HMT Pinjore

Report on industrial training
2016
1. INTRODUCTION
The machine tool industry constitutes the backbone of the industrial sector and is vital for the growth
of the Indian Economy. Even though the Indian machine tool industry is a small segment of the
engineering industry, it plays a very important role in the development and the technology up
gradation of the engineering industry. The quality and cost of engineering products depend on the
mother machine tools and their automation level. The development of the machine tool industry is
therefore paramount importance for a competitive and self-reliant industrial structure. This report
discusses the 6 weeks industrial training at HMTs machine tool division at Pinjore, Haryana. The
training was completed in July 2016.
1.1 HMT AT A GLANCE

By the end of Second World War, the government of India confronted by a big problem of disposing
the colossal war waste. Ultimately, a committee was constituted to inquire into the possibilities. The
committee report of 1948 proposed the establishment of a government owned machine tool industry.
This was expected to fulfill two aspects. The first was being utilization of the Rs.4000 crores of
metallic waste. The second was the incorporation of a state manufacturing facility. The result was
the birth of THE HINDUSTAN MACHINE TOOLS LIMITED, which led to the present multicore, multi-location, multi-unit, multi-product industrial giant HMT Ltd.
Right from the prior H.M.T. has played an important role in providing the much needed industrial
base as well as a launching pad for the growth & development of the country. HMT was conceived
by the Government of India by Our first Prime Minister, Pundit Jawaharlal Nehrus. Who dreams
to build modern India paved the way for setting up of various Public sector undertakings in different
industrial sectors. This initiative led to rapid industrialization of the country and he acknowledged
the same as "Temples of Modern India"
HMT Limited was established in 1953 in technical collaboration with Orleikon of Switzerland. Over
the years, new products have been added to its manufacturing range. Since then different
collaborations, continued in house R&D and tremendous marketing efforts brought HMT, to present
status
The company that started with manufacturing and selling lathes expanded its machine tool products
range to evolve as the ultimate solution in metal cutting. The product diversification efforts tool the
company to the business of watches in 1962, tractor in 1971, die-casting on plastic machinery in
1971, printing machinery in 1972, lamps and lamp making machinery in 1976, food processing
machinery in 1980, CNC systems in 1986, ball screws in 1986 and reconditioning in 1990.
Thus, Hindustan Machine Tools Limited, or HMT began in a small way to meet a big commitment
"To manufacture mother machines to build modern industrial India"
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The multi-product activities made HMT

Ltd. Change its identity as Hindustan
machine tools limited. Today HMT Ltd
has 16 manufacturing units with 22
products division spread through the
length and breadth of India. HMTs
commitment to the development of the
machine tools technology is clearly
reflected in the fact that HMT has as many
as seven exclusive machine tool units,
spread across the country. Each superbly
equipped to meet the most challenging
demand for machine tools. These units are
in
Ajmer,
Bangalore,
Pinjore,
Kalamassery, and Hyderabad are all ISO
9000 certified.
HMT Ltd was restructured in 1992 to facilitate better administration of the multi-product business
activities. Accordingly, the following business groups were established:
Machine tools business group, to concentrate on metal cutting machines.
Industry machinery business group to deal with printing machines, die-casting and plastic
injection molding machines, food processing machines and metal forming machines.
Agriculture business group to concentrate on tractor.
Engineering components business group to deal with casting and ball screws.
Consumer product business group to deal with watches and lamps.
Fig 1: HMT Product range
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In addition to these business groups, the company owns three subsidiaries as follows:
HMT (international) Ltd. Which
undertakes overseas projects &
exports.
PRAGA
tools
Ltd.
Which
manufactures machine tools.
HMT
bearing
Ltd.
Which
manufacture precision bearing in
collaboration with M/s kozo zapan.
Fig 2: Heavy Duty Lathe with Large Bore Spindle
HDL 70/2000
In tune with changing business environment, HMT limited restructured into holding company
tractors as its core business and the following subsidiaries:
1.
2.
3.
4.
5.
6.
HMT Machine Tools Limited,

HMT Watch Limited,
HMT Bearings Limited,
HMT Chinar Watches Limited,
HMT (International) Limited,
Praga Machine Tools Limited.
1.1.1 HMT Machine Tools Limited

The HMT machine tools limited is engaged in the manufacturing and marketing of general purpose
machine tools, special purpose machine tools, computer numerically controlled machine tools,
precision machinery system, printing machines, metal forming
passes, die-casting and plastic injection molding machines,
ferrous and non-ferrous casting.
The product range of HMT Machine Tools:BANGALORE:
Heavy duty lathes

Single and multi-spindle automates
Radial drilling machines
Multi spindle drills
Cylindrical & surface grinders
Fig 3: Radial Drilling Machine
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Laser cutting machines

CNC turn mill centers
CNC wire cut EDM
PINJORE:
Horizontal machining center

Vertical machining center
Milling machines
Broaching machines
Fig 4: knee type milling machine
FN2
KALAMASSERY:
CNC turning center

Turn mill center
Flexible turning cell
Copying lathes
Center lathes
Offset printing machines
Paper cutting machines
HYDERABAD:
Special purpose machines

Horizontal machining center
FMS
CNC horizontal boring machines
Bed type & floor types boring machines
AJMER:
Fig 5: High Speed Horizontal Machining

Center HSM 400 series
Grinding machines
SPM grinders
CNC grinders
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1.1.2 HMT Watches Limited

HMT Watch Limited manufactures and markets watches including hand wound/
automatic & quartz.
1.1.3 HMT Chinar watches

HMT chinar watches limited is also one of the subsidiaries engaged in the manufacture of chinar
model watches located in Srinagar, Kashmir state.
1.1.4 HMT Bearing Limited

HMT bearing Limited is one of the subsidiaries engaged in the manufacture of different types of
industrial bearing situated in Hyderabad.
1.1.5 HMT International limited

HMT International is engaged in the export of HMTs range of products worldwide. HMT also
market and backed up by a good sales & service network. It also under takes turkey project &
technical services for developing countries.
1.1.6 Praga Tools Limited

Praga tools ltd. Is also a subsidiary of HMT limited engaged in manufacture of machine tools located
in Hyderabad.
During 1970s, HMT took over Machine Tool Corporation at Ajmer as its sixth machine tool unit.
Consequent to the wide diversification, in September, 1978, the company dropped the name
Hindustan Machine Tools Limited and instead adopted the acronym "HMT" itself as its name, and
thus the company came to be known as HMT Limited.
1.2 The Pinjore complex of HMT Limited Pinjore

