Project report mechanical BEL ghaziabad

TRAINING REPORT

(01 AUG 2011 TO 10 SEPT 2011)

At“BHARAT ELECTRONICS LIMITED”GHAZIABAD

Submitted in partial fulfillmentForB.Tech (Mechanical Engineering) VI th Semester Examination

Submitted by:-MISS SHUBHANGI BADOLA

Of“G B PANT ENGINEERING COLLEGE PAURI GARWAL

TRAINING REPORT

(01 AUG 2011 TO 10 SEPT 2011)At“BHARAT ELECTRONICS LIMITED

1. ACKNOWLEDGEMENT2. CERTIFICATE3. COMPANY PROFILE OF B.E.L.4. GENERAL PROFILE OF B.E.L. GHAZIABAD 5. ROTATIONAL REPORTS OF VARIOUS SECTIONS

• Production control• Management service• Antennae fabrication• Machine shop• Fabrication shop

6. REPORT ON NUMERICAL CONTROL CELL• CNC (Computer Numerical Control) Machine• DNC ( Direct Numerical Control) Machine• Introduction to programming• Working Procedures of NC Cell• System codes

7. CONCLUSION

1. ACKNOWLEDGEMENT

First of all I would like to express my gratitude to Mrs

VANEETA BHANDARI, MANAGER HRD department for

arranging my training for duration of six weeks. The training

schedule prepared by her got me to have an insight into working

methodology and procedures at BEL. I want to thank department

of HRD for cooperation from their part.

I offer my sincere gratitude to my guide Mr. D K Khanna Dy.

Manager Machine Shop for his continuous guidance and support. I

take the opportunity to thank Mr. P K S Nair, Dy. Engineer (N C

CELL) for helping me to complete Project.

It will be in debt of my part if I forgot to extend my thanks a lot to

all those visible and invisible hands that helped me throughout my

training period.

SHUBHANGI BADOLA

CERTIFICATE

Dated: 10-09-2011

This is to certify that Miss SHUBHANGI BADOLA,

student of B.TECH (Mechanical Engineering), G B PANT

ENGINEERING COLLEGE PAURI GARHWAL

successfully completed her six week training in BHARAT

ELECTRONICS LIMITED, GHAZIABAD from 01 Aug

2011 to 10 Sept 2011

Project “THE STUDY OF CNC MACHINES IN

MACHINE SHOP, SBU – R” was assigned to her. In this

period she worked hard and made valuable contribution in

developing the project. All her work is genuine and original

and was timely completed.

DY. Manager (M/C shop)

CERTIFICATE

This is to certify that Miss SHUBHANGI BADOLA,

student of B.TECH. (MECHANICAL ENGINEERING) from

G B PANT ENGINEERING COLLEGE PAURI has

successfully completed her summer training in BHARAT

ELECTRONICS LIMITED, GHAZIABAD from 01 Aug 2011

to 10 Sept 2011.

A project was assigned to her. In this period she worked hard and

made valuable contribution in developing the project. All her work

is genuine and original and was timely completed.

R.N.TYAGI (HRD)

3.COMPANYPROFILEOFBHARATELECTRONICSLIMITED

BHARAT ELECTRONICS LIMITED (BEL)

THE INDUSTRY

BEL was established in 1954 as a Public Sector Enterprise under the administrative control of Ministry of Defence as the fountainhead to manufacture and supply electronics components and equipment. BEL, with a noteworthy history of pioneering achievements, has met the requirements of state-of —art professional electronic equipment for Defense, broadcasting, Civil Defense and telecommunications as well as the component requirement of entertainment and medical X-ray industry .Over the years, BEL has grown to a multi- product, multi-unit and technology driven company with track record of a profit earning PSU.

BEL was born to meet the growing needs of Indian Defense services for electronic systems. Employing the best engineering talent available in the country, BEL has progressed manufacturing state-of-the-art products in the field of Defense Electronics like Communications including encryption, Radars and strategic components.

Over the years, BEL has diversified to meet the needs of civilian customers as well and has provided products and network solutions on turnkey basis to customers in India and abroad.

With the Research & Development efforts, its engineers have fructified it into a world class organization. The company has a unique position in India of having dealt with all the generations of electronic component and equipment. Having started with a HF receiver in collaboration with T-CSF of France, the company’s equipment designs have had a long voyage through the hybrid, solid-state discrete component to the state-of-art integrated circuit technology. In the component arena also, the company established its own electron valve manufacturing facility. It moved on to

semiconductors with the manufacture of germanium and silicon devices and then to manufacture of Integrated circuits. To keep in pace with the component and equipment technology, its manufacturing and product assurance facilities have also undergone sea change. The design groups have Cad’s facility, the manufacturing has CNC machines and a Mass Manufacture Facility, and QC checks are performed with multi-dimensional profile measurement machines. Automatic testing machines, environmental labs to check extreme weather and other operational conditions are there. All these facilities have been established to meet the stringent requirements of MIL grade systems.

Today BEL’s infrastructure is spread over nine locations with 29 production divisions having ISO-900119002 accreditation. Product mix of the company are spread over the entire electromagnetic(EM) spectrum ranging from tiny audio frequency semiconductor to huge radar systems and X-ray tubes on the upper edge of the spectrum. Its manufacturing units have special focus towards the product ranges like Defense Communications, Radars, Optical & Opto-electronics, Telecommunications, Sound and Vision broadcasting, Electronic components, etc.

Besides manufacturing and supply of a wide variety of products, BEL offers a variety of services like Telecom and Radar Systems Consultancy, Contract Manufacturing, Calibration of test & measuring instruments, etc. At the moment, the company is installing MSSR radar at important airports under the modernization of airports plan of National Airport Authority (NAA).

BEL has nurtured and built a strong in-house R&D base by absorbing technologies from more than 50 leading companies worldwide and DRDO labs for a wide range of products. A team of more than 800 engineers is working in R&D .Each unit has its own R&D Division to bring out new products to the production lines. Central Research Laboratory (CRL) at Bangalore and Ghaziabad works as independent agency to undertake contemporary design

work on state-of-art and futuristic technologies. About 70% of BEL‘s products are of in-house design.

BEL was amongst the first Indian companies to manufacture computer parts and peripherals under arrangement with International Computers India Limited (ICIL) in 1970’s. BEL assembled a limited number of 1901 systems under the arrangement with ICIL. However, following Government’s decision to restrict the computer manufacture to ECIL, BEL could not progress in its computer manufacturing plans. As many of its equipment were microprocessor based, the company continued to develop computers based application, both hardware and software. Most of its software requirements are in real time. EMCCA, software intensive naval ships control and command system is probably one of the first projects of its nature in India and Asia.BEL has won a number of national and international awards for Import Substitution, Productivity, Quality, Safety etc.

VARIOUS UNITS:

Its corporate office is at Bangalore. Bangalore complex is the BEL’s first and largest unit and it accounts for two-thirds of both the Company’s turnover and manpower. This unit’s product range covers over 300 Defence and Civilian products.Ghaziabad is the second largest unit of BEL and it specializes in RADARS, COMMUNICATION EQUIPMENTS & MICROWAVE COMPONENTS.In total BEL has got 9 units. These are distributed in all over the India as:1. BANGALORE (Corporate Office)2. GHAZIABAD3. PANCHKULA4. MACHILIPATNAM5. PUNE6. HYDERABAD7. CHENNAI

8. KOTDWARA9. TALOJAThe passionate pursuit of excellence at BEL is reflected in are pulsion with its customers that can be described in its motto, mission and objectives:

CORPORATE MOTTO“Quality, Technology and Innovation”CORPORATE MISSIONTo be the market leader in Defence Electronics and in other chosen fields and products.CORPORATE OBJECTIVES• To become a customer-driven company supplying quality products at competitive prices at the expected time and providing excellent customer support.• To achieve growth in the operations commensurate with the growth of professional electronics industry in the country.• To generate internal resources for financing the investments required for modernization, expansion and growth for ensuring a fair return to the investor.• In order to meet the Nation’s strategic needs, to strive for self-reliance by indigenization of materials and components.• To retain the technological leadership of the company in Defense and other chosen fields of electronics through in house Research and Development as well as through collaboration/co-operation with Defense/National Research Laboratories, International Companies, Universities and Academic institutions.• To progressively increase overseas sales of its products and services.• To create an organizational culture, which encourages members of the organization to realize their full potential through continuous learning on the job and through other HRD initiatives?

