Isgec Training Report
Isgec Training Report
Isgec Training Report
OF
SIX WEEKS SUMMER TRAINING, UNDERTAKEN
AT
ISGEC HEAVY ENGINEERING LIMITED,
YAMUNANAGAR
IN
Trading (CNC MACHINES)
SUBMITTED IN PARTIAL FULFILLMENT OF THE DEGREE
OF
B.TECH
IN
MECHANICAL ENGINEERING
UNDER THE GUIDANCE OF SUBMITTED BY:
NAME: R. AGHNIHOTRI XYZ
DESIGNATION: DGM B.Tech
Roll No. ********
CONTENTS
Chapter Page No.
Declaration 4
Certificate 5
Acknowledgement 6
Vision 7
Introduction 8
Business Areas 9
Power Sector 9
Industry Sector 10
International Operations 13
Research and Development 13
Human Resource Development 14
Casting 15
Casting Process Simulation 16
Sand Casting 17
Basic Processes 17
Components 19
Design Requirements 22
Mold Materials 25
Types of base sand 27
History 30
Forging 31
History 32
Advantages & Disadvantages 32
Processes 33
Machine Shop 39
Operations Performed 39
Description of Machines 43
Lathe Machine 43
Parts of Lathe 44
Milling Machine 45
Drilling Machine 46
Boring Machine 48
DECLARATION
I hereby declare that the work, which is being presented in this training
report as part of curriculum is an authentic record of my own work, carried
within the premises of ISGEC HEAVY ENGINEERING LIMITED,
YAMUNANAGAR.
XYZ
Dated: 04-08-2013
Place: YAMUNANAGAR
CERTIFICATE
This is to certify that the six week summer training report which has been
submitted to ISGEC Yamunanagar as part of the curriculum by XYZ bearing
Roll no. ******** of MechaNICAL Engineering Department, M.M.E.C.,
MULLANA is a record of authentic work carried out by his under our
supervision and guidance to the best of our knowledge.
R. Aghnihotri
Chief Training Officer
ISGEC Heavy Engg. Ltd.
Yamunanagar (HR)
ACKNOWLEDGEMENT
I am extremely grateful to ISGEC Heavy Engineering Limited,
Yamunanagar for giving me the opportunity to carry out my summer training at
their facility. Special thanks are due to Mr. Rajinder Aghnihotri, Head Training
Officer, ISGEC, for his continuous support and guidance in being my mentor.
And last but not the least, I would also like to extend my gratefulness to all the
engineers and operators, right from the highest to the simplest, for their constant
and enthusiasing support.
XYZ
VISION
ISGECs vision is to become a world-class engineering enterprise
committed to enhancing stakeholder value.
INTRODUCTION
ISGEC Heavy Engineering Ltd. is the largest engineering and manufacturing enterprise
of its kind in India and is one of the leading international companies in the field of
machine manufacture and diversified global engineering. Established in 1933, Isgec
Heavy Engineering Limited is a Rs. 2434 crore multi-product, multi-location public
company providing engineering products to customers across 76 countries. The major
target sectors for the company are: Power, Oil & Gas, Automobiles, Fertilizers, Sugar and
Defence. With a team of over 4000 employees, including 700 qualified engineers and
over 450 designers, the company has its manufacturing plants and design offices spread
across India in Haryana, Uttar Pradesh, Gujarat, Tamil Nadu and Maharashtra.
It is today a subsidiary company. At the time of the nation's independence, the need for an
Indian capital goods industry was recognized and Isgec was established in 1946. The
initial activity was the manufacture of spares for sugar mills. In 1964 it established a joint
venture with John Thompson of the UK to form Isgec John Thompson.. In 2011, the
company name was changed from Saraswati Industrial Syndicate Ltd. to Isgec Heavy
Engineering Ltd. with all businesses consolidated and now marketed under a common
brand name Isgec.