The pinjore unit, the 3rd unit was established in 1963 and it went into production on 1st October
1963. This factory has been designed, built and commissioned entirely by India talent in a record
period of 17 months of breaking the ground on May 2, 1962. Pundit Jawaharlal Nehru, the first
Prime Minister of free India, inaugurated it on October 23, 1963
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Fig 6: HMC 500-M
2016
The unit begin its initial manufacturing of

milling machines with its technical
collaborator fritz Werner in 1963.
Subsequently after acquiring designing
capabilities,
HMTs
self-designed
machines were introduced. Today, the
range includes various types of knee as
well as turtle ram types of milling
machines. Rugged and versatile, these
machines offer wide spindle speeds and
feeds. With high content of mechatronics,
Milling Machines with pre-defined
programmed up to 40 steps have been
introduced.
During the period of 1967-77 the pinjore unit diversified its product range and manufacture of
Broaching Machines was taken up as import substitution. Available in horizontal and vertical
versions, these ruggedly constructed machines have infinitely variable cutting speeds with dead
constant speeds ensuring optimum tool life and fine surface finish.
In tune with HMTS commitment to usher in the latest technologies to the countrys fast developing
industrial base, in 1976 the Unit introduced the state-of-art computerized numerically machines
offering unlimited options in the unmanned manufacturing concept.
The unit has designed a wide range of both Horizontal Vertical CNC Machining Centers to meet
stringent accuracy standards, providing high flexible and productivity with enough muscle to
remove large quantities of materials at low rpm for light metal alloys. High processing speed is
ensured through CNC Systems that have powerful graphics and user friendly features. The machine
can be integrated with other machine tools into flexible manufacturing line. The unit also
manufacturers Moving Column Type Special Purpose Machines which can perform milling,
drilling, taping, boring and reaming operations with recirculating liner motion bearing for high
position accuracys with encoder x, y and z axis.
THE CURRENT MAJOR PRODUCTS
Horizontal machining centers(HMC-320M, 400M, 500, 400, 630, 800)

Vertical machining centers(VMC-400M, 600M, 5SM, 800M, 1000, 1200M)
Vertical & horizontal broaching machines
General purpose milling machines
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Special tooling fixtures

Reconditioning milling & broaching machines
CNC machining centers
In spite of the above product range the Pinjore complex of HMT is also famous for their general
purpose machine, which include milling machine of FN2/FN3 (H, U, and V) and for their horizontal
and vertical type broaching machines.
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2. FOUNDARY DEPARTMENT
The foundry and pattern shop attached to the machine
tool division, HMT Pinjore and part of engineering
components business group is geared to manufacture all
cast iron & spherical graphical iron required for machine
for machine tools and tractors and can also take job
orders. Established in 1963 with polish edge design, it is
semi mechanized foundry producing heavy duty gray &
SG iron casting for machine tool and for tractors using
main frequency induction furnaces for melting and resin
bonded sand for molding and core making.
Foundry is a factory that produces metal castings. Fig 7: Bronze poured from a crucible into
Metals are cast into shapes by melting them into a liquid, a mold, using the lost-wax casting process
pouring the metal in a mold, and removing the mold
material or casting after the metal has solidified as it cools. The most common metals processed
are aluminum and cast iron. However, other metals, such as bronze, brass, steel, magnesium,
and zinc, are also used to produce can A be formed castings in foundries. In this process, parts of
desired shapes and sizes
HMTs foundry shop comprises of two units:
One is the captive foundry, meant for the small production of casting having weight up to 4
tons. The capacity of this foundry is 1000 MT per annum.
And the other is meant for mass production of comparatively smaller tractor and machine
components. The capacity of this foundry is 2000 MT per annum.
2.1 PATTERN MAKING

A pattern is defined as anything used for forming an impression called mould in the sand. Mould
when filled with molten material on solidifying, forms a reproduction of the pattern and is known
as mould. It is slightly larger in size than casting. As the first stage in preparing the casting, the
pattern of the castings is prepared. Pattern of casting is prepared at pattern shop with either of the
materials given below:
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Wood: - Wood is the most commonly used pattern material as it is cheap, easily available
and also easy to join and fabricate. But it has a large rate of moisture absorption and also
warping and wearing is high.
Metals: - Metals have the advantage that they do not warp, are very accurate and have high
strength. But shaping is slightly difficult and it is also subjected to rusting and the costs are
also high.
Plastics: - They are mostly thermosetting plastics. They are light in weight, have very good
surface, do not react with water or air and are not subjected to warping, but cannot
withstand high temperatures.
Plasters: - The most common example is gypsum cement. Repairs cant be easily
Done and it does not need skilled labour.
Wax: - Wax has very good surface finish, can be easily altered to any shape and is very
accurate. But it cannot withstand high temperatures.
Thermocol:- single use patterns are made using thermocol

In the process of casting, a pattern is a replica of the object to be cast, used to prepare the cavity
into which molten material will be poured during the casting process. The pattern needs to
incorporate suitable shrinkage allowances depending on material flow and heat transfer
considerations. Pattern making is a skilled technique that was highly valued in the different cultures
practicing casting through the centuries.
In sand casting, the pattern is usually of wood, whereas it may be metal or other materials in
pressure or centrifugal casting. The patternmaker also decides where the sprues and risers (inlet and
outlet for molten material) will be placed with respect to the pattern. Parts of the object which have
holes or depressions are handled by inserting cores defining volumes that the material will not flow
into. Sometimes patterns may also accommodate chills, solid pieces of the final material, to
enable rapid cooling, resulting in martensitic hardening in the neighborhood of the chill.
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Fig 8: Pattern is used to make impression in sand
2.2 SAND MOLD AND CORE MAKING

The procedure of making a typical sand molding starts by placing a bottom board first either on the
molding platform or on the floor, making the surface even. The drag mounding flask is kept upside
down on the bottom board along with the drag part of the pattern at the center of the flask on
the board. There should be enough clearance between the pattern and the walls of the flask Rest of
the drag flask is completely filled with the backup sand and uniformly rammed to compact the sand.
The ramming of sand should be done properly so as not to compact it too hard, which makes the
escape of gases difficult, nor too loose so that mould would not have enough strength. After the
ramming is over, the excess sand in the flask is completely scraped using a flat bar to the level of
the flask edge. The finished drag flask is now rolled over to the bottom board exposing the pattern.
Using stick, the edges of the sand around the pattern is repaired and cope half of the pattern is placed
over the drag pattern, aligning it with the help of dowel pins. The cope flask on top of the drag is
located aligning again with the help of the pins. The dry parting sand is sprinkled all over the drag
and on the pattern.
In HMT due to complex structure of components (such as gear box) are produced with the help of
master pattern. Here core is first made with the help of master pattern after which the core is allowed
to be baked.
Sand casting is the most common production technique, especially for ferrous castings. Sand is
mixed with clay and water or with chemical binders and then packed or rammed around the pattern
to form a mould half. The two halves are joined together to make the mould - a rigid cavity that
provides the required shape for the casting.
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The core is made with the help of sand such as
Oil sand.
Air setting sand or no bake sand.
Green sand for small castings
2.3 METAL MELTING