QUALITY POLICY

BEL is committed to consistently deliver enhanced value to our customers, through continual improvement of our products and processes.QUALITY OBJECTIVES

1. Effective and Efficient design and development process, considering the present and future needs of customers.2. Enhanced customer satisfaction by on-time delivery of defect free products and effective life cycle support.3. Continual up gradation and utilization of infrastructure and human resources.4. Mutually beneficial alliances with suppliers.5. Continual improvement of processes through innovation, technology and knowledge management.The management of BEL is convinced of the need for Quality Enhancement, on a continuous basis, in the company. Need was felt to impart Education I Training to all the officers on the various facets of quality management. Accordingly, an institute called Bharat Electronics Quality Institute (BEQI) was established in1999.

Regular training programs are conducted for all employees working in different units of the company. Business Excellence models being followed by different organizations are studied and efforts are being made to implement the best possible practices in the functioning of the organization.

Bharat Electronics Ltd., (BEL), a premier Professional Electronics Company of India, has established and nurtured a strong in-house R&D base over the years to emerge and remain as a market leader in the chosen areas of business in professional electronics. Each of the nine manufacturing units of BEL is having its own in- house R&D Division to develop new products in its field of operations. Besides, there are two Central Research Laboratories (CRL) located at Bangalore and Ghaziabad, to address futuristic technologies of interest to BEL.

Main areas of R&D activities at BEL include development of Military Radars, Naval Systems, Military Communication Products, Electronic Warfare Systems, Telecommunication products, Sound and Vision Broadcasting Equipment and Systems, Opto-Electronic Products, and Electronic Components. CRL performs the dual role of carrying out blue sky research for the development of future technologies and supporting the D&E Divisions of BEL’s nine units with state-of-the-art core technology solutions in areas like Embedded Computers and applications, Radar Signal Processing, VLSI designs, RE & Microwave Communication Technologies, Software modules etc.

BEL’s R&D Units have state-of-the-art R&D infrastructure, facilities, and manpower with relevant technical expertise for product development. There are about 1000 engineers working in BEL on various D&E projects. BEL spends around 5 % of company turnover for the year on R&D every year. HRD Divisions of BEL take adequate initiatives for the all round development and expertise up gradation of R&D human resources. State of the art infrastructures, test equipment, computers & workstations, Software packages etc. are augmented every year for the R&D divisions. BEL R&D Units are recognized by the Department of Scientific & Industrial Research under the Ministry of Science & Technology, Government of India.

R&D Units of BEL have close interactions with other National Design Agencies like DRDO, CSIR, C-DOT and a number of Technical Institutes. BEL jointly works with them to tap suitable indigenous designs for commercialization. Technological collaborations with some of the Multinational companies and subsequent absorption of these technologies also have enhanced the technological base at BEL. On an average, about 67% of BEL’s turnover is from indigenous design, and 33 % of it is through foreign technology transfers.

List of world class companies with whom BEL has technological collaborations for different state-of-the-art products are as given below:

Company ProductOerlikon Contraves, Switzerland Naval FC Systems

AWARDS WON BY BEL

R&D Divisions of BEL have been receiving number of National R&D awards. A list showing the various R&D awards received by BEL since 1990 is as given below.

1. FICCI Award for Research in Science & Technology 1990(For the corporate initiative of R&D)

2. DSIR National R&D Award 1992(For successful commercialization of Public Funded R&D)(For D&E project handled at BEL-GAD)

3. DSIR National R&D Award 1993(For in house R&D efforts under Electronics & ElectricalIndustries Sector)(For D&E projects handled at BEL-Bangalore,Machilipatnam & Ghaziabad)

4. DSIR National R&D Award 1995(For in house R&D efforts under Electronics Industries Sector)(For D&E Projects handled at BEL-Bangalore & Ghaziabad)

5. DSIR National R&D Award 1998(For successful commercialization of Public Funded R&D)(For D&E projects handled at BEL-Bangalore & Panchkula)

6. Defense Technology Absorption Award ‘98 1999-2000(Sponsored by DRDO)(For D&E projects handled at BEL-Hyderabad)

7. Award for Excellence in R&D for the year 1998 2000-2001(Sponsored by Ministry of Information Technology, Gol) (For BEL-Ghaziabad’s developments of various 1FF Systems)

8. Award for Excellence in Professional Electronics 2000- 2001For the year 1998.(Sponsored by Ministry of Information Technology, Gd)(For BEL-KOTs excellent performance in Production,R&D & its commitment to Quality & Service)

9. Award for Contribution in areas of Defense R & D 2001-2002To Col. Retd.) H. S. Shankar, Director (R & D) forThe year 2001-2002(Sponsored by Society for Defense Technologists — SODET)

DESIGN AND MANUFACTURING SERVICES

Bharat Electronics Limited today has an integrated approach and systems capability, which is a direct result of its commitment to providing tailor-made solutions to the customers through its philosophy of quality management.

The company has set up impressive infrastructure and manufacturing facilities spread over nine ISO 9001 I 9002 certified modern production units around the country. The infrastructure is regularly upgraded with the latest and state- of-the-art facilities. Manufacturing infrastructure is amply supported by the applicable Quality Assurance infrastructure and skilled technicians. Standards Division of BEL optimizes the processes on a continuous basis. Process and QA standards generated by BEL are used as reference by a number of companies in India.

With the strengths in infrastructure and skilled/experienced manpower, BEL offers Contract Manufacturing Services for both domestic and international customers in the following areas:

PCB ASSEMBLY (SMT, through hole, BGA) and Testing

BEL has set up an exclusive Mass Manufacturing Facility and achieved proficiency in assembly of a wide variety of circuit board designs including Surface Mount Technology (SMT), Mixed Technology and Plated I Pin Through Hole Technology (PTH),. BEL also offers most modern facilities for testing of the products manufactured.Precision machining and FabricationBEL has the experience and expertise in the manufacture of high Precision Machined and Fabricated Parts in its state-of-the-art facilities equipped with latest CNC and special purpose machines. Products manufactured include chassis, enclosures, panels, brackets, rack mounts, card cage flanges and covers, large and medium modular frames and precision machined parts for the electronic, computer, and electrical products being used in commercial, Defense, aerospace and telecommunication industries.Opto Electronic Components and AssembliesBharat Electronics offers cost effective services for design and manufacture of optical and opto-electronic products and components operating in the UV, Visible and IR spectrum. Optical components include lenses, prisms, mirrors, windows, wedges etc. and Optical assemblies include Objective assembly, Eyepiece assembly, Collimator assembly & Imaging assembly.

Microwave integrated Circuit Assemblies

BEL manufactures a variety of Microwave Components and sub-systems using microchip technology which are required for wide range of applications in communication, radar systems including

airborne and space related subsystems. The facility is also qualified for the manufacture of C-Band Receiver for satellite systems.Multilayer PCB Design and ManufacturingBEL has established an excellent infrastructure to manufacture variety of Printed Circuit Boards ranging from single sided to 18 layers. The facilities are equipped to manufacture high technology quick turn prototypes, “Quick-to- Market products” and undertake volume production of buried and blind vias, build-up multi layers (micro vias) and ultra fine lines/spaces.

Cable assemblies and Wiring HarnessesBEL specializes in the manufacture of cable assemblies and

builds custom wiring harness required for its electronic equipment for commercial and military applications.Design and Manufacturing of Professional Grade TransformersBEL manufactures a wide range of transformers (power, audio frequency, modulation, pulse, filament etc.,) coils (audio frequency, radio frequency, air arc, IF, pot case, molded, etc.,) Chokes (smoothing, modulation, radio frequency, etc.,) and Sub-assemblies (HV Units, EHV units, etc.). Most of these products meet the stringent defense specifications for use in Defence equipment.

