INTERNSHIP REPORT

Duration – 11/07/2022 to 06/08/2022

Session: 2022-23

BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING

Submitted to: Submitted by:

Mr. Rajesh Jain Arohan Srivastava

Director Enrollment No. – 0801ME191015
M.P. Engineering and Machine Tools Mechanical Engineering
Sanwer Road, Indore SGSITS, Indore
 Acknowledgement
The entire work presented in this report is done by me at MP Engineering and Machine
Tools, Sanwer Road, Indore.

I am highly obliged and express my thanks to Mr. Rajesh Jain for providing me valuable
guidance and necessary facilities at the factory.

I am equally thankful to Mr. Dilip Tiwari, Mr. Hemant Pawar, and Mr. Vinod Sharma for
their kind cooperation throughout the internship period.

I would also like to thank my fellow interns for their help and cooperation throughout
the internship.

Last but not the least I extend my sincere thanks to the authorities of MP Engineering
and Machine Tools for granting permission and giving me opportunity to do my internship
at their factory.

Arohan Srivastava

0801ME191015

Mechanical Engineering

Shri G.S. Institute of Technology and Science, Indore

 Index
❖ INTRODUCTION 4
➢ PRODUCTS 4
❖ PLANT LAYOUT 11
❖ PRODUCTION DEPARTMENT 15
➢ LATHE MACHINE 18
➢ LATHE OPERATION 19
➢ VERTICAL DRILLING MACHINE 20
➢ MILLING MACHINE 21
➢ TAPPING MACHINE 22

➢ BAN SAW MACHINE 24

➢ CNC MACHINE 25
➢ CNC PROGRAMMING 34
➢ VMC 37
❖ INVENTORY CONTROL 39
➢ APPLICATIONS 39
➢ PURPOSE 40
➢ KAISEN 41
➢ 5S METHODLOGY 42
❖ CONCLUSION 44
 Introduction
Incepted in the year 1994, M. P. Engineering & Machine Tools is accredited as a
foremost name immersed in offering a comprehensive consignment of Earth Moving
Machine Parts, Material Handling Equipments, Jigs and Fixtures, Automobile Parts,
Turned and Machined Components, Pre-Engineering Building and Fabrication Services.
As well, the final consignment is well tested before final shipment at the premises of
our patrons. Offered products are acknowledged for its sturdiness and durability. Our
clients include Case new Holland Construction Equipment Pvt.Ltd. Pithampur, Larson &
Toubro Ltd, ECC Construction Group, Dee Tee Industries Limited, Caparo Engineering
Limited etc.

They have a large circulation network all over the nation due to which we are capable
of delivering our products at the premises of our patrons on a well-timed basis. With
their foremost motive towards conquering supreme level of patron satisfaction, they
have directed all our hard work towards becoming one of the distinguished business
choices. As well to undertake all the activities of our enterprise, they have hired a
capable and enthusiastic workforce with us. Working in a synchronized manner, all our
experts are hired after stern examination of their knowledge.

Since our commencement in this industry, they are working beneath the supervision
and management of Rajesh Jain. His motivational nature and strong comprehending
abilities has assisted us completing bulk orders as per the provisions mentioned by
our customers.

PRODUCTS

1. Earth Moving Machine Parts

• Excavator Bucket Link

• Mounting Bracket

• Earthmoving Machine Parts

• Big Buckets

• Trenching Bucket

2. Jigs and Fixtures

• Welding Fixture
 • Machine Welding Fixture

• Work Holding Fixture

3. Turned and Machined Components

• Dampening Roller
 • Turned and Machined Pats

4. Fabrication Services
• Industrial Vessel Fabrication Service

• Axle Fabrication Service

5. Material Handling Equipments
• Material Handling Conveyor

• Multiple Coil C Hook

6. Automobile Parts
• Automobile Components
7. Pre-Engineering Building
PLANT LAYOUT
The plant is divided into 8 sections or areas, namely:

1. Raw Material Store

Raw material upon arrival is color coded

according to its composition for as cutting
operation may vary for different
materials.
After cutting of long bars of raw material
into smaller billets, it is sent for further
turning operations.

2. Manual Lathe Machine section

There are 8 manual lathes, 3 operational vertical drilling and a vertical tapping machine
in the machine area.
The manual lathes are of MacoPower Industries
weighing around 1800 kgs and a motor of 3HP. They
are equipped with a spindle speed range from 30
RPM to 500 RPM and having a maximum cross slide
length of 240 mm.

The vertical drilling machine are of Prakash Engitech

Pvt. Ltd. weighing around 1100 kgs with a 1.5 HP drill
motor with maximum RPM of 1225 and having a maximum drilling
radius of 990 mm and a spindle travel distance of 240 mm.
 The tapping machine from Prakash EngiTech Pvt. Ltd.
with a motor from Mitsubishi Electric having a
maximum RPM of 600 and a 360° universal head.