The process of melting in HMT is carried out in induction furnaces at a temperature of about 14001450C
PROCESS OF METAL MELTING: At first the induction furnaces are coated with fine
cement clay. Now metal scrap is inserted in the furnace and slag coagulant is added to it. The
requisite amount of coke is added to it. The current is supplied to copper coils provided in the
furnace which induce current in the metal scrap and the scrap gets heated up, when the melting
temperature is reached the molten metal is collected in ladles and taken to the pouring zone. When
this process is being carried out the copper coils are regularly cooled with coolant (water) so that
the coils do not melt due to the high temperature generated in the coils.
The foundry of HMT has three furnaces, two, each having capacity of 3MT and one of 1.5MT.
The two types of induction furnaces are:-
Fig 9: Electric furnace
Main frequency Induction Furnace(50Hz)

Medium frequency Induction Furnace(250Hz)
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Melting of metal ion medium frequency furnaces are faster than the main frequency furnaces.
Molten metal is prepared in a variety of furnaces, the choice of which is determined by the quality,
quantity and throughput required. Electric induction furnaces are the most common type used for
batch melting of ferrous, copper and super alloys. This method involves the use of an electrical
current surrounding a crucible that holds the metal charge. Furnace sizes range from < 100 kg up to
15 tones. For production of super alloys and titanium, melting may be undertaken in a vacuum
chamber to prevent oxidation.
Specifications of 1.5 ton capacity furnace:Line Voltage
11000 Volts
Primary Voltage
440 Volts
Power Voltage
440 KW
Power Rating
5 KA
Melting Power
1 ton per hour
Frequency
50 Hz
Lining Thickness
95 mm
Power Factor
0.9
After the melting process is complete, the molten metal is carried quickly to the moulds to prevent
solidification. The inversion of Induction Furnaces is carried out by hydraulic lifts fitted just below
the whole apparatus.
2.4 CASTING AND SEPERATION

Molten metal is poured into moulds using various types of ladles, or in high volume production,
automated pouring furnaces. Metal is poured into the runner (a channel into the mould cavity)
until the runner bush is full. The riser provides an additional reservoir of feed metal to counteract
the shrinkage that occurs as the casting begins to cool.
When the metal has cooled sufficiently for the casting to hold its shape, it is separated from the
mould by mechanical or manual methods. Where sand moulds are used, the process is often referred
to as shakeout or knockout, and large amounts of dust may be generated.
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2.5 REMOVAL OF RUNNER AND RISER

A riser, also known as a feeder, is a reservoir built into a metal casting mold to prevent cavities due
to shrinkage. Most metals are less dense as a liquid than as a solid so castings shrink upon cooling,
which can leave a void at the last point to solidify.
Risers prevent this by providing molten metal to the casting as it solidifies, so that the cavity forms
in the riser and not the casting. Risers are not effective on materials that have a large freezing range,
because directional solidification is not possible.
They are also not needed for casting processes that utilized pressure to fill the mold cavity. A feeder
operated by a treadle is called an under feeder.
Fig 10: Runner and Riser
After
casting,
these
extraneous pieces of metal
are removed and often
collected for re- melting. In
ferrous castings and larger
non-ferrous castings, they
may be removed by knocking
off, sawing or cutting using
an arc air or oxy-propane
torch. In die-castings, they
are often snapped off
manually.
2.6 FINISHING PROCESS

FETTLING: The complete process of the cleaning of casting, called fettling, involves
the removal of the cores, gates and risers, cleaning of the casting surface and chipping of any of the
unnecessary projections on the surface. The dry sand cores can be removed simply by knocking off
with an iron bar, by means of a core vibrator, or by means of hydro blasting. The method depends
on the size, complexity and the core material being used.
Before fettling, the casting obtained is subjected to removal of projections, chips, core, runner,
riser etc. by the following processes:
Deco-ring
Chipping
Shot blasting (for heavy pattern)
Wheel abrasion (for small pattern)
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Priming and painting

Deco-ring:
Deco-ring is the process of removing the fused sand.
Chipping:
Chipping is the process of removing the runner, riser etc.
Shot Blasting & Wheel Abrasion:
Shot blasting or wheel abrasion is used for removing the sand particles by the usage of air.
After this fettling is done by the following process:
Pneumatic gun- to remove corner sand.

Angle grinder- to give corner finish.
Die grinder- to give finish to inner portion.
Pedestal grinder-to give surface finish.
While making casting for gears, surface finish is not required because gear has to be cut on it with
the help of milling machine after which it is grinded.
Priming & Painting:
After clean and fettling, the casting is subjected to priming and painting to prevent corrosion.
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3. HEAT TREATMENT
Heat Treatment is the controlled heating and cooling of metals to alter their physical and mechanical
properties without changing the product shape. Heat treatment is sometimes done inadvertently due
to manufacturing processes that either heat or cool the metal such as welding or forming.
Heat Treatment is often associated with increasing the strength of material, but it can also be used
to alter certain manufacturability objectives such as improve machining, improve formability, and
restore ductility after a cold working operation. Thus it is a very enabling manufacturing process
that can not only help other manufacturing process, but can also improve product performance by
increasing strength or other desirable characteristics.
In this section, various operations like annealing, normalizing, hardening, carburizing are performed
at various temperatures to improve the physical and mechanical properties of the material. This
section has the furnaces, hot baths, and various types of tanks containing different salts & chemical
to perform the various operations.
Type of Equipments used for hardening process:
1.
2.
3.
4.
5.
6.
7.
8.
9.
Natural Bath Tank

Quenching bath Tank
Carburizing bath Tank
Preheated Furnaces
Stress reliving furnace
Na-OH bath Tank
Washing Tank
Rust Removing Tank
Low temp. Blocking
Cast iron is comparatively low in cost and has the following properties:
Cast ability
Machinability
Wear resistance
Damping characteristics
Dimensional stability
Pressure tightness
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The following four heat treatment processes are the most commonly used:
Annealing is the process for making material softer while producing uniform material properties.
A material can be annealed by heating it to a specific temperature and then letting the material
slowly cool to room temperature in an over. This process is expensive because the oven is unusable
during the cool down process.
Normalizing is also a process for making material softer but does not produce the uniform material
properties of annealing. A material can be normalized by heating it to a specific temperature and
then letting the material cool to room temperature outside of the oven. This process is less expensive
than annealing.
Stress Relieving is also a process for making material softer. However, stress relieving does not
change the material properties as does annealing and normalizing. A material can be stress relieved
by heating it to a specific temperature that is lower than that of annealing or normalizing and letting
it cool to room temperature inside or outside of the oven. This heat treatment is typically used on
parts that have been severely stressed during fabrication.
It is worth noting that many heat treatments and welding processes cause stresses in the material
that can lead to warpage either after the heat treating process or during subsequent machining
operations. Of specific concern is the stress induced by welding. If a weldment is to be machined
it should almost always be stress relieved or normalized before the machining process.
Quench Tempering is the process for making material harder. This method has been known for
hundreds of years but was only perfected in the last century. The metal is heated to a specific
temperature and rapidly cooled (quenched) in a bath of water, brine, oil or air to increase its
hardness.
Carburizing it a heat treatment process in which iron or steel absorbs carbon while the metal is
heated in the presence of a carbon bearing material, such as charcoal or carbon monoxide. The intent
is to make the metal harder. Depending on the amount of time and temperature, the affected area
can vary in carbon content. Longer carburizing times and higher temperatures typically increase the
depth of carbon diffusion.
This manufacturing process can be characterized by the following key points: It is applied to lowcarbon workpieces; workpieces are in contact with a high-carbon gas, liquid or solid; it produces a
hard workpiece surface; workpiece cores largely retain their toughness and ductility; and it
produces case hardness depths of up to 0.25 inches (6.4 mm).
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HEAT TREATMENT SECTION
BATH/FURNANCE
1. Carburizing bath
1. Carburizing bath
APPROX CONTENTS
Sodium cyanide 8-10%
Sodium
cyanidebarium
8-10%chloride
Sodium
chloride,
Sodium chloride, barium chloride
2. Hardening bath
Term
degree
C+-20
Term
910910
degree
C+-20
NaCl, barium chloride
2. Hardening bath
3. Annealing bath
3. Annealing bath
4. Quenching
Bath Bath
4. Quenching
NaCl, barium chloride

