VTR FINAL REPORT
VTR FINAL REPORT
VTR FINAL REPORT
ON
SUBMITTED TO
“BACHELOR OF TECHNOLOGY”
SUBMITTED BY
Prof.. J. G. SHINDE
KOLHAPUR
2022-23
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KOLHAPUR
CERTIFICATE
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DECLARATION
Roll NO- 29
Date –
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ACKNOWLEDGEMENT
I am also thanking You to Mr. NIKHIL KAMALKAR sir and all members of all
the departments of the industry for giving us all required information and training us through
the period.
I feel great pleasure to an opportunity to take up the training work, under the
guidance of Prof. J. G. Shinde and express a deep gratitude having rendered excellent
guidance, encouragement and suggestion throughout the period of VTR presentation for
making it a successful completion. I am also thankful VT R Co Ordinator Prof. S. B.
KAMBLE for continuous support for the completion of this report.
I express deep gratitude to the principal Dr. V. R. GHORPADE Sir and also the
HOD Dr. SUNIL KADAM Sir of our department for giving us an opportunity to completing
my Industrial Training. The training course would have been monotonous and dull had it not
been for my friends, Specially Nathaji Mane and Parth Shendure.
I wish to express my sincere gratitude and apologize to everyone else; I could not
mention in this page that in any way that has helped me, contribute to the training and made it
possible for me to complete.
ROLL NO – 29
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ABSTRACT
Industrial training is one of the requirements for the award of the Degree of
Bachelor of Technology in Mechanical Engineering of Shivaji University. As such, students
are required to write and submit reports at the end of the training. This report is the record of
what I personally did during my industrial training at IPSUMCAM PVT.LTD. Vocational
Training from 15/8/2022 to 30/8/2022. It consists chapters which altogether explain the
objectives of industrial training, entail background information about the IPSCUMCAM
PVT. LTD. , various activities carried out at the Industry , general overview of foundry
Technology, the hands-on activities which I took part in and the skills acquired, challenges
faced, recommendations and conclusion. Chapter one covers the objectives of industrial
training, gives the background information about including its core values, mission, vision,
products and services provided and clientele. Chapter two presents the general overview of
Manufacturing Technology. Chapter three entails all the practical activities undertaken at the
workshop giving for each activity, the different tools and equipment used, technical
proceduresfollowed, common faults, their causes and remedies. Chapter four covers the skills
acquired, challenges faced, recommendations and conclusion.
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REPORT CONTENT
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1 Introduction
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2 Actual Plant Layout
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3 Number Of Departments
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4 Nature Of Product and Manufacturing Process
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5 Types Of Machines and Specification
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6 Maintenance Of Various Machines
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7 Measuring Instruments
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8 Name of Component produced in industry
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9 Raw Material Used
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10 Information About Customer Andand Competitors
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11 Quality System Employed ( KAIZEN 5 S )
12 Case Study 13
13 Conclusion 20
14 Reference 21
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1. INTRODUCTION
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3. NUMBER OF DEPARTMENTS
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A. MANUFACTURING PROCESS
B. NATURE OF PRODUCTS
IPSUMCAM PVT.LTD. Manufacture Components for Excavator From 0.2 Tons To 120
Tons Capacity.
BUCKETS: IPSUMCAM PVT.LTD. Buckets For Excavator, Back Hoe Loaders, Wheel
Loaders And All Other Construction Equipment’s Machineries. Size Of Buckets
Manufacturer By Us Ranges From 0.2 Tons 120 Tons And Weight From Few Kgs To Above
8000 Kgs.
STRUCTURES: IPSUMCAM PVT. LTD. Frames Like Main Frame, Front Frame, Rear
Frame, Center Frame Etc. For Excavator, Back Hoe Loaders and Wheel Loaders.
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COMPANY PRODUCT
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PARTS OF TRACTOR
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1. M. S. – ( Mild Steel )
2. SAILMA - 350 hi
3. SAILMA - 450 hi
4. HARDOX - 400
5. WELDOX - 700
6. WELTEN - 80
7. WELTEN - 60
CUSTOMER
2 MAHINDRA
COMPETITOR
2 RSB LTD
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KAI – CHANGE
ZEN – GOOD
Why kaizen ?
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Abstract
Key words: Cutting condition, tool path, machining time, machining order.
