ABSTRACT

The present report provides a detailed account of a six-week industrial training program
undertaken as part of the Bachelor of Technology curriculum in Mechanical Engineering. The
training was conducted from 12th June to 21st July 2025 at Assa Singh Engg. Works, a
reputed organization engaged in the design, manufacturing, and assembly of a wide range of
heavy-duty machine tools. The primary objective of this training was to expose the student to
the practical aspects of mechanical engineering, with a special focus on the manufacturing
and inspection processes of machine tools, and to provide a bridge between theoretical
knowledge and its industrial application.
The training was structured in two distinct phases. The initial two weeks were dedicated to
gaining a general overview of the company’s operations, safety standards, production
workflow, and the various categories of machines being manufactured — including lathes,
planners, plano millers, shapers, hydraulic shapers, radial drilling machines, and vertical
turning lathes (VTLs). This phase emphasized understanding the organizational structure,
machinery layout, departmental functions, and standard shop-floor practices.
The subsequent four weeks involved a more focused engagement, where the trainee was
assigned to the inspection and final assembly section for the Vertical Turning Lathe
(VTL) and Hydraulic Shaper machines. Here, the trainee observed and assisted in a series
of critical processes, including dimensional and visual inspection of components, verification
of geometrical tolerances, part fitment accuracy, assembly alignment, hydraulic system
checks, and final machine performance testing. Instruments such as Vernier calliper, micro-
meter, dial indicators, and height gauges were used for ensuring the required precision in
manufactured parts.
Throughout the training, an observational and conceptual approach was adopted. The trainee
studied engineering drawings, assembly charts, and quality manuals to understand how
theoretical principles such as limits and fits, material selection, surface finish requirements,
and hydraulic actuation are implemented in real-time production. The training also covered
topics such as defect identification, root cause analysis, and documentation for quality
assurance.
In conclusion, the industrial training proved to be a valuable component of the engineering
curriculum, offering a strong foundation in manufacturing processes and inspection
methodologies. The skills acquired are expected to be highly beneficial in the student’s final
year project, technical interviews, and future professional roles in the domains of production,
quality control, and mechanical design.
 Acknowledgement
I take this opportunity to express my sincere gratitude to all those who supported and guided
me during my six-week industrial training at Assa Singh Engg. Works. This training has
provided me with invaluable exposure to the practical aspects of machine tool manufacturing
and has greatly contributed to my professional development as a mechanical engineering
student.

First and foremost, I would like to extend my heartfelt thanks to Dr. Sushendra K. Misra,
Hon’ble Vice Chancellor of Sardar Beant Singh State University, Gurdaspur, for
providing the academic environment and institutional support necessary to undertake this
training as part of the [Link] curriculum.

I am equally grateful to Dr. Dilbag Singh, Head of the Department of Mechanical

Engineering, for his continued encouragement and guidance throughout my academic journey
and for ensuring that industrial training remains a vital component of the department's
practical learning framework.

My special thanks to Dr. Nrip Jit, Training and Placement Officer, for his assistance in
organizing and facilitating the training process. His support and coordination played a key
role in helping me secure this training opportunity.

I would also like to thank the General Manager of Assa Singh Engg. Works for allowing
me to undergo training in the organization, and to extend my appreciation to all the engineers,
supervisors, technicians, and staff members of the company. Their cooperation, mentorship,
and willingness to share practical knowledge made this training experience both insightful
and productive.

Finally, I wish to thank my faculty, friends, and family members for their constant support,
encouragement, and motivation throughout the training period.

INTRODUCTION
1.1 Introduction
Industrial training is an essential component of the undergraduate engineering curriculum,
designed to enhance students' understanding of real-world industrial practices and expose
them to professional engineering environments. It serves as a bridge between classroom
learning and industry requirements by allowing students to observe and analyze the actual
application of theoretical knowledge in manufacturing, design, maintenance, and inspection
processes.
As a part of the Bachelor of Technology ([Link]) program in Mechanical Engineering,
students are required to undertake industrial training to gain exposure to various
manufacturing systems, quality control methods, and engineering workflows. This training
helps in the development of technical skills, decision-making abilities, teamwork, and
discipline—qualities that are critical for an engineering professional.
The current industrial training was completed at Assa Singh Engg. Works, a reputed
machine tool manufacturing company engaged in the production of machines such as lathe,
planner, plano miller, shaper, hydraulic shaper, radial drilling machine, and vertical turning
lathe (VTL). The training focused primarily on the manufacturing and inspection of
Vertical Turning Lathes (VTLs) and Hydraulic Shapers, both of which are integral to
machining operations in heavy engineering industries.
Through this training, the student was able to understand various processes such as material
preparation, machining, sub-assembly, tolerance verification, and final product inspection.
Exposure to machine components, inspection instruments, hydraulic systems, and assembly
line procedures helped develop a practical perspective on how machine tools are designed,
manufactured, and tested in an industrial setting.
This report documents the key observations, learning outcomes, methodologies, and
evaluations made during the training and highlights the relevance of such industrial
experiences in shaping an engineering student’s professional competence.

