrical field. When the voltage is high
enough, a spark jumps across the gap, eroding a tiny portion of the workpiece material through melting and vaporization.

4. Controlled Movement
The wire is moved along a predetermined path, guided by computer numerical control (CNC) to produce the desired
shape. The movement can be in two dimensions or more, depending on the complexity of the part.
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 5. Material Removal
The process repeats rapidly, with thousands of sparks occurring per second, gradually cutting through the material. The
dielectric fluid continually flushes away the eroded particles and cools the cutting area.

Wire EDM is particularly useful for cutting complex shapes, intricate patterns, and hard materials with high precision and
excellent surface finishes.

Some Important G codes

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 B-20 (Assembly Shop)
This is the weapon factory's last, but most important, shop. Every component used at other shops is transported to this
shop for assembly. This highlights how crucial it is that every small thing within B-20's walls turns into a complete
weapon.

Weapons

List of weapons being assembled in B-20 are listed below:

 G3A3
 MG3
 MP5
 MP5
 POF Eye
 DMR
 .308 Win Sportier
 LSR

 MG3 Section
The MG3 is a powerful, belt-fed machine gun known for its high rate of fire, capable of delivering up to 1,200 rounds per
minute. This rapid-fire capability creates a devastating "wall of bullets," making it highly effective for suppressing enemy
forces and covering large areas with intense fire. The MG3's durability and reliability have made it a staple in various
military forces around the world. Its ability to inflict mass damage and maintain continuous fire makes it a formidable
weapon on the battlefield.

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Assemblies

The machine gun consists of 220 components, 26 sub-assemblies, and 9 major assemblies.

Then one MG is created by assembling these nine parts. Barrel is not a fix component in machine gun, we can replace it,
if required.

Range of Fire

It is positioned firmly on a tripod and bipod.

 When mounted on a bipod, its range increases to 1200 meters.

 When positioned on a tripod, its range extends to 2200 meter.

Loading Rate

It can fire 1000 rounds per minute because of its significantly faster firing speed.

Belts

There are two types of belts used in MG, and one belt holds 250 rounds.

 Integrated Belts
 Non-integrated Belt Systems

When using integrated belts, only bullets are used for firing; however, when using non-integrated belts, both the bullet and
the belt are consumed.

 G3A3 & MP5 Section

In this section all the components of G3A3 are combining together to form a complete rifle. MP5 gun is actually a small
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 scale copy of G3A3.

The main steps of assembling are given below:

 Welding & Soldering

 Pre-range assembling
 Pressure Testing
 Functionality Testing
 Accuracy Testing
 Disassemble
 Cleaning
 Gauges Check
 Assemble (if all Gauges are okay)
 Quality Check

Specifications:

This gun can be used in burst, single fire, and auto firing modes. It can fire 250 bullets per minute.

However, MP5 has a shorter magazine since its butt stocks and barrel length are shorter than those of the G3.
This gun can be used in burst, single fire, and auto firing modes. It firing speed is also 250 bullets per minute.

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Assemblies

G3A3 has 6 main assembly components

 Butt
 Magazine
 Pistol Grip
 System
 Forearm
 Bolt Head Carrier

 IDA
The Inspection & Dimensional Analysis (IDA) Unit works closely with the Quality Assurance (QA) team to ensure that
components are made with precise measurements. They use specialized tools and techniques to check every detail of a
part, making sure it meets exact standards. The IDA unit measures key features like lengths, diameters, angles, and gaps
to ensure that each part will fit perfectly and work well in the final product. They use both visual checks and advanced
measuring tools to make sure everything is accurate and reliable.

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 C-26 (Plastic Shop)
This shop is specialized in manufacturing of plastic components that hold a lot of importance.

Main Machines

 Injection moldings machine

 Jet mold machine
 Bench type press
 Turbo to remove burrs
 Drill Machines
 Riveting Machine

Injection Molding Machine

Injection molding machine consist of following units:

 Injection Unit
 Clamping Unit
 Hydraulic Unit
 Electronics & Electrical Panel
 Water Body Unit

This machine can complete jobs in 5 to 10 mins. Here the grain of raw material is feed into hopper than enter in to heating
unit; where total 9 heaters are attach to melt the grain complete. Ram hit the melt into mold cavity where it solidifies to
form a desire product.

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Suggestion

I suggest that the factory should invest in training programs for employees and workers on various software and technical
skills. This initiative will enhance their capabilities, leading to greater efficiency, innovation, and overall advancement
within the organization. Continuous skill development will not only improve productivity but also ensure the factory
remains competitive in an evolving industry.

The factory could offer a second round of free classes for workers interested in learning different software and machining
processes. By empowering workers with advanced knowledge, the factory can enhance productivity, innovation, and
overall operational efficiency.

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