Internship Final Report

BANSILAL RAMNATH AGARWAL CHARITABLE TRUST’S
VISHWAKARMA INSTITUTE OF TECHNOLOGY

(DEPARTMENT OF MECHANICAL ENGINEERING)
AN INTERNSHIP PROJECT REPORT
SUBMITTED BY
Aniket Nitin Devadkar

(G.R. NO. - 12010256, B.TECH. (MECHANICAL), DIV-A)
IN THE PARTIAL FULFILMENT OF THE DEGREE OF

‘BACHELOR OF TECHNOLOGY’
(MECHANICAL ENGINEERING)
OF
VISHWAKARMA INSTITUTE OF TECHNOLOGY, PUNE

(AN AUTONOMOUS INSTITUTE AFFILIATED TO THE UNIVERSITY OF
PUNE) UNDER THE GUIDANCE OF
PROF. Ramakrishna Bharsakde,
AND MR. Mahesh Takey

ACADEMIC YEAR 2023 – 2024 (SEMESTER I)
Bansilal Ramnath Agarwal Charitable Trust’s
Vishwakarma Institute of Technology

(Department of Mechanical Engineering)
Certificate
This is to certify that the dissertation work carried out by ANIKET DEVADKAR (G.R.
Number - 12010256, B.Tech. (Mech Engg) is an original work done by the student in partial
fulfillment of the requirements for the degree of Bachelor of Technology in Mechanical
Engineering, under my guidance and supervision during the academic year 2023 – 24,
semester I.
Place: Pune
Mr. Mahesh Takay Prof. Ramkrishna Bharsakde
Company Guide, College Guide,
CAD AND CART, Pune Mechanical Engineering Department
Prof Dr. Dattatray Hulwan.
Examiner, Head,
Mechanical Engineering Department Mechanical Engineering Department

Acknowledgement
I hereby take the opportunity to express my profound gratitude towards all those who were
instrumental in the successful completion of my project at Cad and Cart (Spire3d
Technologies PVT LTD).
I would like to whole-heartedly thank our project guide, Mr. Mahesh Takey for his constant
guidance and motivation. In addition, I would like to thank all the people at Spire 3D, who
have helped me develop as a professional.
It would not have been possible without the kind support and help of many individuals and
organizations. I would like to extend my sincere thanks to all of them. I am highly indebted to
Prof. Ramakrishna Bharsakde for his guidance and constant supervision as well as for
providing necessary information regarding the project & also for his support in completing the
project. I would also like to thank the HOD of the Mechanical Engineering Department Prof.
Dr. Dattatray Hulwan.
I would also like to express our gratitude towards my parents & members of VIT Pune for
their kind cooperation and encouragement which helped me in the completion of this project.
Vishwakarma Institute of Technology, Affiliated to Savitribai Phule Pune University, Department of Mechanical Engineering.
Project Report 2|Page

Internship offer letter
Vishwakarma Institute of Technology, Affiliated to Savitribai Phule Pune University, Department of Mechanical Engineering.
Project Report 3|Page

INDEX
INDEX............................................................................................................. 4
LIST OF FIGURES.........................................................................................5
COMPANY PROFILE....................................................................................8
MANUFACTURING COST...........................................................................9
ACCORDING TO TYPES…...............................................................10
NEW SOFTWERE INTRODUCTION..........................................................12
PROJECT 1.....................................................................................................18
1.1 Objective…................................................................................19
1.2 Theory........................................................................................19
1.3 Methodology..............................................................................20
1.4 Conclusion.................................................................................22
PROJECT 2.....................................................................................................23
2.1 Objective….................................................................................24
2.2 Methodology...............................................................................25
2.3 Final product after manufacturing..............................................29
2.4 Conclusion..................................................................................30
PROJECT 3......................................................................................................31
3.1 Introduction.................................................................................32
3.2 Methodology...............................................................................33
3.3 Final product after manufacturing..............................................40
3.4 Conclusion..................................................................................40
PROJECT 4.....................................................................................................41
4.1 Introduction................................................................................42
4.2 Methodology..............................................................................43
Vishwakarma Institute of Technology, Affiliated to Savitribai Phule Pune University, Department of Mechanical
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LIST OF FIGURES
Figure 1 : Cad and cart.com.................................................................8