1.2 Necessity
Industrial training is a crucial part of engineering education, as it enables students to
experience the dynamics of real-world engineering operations beyond the academic syllabus.
While classroom teaching provides foundational concepts and theoretical knowledge,
industrial training introduces students to the practical implementation of those concepts in a
structured and professional environment.
In the field of mechanical engineering, understanding manufacturing methods, inspection
procedures, assembly techniques, and machine tool operation is vital. With rapid
advancements in manufacturing technologies, industries now demand engineers who are not
only academically strong but also equipped with practical exposure and industry-ready skills.
The necessity of this training lies in:
 Enhancing the student’s understanding of real production systems, including
workflows, quality checks, and coordination among departments.
 Developing a clear view of machine tool manufacturing, from raw material to final
inspection and dispatch.
 Bridging the gap between academic knowledge and industrial application, especially
in core mechanical domains like machining, hydraulics, tolerance analysis, and
assembly.
 Introducing students to the use of industrial tools, measuring instruments, and
machine drawings, which are rarely encountered in college labs.
 Preparing students for future roles in production, design, quality control, maintenance,
and R&D, by making them familiar with workplace standards and expectations.
In essence, the training plays a vital role in shaping engineering graduates into competent
professionals capable of handling technical challenges in real-world industrial environments.
It also serves as a preparatory step for project work, competitive exams, and future
employment.

1.3 Objectives
The primary objective of industrial training is to expose students to actual working conditions
in industry, helping them understand how theoretical knowledge is applied in real-life
engineering processes. This experience contributes significantly to the development of
technical competence, practical understanding, and professional discipline in students.
For this specific training conducted at [XYZ Machine Tools Pvt. Ltd.], the following
objectives were outlined:
1. To understand the complete manufacturing process of heavy-duty machine tools,
including material selection, machining, sub-assembly, and final assembly.
2. To study the design and working principles of key industrial machines such as the
Vertical Turning Lathe (VTL) and Hydraulic Shaper.
3. To observe and participate in the inspection and quality control processes, gaining
familiarity with measuring instruments like micrometers, Vernier calipers, and dial
indicators.
4. To understand engineering drawings and tolerance specifications, and how they are
applied during assembly and inspection.
5. To gain insight into hydraulic systems and mechanical linkages, particularly in
machines like hydraulic shapers.
 6. To experience the organizational workflow, from production planning to final
dispatch.
7. To build communication and reporting skills, including technical documentation and
formal observations.
These objectives were pursued through observation, documentation, and interaction with
engineers and technicians, resulting in a well-rounded industrial learning experience. By the
end of the training, the student was expected to have gained not only technical exposure but
also a deeper appreciation of industrial operations and professional conduct in a
manufacturing environment.