3. CNC Machine Section

There are 4 horizontal CNC lathes from Confidence Automation Pvt. Ltd.

The Jyoti DX 150 weighs around 300 kgs and 1950 mm in height and length. It has a
maximum turning length of 350 mm having an 8-station bi-directional servo turret with
a maximum bore diameter of 40 mm and it is laser calibrated for highly precise
positioning. Its spindle can reach a maximum of 4000 RPM.

The Jyoti DX 160 weighs around 3800 kgs and 2690 mm in length and 1485 mm in height.
It also has an 8-station bi-directional servo turret but with a less bore diameter of 32
mm but it has a greater turning length of 500 mm and a maximum spindle speed of
3500 RPM.

The Jyoti DX 200-5A weighs over 3400 kgs and 2350 mm in length and 1710 mm in
height. It also has an 8-station bi-directional servo turret with maximum bore diameter
of 40 mm while it has a maximum turning length of 500 mm. It has a maximum spindle
speed of 4000 RPM.

There is also a VMC Machine also from Confidence Automation Pvt. Ltd. The RX 20 is
capable of Tapping, Drilling and Face Milling with a table size of 1000 mm by 530 mm
 and a maximum table weight capacity of 400 kg. It has a 20-station turret capable of
changing a tool within 2.4 seconds. It has a maximum spindle speed of 6000 RPM.

4. Quality Control and Inspection

The tools used in the inspection were vernier calipers, micrometers, bore gauges,
height gauge and Go and No-Go gauges.

5. Jigs and Fixtures Store

6. Packaging and Finished Goods Section

7. Scrap Yard

8. Office

The whole factory is spread across an area of 5000 sq. ft. while the total machine and
raw material area make up about 3000 sq. ft. There are around 70 workers in total
working in day and night shifts and 12 supervisors and officers.Customers of the
company include:

• Cash New Holland Contruction Equipments India Pvt. Ltd.

• MetaMan India Pvt. Ltd.
• Automech India Pvt. Ltd.
• Sunil Auto Component Pvt. Ltd.
• Sureen Auto Pvt. Ltd.
• Gatiman Auto Pvt. Ltd.
 PRODUCTION DEPARTMENT
Production is the process of combining various material inputs and immaterial inputs
(plans, knowledge) in order to make something for consumption (output). It is the act
of creating an output, a good or service which has value and contributes to the utility of
individuals. The area of economics that focuses on production is referred to as
production theory, which is intertwined with the consumption (or consumer) theory of
economics.

Machining is a process in which a material (often metal) is cut to a desired final shape
and size by a controlled material-removal process. The processes that have this
common theme are collectively called subtractive manufacturing, which
utilizes machine tools, in contrast to additive manufacturing (3D printing), which uses
controlled addition of material.
Machining is a part of the manufacture of many metal products, but it can also be used
on other materials such as wood, plastic, ceramic, and composite material. A person
who specializes in machining is called a machinist. A room, building, or company
where machining is done is called a machine shop. Much of modern-day machining is
carried out by computer numerical control (CNC), in which computers are used to
control the movement and operation of the mills, lathes, and other cutting machines.
This increases efficiency, as the CNC machine runs unmanned therefore reducing
labour costs for machine shops.
Machines present in the factory on which our study was focused are as follows:

Lathe Machine is used in all the engineering applications and also in the college
Workshops. Lathe machine is used to perform all the basic operations such as drilling,
cutting, tapping, turning, etc. with the help of different tools placed in the work
environment.

Lathe Machine is a machine tool that uses a cutting tool for removing the material
from the surface of the workpiece which is held in the chuck for holding the workpiece
and feed was provided by the tool on to the workpiece for the removal of material. It is
the most versatile and widely used machine in industries, institutions, etc.

Parts of Lathe Machine:

The Parts of the lathe machine are as follows.

• Bed
• Lead Screw
• Guideways
• Prime mover
• Transmission system
• Headstock
• Spindle
• Chuck
• Feed Gearbox
• Thread Chasing Dial
• Split nut
• Carriage
• Slideways with saddle
• Compound rest
• Tool post
• Tailstock
• Quill
Lathe Machine Operations:

The operations which are performed on the lathe machine are called lathe operations
and are as follows.

1. Turning
2. Facing
3. Thread Cutting
4. Drilling
5. Boring
6. Counterboring
7. Countersinking
8. Reaming
9. Trepanning
10. Knurling

The detailed explanation of the above lathe operations was as follows.

Turning:

The process of removing material from the circumference of the workpiece is called
Turning Operation.

Step Turning Operation:

If the material is removed in terms of steps from the surface of the workpiece then it
is called a Step turning operation.

Taper Turning Operation:

The turning operation used for producing tapered components is called a taper turning
operation.

Facing or Face Turning Operation:

The turning operation used for reducing the length of the component by removing the
material from the face of the workpiece called a face turning operation.