Working
temp
Working
temp850
850degree
degreeC+-20
C+-20
Same as hardening bath
Same as hardening bath
Working temp 650 degree C+-20
Working
temp
650sodium
degree nitrate
C+-20
Sodium
nitrite,
Sodium
nitrite,
sodium
nitrateC+-20
Working
temp
180 degree
Working temp 180 degree C+-20
ELECTROPLATING SECTION
BATH/FURNANCE
1. Chromium plating bath
APPROX CONTENTS
chromium acid 200gm/liter

300gm/liter H2SO4
Temp 45-50 degree C
2. Blackening Bath
NaOH, sodium nitrite,

Sodium nitrate,
Temp 145 degree C+-10
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4. SMALL PARTS
This section of machine tool, HMT is primarily concerned with the manufacturer of small parts of
machine tools. The machines concerned are CNC machines, lathe machines, milling machines,
drilling machines etc. This department requires precision work.
Small parts manufacture those components and accessories that weigh anything below 40 kg. The
small part division is further divided into the following sections:1.
2.
3.
4.
5.
6.
7.
Turret section
Gear section
Round section
Non-round section
Spindle
Sheet metal
Accessories
The function of each department have been illustrated as following
4.1 TURRET SECTION:

The section is so named because of turret lathes. Turret are the machines which are used for mass
production. This section is concerned with small job construction. These jobs requires precision
works since these parts are to be fitted in small areas and generally screwed up the machines
involved in this process are lathe machine and use of precision measuring instruments like digital
micrometer, dial Vernier caliper etc.
Various machines in the turret section are:
Centerless grinding machine

Polygon grinding machine
Lathe
Radial grinding machine
Bench drilling machine
Vertical milling machine
Horizontal milling machine
Cylindrical grinding machine
Surface grinder
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Components manufactured in the turret section are:Screws, thick washers, hard washer, screw plug, spares, ring studs, nuts, holders, micro nut
Operation performed in the turret section are:Turning, surface grinding, internal grinding, cylindrical grinding, polygon
grinding, drilling, surface grinding, centerless grinding.
4.2 GEAR SECTION:

Gear is used for power transmission of different parts of machines. This section is concerned with
teeth cutting. Proper indexing is maintained in the process with fixtures on the machines concerned.
There are four types of gears used in manufactured here:-
Machines which are installed in gear section are: Center lathe

Gear hobbing machine
Combined turning and drilling lathe
Radial drilling machine
Rotary grinder
Cylindrical grinding machine
High production gear Hobber

Bevel gear shaper
Gear grinding machine
Gear tooth round machine
Metal washing machine
Components manufactured:Spur gears, helical gears, work wheel, bevel gears, worm gear, rack.
4.3 ROUND SECTION:

This section concerned with the round job construction and working. In the round section the job
pieces generally have circular cross-section & the ratio of length to the diameter generally less than
1.2.
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Machine installed in Round section are:

centerless lathe
oil grooving machine
combined turning and drilling lathe
horizontal milling machine
vertical milling machine
thread milling machine
vertical milling machine
horizontal keyway milling machine
slotting machine
linear dividing machine
drum dividing machine
radial drilling machine
tool grinder
surface grinder
cylindrical grinder
horizontal & vertical broaching machine
component manufactured in the round section are:Bush, guide bush, bearing, housings, cylinders etc.
4.4 NON-ROUND SECTION:

All the non-round jobs that are to be used in machines are machined here
Components manufactured :blocks, rectangular strips, Gibs, pump body, stop block, adjustable plate, shift fork, bearing
blocks, arm brace, clump leavers etc.
Operations performed :
marking
vertical milling
drilling
fitting
grinding
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Machines used in this section are: Horizontal milling machine

Surface grinding machine
4.5 SPINDLE:
This section is concerned with the manufacturing of small cylindrical parts or spindles which may
be hollow, solid, shell type etc. according to machines requirement. The jobs concerned are
larger in size as compared to other sections. This section manufactures all the head related obs.
This machine requires for the purpose include lathe machines like LB26 lathe, center lathe, turret
lathe. Also use of drilling machine is there .Thread cutting operation is also carried out in this
section. The job to be worked upon is supplied by the foundry department.
Components manufactured:
Main spindles, bearings housing (spindle shot), lead screw, simple shaft, splined shaft etc.
Machines installed:
Center lathe
Deep hole boring machine
Auto threading machine
Universal milling machine
Vertical keyway milling
Radial drilling
Cylindrical grinder
Universal grinder machine
Operations performed:
Turning
Grinding
Drilling
Keyway milling
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4.6 SHEET METAL:

This section includes the cutting of sheets, bending of sheets at various angles. Various
operations like drilling, bending, shearing etc. are completed in this section. Some of the areas
where sheet metal are used are:
For making outer body manufacturing of CNC machines.