1.4 Theme of Training

The theme of this industrial training revolves around “Manufacturing and Inspection of
Machine Tools”, with a specific focus on the Vertical Turning Lathe (VTL) and Hydraulic
Shaper — two widely used and structurally complex machines in the metalworking industry.
The training was aimed at providing insight into how these machines are manufactured,
assembled, tested, and inspected before delivery.
The entire training program was designed to integrate key mechanical engineering domains
such as:
 Manufacturing Processes – including turning, milling, drilling, grinding, and fitting.
 Machine Design and Assembly – involving mechanical linkages, hydraulic systems,
alignment, and sub-component integration.
 Inspection and Quality Control – using industry-grade tools to ensure accuracy,
performance, and reliability of machines.
 Practical Application of Theory – such as fits and tolerances, fluid power systems, and
kinematic mechanisms studied in academics.
This theme was selected keeping in view the growing importance of practical exposure in
modern-day manufacturing, where the successful operation of any engineering system relies
heavily on precision, testing, and quality assurance.
By focusing on machine tools that are foundational to the manufacturing sector, the training
theme ensures that the student gains an in-depth understanding of not just how machines
work, but also how they are built, tested, and optimized for industrial applications.
1.5 Organization
The industrial training was conducted at [XYZ Machine Tools Pvt. Ltd.], a reputed medium-
scale manufacturing firm specializing in the production of conventional and semi-automatic
machine tools. The company plays a key role in catering to the machining needs of various
sectors including railways, defense, heavy engineering, tool rooms, and private industries.
Established with the vision to deliver high-performance and reliable machine tools, the
organization is known for its robust engineering standards, quality assurance systems, and
customer satisfaction. Its manufacturing facility is equipped with modern workshop
machinery, casting yards, machining sections, assembly bays, inspection departments, and
testing zones. The infrastructure supports end-to-end production — from raw material
processing to final machine dispatch.
The company manufactures a wide range of machine tools including:
 Centre Lathe Machines
 Planner and Plano Miller Machines
 Mechanical and Hydraulic Shaper Machines
 Radial Drilling Machines
 Vertical Turning Lathes (VTLs)
Each department within the organization — such as design, production, machining, assembly,
inspection, and quality control — works in synchronization to ensure smooth workflow and
timely delivery. The firm follows standard industrial practices for tolerance checking, part
interchangeability, vibration analysis, and hydraulic testing.
The organization also emphasizes training and knowledge sharing, often allowing
engineering students to visit, observe, and learn the practical aspects of manufacturing and
mechanical design. The supportive staff and experienced engineers contributed significantly
in making the training experience productive and enriching.
 LITERATURE SURVEY

2.1 Introduction to Machine Tools

Machine tools form the backbone of the manufacturing industry. These are power-driven
devices used to shape or machine metal and other rigid materials by cutting, boring, grinding,
shearing, or other forms of deformation. The primary function of a machine tool is to provide
a guided movement of the workpiece and the cutting tool to perform desired operations with
precision.
Machine tools are essential in almost every sector of engineering — including automotive,
aerospace, defense, railways, and heavy equipment manufacturing — as they enable the
production of accurate and interchangeable components. Over the decades, the evolution of
machine tools has led to the development of highly specialized machines capable of
performing complex operations with great speed and accuracy.
Machine tools can be broadly classified into:
 Turning Machines (e.g., lathe, vertical turning lathe)
 Drilling Machines (e.g., radial drilling machines)
 Milling Machines (e.g., plano millers)
 Shaping Machines (e.g., mechanical and hydraulic shapers)
 Planning Machines (e.g., heavy-duty planers)
The training organization where this industrial training was undertaken is involved in the
design and manufacture of a wide range of such machine tools. The following sections detail
the literature and background study related to the machines manufactured by the company,
particularly focusing on the Vertical Turning Lathe (VTL) and Hydraulic Shaper, which were
the core part of the training module.

2.2 Overview of Machines Manufactured

1. Lathe Machine
A lathe is a fundamental machine tool used for rotating a workpiece against a fixed cutting
tool to perform operations such as turning, facing, grooving, parting, threading, and drilling.
The basic parts include the bed, headstock, tailstock, carriage, and lead screw.
Lathe machines are classified into:
 Centre lathes (manual)
 Turret lathes
 CNC lathes (numerical control)
Lathe machines are essential in industries for manufacturing cylindrical parts like shafts,
bushings, pulleys, and threaded components
2. Planner Machine
Planner machines are used for machining large and heavy components. The workpiece is
mounted on a moving table that reciprocates under a fixed cutting tool. The machine is ideal
for flat surfaces, slots, grooves, and even large dies.
Key features:
 Worktable moves in a horizontal linear motion
 Tool is stationary and mounted on cross-rails
 Used where large castings or weldments need high precision surface finish
Common industries: shipbuilding, defense equipment, and machine-bed machining.

3. Plano Miller Machine

The plano miller is a variant of the planner, but with rotary cutters mounted on spindles. It is
used for milling large workpieces and allows both horizontal and vertical cutting operations.
Unlike the planner, the tool moves along multiple axes while the workpiece is stationary or
slowly moving.
Key advantages:
 Capable of cutting slots, keyways, grooves, and contours
 Higher productivity than planner for similar-size workpieces
 Can handle multiple tool heads for simultaneous machining

4. Radial Drilling Machine

A radial drilling machine is used to drill holes on large and heavy workpieces that cannot be
easily moved. It consists of a radial arm that can rotate and move vertically on a column. The
drill head slides along the arm, allowing flexibility in positioning without shifting the job.
Important parameters:
 Drilling capacity (e.g., 40 mm or 50 mm)
 Arm radius (defines the reach)
 Spindle speeds and feed rates
Applications include drilling holes in engine blocks, machine beds, and heavy frames.