Antenna Manufacturing

Bharat Electronics Limited is engaged in development and production of various types of antennas for use in Radars, Communications, TV- Broadcasting, Satellite Communication etc. The antenna production division also includes a FRP shop capable of producing antennas with hand-lay-up technology. The R&D and production efforts are supported by well-equipped microwave testing laboratory and a microwave outdoor antenna test range. There is also a facility to produce thin film MIC components that are extensively used in phased array antennas.

Many foreign companies like AT&T-USA, GE-Medical-USA, Vishay-Austria,ECHOSTAR-USA, ENCON International-USA, CREC Products Inc-Canada.,Multitone-UK, Elisra, Elta, Ortek, Scitex, ELOP-Israel, TechnologyRendezvous Inc., USA, ERICSSON,SWEDEN and many more are using our facility for meeting their outsourcing requirements.BEL has also established Joint Venture Companies with DeIft, Holland for Image Intensifier Tube and General Electric Medical Systems, USA for X-Ray Tubes.

4.GENERAL PROFILEOFBELGHAZIABAD

GHAZIABAD UNIT

Formation

In the mid 60’s, while reviewing the Defence requirements of the country, the government focused its attention to strengthen the Air Defence System, in particular the ground electronics system support, for the Air Defence Network. This led to the formulation of a very major plan ADGES with Prime Minister as the presiding officer of the apex review committee. At about the same time, public attention was focused on the report of the Bhabha Committee on the development and production of electronics equipment. The Ministry of Defence immediately realized the need to establish production capacity for meeting the electronics equipment requirements for its plan ADGES.BEL was then entrusted with the task of meeting the development and production requirement for the plan ADGES and in view of the importance of the project it was decided to create additional capacity at a second unit of the company.

In December 1970 the government sanctioned an additional unit for BEL. In 1971, the industrial license for manufacture of radar and microwave equipments was obtained; 1972 saw the commencement of construction activities and production was launched in 1974.

Over the years, the unit has successfully manufactured a wide variety of equipment needed for Defence and civil use. It has also installed and commissioned a large number of 1FF systems needed to match a variety of Primary Radars. More than 3 versions of IFFs have already been supplied traveling the path from vacuum tubes technology to solid-state to latest Microwave component-based system.

Organizational Structure of BEL :

The operations of BEL Ghaziabad are headed by General Manager with Additional/Deputy General Manager heading various divisions as follows

Design &Engineering Divisions:

• Development and Engineering-R• Development and Engineering-C• Development and Engineering-Antenna

Equipment Manufacturing Divisions:• Radar• Communication• Antenna• Systems• Microwave Components

Support Divisions

• Material Management• Marketing and Customer Co-ordination• Quality Assurance and Torque• Central services• Information Systems• Finance and Accounts• Personnel and Administration• Management Services

Design and Engineering:

The pace of development and technological obsolescence in the field of electronics necessitates a strong Research and Development base. This is all the more important in the area of Defense Electronics. BEL Ghaziabad has since its inception laid a heavy emphasis on indigenous Research and Development. About 70% of its manufacture today relate to items developed in-house. For the development and production of the Mobile Troposcatter System and the 1FF equipment, BEL was awarded the Gold Shield for Import Substitution.

Design facilities are also constantly being modernized and substantial computer-aided design facilities are being introduced including installation of mini and micro-computers and dedicated design application. About 170 graduate and post-graduate engineers are working on research and development and indication of the importance R&D has in BEL’s growth.

Three Design and Engineering groups are product based viz. Communication, Radar and Antenna; these divisions are further divided into different departments to look after products of a particular nature. Each of them has a drawing office attached to them, which are equipped with latest drafting and engineering software. The PCB layout and PCB master making is done at CADD’s center. A central Records and Printing section takes care of the preserving the engineering documents and distribution thereof. Most of the engineering documents are available online.

Equipment Manufacturing Divisions:

As a supplier to the defense services and professional user, strict adherence to specifications and tolerances has to be in-built into the design and manufacturing process. For this. BEL Ghaziabad has well defined standards and process for as well as manufacturing and testing activities. Activities are divided into various departments like Production Control, Works assembly and QC works. The manufacture and control of production is through a central system, BELMAC, BEL’s own homegrown ERP system.Apart from conventional machines, BEL Ghaziabad has been equipped with several Computer Numeric Control (CNC) machines for ensuring repeat occurrences and increased throughput. A separate NC programming cell has been set up to develop the programs for execution on the CNC machines.

Microwave Component Group:

Frequencies greater than 1 GHz as Microwaves, Microwave Integrated Circuits(MIC) used extensively in the production of subsystems for radar and communication equipment constitutes a very vital part of the technology for these4 systems and is generally imported. Owing to the crucial and building block nature of the technology involved, BEL is currently setting up a modem MIC manufacturing facility at a planned expenditure of Rs 2crores. When in full operation, this facility will be the main center for the MIC requirements of all the units of the company.

The manufacturing facilities of hybrid microwave components available at BEL Ghaziabad includes facility for the preparation of substrates, assembly of miniaturized components viz, directional couplers, low noise amplifiers, phase shifters, synthesizers etc. involves scalar as well as vector measurements. For this state of the network analysis are used.

Material Management:

Material Management division is responsible for procurement, storage binding, issue of purchased parts as well as raw materials required to manufacture various equipment and spares. It also takes care of disposal of unused or waste material.This division is divided into Purchase, Component store, raw material store, Chemical store, Inwards good store, Custom clearance cell, Inventory management & disposal.

Marketing and Customer Co-ordination:

This division is responsible for acquisition and execution of customer orders and customer services. Marketing department looks after the order acquisition, Commercial department looks after the order execution, and Shipping takes care of the packing and dispatch of material to customer Quality Assurance & Torque.In the area of professional defense electronics, the importance of Quality and reliability is of utmost importance. BEL has therefore established stringent processes and modern facilities and systems to ensure product quality-from the raw material to the finished product. IGQA Environmental labs, Test Equipment Support and QA departments are grouped together under this division.

All material for the consumption in the factory passes through stringent inward goods screening in IGQA department before being accepted for use Subsequent to manufacture and inspection, the end product is again put through a rigorous cycle of performance and environmental checks in Environmental Labs. The testing, calibration and repair facility of test instruments used in the factory is under the control of Test Equipment Support. All the instruments come to this department for periodic calibration Quality Assurance department facilitates 1S09000 certification of various divisions. All the production divisions of BEL Ghaziabad are 1S9000 certified. The microwave

division is 1S09001 certified whereas the remaining three divisions viz. Radar, Communication and Antenna are also 1S09002 certified.

Central Services:

Central Services Division looks after plant and maintenance of the estate including electrical distribution captive power generation, telephones, transport etc.

PCB Fabrication & Magnetics:

PCB Fabrication, Coil and Magnetic, Technical literature, Printing press and Finished goods are the areas under this division.Single sided PCB blanks-having circuit pattern only on one side of the board and double-sided-having circuit pattern on both sides of the board are manufactured in house. However, Multilayered PCBs, having many layers of circuit are obtained from other sources.

Magnetic department makes all types of transformers & coils that are used in different equipment. Coils and transformers are manufactured as per various specifications laid down in the documents released by the D&E department.

Information Systems:

IS department is responsible for BEL’s own homegrown manufacturing and control system called BELMAC. It comprise of almost all modules a modern ERP system but is host and dumb terminal based.

Finance &Accounts:

The F&A division are divided into Budget & Compilation, Cost and Material Accounts, Bills payable, Payrolls, PF section, Cash sections.

Personnel & Administration:

There are at present about 2300 employees at BEL Ghaziabad, of which more than 400 are graduate and post graduate engineers. P&A Division is divided into various departments like Recruitment, Establishment, HRD, Welfare, Industrial Relations, Security and Ml Room.