Thread Cutting:

The turning operation used for producing the threads on the surface of components is
called as thread cutting operation.

Drilling Operation:

It is an operation used for producing holes in the components.

Boring Operation:

It is an inter turning operation used for enlarging the existing hole by some amount
called boring operation.

Counterboring Operation:

The Boring operation used for enlarging the end of the hole is called as counterboring.

Counter Sinking Operation:

Conical enlargement of an end of the hole is called a countersinking Operation.

Reaming:

Reaming is similar to drilling operation used for removing a small amount of material
for sizing and finishing of the hole to get exact dimensions.

The maximum size of the hole produced by using in stages method of drilling operation
is up to 50 mm only.

Trepanning Operation:

It is the operation of producing large size holes without drilling operation called the
Trepanning.

Knurling Operation:

It is a pattern of straight, crossed or angled lines on the surface of the tool which is
pressed against the workpiece such that it can forms an impression on the surface of
workpiece. The holding of the workpiece will be better by this operation.
Vertical Drilling Machine A drilling machine with a vertical arrangement of
spindles and a fixed centre position, referred to as a vertical drill. It is often used in
machinery manufacturing and repair factories to process holes for small and medium-
sized workpieces.

Vertical drilling machine, as a kind of drilling machine, is also a relatively common

metal cutting machine tool, which has the characteristics of wide application and high
precision. Suitable for batch processing.

The vertical drilling machine can feed automatically, and its power and mechanical
strength allow the use of higher cutting consumption. Therefore, the use of this drilling
machine can obtain higher labour productivity and higher processing accuracy. The
spindle speed of the vertical drilling machine, the feed rate has a relatively large range
of variation, which can be adapted to the processing of different material tools on
different material workpieces. And it can meet the needs of various processes such as
drilling, countersinking, reaming, tapping, etc. A set of multi-axis transmission heads
are installed on the vertical drilling machine, which can drill dozens of holes at a time
and can be used as a special machine tool for mass production.
Milling is the process of machining using rotary cutters to remove material by
advancing a cutter into a workpiece. This may be done by varying direction on one or
several axes, cutter head speed, and pressure. Milling covers a wide variety of
different operations and machines, on scales from small individual parts to large,
heavy-duty gang milling operations. It is one of the most commonly used processes for
machining custom parts to precise tolerances.

In the vertical milling machine, the spindle axis is vertically oriented. Milling
cutters are held in the spindle and rotate on its axis. The spindle can generally be
lowered (or the table can be raised, giving the same relative effect of bringing the
cutter closer or deeper into the work), allowing plunge cuts and drilling. The depth to
which blades cut into the work can be controlled with a micrometer adjustment nut.
There are two subcategories of vertical mills: the bed mill and the turret mill.

• A turret mill has a fixed spindle and the table is moved both perpendicular
and parallel to the spindle axis to accomplish cutting. Some turret mills have
a quill which allows the milling cutter (or a drill) to be raised and lowered in
a manner similar to a drill press. This provides two methods of cutting in the
vertical (Z) direction: by raising or lowering the quill, and by moving the
knee.
• In the bed mill, however, the table moves only perpendicular to the spindle's
axis, while the spindle itself moves parallel to its own axis.
Turret mills are generally considered by some to be more versatile of the two designs.
A third type also exists, a lighter, more versatile machine, called a mill-drill. The mill-
drill is a close relative of the vertical mill and quite popular in light industry; and with
hobbyists. A mill-drill is similar in basic configuration to a very heavy drill press, but
equipped with an X-Y table and a much larger column. They also typically use more
powerful motors than a comparably sized drill press, most are muti-speed belt driven
with some models having a geared head or electronic speed control. They generally
have quite heavy-duty spindle bearings to deal with the lateral loading on the spindle
that is created by a milling operation. A mill drill also typically raises and lowers the
entire head, including motor, often on a dovetailed (sometimes round with rack and
pinion) vertical column. A mill drill also has a large quill that is generally locked during
milling operations and released to facilitate drilling functions. Other differences that
separate a mill-drill from a drill press may be a fine-tuning adjustment for the Z-axis,
a more precise depth stop, the capability to lock the X, Y or Z axis, and often a system
of tilting the head or the entire vertical column and powerhead assembly to allow
angled cutting-drilling. Aside from size, the principal difference between these lighter
machines and larger vertical mills is that the X-Y table is at a fixed elevation; the Z-
axis is controlled by moving the head or quill down toward the X, Y table. A mill drill
typically has an internal taper fitting in the quill to take a collet chuck, face mills, or a
Jacobs chuck similar to the vertical mill.
Tapping may either be achieved by hand tapping by using a set of taps first tap,
second tap & final (finish) tap or using a machine to do the tapping, such as a lathe,
radial drilling machine, bench type drill machine, pillar type drill machine, vertical
milling machines, HMCs, VMCs. Machine tapping is a process to produce the female
threads inside the drilled hole. Machine tapping is faster and generally more accurate
because human error is eliminated. Final tapping is achieved with single tap.
Although in general machine tapping is more accurate, tapping operations have
traditionally been very tricky to execute due to frequent tap breakage and inconsistent
quality of tapping.