5. Mechanical and Hydraulic Shaper

Shaper machines produce flat or contoured surfaces by moving a single-point cutting tool in a
linear path. In mechanical shapers, the movement is cam- or crank-driven. In hydraulic
shapers, hydraulic cylinders provide smoother, adjustable cutting strokes.
Key applications:
 Cutting keyways, splines, slots, flat surfaces
 Low-cost solution for simple geometry
 Suitable for single-piece or low-volume batch production
Hydraulic shapers are more commonly used in modern setups due to better speed control and
reduced vibration.

6. Vertical Turning Lathe (VTL)

The VTL is a special type of lathe where the spindle is oriented vertically. It is used for
machining large, heavy, and cylindrical workpieces (like flywheels, pulleys, turbine casings).
In a VTL, the workpiece is mounted on a rotating table (chuck), and tools approach vertically.
Key features:
 High load capacity due to vertical orientation
 Suitable for turning, facing, tapering, and boring operations
 Often used in railway, power generation, and heavy machinery manufacturing
2.3 Vertical Turning Lathe (VTL)
A Vertical Turning Lathe (VTL) is a specialized lathe machine in which the workpiece is held
vertically and rotated around a vertical axis. It is primarily used for machining large, heavy,
and cylindrical components that cannot be easily mounted or balanced in a horizontal lathe.
In a VTL, the rotating table acts as the chuck, and the tool post or turret is mounted vertically,
allowing cutting tools to feed horizontally or vertically into the rotating workpiece.

2.3.1 Working Principle

The working principle of a VTL is similar to that of a conventional lathe — the job rotates,
and the cutting tool removes material. However, the VTL is oriented vertically, making it
ideal for handling large-diameter, heavy parts like turbine casings, railway wheels, bearing
housings, or large gear blanks.
 The rotary table (chuck) holds and rotates the workpiece.
 The vertical column and cross-rail support tool heads that can move up/down (Z-axis)
and sideways (X-axis).
 The cutting tool, mounted on a turret or ram, performs turning, boring, grooving, or
facing operations.
2.3.2 Main Components
 Rotating Table (Chuck): Mounted on a heavy-duty bearing system to handle massive
loads.
  Cross Rail: Horizontally movable to adjust tool position.
 Vertical Ram or Turret Head: Carries the cutting tool, allows vertical movement.
 Column: Provides support and rigidity to the system.
 Gearbox/Drive System: Controls the speed of the rotating table.
 Hydraulic and Electrical Panels: Control ram feed, coolant flow, and table motion.
2.3.3 Types of VTLs
 Single Column VTL – Suitable for medium-sized jobs
 Double Column VTL (or Vertical Boring Mill) – Used for extremely large or heavy
parts; offers better stability
 CNC VTLs – Offer automated precision machining and multi-axis control
2.3.4 Advantages of VTL
 Excellent for handling heavy, unbalanced, or large-diameter workpieces
 Vertical orientation uses gravity to help with centering and stability
 Reduces setup time and improves surface finish for large parts
 More accessible tooling compared to conventional horizontal lathes
2.3.5 Inspection and Testing in VTL
During inspection, the following parameters are checked:
 Table flatness and runout
 Spindle radial and axial play
 Ram alignment and vertical feed accuracy
 Stroke length of tool slide
 Surface finish of machined parts
 Cutting force vibrations (if dynamic testing is performed)
 Speed and torque of rotating table (measured with tachometer or torque sensor)
Common tools used:
 Dial Indicator
 Spirit Level
 Micrometer
 Surface Plate
 Feeler Gauge
  Vibration Analyzer
 Tachometer
2.3.6 Applications
 Machining of large circular components like:
o Railway wheels and axles

o Large pulleys and gears

o Generator housings and turbine cases

o Valves and flange bodies

Used extensively in:

 Power generation
 Heavy engineering
 Shipbuilding
 Railway workshops
 Oil & gas equipment manufacturing
2.4 Hydraulic Shaper
The hydraulic shaper is a machine tool designed to produce flat surfaces, grooves, and
keyways by means of a single-point cutting tool that moves linearly across the workpiece.
Unlike mechanical shapers which rely on crank and gear mechanisms, hydraulic shapers use
pressurized hydraulic fluid to control the motion of the ram, making them smoother,
quieter, and more adjustable in terms of speed and stroke.
Hydraulic shapers are commonly used in tool rooms, maintenance workshops, and medium-
scale manufacturing units for precision shaping tasks.