Management Services:

This department deals with the flow of information or from the company. It is broadly classifies into three major sub-sections-Management Information System, Industrial Engineering Department and Safety.

5.ROTATIONAL REPORT OF VARIOUSSECTIONS

1. PRODUCTION PLANNING AND CONTROL

Production control

The main goals of the production control are:

1. To improve the profit of the company by better resource management.2. To ensure own time delivery product to customer3. To improve quality of the products4. To reduce the capital investment 5. To reduce the working capital needs by better inventory management.

Production control is responsible for producing the product, right from the stage engineering drawing are received to the stage where it is store credit as finished products.

Its basic function is to identify the parts /operations to be made the best way of making them, and the time when they have to make and to arrange the production resources to the optimum. The commercial department obtains order for equipment through quotations. The equipment stop order (ESO) is released by commercial department.The management service department, issue the work order for the quality of the equipment to be made. This is for the calculation of the cost of the project. Then D&B department develops the equipment and releases the following engineering documents:

• KS - Key sheet• GA - General assembly diagram• WD - Wiring diagram• PL - Part list• CL - Connection list

Now the production control takes the responsibility of manufacturing the equipment. Pc decides for items to be purchased

from outside, for items to be manufactured by other companies and prepares documents for items to be made inside the company.

Documents issued by PC

1. Process sheet (Fabrication): this process sheet indicates the process and the sequence of operation to be followed in various work cells and work centres. Every item timed by productivity services

2. Process sheet (Assembly): This is similar to PS (fabrication) except that, it is used in electronic assembly, PCB assemblies, cable from the cable assemblies.

3. Process sheet (Coils): This indicates operational analysis for transformer and coils.

4. Schedule for RM, fasteners and PP’s: This gives the gross requirement for raw materials, purchased parts, fasteners etc. Based on this material control department initiates procurement action and store requisitions are released with reference to this schedule.

TOOL PLANNING

Some of the items while under fabrication require the use of some jigs and fixtures or some special purpose tools. This department arranges all these items, because the jobs can e made fast and accurate by using any jig or fixture.The working format of this department is as follows:

1. Procurement of PPS2. Procurement of raw material.3. Writing of process sheet for machines shop

• Sheet metal working• Turning shop• Welding shop• Process sheet for assembly

4. Launching of manufactured parts in various shops5. Assembly activity6. Testing7. Dispatch.

2.MANAGEMENT SERVICES

This department deals with the flow of information to or from the company. It is broadly classified into the major sections:

1. Productivity service2. EDP section

Productivity service

The basic work of this department can be summarized as:

1. To prepare plans for next five years called “Roll-on” plan and evaluate the current “roll on” plan that has been drawn 5yrs age.

2. The cost estimation, revenue and budget plans are got approved by the board of management

3. Standard hour is approved by the department.4. Report on production value is evaluated for each unit.

Material management

The responsibility given to this section is to obtain raw materials and items essential towards daily usage of the factory. The division further consists of two departments:

1. Purchase2. Components store

BEL as a frontrunner has installed three automatic components holding machine in its component store. The system is KARDEX system installed in 2002. This systems aims at;

1. Utilizing vertical space for storing2. Making the process of searching components, fatigue, less as

well as time saving (components to man instead of man )

3. Also provide facility of inventory control.

Its specifications are:-

1. Vertical height of 6mtrs.2. Tray length if 1.2mtrs3. Horizontal depth of 2.5mtrs.4. 3 motors5. Eight sensors6. Sprocket chain drive mechanism7. 54 components housing trays adjusted to some height

(changeable)

3. ANTENNA

Various antennas types are being fabricated and assembled in this shop:

a. Radar or communication antennas consists of:i. Main panel fixture or reflector

ii. Feed fixture assemblyiii. Backup frameiv. Rotary joint assemblyv. Transportation frame assembly

b. Satellite antennae of different diameter consist of:• Reflector:

a. FRP sandwich typeb. Panel fixture type

• Feed:a. C-Bandb. Ext.C-Band

• Feed support assembly• Mount assembly

a. Manually operated or motor controlled operatedb. Remote operated with control unit

Various sections in this shop are:a. Precision Fittingb. Dip brazingc. Weldingd. Paintinge. Fiber reinforced poly urethane molding shop(FRPE)

TYPICAL ALUMINIUM DIP BRAZIG SHOP

DIP BRAZING

Dip Brazing is a process of joining of Aluminum alloy parts by means of flowing a

filler metal between the joint interfaces at a temperature below the melting point

of the base metal. Upon cooling to the solid state it forms a strong metallic bond

throughout the joined area. This process is different from other joining process

e.g. welding, brazing, soldering in following aspect:

a) No distortion

b) Close dimensional accuracy

c) More than scores of joints can be dip brazed in one dip

d) Quick, Leak-proof

Consequently the application has been use in those areas:

• Where the job is intricate and conventional manufacturing process is

either very costly or takes a longer cycle time.

• No distortion is allowed in the parent item after joining process.

• Leak proofing at joints

• Joining of thin sheet to a thicker one.

The wave guides, with all the bends and twists, for RF plumbing of any

communication Equipment, are the ideal items for dip brazing.

Parts to Be Dip Brazed Are

Cleaned of oil, grease and freed of excess oxide,

Assembled and jigged along with the necessary filler metal (dry flux).

Heated to approximately 580 deg Celsius for about 45 minutes

Immersed in molten flux at 605 deg Celsius for about 2-3 minutes.

Removed from the molten flux, cooled and cleaned,

The assembly is now ready for use for further treatment.

One joint or a hundred can be formed during the few minutes the assembly is

submerged in the molten salt.

It is a welding method, which involves welding of material via an unknown salt or

aluminum power exported from U.S.A.

The various stages involved are:

1) Cleaning of raw material: - It involves the surface cleaning of the material

part to be joined.

2) Setting of raw material: - the different parts to be joined of various types

can be set by tag welding or by tightening by wires.

3) Cleaning

Descaling It can be done by treating it with HNo3 + HF in the ratio

of 6:4 (Removal of scales).

Degreasing this can be done by treating it with Tetra-chloro

ethylene (TCE).

4) Reassemble: - Guiding them reassembles the material parts.

5) Application of Filler material: - This filler material of aluminum powder of

same compound is applied on the place where it is to be welded.

6) Pre-heating: - the material is heated to a temperature of 580oc so that it

may come to plastic state. The time period depending upon the job. Then

due to capillary action, it sweeps into the joints.

7) Dipping in Salt water: - It is put in salt bath, which is at a temperature of

605o c. It is done so that it gets hardened and also external powder is

washed away.

8) Air-cooling: - The job is then air-cooled.

9) Hot water cooled: - It is done in order that the stresses may not develop if

sudden cold water is applied.

10)Further cleaning is done

ADVANTAGES OF DIP BRAZING

LESS DISTORTION:

Large and extremely complex shapes can be brazed with minimal distortion at

relatively lower than welding temperatures. Dip Brazing utilizes uniform

application of heat both in the pre-heating furnace & in molten salt bath and

works in conjunction with high thermal conductivity properties associated with

Aluminum. This uniform application of heat reduces the incidence of distortion.

REDUCED TOOLING COST:

The dip brazing process uses little if any specialized tooling. Fixturing is generally

accomplished with common fixtures that allow for quick and inexpensive

configuration changes.

MATERIAL SAVINGS:

Unlike castings or machined parts, dip brazing can be done at near final

dimension.

IMPROVED STRUCTURAL INTEGRIT:

Dip brazing offers a continuous leak-proof and EMI shielded joint even with a

variety of material thicknesses.

BETTER CONDUCTIVITY:

As the dip brazed joint is made up of aluminum, conductivity is clearly better than

that achieved with an adhesive bonded or mechanically attached assembly.

LOWER COST:

The dip brazed process yields the lowest cost given the superior characteristics

achieved.

DESIGN FREEDOM:

The design engineer will enjoy a greater range of options using the dip

brazed process.