For making junction boxes for CNC machines.
Machines installed in this section are:
Radial arm drilling machine

Nibbling machine
Shearing machine
NC machine
4.7 ACCESSORIES:
The accessories division manufactures components that are required to make up various machines.
The following list is of accessories manufactured by this division:
Universal dividing head of different sizes

Round table (hand driven)
Round table (power driven)
Universal milling head
Vertical milling head
Rack milling attachment
Slotting attachment
Horizontal indexing head
Here manufacturing & assembly of accessories of milling machines is done & also
accessories of FN1 & FN2 are made.
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5. HEAVY PARTS AND TOOL ROOM

5.1 HEAVY PARTS:
It is the shop which gives the shape to the largest castings which come from the foundry after being
painted rough. In this section various operations are performed by the help of planers, boring and
planning-boring machines.
In this section, first of all the jobs are checked for the castings to be over-size or undersize. If they
are undersize, they are sent to scrap. If they are oversize, they are marked and sent for machining.
Different types of operations are done by using different machines including various measuring
devices.
This section also includes in itself a high technology section in which advanced machines are placed
to machine crucial parts generally guide ways etc. It accommodates a tool preset device which is
used to set the tool of all machines and CNC machines. It is used to measure the length and diameter
of the tool with the help of leases.
The various parts manufactured in heavy parts department are:
Lathe bed
Legs
Carriage
Headstock
Tailstock
Knee
Gear box housing
Machine columns
The various operations performed in heavy parts are:
Milling
Facing
Drilling
Grinding
Housing
CNC turning
Turning
Boring
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Various types of machine installed in heavy parts department are:
CNC Plano type milling machine

Plano milling machine
Double housing planer
Radial drilling machine
Surface grinding machine
SPM deep hole boring machine
Horizontal and vertical boring machine
Vertical turret
Heavy parts section are generally divided into the following sections:
1. PLANNING SECTION
2. BORING SECTION
5.1.1. PLANNING SECTION

This section essentially consists of planners mounted on one side of the section. In this section the job
planning is one of the basic operations done for machining to large process, it is primarily intended for
machining to large flat surfaces. The surface which is to be machines may be flat or vertical.
PLANNING SECTION CONSIST OF TWO TYPE OF MACHINES

A. PLANO MILLER:-Milling machine uses a multipoint cutting tool in Plano type milling machine.
Heavy jobs can be seated and using above arbor and gang milling cutter profile can be milled very
easily. Planners are used for planning for planning and finishing the milled surface. It can set up to 4
meter length.
Fig 11: HMT Plano miller
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B. CNC PLANO MILLER:

This CNC type Plano miller is used for milling heavy parts like body, bed, and head stock.
The threads duration can be easily achieved by using the universal tool head and the table
movements areas. It uses a tool head and can be swirled to 360 degree and can be replaced
by a universal tool head. It can be set at any angle in any direction.
Fig 12: CNC Plano miller
5.1.2. BORING SECTION:

Boring section consists of enlarging an already drilled hole. The holes are pre drilled as in castings
only the operations of boring can also be done on small scale on lathe whether it may be capstan
lathe or turret lathe. The operations of boring machines are used according to requirements.
Machining time in boring:Machining time is the time required to complete the work place in a request period of time.
Time required = Length of cut/ (RPM feed per meter)
Types of boring machines installed

1. VERTICAL TYPE
2. HORIZONTAL TYPE
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A. VERTICAL BORING MACHINE:This type of machine is large in size and vertical. The spindle is vertical and bores vertical holes in
the spindle. Vertical boring is a machining process whereby a part to be machined is clamped to a
bed and a machining tool is rotated to produce some cylindrical, internal feature in the work piece.
The cylindrical surface to be produced is oriented in the vertical direction and the tool is typically
fed down into the work piece.
Many vertical boring operations can be performed by a conventional mill and boring attachment,
so in general vertical boring machines are used to machine large castings and blocks of metal too
heavy for a regular mill.
One of the advantages of carrying out the boring operation in the vertical position is the ease of
clearing cuttings from around the cutting tool. Another key advantage is that the need for a large
amount of power to rotate a very large block of steel and the associated dangers are avoided.
Another variation on the vertical borer is the vertical lathe. With this type of machine, the work
piece is rotated instead of the cutting tool, but the general operation and application is similar but
the application is for smaller, lighter work pieces. The machine can also be used as a drilling
machine.
Typical applications for vertical boring are:
Line boring of large machine tool casings and engine blocks.
Machining internal bearing diameters in large castings.
Finish machining of cylindrical surfaces on very large work pieces.
Figure 13: Vertical Boring Machine
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B. HORIZONTAL BORING MACHINE:In horizontal boring machine operations are performed on those workpieces which relatively large
and which cannot be rotated and require operations on its many surfaces. The worktable can be
transverses along and across the machine bed. It is possible to machine a flat surface with the based
hole by mounting a facing head over the spindle. A horizontal boring machine has its work spindle
parallel to the ground and work table. Typically there are three linear axes in which the tool head
and part move. Convention dictates that the main axis that drives the part towards the work spindle
is the Z axis, with a cross-traversing X axis and a vertically traversing Y axis. The work spindle is
referred to as the C axis and, if a rotary table is incorporated, its center line is the B axis.
Fig 14: Horizontal Boring Machine
Boring head: Boring head on Morse taper shank. A small boring bar is inserted into one of the
holes. The head can be shifted left or right with fine gradation by a screw, adjusting the diameter of
the circle that the cutting tip swings through, thus controlling the Hole size, even down to within 10
micrometers if all machining conditions are good.
Fig 15: Boring Head
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5.2 TOOL ROOM:

Tool room is the place where special purpose tools, jigs & fixture are produced. Jigs are used in
machining operations for guiding tool. Fixtures are used for fixing the workpiece on the table.
This is one of the necessary sections in any industry which deals with the requirement of tool of
its other section. In HMT the tool room has been divided into two sections one in HIGHTECH
and NEOLOGY section and other is traditional one. In the high technology section the more
complex machinery imported one like Jig boring machines and CNC cylindrical grinding
machine. As both type of machine provide the better accurate finishing this is up to microns.
Machine installed in this section are:

I.
II.
III.
Jig boring machine

Center grinding machine
Engraving machine
5.2.1 Jig boring machine:A metal-cutting machine for finishing holes, planes and slots with a highly precise location of
centers or surfaces without the use of special attachments for toll alignment. Jig-boring machines
are used for boring, drilling, counter-sinking, reaming, milling, and other types of finishing in
individual and small-scale production during the manufacturer of cutting and measuring tools, jigs,
dies, and key components of machines and instruments.
Fig 16: jig boring machine
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Jig boring is an expensive operation, here the holes are bored with respective to any other dimension
using a highly accurate boring machine Jig boring machine. Jig boring machine are used for boring,
drilling, counter sinking, reaming, milling and other type of finishing in individual and small-scale
production during the manufacturing of cutting and measuring tools, jigs, dies and keys components
of machine and instruments.
The table moved along X &Y axis and the saddle moved along Z-axis. The movement of this
machine is highly accurate and using three optical systems, one for each axis. The accuracy of the
machine is 1/1000mm. the tools are automatically gripped on the tie rod by threading. The tie rod
rotates on the opposite direction for removing the tool. Table can be tilted 0 to 90 degree and rotated
360.
5.2.2 CENTER GRINDING MACHINE:

This machine is used for grinding center holes of parts so that they can be machined with respect to
a straight axis when being machined between two centers. The end of the holes id ground so as to
produce a 90 degree counter sinking at the hole. The grinding wheel having a required angle is fed
from the top. The grinding wheel is replaced after sufficient use.
Fig 17: center grinding machine
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5.2.3 ENGRAVING MACHINE