Figure 2 : On Demand Manufacturing.................................................9
Figure 3 : Additive Manufacturing Process.........................................11
Figure 4 : Subtractive Manufacturing Process.....................................12
Figure 5 : General structure of NC system...........................................13
Figure 6 : Stock Model.........................................................................16
Figure 7: Model After Completion of toolpath...................................16
Figure 1.1 : Unitron UE22 Plus...............................................................19
Figure 1.2 : Wind Mill Blade Selection...................................................20
Figure 1.3 : Structure...............................................................................20
Figure 1.4 : Knuckle................................................................................21
Figure 1.5 : Circular Hub........................................................................21
Figure 1.6 : Circulat Plate Holding 9 Blades...........................................21
Figure 1.7 : DXF For Laser Cutting........................................................21
Figure 1.8 : For Drilling..........................................................................21
Figure 1.9 : Hub Drawing for Lathe........................................................22
Figure 1.10 : Drawing for milling.............................................................22
Figure 2.1 : Fuel Tank setup...................................................................24
Figure 2.2 : LOX Tank Size....................................................................25
Figure 2.3 : RP Tank Size........................................................................25
Figure 2.4 : Difference Between Seamless and welded pipe...................26
Figure 2.5 : RP Flange Design Change....................................................26
Figure 2.6 : LOX tank Raw Materila Sheet..............................................27
Figure 2.7 : LOX Tank Tank Manufaacturing Process Sheet...................27
Figure 2.8 : LOX Flange...........................................................................28
Figure 2.9 : Side Holders...........................................................................28
Figure 2.10 : Final Design Check Sheet......................................................28
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Figure 2.11 : During Manufacturing..........................................................29
Figure 2.12 : Assembly of Tank and Plumbing Flanges............................29
Figure 3.1 : Total Assembly of Fuel Injector...........................................32
Figure 3.2 : Fuel Flow Direction..............................................................33
Figure 3.3 : Divided assemblies in Exploded View.................................33
Figure 3.4 : Groove Dimensions..............................................................34
Figure 3.5 : Most Important Tollerance...................................................34
Figure 3.6 : For 14 Slots Rotating 7 Times..............................................35
Figure 3.7 : For 9 Slots Rotating 9 Times................................................36
Figure 3.8 : EDM Drilling and Indexing Fixture Used............................36
Figure 3.9 : Material Dimension Sheet.....................................................37
Figure 3.10 : RP injector Detailed Drawing...............................................38
Figure 3.11 : LOX Injector Detailed Drawing...........................................38
Figure 3.12 : BOM For Assembly..............................................................39
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LIST OF ABBREVATIONS:
OD Outer Diameter
ID Internal Diameter
EDM Electric Discharge Machine
VMC Vertical Machining Center
HMC Horizontal Machining Center
R Roughness
NOs Number
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About the Company
Cad and Cart (Spire3d Technologies PVT LTD) is a Pune-based start-up company
working in the field of industrial machining and process automation. The company
aims to establish its trademark in the field of manufacturing by optimizing the overall
manufacturing process right from providing an instant quotation to delivering the final
product on time by managing the logistics and manufacturing the product through a
trusted vendor. The founder of the company, Mr. Mahesh Takey is himself a
Vishwakarma Institute of Technology mechanical engineering alumnus who in his
college days not only led the Baja team of VIT, Pune but also learned various
manufacturing processes like welding and CNC programming all by himself
developing an interest in the machining industry.
Fig. 1 Cad and cart.com
As of today, the company is mainly working and researching in four domains, each of
which focuses on providing a unique platform and opportunity to the customers
according to their requirements. Designing as a Service (DAS) sector focuses on
helping new start-ups and new companies with an option to create a mechanical design
on a contract basis. Design Manufacture Sell (DMS) is an e-commerce platform for
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start-ups
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and small businesses to grow and help them put their products in the online
marketplace and reach out to customers. PMAS is a service-based platform through
which the company contracts with other companies to make their project plans and
work on their drawings and CAD parts for optimization and cost planning before
manufacturing it. Lastly, On Demand Manufacturing (ODM) is a sector that focuses on
providing customers the flexibility to get their components manufactured at the best
market price possible.
ODM sector of the Spire3D promises their customers to provide perfect and guaranteed
machining in time. The first phase of the ODM involves providing customers with an
instant quotation using the raw CAD model of the component and other basic
necessary information, including the raw material specifications and the expected type
of machining. Once the guaranteed quote is generated, the company takes care of the
ordering, inventory management, and sourcing for all the parts needed for the
Customer Order. The company then handles all order logistics and communications,
making sure that the order arrives on time. The company also accepts the customer's
inbound shipment of other items and manages that inventory.
Fig. 2 On Demand Manufacturing.
As a part of the first phase of ODM, the company is working on developing an accurate
method for calculating the minimum time required for various manufacturing processes
to give their customers a real and practical cost estimate to work with. One such
manufacturing process is the CNC and VMC machining, the cost of which requires a
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lot
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of research and calculations.
Responsibilities at Cad and Cart as Project Intern