1. Introduction
Machining is a manufacturing process in which a cutting tool is used to obtain desired shape
by cut away unwanted segment of material from a workpiece [1]. As well-known, turning,
milling, and drilling are the most common machining operations. From 1775 (cannon-boring
machine by John Wilkinson) to 1960s (CNC machines), machining has come to a modern
stage and it continues to progress with development of new machining technologies and
methods [2]. An important goal in the machining also is determination of optimal machining
strategy. Optimization of machining processes is very critical in metal cutting industry due to
the increasing demand for high quality and low cost products in the market [3]. Therefore, to
achieve minimum production costs and time, and maximum production rate, machining
operations need to be planned in accordance with optimal machining strategies. In workshop
practices, machining parameters are chosen according to machining databases, catalogues,
handbooks and/or experience of the operator. However, some aspects such as fixture design,
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machining order, etc. need to be considered to obtain an optimal process plan of a complex
part. Therefore, a large number of studies related to optimization and improvement of
machining processes have been recently conducted. Rodriguez-Alabanda et al. [4]
investigated the effects of different cutting strategies and cutting parameters on optimization
of surface roughness and energy consumption when machining of Al-Zn-Mg-(Cu) alloy. They
*Corresponding author: Necati Uçak. Address: Faculty of Engineering and Natural Sciences,
Department of Mechanical Engineering, Ankara Yıldırım Beyazıt University, 06010, Ankara
TURKEY. E-mail address: nucak@ybu.edu.tr, Phone: +903129062333.
reported that it is possible to reduce energy consumption of 40% and improve surface quality
of 70% with proper selection of cutting strategies. In another study [5], shorter cutting times
and lower cutting forces are achieved with selection of optimal feed rate values when
machining aluminum mold geometry of a bottle. The authors achieved an improvement of
13% in cutting time and a decrease of 70% in maximum forces in finish cutting operations.
The tool paths directly affect finish part quality [6] and machining time [7]. As well-known,
possible toolpaths and collision scenarios between cutting tool and workpiece can be checked
in CAD/CAM software, thus, potential additional time and costs can be prevented. An
optimization study on CNC face milling operation of an aluminum flange (Al-6061-T6) was
performed by Jarosz et al. [8]. They found that it is possible to reduce machining time up to
37% with selection of proper optimization strategy without exceeding imposed machining
parameter limits. In another study, Souza et al. [9] investigated the effects of different tool
path strategies on surface roughness and machining time during finish milling of a mold
cavity.The results showed that when compared to the less appropriate option, selection of an
improvedtool path strategy can decrease the machining time and machining costs by 88% and
40%, respectively.
After examination of process plan of boom-body connector, it is determined that there are 22
different machining operations. In addition, current fixture design for CNC bohrwerk and
existing limitations were analyzed. Then, 3D CAD model of the boom-body connector was
prepared in accordance with the cast product. Thus, improvement studies of the cast model
and tool paths were performed on this model. Tool path improvements were performed with
the aid
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of MasterCAM software [11]. Each machining operation was simulated, and the improved
machining time was determined according to simulation results. In addition, possible
collision scenarios between tool and workpiece were checked. Then, a boom-body connector
was machined under improved conditions. The real machining time of improved operations
was determined and correlated with simulation results. Figure 1 indicates an example for
simulation of a milling operation. During the improvement stages, to avoid wasting time
between the successive operations, the order of the required machining operations was
rearranged.
After determination of the optimal machining orders, cutting parameters (cutting speed, feed,
and depth of cut) were rearranged according to tool manufacturers recommendations and
some limitations such as vibration and workpiece clamping conditions. In addition, cutting
tools for some operations were also revised. The surface roughness and machining tolerances
were accepted as success criterion for each machining operation. Figure 2 gives the flow
chart of the improvement process in this study.
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As a first stage of the improvement studies, possible improvements on casting geometry was
investigated to reduce the number of machining operations. Figure 3 shows the cast geometry
before and after improvement. With adding two new holes on cast geometry (Figure 3), a
drilling operation (operation 2 in Figure 5) was eliminated. Thus, when considering the set up
and machining time, a reduction of 60 min in total operation time was achieved
Figure 3. The pictures of the boom-body connector a) before and b) after improvement on
casting geometry.
addition to improvements on casting geometry, an improvement was also conducted on
cutting methods. Figure 4 indicates an example (operation 9) for cutting method
improvement. As shown in Fig. 4, new cutting method is end milling while previous cutting
method for operation 9 is fly cutting. End milling and its tool path is simpler and more
effective than fly cutting. The significant reductions in setup and machining time were
achieved with new cutting method for operation 9. Besides, better surface quality and higher
cutting parameters (Table 2) were also achieved with new cutting method.