Reduced Tooling Costs

Reduced Design Change cost and implementation time

FATIGUE AND THERMAL PROPERTIES:

The natural shape of the meniscus formed by the filler material is ideally shaped

to resist fatigue. Any stress of the assembly is evenly distributed around the fillet

and disperses the stress uniformly over a large stress area.

2. Painting

After production the work comes for painting which is the last operation on the job.He paints used are:

a. Enamel paintb. Nitro cellulose polyurethane

Enamel paint: It is used in writing work for example, mono….. of BEL done by enamel paint.Nitrocellulose and polyurethane: It can’t be done by brush as it dries down very fast so it is done by spray.The procedure adopted is:

1. Cleaning: cleaning work on the job is done by applying Tricloro ethylene.

2. The OIC primer is put on it i.e. the red oxide and it is left for drying for 24 hours.

3. Then primer sur…. Is put on it which is of grey colour for 24 hours. It is coated such that the paint may have strong catch and is left for 24 hours to dry.

4. Then the paint is sprayed over it. It takes 8-24 hours to dry.

Antennae shop also houses Shot blasting machine. This machine is used for removing rust from heavy rusted assemblies before painting them. It consists of steel grit, which is sprayed under pressure to remove rust.

3. Welding

Various types of welding being used are:• Silver brazing with brass base metal (brazed with Ag

because it has lower MP as compared to brass.)• Tungsten inert gas welding (TIG): It uses argon gas and

electric arc Filler material is aluminum.• Arc welding using consumable electrode, which I flux,

coated.

3. Fiber reinforced poly urethane section:

The transmitters and covers of track antennae are manufactured here. The redum covers of RADAR are made here. It also makes reflectors for reporter as well as FLYCATCHER RADAR.

Fiberglass is used as reinforcing material to increase mechanical strength as well as insulation properties. Carbon fibers improve the electrical properties of components

The constituents for making reinforced assembly are fiberglass mats. They are of 3 types:

• Winovin mat • Surface mat• Zobistan mat.

For making antennae for RADARS, the procedure is:Mould which is used for making antennae is covered with the

separator gel which also doubles up to give better surface finish. It is covered with polyester resin +1% accelerator +1% catalyst (depends upon climate, room temperature and conditions). It is then set in mould for about 24hours. After setting it is put in Curing chamber for Thermosetting, in stage 1 the temperature maintained is 250C and in stage 2 it is reduced to 125C.

4. RADAR AND MACHINE SHOP

MACHINE SHOP

To meet the requirement of various projects, their manufacturing parts are

processed in machine shop. Different operations are carried out to complete the

job as required. Operations mainly covered under machine shop are:

1. Turning (conventional)

2. Milling (conventional)

3. CNC turning

4. CNC milling

5. Jig boring

6. Grinding

7. Sheet metal work

TURNING

Turning is done on a lathe machine. In turning normally single point cutter tool is

used, job is generally hold in chuck or collet (fixture) that rotates and tool is

allowed to cut the material. Different process performed on lathe machine.

• Turning

• Facing

• Drilling

• Boring

• Knurling

• Taper turning

• Thread cutting

• Parting off

• Chamfering

There are various types of lathes in this section

i. Centre lathe

ii. Capstan and turret lathe

iii. Engine lathe

There make/types are as follows:

1. SCHAUBLIN 135:

It is a very precise machine and is used to perform high accuracy jobs. It

is centre lathe. 135 specify the height of center.

2. HMT LATHE:

It is also a very accurate machine and can take heavy load as well. It is

generally used for machining of large sized precise jobs. It is of type H22

is the height of centre. It is also a centre lathe. Job diameter range is 15 –

440mm. length of the bed is 1.5m and its speed is 40 – 2300 r.p.m. the

speed depends upon the diameter of the work piece.

3. GEE DEE WEILER:

It is having a turret a capacity of SIX tools, which can be set as per

required dimensions, with an additional provision of utilizing two more

tools on auxiliary slide. It is used for manufacturing small jobs in large

quantity. Job diameter range: 2 – 25mm and speed range: 440 – 3600

r.p.m

MILLING

In cell-22, milling operation is done on milling machines. On milling machines

operations are performed by multipoint cutting tool known as milling cutter.

Generally, cutter hold in arbor and the job hold in the vice/fixture/machine bed

and required machining operations are performed as per drawing.

Milling operation is basically of two types:

i. Conventional (up) milling

ii. Climb (down) milling

CONVENTIONAL (UP) MILLING

If the rotation of the cutter and feed of the job is in opposite direction, it is known

as up milling. In this process we can take heavy cut but finishing is not good.

CLIMB (DOWN) MILLING

If the rotation of the cutter and feed of the job is in same direction, it is known as

CLIMB MILLING. In this process we cannot take heavy cut but finishing is good.

TYPES/MAKE OF MILLING MACHINES:

. SCHAUBLIN:

It is a universal type-milling machine, as it may be adapted to very wide

range of milling operations. Its bed moves in longitudinal, crosswise &

vertically. There is a D.R.O attached to it, which stands for Digital Read

Out. It is a Swiss machine.

Specifications:

Bed movement

Longitudinal - 700mm

Crosswise - 200mm

Vertical - 500mm

Feed range - 12 to 1050mm/rev.

Speed range - 38 to 1510 r.p.m

2. PRAGA-GAMBIN:

It is one of the few Indian machines in BEL. It is also a universal milling

machine. It is one of the oldest machines in Cell-22.

Specifications:



3. HURON:

It is an omniversal type milling machine. It is a French machine.

Specifications:

Bed movement


Vertical - 600mm

Head movement

Crosswise - 700mm

Speed range - 30 to 2050mm/rev.

Feed range

Bed - 1.6 to 820 mm/ rev.

Head - 0.8 to 410 mm/ rev.

4. DECKLE FP 3L:

It is universal type milling machine. It has a fixed bed and has a D.R.O

attached to it. It is a French machine.

Specifications:

Bed movement


Crosswise - 300mm

Vertical - 400mm



5. DECKLE FP2:

It is conventional milling machine. It has a head movement of 45° on both

sides. Both vertical and horizontal work can be done on it.

Specifications:

Bed movement


Crosswise - 200mm

Vertical - 400mm



CNC TURNING:

In cell-21 there are three CNC lathes, in which two are from Index, (FRANCE)

and one from Wasino (JAPAN). Index CNC is based on SINUMERIC system and

used for small/medium size large quantity precise jobs. Wasino CNC is based on

FANUC system and is used for large size job.

Specification (WASINO):

Bar capacity - 77 mm (max.)Chuck capacity - 260 mm (max.)Spindle speed range - 8 to 3000 r.p.mFeed rate range - 0.001 to 400 mm/rev.Tool station - 12 (in numbers)X-axis turning - 330 mmZ-axis turning - 500 mmSpindle power - 15 KW

Specification (Index-GU 600):

Bar capacity - 10 to 65 mm Chuck capacity - 200 mm (max.)Spindle speed range - 25 to 5000 r.p.mFeed rate range - 0.001 to 400 mm/rev.Tool station - 12 (in numbers)X-axis turning - 175 mmZ-axis turning - 700 mmSpindle power - 32 KW

Specification (Index-GS 600):

Bar capacity - 9 to 30 mm Chuck capacity - 100mm (max.)Spindle speed range - 37.5 to 7000 r.p.mFeed rate range - 0.001 to 400 mm/rev.

Turret 1 Turret 2Tool station 12 8X-axis - 95 mm 100 mmZ-axis - 238 mm 128 mmSpindle power - 32 KW

CNC MILLING

In cell-22 there are four types of CNC milling machine. In which two are from

Kitamura (JAPAN) and the other two from Mitsui Seiki (JAPAN). Both are based

on the FANUC 6M system.

Specification (Mitsui Seiki VR3A):

X-axis travel - 750 mm

Y-axis travel - 450 mm

Z-axis travel - 450 mm

Spindle speed range - 60 to 6000 r.p.m

Feed rate range - 0.1 to 4000 mm/rev

Rapid Transverse - 12000 mm/ min.