Machine tapping can be performed by electric drives and the problems concerned
with the machine tapping can be eliminated with the application of pneumatic tapping
machine.
Band Saw Machine
A band saw (also written bandsaw) is a machine with long tooth blade rotating on
wheel that cut material held by a table. It is one of the most common machine tools
found in cutting workshop and industry. Basically, the job of a band saw is to give
shape to material that has irregular appearance. The band saw shapes material by
sawing straight, round or cutting curve. Metal, wood, plastic and other materials are
cut by band saw. Depending upon the material there are different type of blades used
by band saw. The power to a band saw machine comes from electric motor. Many
kinds of band saw machines are used today. Each of them performs similar task but
has different characteristics for sawing different material.
CNC MACHINING
Computer Numerical Control (CNC) machining is a manufacturing process in which
pre-programmed computer software dictates the movement of factory tools and
machinery. The process can be used to control a range of complex machinery, from
grinders and lathes to mills and CNC routers. With CNC machining, three-dimensional
cutting tasks can be accomplished in a single set of prompts.

The CNC process runs in contrast to — and thereby supersedes — the limitations of
manual control, where live operators are needed to prompt and guide the commands
of machining tools via levers, buttons and wheels. To the onlooker, a CNC system
might resemble a regular set of computer components, but the software programs and
consoles employed in CNC machining distinguish it from all other forms of
computation.

When a CNC system is activated, the desired cuts are programmed into the software
and dictated to corresponding tools and machinery, which carry out the dimensional
tasks as specified, much like a robot.

In CNC programming, the code generator within the numerical system will often
assume mechanisms are flawless, despite the possibility of errors, which is greater
whenever a CNC machine is directed to cut in more than one direction simultaneously.
The placement of a tool in a numerical control system is outlined by a series of inputs
known as the part program.

With a numerical control machine, programs are inputted via punch cards. By contrast,
the programs for CNC machines are fed to computers through small keyboards. CNC
programming is retained in a computer’s memory. The code itself is written and edited
by programmers. Therefore, CNC systems offer far more expansive computational
capacity. Best of all, CNC systems are by no means static since newer prompts can be
added to pre-existing programs through revised code.

CNC Machine Programming

In CNC manufacturing, machines are operated via numerical control, wherein a

software program is designated to control an object. The language behind CNC
machining is alternately referred to as G-code, and it’s written to control the various
behaviours of a corresponding machine, such as the speed, feed rate and coordination.

Basically, CNC machining makes it possible to pre-program the speed and position of
machine tool functions and run them via software in repetitive, predictable cycles, all
with little involvement from human operators. In the CNC machining process, a 2D or
3D CAD drawing is conceived, which is then translated to computer code for the CNC
system to execute. After the program is inputted, the operator gives it a trial run to
ensure no mistakes are present in the coding.

Due to these capabilities, the process has been adopted across all corners of the
manufacturing sector, and CNC manufacturing is especially vital in the areas of metal
and plastic production. Find out more about the types of machining systems used and
how CNC machine programming fully automates CNC manufacturing below:

Open/Closed-Loop Machining Systems

During the CNC manufacturing process, position control is determined through an

open-loop or closed-loop system. With the former, the signaling runs in a single
direction between the CNC controller and motor. With a closed-loop system, the
controller is capable of receiving feedback, which makes error correction possible.
Thus, a closed-loop system can rectify irregularities in velocity and position.

In CNC machining, movement is usually directed across X and Y axes. The tool, in turn,
is positioned and guided via stepper or servo motors, which replicate exact
movements as determined by the G-code. If the force and speed are minimal, the
process can be run via open-loop control. For everything else, closed-loop control is
necessary to ensure the speed, consistency and accuracy required for industrial
applications, such as metalwork. In today’s CNC protocols, the production of parts via
pre-programmed software is mostly automated. The dimensions for a given part are
set into place with computer-aided design (CAD) software and then converted into an
actual finished product with computer-aided manufacturing (CAM) software.

Any given workpiece could necessitate a variety of machine tools, such as drills and
cutters. In order to accommodate these needs, many of today’s machines combine
several different functions into one cell.
Alternately, an installation might consist of several machines and a set of robotic
hands that transfer parts from one application to another, but with everything
controlled by the same program. Regardless of the setup, the CNC process allows for
consistency in parts production that would be difficult, if not impossible, to replicate
manually.

The Different Types of CNC Machines

The earliest numerical control machines date to the 1940s when motors were first
employed to control the movement of pre-existing tools. As technologies advanced,
the mechanisms were enhanced with analog computers, and ultimately with digital
computers, leading to the rise of CNC machining.