ISGECs range of services extends from project feasibility studies to after-sales-service,
successfully meeting diverse needs through turn key capability. The quality and reliability
of its products is due to the emphasis on design, engineering and manufacturing to
international standards by acquiring and adapting some of the best technologies from
leading companies in the world, together with technologies developed in its own R&D
centers. Isgec Heavy Engineering Limited, India and Hitachi Zosen Corporation, Japan
have a joint venture - Isgec Hitachi Zosen Ltd. - for manufacturing specialized and
critical process equipment. The Company has been constantly adapting itself to face the
challenges thrown-up by the business environment. ISGEC has already attained ISO 9000
certification for quality management and all the manufacturing units /divisions have been
upgraded to the latest ISO 9001-2008 version. ISGEC has also secured ISO 14001-2004
certification for environmental management systems & OHSAS -18001-2007 certification
for occupational health and safety management systems for all its units/divisions. ISGEC
is continuing its journey towards Business Excellence. ISGEC has committed to support
the Global Compact & the set of core values enshrined in its ten principles in the areas of
human rights, labour standards and environment.
BUSINESS AREAS
ISGEC has the following business units - Process Equipment, EPC Power Plants,
Boilers, Sugar Plants & Machinery, Mechanical & Hydraulic Presses, Steel & Iron
Castings, Contract Manufacturing, and Trading. This enables ISGEC to have a strong
customer orientation and respond quickly to the changes in the market.
Process Equipment
Wall thickness upto 300 mm (12 inches)
Weight up to 1000 MT (Single Piece)
Materials include Low and High Alloy (with or without cladding), Stainless Steel,
Non Ferrous material and Carbon steel (with or without cladding).
ISO 9001:2008, ISO14001:2004, OHSAS 18001:1999
ASME 'U3', 'U2', 'U', 'S' stamps
'R' and 'NB' certificates of Authorization from National Board of Boiler and
Pressure Vessel Inspectors, USA
CE Certification
EPC Power Plants
The demand for energy has never been greater and we are geared up to deliver
solutions for power and energy demands.
They provide complete EPC solutions from concept to commissioning.
Customized solutions with our standardized power plant designs to provide
optimum results.
Skilled manpower available to execute any Greenfield or Brownfield projects
Collaborative approach with associates for critical bought outs and systems
Proven experience with boiler technology such as CFBC, AFBC, Traveling Grate,
Oil & Gas Fired Boilers
Till date executed projects totaling to 275 MW
Currently executing projects totaling to 460 MW
Boilers
Over 600 High Capacity and High Pressure Boiler installations across 30
countries.
Wide Experience in Cogeneration, Captive Power applications and Independent
Power Plants.
Foster Wheeler, USA Technology for Pulverized Coal Fired, CFBC and Oil & Gas
Fired Boilers.
Boiler Technologies for Firing Solid and Biomass Fuels:
Oil / Gas Fired Boiler
Spent Wash (Slop) / Vinasse Fired Boiler
Municipality Solid Waste (MSW) / RDF Fired Boiler
Waste Heat Recovery Boiler (Cement & Sponge Iron Kiln)
Heat Recovery Steam Generators for GT Exhaust (HRSG)
Blast Furnace Gas (BFG) Fired Boiler
World class manufacturing facilities
Iron Casting
Iron & Alloy Iron Casting conforming to International standards including DIN,
BS, JIS, ASME
Single piece casting weighing upto 20 tonnes
Modern Pattern Shop
Facility for Full Mould Process Castings
Facility to offer fully machined Castings
Hydro Pressure tested castings upto 10 Kg /sq. cm
Can offer equipment under third party inspection by International agencies like
Lloyds, TUV, SGS, Inspectorate Holland
Contract Manufacturing
Custom job shop specializing in building Heavy Equipments to meet your
Drawing and Design specifications
45,000 sq. mtrs. of manufacturing space under heavy crane
Can handle single piece equipment upto 150 tonnes
Our modern fabrication, machning and assembly facilities allow us to meet your
delivery needs while maintaining International Quality standards at competitive
prices
Can offer equipments under third party inspection by International agencies like
Lloyds, TUV, SGS, Inspectorate Holland
Offer extensive drawing capability using Auto CAD & other design packages and
easy electronic transfer of data files via internet
Trading
CNC Vertical Machining Centres - Single / Double Column
CNC Horizontal Machining Centres
CNC Lathe - Slant / Flat Bed
Automation line for Bearing Industry
CNC Gear Grinding Machines
CNC Centerless & Double Disc Grinders
Surface Grinders
CNC High Speed Tap Centres
Heavy Duty Plano Millers CNC Horizontal Borers
Conventional Milling Machines
Broaching Machines
Robots
Laser Cutting Machines
Plasma Cutting Machines
Plate Bending Machines
Machine Frames
HUMAN RESOURCE DEVELOPMENT
The greatest strength of ISGEC is its highly skilled and committed manpower. Every
employee is given an equal opportunity to develop himself and improve his position.