This is used for engraving the numbers and letters in tools and jigs. It uses the principle of
pantograph. Templates are used for this purpose. The tracing arm is moved on the template while
the engraving tool engraves on the surface of the workpiece.
Fig 18: Engraving machine
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6. HIGH TECHNOLOGY CENTER

A machine tool is a power driven machine which can be used for the manufacture of components
of other machines. HMT pinjore unit is a machine tool factory. In the High Technology Centre there
are 5 CNC machines.
VMC
HMC
HSM
VTC
VTC2
All these machines are working with the help of CNC control. Controlling a machine tool by
means of a prepared programme which consists of blocks or series of numbers is known as Numeric
control. It contain machine control unit and machine tool itself.
VMC 400
It can do drilling and milling operation. It can hold 12 tools in the magazine. The worktable
movement in X and Y axis are 400 mm and z axis is 420 mm. System 802- Auto tool changepneumatic control.
HMC (Horizontal milling machine)
Spindle works horizontally. It table length of X axis 630mm, Y axis 560mm and Z axis500mm. It
can hold 60 tool. It has 4 axis X, Y, Z and B.HM4 its table capacity is x axis 1600 y axis 1200
and B axis 360 degrees. It can hold 60tools in the magazine.
VTC 1 AND 2
Vertical Machining Centre with automatic tool changer. Its capacity is X axis 1150mm, Y-axis is
640mm and z axis is 500 mm. It can hold 30 tools
HSM 400
Thermo symmetric structure and heavily ribbed, stress relieved structures for high accuracy and
heavy duty cutting capability.
HSM 400 consists of a table size of 400*400 mm. this machine can achieve a maximum spindle
speed of 12000. One of the main advantage of this machine is that, it lowers the pallet changing
time to 8sec
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6.1 Applications of CNCs

It includes both for machine tools as well as nonmachine tools. CNC is widely used for lathe, drill
press, milling machine grinding unit, laser, sheet
metal press, tube bending machine.
Elements of a CNC
Part program
Machine control unit
Machine tool
Fig 19: HINUMERIC 2100M CNC control system
Part program is a detailed set of commands to be followed by the machine tool. Each command
specifies a position in the Cartesian coordinate system. Programmers should be well versed with
machine tools machining process.
Machine Control Unit (MCU) is a microcomputer that store the program and executes the
command into actions by the machine tool. It consists of two main units the date processing unit
(DPU) and control loop unit (CLU). DPU software includes control system software, calculations
algorithm, translation software that converts path program into usable further, interpolation
algorithm to achieve smooth motion of cutter, editing of part program. CLU consists of the circuits
for position and velocity control loops, deceleration and backlash take up, and function controls
such as spindle on/off.
Point to Point systems
That move the tools or the workpiece from one point to another and then the tool programs the
required task.
Continuous path systems
It provides continuous path such that the tool can perform while the tools are moving, enabling the
system to generate angular surfaces, two dimensions or three dimensional contours. Velocity error
is significant in affecting the position of the cutter.
Interpolator
The input speed of 1in/sec in example 2 is converted into the velocity components by an interpolator
called the linear interpolator whose function is to provide the velocity signals to X and Y directions.
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Incremental and absolute systems

In incremental, sister distance is measured from one point to the next. An absolute system is one
which all the morning commands are referred from a reference point.
Open loop control
There is no feedback and uses motors for driving the lead screw. A motor is a device whose output
shaft rotates through a fixed angle in response to an input pulse.
Closed loop control
There is a force resisting the movement of the tool/work piece. Milling and turning are typical
examples. Servo motors and feedback devices are used to ensure that the desired position is
achieved.
Manual part programming
It first prepares the program manuscript in a standard format .Manuscripts are typed with advice
known as flexo writer. The punch type of prepared on the flexo writer. Computer aided
programming Complex shaped component require calculation to produce the component done
by programming software contained in the computer. Program communicates through system
language which is based on words. Programming languages are: APT, ADAPT, AUTOSPOT,
COMPAT 2, CLROMANCE, SPLIT.
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7. GPM ASSEMBELY
GPM stands for general purpose machines. These are generally manually worked machines
involving no computerized or numerical control. These machines are semiautomatic in nature and
some of its operation like table movement, job movement, tool movement etc. can be carried out
either automatically or even manually. These are operated by concerned operations only. The
concept of modern days machines originated from GPMs itself. These are the simplest form of the
metal working machines.
Examples of these machines- Lathe machines, milling machines, drilling machines, grinding
machines etc.
In HMT, Pinjore unit primarily four types of GPM are manufactured
FN2 milling machines

FN3 milling machines
Turret Ram milling machines
Broaching machines.
The machines are further classified into horizontal, vertical and universal milling machines.
a) When the rotating spindle lies vertical w.r.t. the table the machine is termed as vertical (V)
milling machine.
b) When the rotating spindle lies horizontal w.r.t. the table the machine is as horizontal (H) milling
machine.
c) When the cutting can be done at any angle of the job with the help of rotary motion of tile table
the machine is termed as universal (U) milling machine.
Thus, these machines are named as FN2V, FN2H, FN2U, FN3H, FN3V, FN3U, TRM3V, and
TRM3H. Now here we would discuss the features of the three types of milling machines with their
properties:-
Fig 20: Knee Type Milling Machine FN2/FN3
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Procedure followed in GPM Assembly:1. First of all the best is set and its grinded face is scrapped to make it flat.
2. The bottom surface of the column is scrapped to make it perpendicular to bed. The dove
tails are made parallel to each other by scrapping. After the column is mounted on the
base.
3. The gear trains are mounted in the bearings in the column.
4. The leaves for changing the gear are placed.
5. The main motor is mounted on the back of the column.
6. In the horizontal milling machine, the spindle is mounted in the column.
7. Coolant motor and lubricant pump are mounted in the column. The lubricants pipes are
arranged with the progress of assembly.
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8. Dove tails of the knee are also scrapped to make them parallel to each other and
perpendicular to the base. The upper surface is also scrapped to make it perpendicular to
the column.
9. Knee is mounted and supported on the thrust bearing. Its feed screw is also mounted.
10. Gibb is inserted between the dove tails; then the dove tails are checked for the
perpendicular motion of the knee. Any error removed by the scrapping of the gab.
11. The gear train and feed box containing gear train also mounted at the knee.
12. Feed motor is mounted on the feedbox of the knee. In horizontal milling machine, the
derive box containing the splinted rod is also mounted.
13. The electric cabinet is mounted to the knee.
14. The feed screw for the movement of the saddle is also placed in the feed nut blocks of the
knee.
15. The saddle is mounted at the knee. The dove tail and the gab are already being scrapped
for parallelism and even sliding. Gibb is inserted and its screws are tightened.
16. In case of universal horizontal milling machine, the swivel is mounted on the saddle.
17. Feed screw for the table is mounted on the table or the swivel.
18. The table is then mounted. Same treatment is given to the dove tail and to the gab.
19. In horizontal milling machine the over arm is mounted on the column. Its parallelism to
the saddles movement and the spindle is made highly accurate by scrapping.
20. In horizontal milling machine the arbor and the over arm bracket are mounted.
21. In case of the vertical milling machine the head is mounted. Its perpendicularity to the
table is checked.
22. Electric connections are made. Hand wheels, leavers and the limit switches are attached
and the pins are inserted. Coolant pipes are led.
23. Testing and quality assurance of the machine is done.
24. Machine is sent for paining.
25. Remaining electrical and hydraulically connections are made.
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26. The machine is packed in wooden case along with necessary accessories.
27. The machine is ready to dispatch.
BROACHING ASSEMBELY
A broach is a multipoint cutting tool consisting of a bar having a surface containing a series of
cutting teeth or edges which gradually increases in size from starting and to the rear end. The basic
purpose of the machine is to form splines to hollow jobs. Splines are multiple slots on the hollow
surface of the job. The surface may be flat, circular, or any intricate shape. In broaching, the broach
is pushed or pulled over/through a surface of workpiece. Each tooth of the tool takes a slice from
the surface. Broaching of inside surface is
called internal or hole broaching and that of
outside surface is called surface broaching.
Material:High speed steel, brazed carbides or
disposable inserts are sometimes used for
cutting edges for machining of cast iron parts.
Carbide tools are used to an advantage on steel.
Fig 21: HMT Horizontal Broaching Machine
HMT manufacturers two types of broaching