The vast majority of today’s CNC arsenals are completely electronic. Some of the more
common CNC-operated processes include ultrasonic welding, hole-punching and laser
cutting. The most frequently used machines in CNC systems include the following:

CNC Mills

CNC mills are capable of running on programs comprised of number- and letter-based
prompts that guide pieces across various distances. The programming employed for a
mill machine could be based on either G-code or some unique language developed by
a manufacturing team. Basic mills consist of a three-axis system (X, Y and Z), though
most newer mills can accommodate three additional axes.

Lathes

In lathe machines, pieces are cut in a circular direction with indexable tools. With CNC
technology, the cuts employed by lathes are carried out with precision and high
velocity. CNC lathes are used to produce complex designs that wouldn’t be possible on
manually run versions of the machine. Overall, the control functions of CNC-run mills
and lathes are similar. As with CNC mills, lathes can be directed by G-code or unique
proprietary code. However, most CNC lathes consist of two axes — X and Z.
Plasma Cutters

In a plasma cutter, a plasma torch cuts the material. The process is foremost applied
to metal materials but can also be employed on other surfaces. In order to produce the
speed and heat necessary to cut metal, plasma is generated through a combination of
compressed-air gas and electrical arcs.

Electric Discharge Machines

Electric-discharge machining (EDM) — alternately referred to as die sinking and spark

machining — is a process that moulds workpieces into particular shapes with
electrical sparks. With EDM, current discharges occur between two electrodes, and
this removes sections of a given workpiece.

When the space between the electrodes becomes smaller, the electric field becomes
more intense and thus stronger than the dielectric. This makes it possible for a current
to pass between the two electrodes. Consequently, portions of a workpiece are
removed by each electrode. Subtypes of EDM include:

• Wire EDM: Wire EDM uses spark erosion to remove portions from an
electronically conductive material.
• Sinker EDM: Sinker EDM utilizes an electrode and workpiece soaked in
dielectric fluid for the purpose of piece formation.

In a process known as flushing, debris from each finished workpiece is carried away
by a liquid dielectric, which appears once the current between the two electrodes has
stopped and is meant to eliminate any further electric charges.

Water Jet Cutters

In CNC machining, water jets are tools that cut hard materials, such as granite and
metal, with high-pressure applications of water. In some cases, the water is mixed
with sand or some other strong abrasive substance. Companies often shape factory
machine parts through this process. Water jets are employed as a cooler alternative
for materials that are unable to bear the heat-intensive processes of other CNC
machines.
Due to their cooler nature, several sectors like the aerospace and mining
industries rely on water jets, where they use them for carving and cutting, among
other functions. Companies also use water jet cutters for applications requiring very
intricate cuts in material, as the lack of heat prevents any change in the
material’s intrinsic properties that may result from metal-on-metal cutting.

Table 1 - M-Codes Commands Summary for Lathe Operations

M code* Description*
M00 Program stop
M01 Optional program stop
M02 End of program
M03 Spindle start forward CW
M04 Spindle start reverse CCW
M05 Spindle stop
M08 Coolant on
M09 Coolant off
M29 Rigid tap mode
M30 End of program reset
M40 Spindle gear at middle
M41 Low Gear Select
M42 High Gear Select
M68 Hydraulic chuck close
M69 Hydraulic chuck open
M78 Tailstock advancing
M79 Tailstock reversing
M94 Mirror image cancel
M95 Mirror image of X axis
M98 Subprogram call
M99 End of subprogram
Table 2 - M-Codes Command Summary for Milling Operations