Specification [Mycenter-4 (Kitamura)]:


Y-axis travel - 508 mm




Rapid transverse - 10000 mm/ min.

Specification [Jigcenter-7 (Kitamura)]:






Rapid transverse - 10000 mm/min.

JIG BORING:

Jig boring operations are preformed to get close tolerance on different types of

holes/bore and counter bore as per requirement. These machines are also very

accurate and give repeatability very precise in microns.

There are two types of jig boring machines, both are Swiss made Henri Hauser.

They are very temperature sensitive. They work at 20°±2°C.

Specification:

Henry Hauser(Type I)


Y-axis - 500 mm

Rapid transverse - 1200 mm/ min.

Feed range - 0 to 4000 mm/ min.


Henry Hauser(Type I)


Y-axis - 250 mm

Z-axis - 400 mm


Accuracy - upto 0.1 microns

6. FABRICATION SHOP

Fabrication Shop is one of the mechanical workshops in the company. There are

several kinds of machine used for different kind of operation.For sheet metal

work first of all the work is done on sheering machine. Shearing machine cuts the

sheet. It firstly bends the sheet & then breaks the sheet by application of heavy

force through a ram.

After cutting the sheet the work piece is sent to punching machine. In this

machine punch can make holes of any shape. This punching machine is a CNC

machine, which has twenty-tool station. The program is feed into the machine

manually, by floppy or by compact disc. After punching, job is sent forward for

other operations. After punching if there is any bending work in that job then it is

sent to bending machine where bending work is done.

In circular saw the waste material is cut of the original piece. Now after

performing such operation the level of the sheet get wreck so before performing

more operations. It is sent to leveling machine in which there are rollers, which

are moving in opposite directions. The sheet is inserted in the machine and

machine levels the surface.

In Fabrication Shop there are various kinds of machine but mainly the work is

done on some machine and they are:

1. Shearing Machine (PC-1).

2. CNC-LVD Punching Machine.

3. NPB- Bending Machine.

4. 120 T- Bending Machine

5. Leveling Machine.

6. Tapping Machine.

7. Circular Saw.

8. Radial Drilling Machine. ( AUTO MULLER )

The brief description and working of the machine is given below:

1. Shearing Machine (PC-1):-

Shearing Machine is one of the most important machines of the fabrication shop,

because the work starts from this machine as it cuts the sheet. This machine

works on hydraulic pressure. The ram is fixed and it slides horizontally and cut

the sheet. Actually this machine do not cut, it bends the sheet and then breaks by

the action of ram. As the sheet bends and the work done in great accuracy so

clearance must be taken in account before cutting the sheet .The clearance is

the 3% of the thickness of the sheet. For holding the sheet firmly, when we press

the button first the hammer press the and then the ram perform its work. For the

long life of the cutter the ram do not act from both side, instead of that it starts

cutting from one side just like scissor.

Specification:-

Maximum sheet thickness

Aluminum - 0.5 - 6 mm

Mild steel - 0.5 - 4 mm

Stainless steel - 0.5 - 3mm

Maximum length of the sheet - 3mm

Number of strokes per minute - 18-28

Distance of frame cutting slide - 30HP

Voltage of motor - 415V

Approximate weigh - 7 tones

2. CNC-LVD Punching Machine: -

This machine is a CNC turret machine in which there are 20 – tool stations in a

turret, which acts as there programming. In this machine there are four ways to

feed the program, first way is simple manual programming, second by magnetic

tape/reel, third way is by floppy and fourth by compact disc. Programming is

based on trigonometry. X & Y indicates the desired length & width of the sheet.

Working of the machine is simple the data is fed into machine by any one of the

method & the sheet is inserted in the machine. The machine automatically works

and finally completes the job. For holding the job firmly there are two vices, which

are movable and which moves the sheet. Their jaws are operated by oil

compression.

Specification: -

Company - LVD BelgiumModel - Delta 1000 thick turret 3 indexesCNC control - Fanuc 180iElectric consumption - 23.4 KWMaximum punch tonnage - 200 KWWorking Area - 1275 mmMaximum sheet thickness - 6 mmMaximum punch dia - 88.9 mmMaximum work piece weight - 80 KgPosition Accuracy - 0.1 mmAverage repeatability - 0.05 mmNumber of tool stations - 20

7A type (up to 12.7 mm)7B type (dia 12.7 to 31.7 mm)2C type (dia 31.7 to 50.9 mm)4D type (dia up to 88.9 mm)

No. Of index station - 3(D type)Inhibited clamp zone - 220 mm (X direction)

80 mm (Y direction)

Maximum speed - 75 mm/min for X & Y direction106 mm/min for X & Y movement

Nibbling - 400 mm/min (+/- 5 %) for X= 1mmAnd y=0 (without sheet)

Punching - 200 mm/min (+/- 5 %)for X = 25 mmAnd Y = 0 (without sheet)

Noise level - 90 to 100 dB

3. NPB Bending Machine:-

In this machine the tool is fixed between the jaws and the die is selected as per

our need. It is also an automatic machine. It’s an air compressor operated

machine in which applying air pressure does the work.

The die is selected and fitted at the die holder. The job, which is to bend, is

placed on the die, which is fixed on the bed. The most important feature of this

machine is that in this machine the ram do not move, instead bed move upward

and downward and the bending work is done.

This is a kind of automatic machine; so the power of stroke, length of stroke and

the dimension of the job is numerically control where the angel of bending is

dependent on the die.

4. 120T Bending Machine:-

This is simple kind of press, working on hydraulic principle. Its tonnage is 120

tones and is completely manual operated machine. It has two hydraulic cylinders,

which are attached with the hydraulic pistons. There is oil tank behind the

machine, which is filled with oil and is used as a fluid for hydraulic piston.

As this is a manually operated machine, so the stroke length, the die and

bending angle all are set manually. The bending angle is set by die and stroke

length is set up by scale, which is situated on the machine. To hold the job firmly

there is also clamp, which holds the job. In this machine the bed is stationary and

the ram moves upward and downward.

5. Tapping Machine:-

Tapping machine in its simplest kind consists of AC motor in which the spindle is

fitted from which a belt is fitted from motor spindle to chuck spindle on the both

spindle. There are some steps for the belt, by means of that the speed of

machine is controlled.

An important feature of this machine is that the chuck of this machine can be

rotated clockwise when the moving chuck is pressed upward. By using this

machine we can tap from 2 mm to 10 mm.

6. Leveling Machine:-

Leveling Machine is used only for leveling the surface of sheets, when the

surface of the sheet gets wrecked after performing the operation such as cutting,

punching etc.

In this machine there are rollers, which are fitted, parallel and moving in opposite

direction, when sheet is inserted in machine the rollers press the sheet by which

the sheet gets leveled.

In this machine the thickness of the sheet must be pre entered and the sheet of

roller must also be set.

7. FS Circular Saw:-

Circular saw, as the name indicates is a saw, which is circular in shape. It has

two types of cutting saw used as per need. Both cutters cannot be fitted on the

machine simultaneously. The blade is ejected and changed when we need.

The cutters used in the machine are of two types:

• Diamond edge cutters

Diamond edge cutter is a simple cutter, in which small particles of

diamond are fixed on the edge of the cutter. This type of cutter is used to

cut acrylic or non-metal sheets varying thickness from 0.5 mm to 5 mm.

The most important feature of this machine is that it is used only for cutting

non-metals.

• Metal edge cutters

This is a type of cutter in which the blades are made up of metal such

as high carbon steel (HCS), high-speed steel (HSS) and other kinds of

hard metals. This cutter is used to cut the sheets of varying thickness of 5

mm to 50 mm, and it also cuts non-metals.

8. Radial drilling machine:-

Radial drilling machine in its simplest kind consists of motor, which is attached

with drill chuck, and the chuck is hanging on the shaft, which is attached with drill

chuck, and the chuck is hanging on the shaft, which can move in the angles. This

machine can drill up to 29 mm diameter.