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Figure 4. The pictures of operation 9 a) before and b) after optimization of cutting method.
Previous New
Machining operation operation operation
order order
Face milling 5 1
Face milling 7 2
Face milling 4 3
Face milling 9 4
Face milling 11 5
Face milling 8 6
Boring - Ø85 rough 13 7
machining
Boring - Ø85 finish 14 8
machining
Boring - Ø80 rough 15 9
machining
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Figure 5. Machining operations on 3D CAD model of boom-body connector and their orders
before and after improvement process
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According to the improved cutting conditions, new machining time for each machining
operation was determined. The machining time before and after improvement studies is given
in Figure 6. A significant reduction was achieved in operation 1 with increasing cutting speed,
feed values. In addition, depth of cut value was increased 1.5 times for rough machining. This
strategy was also applied to operation 2 (from 0.5 to 3). In operation 3, considering the
clamping conditions depth of cut value was increased from 1.5 to 2.5 mm for down milling.
In the successive operations, only cutting conditions and tool paths were improved.
Generally, in all operations, cutting parameters were increased, thus an important
improvement was achieved in machining time. In face milling operations (the operations from
1 to 6), the feed rate values were increased and cutting speeds kept almost as it is when
compared to previous values. In majority of the rough and finish boring operations, feed rate
increased significantly and depth of cut values decreased in some operations (operations 11
and 12) to provide rigid machining conditions. On the other hand, in drilling and tapping
operations due to lesser material removal rate and narrow machining parameters range, lesser
increase in productivity was observed generally. Since the number of holes (12 holes) to be
drilled is higher, the most reduction in machining time was observed in operation 17 among
the other drilling operations. In some operations (operation 13), due to surface quality
requirements, cutting parameters were used as it is. When compared to the previous
conditions, a reduction of about 55% (from 1013 min to 458 min) is achieved in machining
time. It was observed that to keep machining time and cost low, the most effective cutting
parameter is depth of cut.
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Conclusions
Acknowledgements
This Work Was Supported By The Scientific And Technological Research Council Of
Turkey
References
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13.CONCLUSION
During this industrial training I come across the casting process that involves
patternmaking, core making, molding melting and pouring and lastly finishing. I learned how
to nullify the casting defects. the training for moisture testing is also i hand performed. They
were using this by adding dust powder dust and betonies to increase the strength of the
mound
. After the completion of industrial training, I enhanced competencies &
competitiveness in our representative area of specialization. I tried to relate the experience in
the workplace with knowledge in the institute and applied the knowledge on the job under
supervision.
Here, I gained the experience and knowledge that, can be used for suitable job
without delay after studies. I learned to hone soft skills appropriate to the work environment.
Also get improvised in communication skills. I assessed career ability, knowledge and
confidence as well enhanced our marketability our marketability to be more competitive.
With experience, knowledge and skills acquired during industrial training I will be
better prepared to face working world. The internship was a fruitful experience. Through the
application of the theoretical knowledge into real-life problem-solving situations, I gained a
lot of experience especially in the automotive field. I also got insight into professional
practice, learnt how life can be fruitful as well as challenging under employment; and how to
face and deal with these challenges. It was also a great opportunity for developing personal
networking activities and making contacts with influential people; which is of great value to
me as far as my career is concerned. The training also enabled me to discover my strengths
and weaknesses. This further helped me to identify areas to improve on. In a nutshell, I
achieved most of my learning objectives from the training
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14 REFERENCE
[1] Gologlu C, Sakarya N. The effects of cutter path strategies on surface roughness of
pocket milling of 1.2738 steel based on Taguchi method. J. Mater. Process. Technol.
2008;206(13):7-15.
[2] Sales HR, Amirabadi H., Hosseinabadi HN, Bagheri MR, Experimental study of tool
path strategies for three and five axes milling along with feed rate optimization, Indian
J. Sci. Technol. 2016;9(43):1-12.
[3] Jarosz K, Löschner P, Nieslony P, Krolczyk G, Optimization of CNC face milling
process of Al-6061-T6 aluminum alloy. Journal of Machine Engineering 2017;17(1),
69-77.
[4] Souza AF, Machado A, Beckert SF, Diniz AE. Evaluating the roughness according to
the tool path strategy when milling free form surfaces for mold application. Procedia
CIRP 2014;14:188-93.
[5] “Pi makina-1.” [Online]. Available: https://pimakina.com.tr/is-makinasi. 19 October
2019. [11] MasterCAM.2018. CNC Software, Inc., Tolland, Connecticut, US.
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