M code* Description*
M00 Program stop
M01 Optional program stop
M02 End of program
M03 Spindle start forward CW
M04 Spindle start reverse CCW
M05 Spindle stop
M06 Tool change
M07 Coolant ON – Mist coolant/Coolant thru spindle
M08 Coolant ON – Flood coolant
M09 Coolant OFF
M19 Spindle orientation
M28 Return to origin
M29 Rigid tap
M30 End of program (Reset)
M41 Low gear select
M42 High gear select
M94 Cancel mirror image
M95 Mirror image of X axis
M96 Mirror image of Y axis
M98 Subprogram call
M99 End of subprogram
 Fanuc G-Code List (Lathe)
G code Description
G00 Rapid traverse
G01 Linear interpolation
G02 Circular interpolation CW
G03 Circular interpolation CCW
G04 Dwell
G09 Exact stop
G10 Programmable data input
G20 Input in inch
G21 Input in mm
G22 Stored stroke check function on
G23 Stored stroke check function off
G27 Reference position return check
G28 Return to reference position
G32 Thread cutting
G40 Tool nose radius compensation cancel
G41 Tool nose radius compensation left
G42 Tool nose radius compensation right
G70 Finish machining cycle
G71 Turning cycle
G72 Facing cycle
G73 Pattern repeating cycle
G74 Peck drilling cycle
G75 Grooving cycle
G76 Threading cycle
G92 Coordinate system setting or max. spindle speed setting
G94 Feed Per Minute
G95 Feed Per Revolution
G96 Constant surface speed control
G97 Constant surface speed control cancel
 Fanuc G-Code List (Mill)
G code Description
G00 Rapid traverse
G01 Linear interpolation
G02 Circular interpolation CW
G03 Circular interpolation CCW
G04 Dwell
G17 X Y plane selection
G18 Z X plane selection
G19 Y Z plane selection
G28 Return to reference position
G30 2nd, 3rd and 4th reference position return
G40 Cutter compensation cancel
G41 Cutter compensation left
G42 Cutter compensation right
G43 Tool length compensation + direction
G44 Tool length compensation – direction
G49 Tool length compensation cancel
G53 Machine coordinate system selection
G54 Workpiece coordinate system 1 selection
G55 Workpiece coordinate system 2 selection
G56 Workpiece coordinate system 3 selection
G57 Workpiece coordinate system 4 selection
G58 Workpiece coordinate system 5 selection
G59 Workpiece coordinate system 6 selection
G68 Coordinate rotation
G69 Coordinate rotation cancel
G73 Peck drilling cycle
G74 Left-spiral cutting circle
G76 Fine boring cycle
G80 Canned cycle cancel
G81 Drilling cycle, spot boring cycle
G82 Drilling cycle or counter boring cycle
G83 Peck drilling cycle
G84 Tapping cycle
G85 Boring cycle
G86 Boring cycle
G87 Back boring cycle
G88 Boring cycle
G89 Boring cycle
G90 Absolute command
G91 Increment command
G92 Setting for work coordinate system or clamp at maximum spindle speed
G98 Return to initial point in canned cycle
G99 Return to R point in canned cycle
CNC LATHE
A computer numerical control lathe is a machine that turns material around a central
spindle and stationary cutting tool. Your material’s movement is dictated by coded
instructions fed through a computer rather than operated with manual labour. Multiple
steps can be programmed at once, so your material doesn’t have to leave the lathe
between manufacturing, guaranteeing correct placement for cuts.
A simple CNC lathe operates on 2 axes and moves the material it is cutting with a
rotation. The material’s rotation is commonly called ‘turning’, so you may hear CNC
lathes being referred to as CNC turning machines. Lathe machines with more than 2
axes, perhaps with an additional Y-axis or sub-spindle, will likely be nicknamed a CNC
turning centre rather than a CNC turning machine.

The Benefits of a CNC Lathe

There are numerous benefits to investing in a computer numerical control lathe over a
manual lathe. Firstly, computer-operated lathes are incredibly precise since their
movement is managed by code. Extra precision means fewer mistakes, cheaper
operation, and less wasted material during the manufacturing process. Manual lathes
are subject to human error during their turning.

One operator can also manage multiple CNC lathes at a time, whereas manual lathes
require closer attention! While CNC lathes are a pricier investment initially, they prove
cheaper to run in terms of hiring staff for oversight. Manufacturing times are quicker,
with more CNC machines on the go at one time, and all products created are nearly
identical due to the reliability of computer numerical control.
CNC PROGRAMMING:

1. Pivot Pin

G98G95G71G64
M03S1000
T01D1
M16
M08
G96S200LIMS=800
G0X117.0Z5.0
G0Z3.0
G01X50.0F0.18
G0X117.0Z4.0
G0Z2.01
G01X50.0F0.18
G0X117.0Z3.0
G0Z1.0
G01X50.0F0.2
G0X117.0Z2.0
G0Z0.2
G01X50.0F0.2
G0X110.50Z2.0
G01X110.50Z-114.0F0.25
G0X117.0Z2.0M09
G75X0.0Z0.0
M01
M05
G97M03S1000
T01D1
M16
M08
G96S200LIMS=1800
G0X110.0Z2.0
G01Z0.0F0.2
G01X110.10Z-114.20F0.22
G0X117.0Z5.0M09
G0X107.0Z2.0
G01Z0.0F0.25
G01X110.0Z-1.60F0.25
G75X0.0Z0.0
M01
M05
G97M04S1000
T06D1
M16
M08
G96S180LIMS=1000
G0X58.50Z2.0
G0X59.950
G01Z-113.0F0.2
G0X55.0Z2.0M09
G75X0.0Z0.0
M05
M01
G97 M03S1800
T04D1
M16
M08
G96S180LIMS=1400
G0X63.0Z2.0
G01Z0.0F0.2
G01X60.50Z-1.50F0.1
G01X60.690Z-110.0F0.22
G01X60.350Z-113.0F0.25
G0X57.0Z2.0M09
G75X0.Z0.0
M05
M01
M00
G97M03S1000
T01D1
M16
M08
G96S200LIMS=1400
G0X110.01Z2.0
M03S600
G01X110.10Z-106.0F0.25
N800 G0X117.0Z5.0M09
G75X0.0Z0.0
M05
M01
G97M03S1000
T04D1
M16
M08
G96S220LIMS=1400
G01Z0.0F0.2
G01X60.50Z-1.50F0.1
G01X60.690Z-110.0F0.22
G01X60.350Z-113.0F0.25 FINAL OUTPUT
G0X57.0Z2.0M09
G75X0.Z0.0
M05
M30
VERTICAL MACHINING CENTER(VMC)
VMC machining refers to machining operations that utilize vertical machining centers
(VMCs), which, as the name suggests, have vertically oriented machine tools. These
machines are primarily utilized to turn raw blocks of metal, such as aluminium or
steel, into machined components. They can be used to perform a variety of machining
operations, including, but not limited to, the following: cutting, drilling, tapping,
countersinking, chamfering, carving, and engraving. This versatility, combined with
their relatively low cost, has made them a highly common machine shop tool.