2.4.1 Working Principle

In a hydraulic shaper, the cutting stroke is powered by a hydraulic cylinder. The ram is
pushed forward by pressurized oil and retracted through a control valve mechanism. This
provides:
 A uniform and adjustable cutting speed
 Higher cutting force due to oil pressure
 Less wear and vibration compared to mechanical shapers
The machine generally includes:
  Hydraulic power pack
 Directional control valves
 Adjustable stroke length
 Speed control levers

2.4.2 Main Components

 Ram: The main body that holds the cutting tool and moves back and forth.
 Tool Head: Mounted on the ram, holds the single-point cutting tool.
 Work Table: Supports the workpiece and can be adjusted vertically or horizontally.
 Hydraulic Cylinder: Drives the ram during forward stroke.
 Hydraulic Reservoir and Pump: Stores and circulates pressurized oil.
 Control Valves: Regulate flow and direction of hydraulic fluid.

2.4.3 Advantages of Hydraulic Shaper

 Smooth, uniform cutting strokes
 Adjustable speed and stroke length
 Fewer moving parts – low maintenance
 Less vibration – improves surface finish
 Ideal for batch production and maintenance work

2.4.4 Inspection and Testing in Hydraulic Shaper

The performance of a hydraulic shaper is evaluated based on:
 Ram stroke length and straightness
 Cutting stroke time vs. return stroke time
 Hydraulic pressure levels
 Leakage check in hoses, cylinder, and valves
 Tool head alignment with table
 Vibration during operation
 Surface finish on test workpiece
Instruments used include:
 Vernier caliper (stroke length measurement)
 Dial gauge (for ram straightness)
 Pressure gauge (for hydraulic system)
 Spirit level (for alignment checking)
 Stopwatch (to compare stroke times)

2.4.5 Applications
Hydraulic shapers are widely used for:
 Cutting internal and external keyways
 Machining flat surfaces on blocks and plates
 Slotting and groove cutting
 Finishing of machine tool beds and slides
 Toolroom and maintenance job work
They are commonly used in:
 Tool rooms
 Automobile and railway workshops
 Foundries and fabrication shops
 Gear and coupling manufacturing units
2.5 Inspection and Manufacturing Standards
In any machine tool manufacturing setup, maintaining dimensional accuracy, surface quality,
and functional reliability is critical. To achieve this, manufacturers follow established
inspection techniques and international/national quality standards during and after the
manufacturing process.
Inspection is a key phase of quality control, where the machine and its components are tested
to ensure they meet the design tolerances, surface finish requirements, and performance
specifications provided in technical drawings and standard codes.

2.5.1 Inspection Parameters and Objectives

During training, several parameters were observed being inspected on machines like the VTL
and hydraulic shaper. These included:
  Dimensional Accuracy – Overall length, diameter, bore size, stroke length
 Geometrical Tolerances – Flatness, straightness, concentricity, parallelism
 Surface Finish – Quality of the machined surface, measured visually or using surface
finish testers
 Operational Performance – Machine vibration, speed, feed rate, noise, smoothness
of stroke
 Alignment and Runout – Of the table, tool head, ram, and spindle
These parameters are inspected at different stages:
 After machining individual parts
 After assembly of subcomponents
 During final trial runs of the fully assembled machine

2.5.2 Common Inspection Tools and Instruments

The following tools are commonly used on the shop floor for measurement and inspection:

Tool/Instrument Purpose

Vernier Caliper Length, diameter, and depth measurements

Micrometer Precise diameter or thickness measurement

Dial Indicator Checking flatness, runout, and parallelism

Height Gauge Vertical distance and marking

Feeler Gauge Gap measurements between mating surfaces

Spirit Level Checking alignment and leveling of machine beds

Tachometer Measuring spindle or ram speed

Surface Plate Reference surface for inspection

Pressure Gauge Measuring hydraulic pressure

Surface Roughness Tester (if available) Checking surface finish value in Ra

2.5.3 Standards Followed

The company adheres to relevant BIS (Bureau of Indian Standards) and ISO
(International Organization for Standardization) norms to ensure product quality and
uniformity. Some commonly referred standards include:
  ISO 230 Series – Geometrical accuracy testing of machine tools
 ISO 3443 – Accuracy requirements for forming and machining machines
 BIS IS 11795 – Accuracy testing of horizontal/vertical lathes
 IS 8170 – General tolerances for linear and angular dimensions
 IS 919 – Limits, fits, and tolerances
These standards help ensure:
 Interchangeability of components
 Safe operation of the machine
 Reduction of errors during production
 Higher customer satisfaction

2.5.4 Importance of Quality Control

Proper inspection during production and post-assembly:
 Prevents defective machine delivery
 Enhances machine life and reliability
 Ensures compliance with technical drawings
 Builds company reputation and customer trust
In high-precision applications (such as railway, energy, or defense manufacturing), even
minor deviations can lead to major failures. Therefore, rigorous inspection is considered a
non-negotiable process in machine tool manufacturing.
 Training Wrok
3.1 Introduction
The midterm phase of this industrial training is focused on developing a comprehensive
understanding of the complete manufacturing and inspection process followed in a typical
small-scale machine tool production facility. Instead of limiting the training to any specific
machine or component, the objective is to observe and conceptualize the step-by-step journey
from raw material to final tested machine — identifying how parts are machined, assembled,
aligned, tested, and finalized for dispatch.
Through continuous shop-floor visits, interactions with experienced workers, and exposure to
real-time production tasks, the training has emphasized learning how:
 Machines are structurally fabricated and mechanically assembled
 Dimensional accuracy and surface quality are ensured
 Inspection techniques are applied at every major stage
 Defects are identified and addressed based on their type and criticality
 Final testing is conducted before the machine is delivered to the client
This chapter documents the observational learning and the conceptual framework derived
from practical exposure to the shop floor and its operational workflow.

3.2 Methodology
Since this report reflects the midterm stage of training, the following approaches were
adopted to understand and document the work:
 Observation-Based Learning: Regular walkthroughs of the shop floor, assembly
sections, and inspection zones to study live operations and technician practices
 Conceptual Analysis: Understanding the rationale behind each step — why certain
machining sequences are followed, why specific tools are used, and how processes are
optimized
 Stage-Wise Documentation: Breaking down the entire production process into defined
stages — from casting and machining to final inspection
 Reference Support: Cross-verifying observed practices with engineering standards
from books like Bhandari’s Machine Design Data Book and Shigley’s Mechanical
Engineering Design

3.3 Manufacturing and Assembly Stages (Detailed Breakdown)

The manufacturing of machine tools — whether it is a heavy-duty lathe, shaper, or plano
miller — follows a set of structured stages that are almost universal. These include casting
preparation, machining, fitment, assembly, trial, and inspection.
Below is the expanded breakdown of each phase with precise technical steps, observations,
and instruments involved.

🔸 Stage 1: Raw Material Handling and Casting Preparation

1.1 Material Procurement and Storage

 Raw materials such as cast iron (for beds and columns), mild steel (for slideways
and arms), and alloy steels (for spindles, shafts) are procured from registered
vendors.
 Stored under covered sheds to avoid corrosion or rusting.
 Large parts are cast in-house or outsourced to local foundries.
1.2 Pattern Making and Molding
 Wooden or aluminum patterns are used to create molds.
 Patterns have extra dimensions called “machining allowance” to accommodate
material removal later.
1.3 Sand Casting
 For large parts like lathe beds or columns, green sand casting is used.
 Molding box (cope and drag) is prepared; molten metal is poured into the cavity.
 The cooling time depends on part thickness (can range from hours to a full day).
1.4 Fettling and Cleaning
 After solidification, the casting is removed and cleaned using chipping hammers,
grinders, and wire brushes.
 Sharp edges and risers are removed manually.
1.5 Initial Inspection
 Visual check for surface cracks, shrinkage, and blowholes.
 Hammer test (tapping) is used to identify internal voids.
 Ultrasonic flaw detectors are sometimes used for critical parts.