Continuous training & retraining, career planning, a positive work culture and
participative style of management have engendered development of a committed and
motivated work force ready to take up the challenge of making BHEL a competitive
world-class organization.
As a process of linking HRM to market forces / stakeholder driven policies, an
e-enabled Performance Management System has been established for executives - a
new benchmark in promoting performance-led growth. To encourage individuals for
capability building and for continuous improvement through creativity & innovation in
every sphere of activity, an e-network based Improvement Projects Rewards Scheme
(IMPRESS) has been introduced company wide.
National Operations
Isgec has its manufacturing operations across Yamunanagar, Dahej, Bawal &
Muzaffarnagar, with offices in Noida, Pune, Chennai, Mumbai & Kolkata in India.
Spread over 100 Hectares (250 acres), the Company's manufacturing facilities have a
shop floor area of over 55,000 square meters (66,400 square yards) with world class
manufacturing & testing facilities.
International Operations
Isgec products have been supplied to reputed companies across 74 countries, many of
whom have placed repeat orders to them. These include:
ABB Group, Japan
Siemens, Germany
Foster Wheeler, China
Sumitomo, Japan
Foster Wheeler, USA
Valeo, France
GE Hydro, Canada
Virginia Tech, USA
Luk, Germany
Wesfarmers Group, Australia
Strategic Partnerships
Foster Wheeler, USA: License Agreement for PC Fired Boilers up to 1000 MW
Foster Wheeler, Spain: Licensing Agreement for HP & LP Feedwater Heaters &
Condensers
Bosch Projects, South Africa: Technology Transfer for Chainless Cane Diffusers
Foster Wheeler, USA: Collaboration Agreement for Power Plants up to 99.99
MWe
Belleli, Italy: Technology Agreement for manufacture of Breech Lock Heat
Exchangers
ABB Lummus Heat Transfer, USA: Technology License Agreement for Helix
Heat Exchangers
Hitachi Zosen Corp., Japan: Technology Transfer Agreement for Chrome-Moly
Vanadium Reactors
Hitachi Zosen Corp., Japan: Agreement for Critical Heat Exchangers for Fertilizer
industry
International Centres
Isgec has international offices in North America (California, USA) and Germany
(Dsseldorf).
New Joint Venture
Isgec Heavy Engineering Limited, India and Hitachi Zosen Corporation, Japan have a
joint venture - Isgec Hitachi Zosen Ltd. - for manufacturing specialized and critical
process equipment. The new company has a shareholding pattern of 51% (Isgec) to 49%
(Hitachi Zosen Corp.).
CNC MACHINE
CNC is an Acronym for Computer Numeric Control. A CNC is something controlled
using a computer or PLC (Programmable Logic Controller). Its a machine tool that uses
programs to automatically execute a series of machining operations. CNC machines offer
increased productivity and flexibility
In modern CNC systems, end-to-end component design is highly automated using
computer-aided design (CAD) and computer-aided manufacturing (CAM) programs. The
programs produce a computer file that is interpreted to extract the commands needed to
operate a particular machine via a postprocessor, and then loaded into the CNC machines
for production. Since any particular component might require the use of a number of
different tools drills, saws, etc., modern machines often combine multiple tools into a
single "cell". In other installations, a number of different machines are used with an
external controller and human or robotic operators that move the component from
machine to machine. In either case, the series of steps needed to produce any part is
highly automated and produces a part that closely matches the original CAD design.