Advantages of VMC Machining

Compared to horizontal machining centers, vertical machining centers offer a number

of advantages, such as:

• Simpler structure. The simple structure of VMCs makes it easy to clamp the
workpiece in the necessary position.
• Better cooling efficiency. Gravity works with the VMC design. Coolant sprayed at
the top of the machine tool and workpiece trickles down to cover the rest of the
target.
• Easier setup and operation. VMCs have a wide field of vision, enabling operators
to observe the operations and, if needed, make modifications to resolve any
issues.
• Smaller space requirements. The vertical design takes up less floor space than
a horizontal design.
• Higher accuracy. VMCs can produce complex shapes and structures with a high
degree of accuracy.

Applications of VMC Machining

Vertical machining centres can be used to manufacture parts and products for a wide
range of industries and applications. However, they are primarily used for high-
precision, high-accuracy, and mass-production projects, including those involving the
following machined components:

• Complex curved parts. Examples of parts with complex curves include cams,
impellers, and propellers. While these parts are difficult to manufacture with
precision and accuracy using conventional machining methods, a multi-axis
VMC with CNC technology can produce them easily and quickly.
• Special or irregularly shaped parts. Examples of parts with irregular or special
shapes include brackets and bases. These components often have highly
complex designs, which are hard to produce using other manufacturing
methods but easy to produce using VMCs with automatic machining capabilities.
• Military parts. The military industry is subjected to a variety of standards that
dictate how a part can be designed and built. The accuracy and precision of
VMCs ensure the machined components produced fully meet the necessary
application and industry specifications
 Inventory Control
Inventory Control is the supervision of supply, storage and accessibility of items in
order to ensure an adequate supply without excessive oversupply.
It can also be referred as internal control - an accounting procedure or system
designed to promote efficiency or assure the implementation of a policy or safeguard
assets or avoid fraud and error etc.

Inventory control may refer to:

• In economics, the inventory control problem, which aims to reduce overhead cost
without hurting sales
• In the field of loss prevention, systems designed to introduce technical barriers to
shoplifting

Applications
An inventory control system may be used to automate an order fulfillment process.
Such a system contains a list of orders to be received, and then prompts workers
to pick the necessary items, and provides them with packaging and shipping. An
inventory system also manages in and outwards material of hardware. Real-time
inventory control systems may use wired, mobile terminals to record inventory
transactions at the moment they occur. A wired LAN transmits the transaction
information to a mobile network. Physical inventory counting and cycle counting
are features of many inventory control systems which can enhance the
organization.

Business Inventory

Reasons for keeping stock

There are four basic reasons for keeping an inventory:

1. Time - The time lags present in the supply chain, from supplier to user at every
stage, requires that you maintain certain amounts of inventory to use in this
lead time. However, in practice, inventory is to be maintained for consumption
during 'variations in lead time'. Lead time itself can be addressed by ordering
that many days in advance.

2. Uncertainty - Inventories are maintained as buffers to meet uncertainties in

demand, supply and movements of goods.
 3. 3. Economies of scale - Ideal condition of "one unit at a time at a place where a
user needs it, when he needs it" principle tends to incur lots of costs in terms of
logistics. So bulk buying, movement and storing brings in economies of scale,
thus inventory.

4. 4. Appreciation in Value - In some situations, some stock gains the required

value when it is kept for some time to allow it reach the desired standard for
consumption, or for production. For example; beer in the brewing industry All
these stock reasons can apply to any owner or product

Purpose: Inventory proportionality is the goal of demand-driven inventory

management. The primary optimal outcome is to have the same number of days' (or
hours', etc.) worth of inventory on hand across all products so that the time of runout
of all products would be simultaneous. In such a case, there is no "excess inventory,"
that is, inventory that would be left over of another product when the first product runs
out. Excess inventory is sub-optimal because the money spent to obtain it could have
been utilized better elsewhere, i.e., to the product that just ran out.