machine:a) Vertical Broaching Machines.
b) Horizontal Broaching Machines.
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8. CNC ASSEMBELY
The increasing demands the need for high accuracy, scrap reduction etc. have pulled for
development in the field of machining and manufacture. All these have led to the invention and
improvement of CNC machines which can undoubtedly be termed as one of milestones of century.
In GPMs mass production is not possible. Moreover complex shaped jobs require high precision.
They need for flexible automation has always been felt. And this is an era of machine tool
automation. So, flexible automation is implemented in machine tools in the form of NC and CNC
(Computerized Numerical Control) technology. Today HMT is producing a lot of CNC variants
of conventional machine tools with the specialized functions and mostly CNC products.
Fig 22: HMT stallion 200 series
CNC machines are part of the field named mechatronics. This field is the combination of electronics
and mechanical engineering fields. When they work in combination they are termed as above. A
single CNC machine can perform variety of machining operations in a sequential order (based upon
the programe). For example drilling, tapping, slotting, milling, etc. operator is used only for
clamping and de-clamping purpose (after feeding the programe). These machines ensure
repeatability of the dimensions (precision). Accuracy of these machines is in microns.
A CNC machine may be of three dimensional coordinate system with XYZ axis. Rest two are
available on machines whose table can rotate and tilt. These are 4th and 5th axis. The axis of the
spindle is termed as Z axis. The axis which crosses Z axis perpendicularly is X axis and the other
mutually perpendicular axis is Y axis. CNC machines differ in orientation of the main spindle.
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If spindle is horizontal it is termed as HMC (horizontal machining center) and if the spindle is
vertical it is termed as VMC (vertical machining center).
Model number of machine depends upon capacity of machine. Capacity means traverse length along
various axis or maximum size of the pallet. Thus a VTC 1000 designates a CNC machines whose
spindle is vertical with pallet size or traverse length of 1000mm.
Various CNCs produced here: - HMC 320M, HMC 400M, HMC 500M, HMC 600M, HMC 800M,
VMC 400M, VMC 500M, VMC 800M, VMC 1000M etc.
ASSEMBLY OF THE CNC MACHINES:

First of all the parts are obtained from the foundry and machined accordingly in the given
desired shape.
The base is leveled properly with proper instruments.
Column is fixed on the bed
Ball screws and drive motors are installed.
Then the Laser test is done. In this test the laser beam is thrown on the pairs of prism one
attached to the table and other on the spindle of the machine and reflected back through the
same part and data is collected on the computer and thus can be corrected.
After that tool magazine is assembled and attached to the machine.
Oiling system is attached to the machine as separate apparatus.
Electric cabinet of machine is taken from the concern shop and then attached to the machine
After attaching the operating system and computer hardware the next job refers to the
electronics lab.
The concern department examines the exact circuits and wiring of the machine.
After all of these activities its time to decorate and surround it for its good looking and for
safety purposes
The machine is then dispatched at then delivered to the concerned customer
MAIN MECHANICAL ITEMS OF CNC MACHINE ARE
Ducts
CRT(continuous rotary table)
Pallet changer
Spindle
Head
Column (including Y motor)
Bed
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Ball screw an rod

Guide way
Magazine
Machine Description:Salient features of CNC machines are as follows:Bed type machine configuration:Bed type construction with longitudinal and cross movement to work table and vertical movement
to head, provides stable cutting condition and maximum rigidity. Box type construction of bed and
column with properly ribbed reinforcement minimizes torsion and flexural deflection.
Linear motion with guide ways:Preloaded anti friction linear motion type. Guide ways in the entire three provide clearance free
guidance for slides during cutting. Their use significantly reduces the coefficient of friction and
eliminates stick slip and thermal generation during high speed positioning. In addition they offer
high positioning and outstanding contouring capability.
Automatic Tool Changer (ATC):Machine is equipped with a suitable number of tool