This machine is called Radial drilling machine because it can move 360 degree.

To set it in any position there is a magnetic lock which the shaft and do not allow

it to move.

6.REPORTONNUMERICALCONTROLCELL

NUMERICAL CONTROL

INTRODUCTION

Numerical control machines are those which are capable of being controlled by a

series of formatted data, called NC part program, and thus produce desired

output without the need of human intervention. The NC part program can be

changed at any time to get different desired outputs.

DEFINITION:

Systems in which action are controlled by direct insertion of numerical data at

same time. The system must automatically interpret at least some portion of

numerical data.

OR

Simply as, control of machine tool by means of numbers.

NEED OF NC

Human being has always tried to reduce his efforts in carrying out various tasks

to make life more and more comfortable. For this machines have been designed

right from sharpened stones to turbines and computers. In this series of efforts,

machine tools like lathe and milling machines etc. were designed and automated.

During World War II, it become clear that fixed type of automation,

offer by existing mechanically automated machines, was insufficient to handle

complex and small batch requirement of aircraft parts. In 1948, John T Parson

demonstrated the concepts of NC to U.S. Air force. The first prototype of NC was

developed and demonstrated at MIT in 1952.

Present competitive word demands that a variety of quality products

be produced at high rate of production at a minimum of cost. NC machine

enables us to meet this challenge by providing a solution, which can be termed

as FLEXIBLE-AUTOMATION.

ADVANTAGES OF NC:

NC machines are today serving a host of industry in a variety of applications.

Some are indicated as below:-

• High productivity, low WIP (work in progress).

• Accuracy and consistency.

• Low operator fatigue.

• Reduce human error.

• In process, measurement not required.

• Flexibility in manufacturing.

LIMITATION:

As is with any other system of technology around the world, NC technology also

suffers from limitation, some of which are enumerated as below;-

• High capital and revenue cost of machines.

• Complicated and costly maintenance.

• Temperature, humidity and dust controlled environment required.

• Highly skilled programmers and machine operator required.

COMPUTER NUMERICAL CONTROL (CNC)

MACHINES

Since 1970, CNC based MCU’S have been increasingly replacing the hardware

MCU’S and currently only CNC systems are manufactured. The diode was

replaced by transistor in 60’s giving rise to more reliable, relatively smaller than

MCU. Also microprocessors replaced large sized hardware circuitry in NC

machines, which made arithmetical and logical operations easier. But in practice

CNC machines have been continued to be mentioned NC in general. CNC

machines certainly offers better and easy machining. The best thing about CNC

is that for some further modifications, we need not require a new hardware but

we can simply upgrade the software and modify it as required.

DIRECT NUMERICAL CONTROL (DNC)

DNC is the first step towards the factory of future. It is a manufacturing system in

which a central computer communicates with the controllers of several machine

tools by a direct connection in real time. Its essential functions in addition to

NC/CNC are:

(1) To use memory of the central computer for storing part programs

meant for several NC/CNC machines.

(2) To transfer or download directly the part programs from central

computer to individual MCU’S of machines.

(3) To provide downloading in real time on shop floor.

(4) To stabling two way communication i.e., in addition to down loading

central computers can also receive messages and other manufacturing

information in real time.

WORKING PROCEDURE OF NC CELL

The NC cell works with a model practice.

1. Receiving of drawing with programming request.

2. Updating of master file.

3. Study of drawing and deciding the process of manufacturing on CNC.

4. Selection of tools (normal), special tools (if required).

5. Writing the program and tools lay Out (TLO).

6. Feeding the program into computer and taking out of tape.

7. Handling over the blue print of TLO, punched tape, Pre-machining and

post machining details and drawing as and when required to the CNC

MACHINING CELL.

8. Taking out the list off on the machine getting it approved for the

production.

9. Updating program if required and if any change in drawing.

However it may be added that one set of documents is sent to production Control

Engineer in advance which help him in getting time study done in advanced and

also he can know about pre and post machining operation details.

WHAT IS PROGRAMMING?

The NC machine tool moves as directed by a program punched on a NC tape.

While machining a part using a NC machine tool, the tool path and other

machining conditions are programmed. This program is called a part program.

The part program tells the NC the tool path and auxiliary motions of the machine

tool. This is written on the process sheet. The program on this process sheet is

punched on a paper tape (or taken on any other suitable medium).

COMPOSITON OF PROGRAM

A program is divided into a main program and a sub-program. Normally the NC

operates according to the main program, but when a command calling a sub-

program is encountered in the main program, control is passed to the sub-

program and when the command in sub-program says to return to the main

program, control is return to the main program. Total of 95 main and sub-

programs may be stored in the NC memory.

BLOCK:

Program is composed of several commands, each command is known as block.

WORD:

Block is composed of one or more words. Word has an address followed by

number. Address is the letter, which prescribes the meaning of the numerical

value following the address.

Example: X -- 100

Address Numerical value

WORD

INPUT FORMAT:

Input format used by the system -6M is known as the variable block format since

the number of words in a block and the number of characters in a word can be

changed. Input can be in inch or metric system.

For example:

X L +0 5 3

3 digits below the decimal point

5 digits above decimal point

Leading zero suppression

With sign

Absolute or incremental

Address

DECIMAL POINT PROGREAMMING:

FANUC 6T can take the input numerical values with decimal point.

ABSOLUTE AND INCRMENTAL PROGRAMMING:

The distance of tool travel in each axis may be commanded by either by

incremental or absolute command. Using incremental command traveling

distance in the block is directly programmed while in absolute command the end

location of the tool within a block is represented by coordinate values in the work

coordinate system and the coordinate values are also programmed.

SYSTEM CODES

1. PREPARATORY CODES (G CODES)

2. AUXILLARY CODES

(a) M CODES

(b) TOOL CAMMAND (T)

(c) SUB-PROGRAM (L)

(d) TRAVERSE INFORMATION (X, Z)

(e) SPINDLE SPEED (S)

(f) FEED INF. (F)

(g) OTHERS (A, B+, B-, I, K, R, N)

PREPARATORY CODES

*G00 : This code is for positioning is for positioning the tool. For each axis the

point is programmed by the address X, Y, Z or U, V, W. in FANUC-6T only X and

Z-axis are programmed.

G00 X--- Z---

any movement in ’X’ and (or) ‘Z’ axis will result in movement with given rate of

feed under address ‘F’.

G01 X--- Z--- F---

*G02/03: These codes are for circular interpolation/movement. Starting point is

point where tool presently stayed or it is determined by previous block. End point

of arc or circle is determined by given axis value. The interpolation parameters

determine circle center by using ‘I’ and ‘K’ with sign over a range of 0 t0 360

degrees.

G02 / G03 X--- Z--- R--- I--- K--- F---

*G04 : It is used for dwell, when the previous block is completed and the next

block is about to start.

G04 (or P) Time in seconds

*G27 / G28 / G29: A point fixed on the machining plane is called the

reference point and by reference point return function the tool is positioned at this

point. G27 checks whether the tool is positioned at this point. By G28 the tool is

positioned at the reference point automatically. The end point of this command is

called the intermediate point. By G29, the tool is positioned at the command point

via all intermediate point.

G27/G28/G29 X--- Z---

*G31: This code commands linear interpolation; input of skip signal during

execution of this command interrupts the rest of block and executes the next.

*G33: This is used for thread cutting, giving screw end point (is incremental

command) or screw end point (in absolute command) and the thread lead are

given by z and F respectively.

G33 X--- Z--- F---

*G34: It is used for variable lead thread cutting, commanding an increment or a

decrement for a lead per screw revolution enables variable thread lead cutting to

be performed, K specifies an increment or decrement in the following command

G34 X---Z--- F--- K---

*G40/G41/G42: These are tool nose radius compensation codes. As we

assume machining behind the tuning axis G41 code is used when tool is left to

workpiece and tool be to traverse left to right as tool carriage traverse when

producing L.H. threads. The code G42 is used when tool is left to workpiece and

tool is to traverse right to left as tool carriage traverse when producing R.H.

threads. Using CRC codes the workpiece contour is programmed. The control

calculate the path for tool tip radius center (equidistant* calculation) and the

intersection points of these equidistant paths at acute transition. The benefit of

using CRC codes is that there is no contouring error left. CRC codes may be

used for inside and outside contouring obtuse and acute angles and at acute and

tangential transition. These codes are effective in a block and programmed with

or without path data and with codes G00/G01. The codes G41 and G42 are

deactivated by using G40 code.