History
The first NC machines were built in the 1940s and 1950s, based on existing tools that
were modified with motors that moved the controls to follow points fed into the system
on punched tape. These early servomechanisms were rapidly augmented with analog and
digital computers, creating the modern CNC machine tools that have revolutionized the
machining processes.
CNC, or computer numerical control, allows a computer to dictate the moves a machine
makes to perform cutting function. Originally, all machines were operated manually with
the distinct possibility of mistakes. The CNC machine performs these same actions with
more precision as well as more speed. The first CNC machines were manufactured in the
1970s to speed up production at large manufacturing plants and were very expensive and
difficult to use.
Overview of CNC Setup and Operation
CNC machine setup and operation follows the process shown in Figure
Pre-Start
Before starting the machine, check to ensure oil and coolant levels are full. Check the
machine maintenance manual if you are unsure about how to service it. Ensure the work area
is clear of any loose tools or equipment. If the machine requires an air supply, ensure the
compressor is on and pressure meets the machine requirements.
Start/Home
Turn power on the machine and control. The main breaker is located at the back of the
machine. The machine power button is located in the upper-left corner on the control face.
Load Tools
Load tools into the tool carousel in the order listed in the CNC program tool list.
Set Tool Length Offsets
For each tool used, jog the machine to find and then set the TLO.
Set Fixture Offset XY
Once the vise or other fixture is properly installed and aligned on the machine, set the fixture
offset to locate the part XY datum.
Set Fixture Offset Z
Use a dial indicator and 1-2-3 block to find and set the fixture offset Z.
Load CNC Program
Download the CNC program from your computer to the machine control using RS-232
communications, USB flash memory, or floppy disk.
Run Program
Run the program, using extra caution until the program is proven to be error-free.
Adjust Offsets as Required
Check the part features and adjust the CDC or TLO registers as needed to ensure the part is
within design specifications.
Shut Down
Remove tools from the spindle, clean the work area, and properly shut down the machine. Be
sure to clean the work area and leave the machine and tools in the location and condition you
found them.
Numerical accuracy vs Equipment backlash
Within the numerical systems of CNC programming it is possible for the code generator
to assume that the controlled mechanism is always perfectly accurate, or that accuracy
tolerances are identical for all cutting or movement directions. This is not always a true
condition of CNC tools. CNC tools with a large amount of mechanical backlash can still
be highly accurate if the drive or cutting mechanism is only driven so as to apply cutting
force from one direction, and all driving systems are pressed tight together in that one
cutting direction. However a CNC device with high backlash and a dull cutting tool can
lead to cutter chatter and possible workpiece gouging. Backlash also affects accuracy of
some operations involving axis movement reversals during cutting, such as the milling of
a circle, where axis motion is sinusoidal. However, this can be compensated for if the
amount of backlash is precisely known by linear encoders or manual measurement.
The high backlash mechanism itself is not necessarily relied on to be repeatedly accurate
for the cutting process, but some other reference object or precision surface may be used
to zero the mechanism, by tightly applying pressure against the reference and setting that
as the zero reference for all following CNC-encoded motions. This is similar to the
manual machine tool method of clamping a micrometer onto a reference beam and
adjusting the Vernier dial to zero using that object as the reference.
ADVANTAGES AND DISADVANTAGES OF CNC MACHINES
ADVANTAGES
1. CNC machines can be used continuously 24 hours a day, 365 days a year and only
need to be switched off for occasional maintenance.
2. CNC machines are programmed with a design which can then be manufactured
hundreds or even thousands of times. Each manufactured product will be exactly
the same.
3. Less skilled/trained people can operate CNCs unlike manual lathes / milling
machines etc.. which need skilled engineers.
4. CNC machines can be updated by improving the software used to drive the
machines
5. Training in the use of CNCs is available through the use of virtual software. This
is software that allows the operator to practice using the CNC machine on the
screen of a computer. The software is similar to a computer game.
6. CNC machines can be programmed by advanced design software such as
Pro/DESKTOP