station/pocket (mainly12, 30, 60,120). Using cam the
automatic tool changer changes a tool accurately and
swiftly.
Fig 23: ATC of a CNC machine
Long nose quill type spindle:Cylindrically shaped head end and prevents any interference with the work complicated shape. This
configuration also eliminates interference even with large steep work. Machining of deep holes in
the work are also possible with full power and without compromising tool rigidity.
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Spindle cooling (for machine with spindle speed of 6000 rpm):Circulation of cooled oil through the oil jacket around the main spindle bearing, maintains precision
even in long and continuous runs.
Steeples AC spindle motor:AC spindle motor eliminates the troublesome brush inspections and replacements required in case
of DC motors. Another advantage of DC motor is that it reduces electrically consumption.
Electronic spindle orientation:The spindle motor has built in encoder for position feedback of the spindle. Spindle orientation
stops spindle in a particular position. This helps in retracting bars without damaging bores in boring
operations and counter-boring/Facing. Automatic tool change is also achieved through the features.
AC servomotors:All the three axes are driven through AC servomotors. Their use
provides a higher rapid rate of revolution with minimum
maintenance. They also provide high acceleration and deceleration
property and subsequently increase the machining efficiency.
Lubrication:-
Fig 24: servomotor
Automatic lubrication is provided for minimal operator attention. Main spindle bearing and all axes
drive bearing are fitted with synthetic grease, requiring no attention for long periods. All axes ball
screws and linear re-circulating bearings are also lubricated.
Automatic chip collection:Flushing coolant with discharge of 100lpm is used for automatic flushing of chips and is collected
in tray at rear of machine. Wide channels with sufficient scope are provided in both sides of bed
for easy disposal of chips at rear of machine.
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CRT (CONTINUOUS ROTARY TABLE):A rotary table is a precision work positioning device used in
metalworking. It enables the operator to drill or cut work at exact
intervals around a fixed (usually horizontal or vertical) axis. Some
rotary tables allow the use of index plates for indexing operations,
and some can also be fitted with dividing plates that enable regular
work positioning at divisions for which indexing plates are not
available.
Fig 25: Continues rotary table
Machining Features (Optional):1. External coolant on spindle: - External coolant facilities the machining of steel/aluminum. It also helps
in taking away chips from machining zone with its large flow.
2. Mist coolant: - Machining of light metals is facilitated with mist coolant. Mist coolant takes away heat
from work zone, with change of state. It does not require any return path.
3. Chip conveyor: - It takes away large volume of chips produced out of the machine continuously with its
independent drive.
4. Refrigeration type of spindle coolant: - Coolant of cooled oil with heat exchanger (refrigeration type),
through spindle jacket provides higher spindle stability which results in improved working accuracy.
5. Spindle mounted probe: - Spindle mounted probe with auto measuring cycle and datum cycle makes
fixture/job setting simple.
6. Higher speed spindle up to 8000 rpm: - It facilitates machining of light metals with latest tool
technology.
7. Pallet changer: - This part is concerned with handling of additional table on which the next job can be
mounted for machining meanwhile machining of the current job is going on which considerably reduces the
mounting time.
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Following is the list of M codes and G codes used in Machine

M-CODES
M00 Program Stop
M01 Optional (Planned) Stop
M02 End of program
M03 Spindle CW
M04 Spindle CCW
M05 Spindle OFF
M06 Tool change
M07 Coolant #2 ON
M08 Coolant #1 ON
M09 Coolant OFF
M10 Clamp
M11 Unclamp
M12 Unassigned
M13 Spindle CW & Coolant ON
M14 Spindle CCW & Coolant ON
M15 Motion +
M16 Motion M17
Unassigned
M18 Unassigned
M19 Oriented spindle stop
M20-M29 Permanently Unassigned
M30 End of tape
M31 Interlock bypass
M32-M35 Unassigned
M36-M39 Permanently Unassigned
M40-M45 Gear changes if used, otherwise
unassigned
M46-M47 Unassigned
M48 Cancel M49
M49 Bypass override
M50-M89 Unassigned
G-CODES
G00 Rapid Positioning
G01 Linear Interpolation
G02 CW circular Interpolation
G03 CCW circular Interpolation
G04 Dwell
G05.1 Q1 Ai Nano contour control
G05 P10000 HPCC
G07 Imaginary axis designation
G09 Exact stop check
G10/G11 Programmable Data input/ Data write
cancel
G12 CW Circle Cutting
G13 CCW Circle Cutting
G17 X-Y Plane selection G18
X-Z Plane selection
G19 Y-Z Plane selection
G20 Programming in inches
G21 Programming in mm
G28 Return to home position
G30 2nd reference point return
G31 Skip function
G33 Constant pitch threading
G34 Variable pitch threading
G40 Tool radius compensation off
G41 Tool radius compensation left
G92 Programming of absolute zero point
G94/G95 Inch per minute/ Inch per revolution
feed
G96 Constant surface speed
G97 Constant spindle speed
G98/G99 Return to initial Z plane/ R plane in
canned cycle
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9. CONCLUSION
HMT Machine Tools Pinjore, is the first public sector to Develop, Design, manufacture and
commissioning of fully automatic horizontal and vertical machining centers in the country. They
are also the first to manufacture high speed machining centers. There designed machines are used
in various auto sector companies. There designed machines are also exported to Europe, America,
Middle East and Russia.
Perhaps one point that is a big boost to this company is the tremendous respect it has for quality of
service. From microscale precision right in the convexity of lathe beds, rigorous testing of all
equipment, and secured delivery and training services, HMT is now generating clientele in the
public as well as private sectors.
Fig 26: The Main Manufacturing Facility of HMT Pinjore
My experience has been one of thrill as well as intense learning. The on-site exposure to the
traditional methods of manufacturing using lathes, cutting, drilling, milling and slotting machines,
using collimators for measurement, as well as hands on experience with modern Computer
Integrated Manufacturing using VMC and HMC machines, multi-point cutting tools, multi tool
turret systems, etc. The exposure to areas like Production and Operations management, Job Shop
Scheduling, Aggregate Planning, etc. were a key aspect of the training period.
At the end of it, I have had quite a bit to take back from this place, and recognize the contribution
it made in my understanding of the industry in engineering.
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10. REFERENCES
All content in this report are based solely on company reports and documentation at HMT. All
procedures mentioned are HMT customized versions of standards available in open source. Any
images of machines are taken from the website of Hindustan Machine Tools. The company profile
and product range is readily available for further perusal at
1. http://hmtmachinetools.com/pinjore-complex.htm
2. http://www.hmtmachinetools.com/.
3. https://en.wikipedia.org/
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Report on industrial training

1.1 HMT AT A GLANCE

Report on industrial training

The multi-product activities made HMT

Fig 1: HMT Product range

Report on industrial training

HMT Machine Tools Limited,

1.1.1 HMT Machine Tools Limited

Heavy duty lathes

Fig 3: Radial Drilling Machine

Report on industrial training

Laser cutting machines

Horizontal machining center

CNC turning center

Special purpose machines

Fig 5: High Speed Horizontal Machining

Report on industrial training

1.1.2 HMT Watches Limited

1.1.3 HMT Chinar watches

1.1.4 HMT Bearing Limited

1.1.5 HMT International limited

1.1.6 Praga Tools Limited

1.2 The Pinjore complex of HMT Limited Pinjore

Report on industrial training

Fig 6: HMC 500-M

The unit begin its initial manufacturing of

THE CURRENT MAJOR PRODUCTS

Horizontal machining centers(HMC-320M, 400M, 500, 400, 630, 800)

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Special tooling fixtures

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2.1 PATTERN MAKING

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Thermocol:- single use patterns are made using thermocol

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Fig 8: Pattern is used to make impression in sand

2.2 SAND MOLD AND CORE MAKING

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The core is made with the help of sand such as

2.3 METAL MELTING

Fig 9: Electric furnace

Main frequency Induction Furnace(50Hz)

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Specifications of 1.5 ton capacity furnace:Line Voltage

1 ton per hour

2.4 CASTING AND SEPERATION

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2.5 REMOVAL OF RUNNER AND RISER

Fig 10: Runner and Riser

2.6 FINISHING PROCESS

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Priming and painting

Pneumatic gun- to remove corner sand.

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Natural Bath Tank

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HEAT TREATMENT SECTION