🔸 Stage 2: Rough Machining and Surface Preparation

2.1 Objective: Remove excess material and prepare a base for fine machining.
2.2 Equipment Used
 Plano millers for top and side surfaces
 Horizontal borers for bore holes in large castings
 Conventional lathe for shafts and cylindrical parts
 Belt-driven shapers for creating flat guideways
2.3 Trainee Observations
 Machines are manually controlled or semi-automatic. Operators use measuring
tapes, calipers, and steel rules during machining.
 A reference face is always machined first to serve as a locating surface for further
operations.
 Multiple passes are required. The first rough pass removes up to 4–5 mm depth per
side.
2.4 Safety Note: Coolants are often not used in roughing unless temperature affects accuracy.
Trainees must observe from a safe distance.

🔸 Stage 3: Stress Relieving and Aging

3.1 Importance: Internal stresses due to uneven cooling and machining can cause bending or
warping.
3.2 Methods Observed:
 Thermal stress relieving in a furnace (500–600°C) for 6–8 hours, followed by
gradual cooling.
 Natural aging where the casting is kept under ambient conditions for 7–15 days
before machining.
3.3 Changes Post-Process
 Machined faces are re-checked. Any twist, bow, or flatness deviation is corrected.
 Surface re-facing might be needed if distortion exceeds tolerance (typically 0.05
mm/m).

🔸 Stage 4: Finish Machining and Critical Dimensions

4.1 Operations Performed

 Boring and facing of bearing housings
  Grinding of guideways (using hand scraping and straight edge)
 Drilling and tapping of mounting holes
 Turning and threading of shafts and spindles on lathe machines
 Milling of T-slots, keyways
4.2 Inspection Tools Used
 Micrometer (0.01 mm accuracy)
 Slip gauges and sine bars
 Dial test indicators for runout and parallelism
 Feeler gauges to check gaps between slide surfaces
 Height gauges and surface plates for flatness verification
4.3 Trainee Insights
 Operators take multiple trial cuts and measure after each.
 Parts like lead screws are rotated and checked for axial play and concentricity.
 Accuracy of mating surfaces is prioritized to avoid vibrations in final assembly.

🔸 Stage 5: Sub-Assembly (Gearbox, Slides, Hydraulic Units)

5.1 Gearbox Assembly

 Gears are pressed onto shafts using hydraulic presses.
 Clearance and backlash checked using feeler strips and by rotating shafts by hand.
 Oil channels and seals are tested for leaks.
5.2 Slideways and Ram
 Slide components are adjusted using tapered gibs.
 Operator uses blue paste to check contact area during scraping.
 Movements are manually tested for smoothness and tightness.
5.3 Hydraulic System
 Pumps and valves are mounted.
 Hydraulic cylinders tested using pressure gauges (100–300 bar rating).
 Return line and filters are verified.
🔸 Stage 6: Main Assembly and Alignment

6.1 Frame Setup

 Bed, column, and base are mounted using crane or chain pulley blocks.
 Reference marks on casting are used to align parts.
6.2 Mounting Sub-assemblies
 Slideways, feed screws, rams, motors are mounted in sequence.
 Shaft alignment is done using laser alignment tool or manually with DTI.
6.3 Electrical Panel Installation
 Motor wires, limit switches, emergency stops are installed.
 Wiring is neatly routed through PVC channels and flexible conduits.
6.4 Trainee Observations
 Trial movements of table and slides are done manually first.
 No-load testing is performed to check smooth rotation and movement.

🔸 Stage 7: Painting and Finishing

7.1 Preparation
 Surface is cleaned with degreaser and scrubbed.
 Masking is applied to critical surfaces.
7.2 Painting
 Applied using spray guns; mostly PU or epoxy enamel paints
 Primer → Filler → Base Coat → Final Coat
 Drying time between coats is 4–8 hours.
7.3 Inspection
 Coating thickness gauge used (standard: 40–80 µm)
 Visual inspection for bubbles, drips, uneven areas

🔸 Stage 8: Final Inspection and Trial

8.1 Dimensional Checks

 Complete machine is inspected using:
 o Height gauge + surface plate

o Dial gauge for backlash

o Go/No-Go gauges for fitment

8.2 Trial Run

 Power is turned on, machine is tested under no-load and light-load conditions
 Speeds, feeds, directional control, emergency stop — all are checked.
8.3 Defect Identification
 Common final issues:
o Excessive vibration → due to poor balancing or misalignment

o Oil leakage → gasket/seal issues

o Ram jamming → uneven slideway scraping

 Rectified through re-machining, seal replacement, or alignment adjustment