*G20/G21: these are codes for determining the input system that is the data

supplied are in INCHES or METRIC system. For data input in inch code is G70

otherwise it is G71. We are using the metric data input system.

*G90/G91: these are code for absolute or incremental data input. When

using G90, absolute data input all data refers to the fixed zero point of workpiece.

All ‘X’ values are recognized as diameter. G91 is used for incremental data input

means that each dimension corresponds to distance to be traversed. Incremental

data are preferred in the subroutine programming. All ‘X’ values are recognized

as radius.

MISCELLANEOUS FUNCTIONS ‘M’

*M00: it makes possible in order to make a measurement or some other

similar purpose. This is unconventional stop and operational in all automatic

modes.

*M02: with use of this code (end of program code) program return to program

start is written in last block.

*M03/M04/M05: these all are spindle control command. M03 is used for

spindle for spindle rotation in clockwise direction. M04 is used for spindle rotation

in counterclockwise direction. M05 is used for spindle rotation stop.

*M17: this code is for end of subroutine is written in last block of the

subroutine.

*M30: this code is used for end of program and is similar to M02.

*M19: this code is used for oriented spindle stop. Orientation of spindle is given

under address ‘S’. Spindle always orient in C.C.W direction. This code is used

when drilling or milling is required on periphery of workpiece (this is done with

help of driving attachment).

The command is given as M19 S90 LF. This will result in orientation of spindle by

90 degree.

*M08/M09: both of these codes are used to control coolant. M08 is used for

to on coolant associated with tool. Whereas M09 is used for to off coolant

associated with tool.

PATH DATA

‘ X’ AND ‘Z’ AXIS COMMANDS:

The address for the axis commands X and (or) Z determines the axis which is to

be traversed in accordance with the associated digital value. Both axes can

move simultaneously or individual according to path data is fed. When using G90

(absolute programming code) input data treated as diameter values for x-axis by

the control. Whereas using G91 (incremental programming code) the input

values for X axis refer to the radius.

T WORD TOOL COMMAND

T CODE:

The tool command determines the tool (tool no.) required for a particular

machining section and also relevant tool data (tool offset number). Tool

command is given as below

T mm- -- --

Tool command address =T

Tool number 00 to 99 (1 or 2 decades) = mm

Tool offset number (to select: 01 to 16) = n

(To cancel: 00)

TOOL OFFSET

As we know that different tools (i.e. for drilling, turning, boring etc.) are made

under different designation and length. Even tool used for similar operation are

not of same length. So when these tools are fitted to turret (too magazine) their

cutting edge projections are different. So a given program zero is not suitable for

all tools as some were short to workpiece and some dig into the workpiece with

respect to their size. Therefore it is necessary either to set different zeros for

different tools or to give an instruction initially that this much length tool travels

less or more to approach the workpiece without damaging or being short to it.

The distance it has short or more then ZERO set with respect reference tool is

known as tool offset. According to distance tool offset are given number from 01

to 16. it is find out on machine with help of an equipment (accessory) provided by

manufacturer. Tool offset consists of:

X…. Tool length offset x-axis

Z…. Tool length offset z-axis

CHAMFER AND RADIUS COMMAND

To insert a radius or a chamfer can be inserted automatically by using B code.

The instruction is given as:

N10 X (1). Z (1). B_..

N12 X (2). Z (2). Means insertion of chamfer.

N12 X (2). Z(2). B+..

N12 X (2). Z(2).. means insertion of radius.

‘+’ writing is optional

This code is given with path data of sharp corner [ X (1), Z (1) ] which is to be

rounded or to be chamfered with B code and followed by the position co-

ordinates [ X (2), Z (2) ] at which tool to reach. The inserted radius/chamfer must

not be bigger than the smaller one of the both distances.

PROGRAM NUMBER:

This control can store program in its memory. The program number is used to

differentiate one program from another.

SEQUENCE NUMBER;

A sequence number can be specified with a number (1-9999) following the

address. It is placed at the head of the block. The order of the number is arbitrary

and need not be consecutive.

OPTIONAL BLOCK SKIP:

With a slash followed by the number (/n)

(n=1 to 9) programmed at the beginning of a block. With the optional block skip

switch n on the machine operator’s panel set ON, information of the block with /n

of the number corresponding to switch number n are ignored.

PROGRAM ZERO POINT AND COORDINATE SYSTEM:

While programming, a program zero point and a coordinate point must be

determined. Usually, program zero point is placed at an arbitrary position on the

workpiece and the coordinate system is called the work coordinate system.

START POINT AND REFERENCE POINT:

A tool moves from the start point and the program also starts from the start point,

but the NC must know the coordinate values of the start point.

The reference point is the fixed position of the machine tool. A tool may return to

this point rather than the start point to cut down the idle time.

S.NOG-CODE

FUNCTION

1 G00 POSITIONING2 G01 LINEAR INTERPOLATION3 G02 CIRCULAR INTERPOLATION (CW)4 G03 CIRCULAR INTERPOLATION (CCW)5 G04 DWELL6 G10 OFFSET VALUE SETTING7 G20 INPUT IN INCH8 G21 INPUT IN MM.9 G22 STORED STROKE LIMIT ON10 G23 STORED STROKE LIMIT OFF11 G27 REFERENCE POINT RETURN CHECK12 G28 RETURN TO REFERENCE POINT13 G29 RETURN FROM REFERENCE POINT14 G30 RETURN TO 2ND REFERENCE POINT15 G31 SKIP CUTTING16 G33 THREAD CUTTING17 G34 VARIABLE LEAD THREAD CUTTING18 G36 AUTOMATIC TOOL COMPENSATION X-AXIS19 G37 AUTOMATIC TOOL COMPENSATION Z-AXIS20 G40 TOOL NOSE RADIUS COMPENSATION CANCEL21 G41 TOOL NOSE RADIUS COMPENSATION LEFT22 G42 TOOL NOSE RADIUS COMPENSATION RIGHT

23 G50PROGRAMMING OF ABSOLUTE ZERO POINT MAXIMUM SPINDLE SPEED SETTING

24 G68 FEED PER MINUTE25 G69 FEED PER REVOLUTION26 G70 FINISHING CYCLE27 G71 STROKE REMOVAL IN TURNING28 G72 STROKE REMOVAL IN FACING29 G73 PATTERN REPEATING30 G74 PEEK DRILLING IN Z-AXIS31 G75 GROVING IN X-AXIS32 G76 THREAD CUTTING CYCLE A33 G80 CANNED CYCLE FOR DRILLING CANCEL34 G83 FRONT DRILLING CYCLE35 G84 FRONT TAPPING CYCLE36 G85 FRONT BORING CYCLE37 G87 SIDE DRILLING CYCLE38 G88 SIDE TAPPING CYCLE39 G89 SIDE BORING CYCLE40 G90 CUTTING CYCLE A41 G92 THREAD CUTTING CYCLE B42 G94 CUTTING CYCLE B43 G96 CONSTANT SURFACE SPEED44 G97 CONSTANT SURFACE SPEED CANCEL45 G98 INITIAL LEVEL RETURN46 G99 R POINT LEVEL RETURN

The practical training aims at familiarizing the students with the working condition in a professional firm as well as to apply their theoretical knowledge acquired in the institute into practice.

This training was helpful to me in various direct and indirect ways, like understanding of machines as well as procedure followed in manufacturing a product. A good insight into inspection and Quality check of products.

This training has added a whole new dimension to my observation and practical approach as well as introducing me to Organizational Hierarchy.

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