The secondary goal of inventory proportionality is inventory minimization. By

integrating accurate demand forecasting with inventory management, rather than only
looking at past averages, a much more accurate and optimal outcome is expected.

Integrating demand forecasting into inventory management in this way also allows for
the prediction of the "can fit" point when inventory storage is limited on a per-product
basis.
 Quality System Employed in Industry: KAIZEN

What is Kaizen?

Kaizen is the practice of continuous improvement. Kaizen was originally introduced to

the West by Masaaki Imai in his book Kaizen: The Key to Japan’s Competitive Success
in 1986. Today kaizen is recognized worldwide as an important pillar of an
organization’s long-term competitive strategy.
Kaizen is continuous improvement that is based on certain guiding principles:
• Good processes bring good results
• Go see for yourself to grasp the current situation
• Speak with data, manage by facts
• Take action to contain and correct root causes of problems
• Work as a team
• Kaizen is everybody’s business
• And much more!

KAI = CHANGE

ZEN = GOOD

Kaizen = Continuous Improvement...By Everybody! Everyday! Everywhere!

Why Kaizen?

➢ To remain competitive, we need to change for better.

➢ We may become worse by not using our ability to think.
➢ Make our job simpler, safer and faster.
➢ Improves customer service and makes them happier.
➢ Improves productivity and quality.
➢ Helps achieve growth of the organization.
➢ To get satisfaction by seeing our idea being implemented.
➢ Work smarter, not harder.
 5S METHODOLOGY
Tools drawer at a 5S working place 5S is the name of a workplace
organization method that uses a list of five Japanese words: seiri,
seiton, seiso, seiketsu, and shitsuke. Transliterated or translated
into English, they all start with the letter "S".

The list describes how to organize a work space for efficiency and
effectiveness by identifying and storing the items used,
maintaining the area and items, and sustaining the new order. The
decision-making process usually comes from a dialogue about
standardization, which builds understanding among employees of
how they should do the work.

The 5 S's
o 1. Seiri (sort)
o 2. Seiton (straighten or streamline)
o 3. Seiso (shine)
o 4. Seiketsu (standardize)
o 5. Shitsuke (sustain)
Additional S's
o 2.1 Safety
o 2.2 Security

The Origins of 5S
The 5 S’s: There are five primary 5S phases: They can be translated from the Japanese
as Sort, Systematize, Shine, Standardize and Self-Discipline. Other translations are
possible.
1. Seiri (sort)
• Remove unnecessary items and dispose of them properly
• Make work easier by eliminating obstacles
• Reduce chance of being disturbed with unnecessary items
• Prevent accumulation of unnecessary items
• Evaluate necessary items with regard to dept/cost/other factors.
2. Seiton (straighten or streamline)
• Arrange all necessary items in order so they can be easily picked for use
• Prevent loss and waste of time • Make it easy to find and pick up
necessary items
• Ensure first-come-first-serve basis
• Make work flow smooth and easy • Can also be translated as "set in
order"
 3. Seiso (shine)
• Clean your workplace completely
• Use cleaning as inspection
• Prevent machinery and equipment deterioration • Keep workplace safe
and easy to work
• Can also be translated as "sweep"
4. Seiketsu (standardize)
• Maintain high standards of housekeeping and workplace organization at
all times
• Maintain cleanliness and orderliness • Maintain everything in order and
according to its standard.
5. Shitsuke (sustain)
• To keep in working order
• Also translates to "Self-Discipline" meaning to do without being told

Additional S's
Other phases are sometimes included e.g., safety, security, and satisfaction. These
however do not form a traditional set of "phases" as the additions of these extra steps
are simply to clarify the benefits of 5S and not a different or more inclusive
methodology.

Safety
The phase, "Safety", is sometimes added. There is debate over whether including this
sixth "S" promotes safety by stating this value explicitly, or if a comprehensive safety
program is undermined when it is relegated to a single item in an efficiency-focused
business methodology.

Security
The phase, "Security", can also be added. To leverage security as an investment rather
than an expense, the seventh "S" identifies and addresses risks to key business
categories including fixed assets (PP&E), material, human capital, brand equity,
intellectual property, information technology, assets-in-transit and the extended
supply chain. Techniques adapted from those detailed in Total security management
(TSM) or the business practice of developing and implementing comprehensive risk
management and security practices for a firm’s entire value chain.
 Conclusion
After the completion of internship, we enhanced competencies & competitiveness in

our respective area of specialization. We tried to relate the experience in the

workplace with knowledge learned in the institute & applied the knowledge on the job

under supervision.

Here, we gained the experience & knowledge that can be used for suitable job without

delay after studies.

We learned to hone soft skills appropriate to the work environment. Also get

improvised in communication skills. We assessed career ability, knowledge &

confidence as well as enhanced our marketability to be more competitive.

With experience, knowledge & skills acquired during industrial training we will be

better prepared to face working world.