 Understanding various manufacturing processes and their cost calculation
methods.
 Designing and analysis if needed. Understanding design and
selecting manufacturing process sheets.
 Project Management.
 Preparing production drawings with all details considering the
manufacturing process.
 Preparing Dimensions check sheets for project analysis.
 Collecting the standard material availability data for creating the dataset for the
back end of the website.
 Collecting information about the different manufacturing processes and standard
machines used.
 Collecting the specifications of those machines for the website.
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Manufacturing Costs
Manufacturing cost calculation is more of an art than a science as the cost of various
manufacturing processes varies from vendor to vendor for the same product. Hence, it
becomes very important to find a method to the madness and try to chalk out how machining
costs are calculated so we can move towards generalizing the costing characteristics of the
machining processes. To understand the costing Manufacturing Process can be broadly
divided into two categories - Additive and Subtractive Manufacturing.
Types of Manufacturing
Additive Manufacturing
Additive manufacturing is the process of creating an object by building it one layer at a time.
The work floor is empty at first and then layer by layer decomposition of material part is created.
Technically, additive manufacturing can refer to any process where a product is created by
building something up, such as molding, but it typically refers to 3-D printing.
Fig. 3 Additive Manufacturing Process.
Manufacturing Cost in Additive Manufacturing
For Additive Manufacturing the cost depends on the material that is deposited by the machine.
The volume of the part is generally obtained from the cad model. This volume is then
multiplied by the density of the material used for manufacturing cost. This weight is then
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multiplied by an
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appropriate factor to get the cost of manufacturing. In the case of injection model or sand
moulding the cost of making the mould is also added to the initial cost to give the final costing
of the process.
Subtractive Manufacturing Process
Subtractive manufacturing or subtractive fabrication involves cutting away from a solid block
of material. It could be a block of, for example, metal, plastic, or wood. A milling machine
cutting/hollowing out a piece of metal or plastic is an example of subtractive manufacturing.
Subtractive manufacturing by manually cutting the material is also possible. Examples of
subtractive manufacturing processes are laser cutting, water jet cutting, CNC machining, etc.
Fig. 4 Subtractive Manufacturing Process
Cost Calculation in Subtractive Manufacturing
In subtractive manufacturing processes, the costing pattern is different according to

whether the manufacturing process is a 2D process or a 3D process.
2D machining processes
In this type of machining process, the tool moves only on a plane is the motion is only
along the x and y axis. For this type of process, the perimeter of the part is calculated.
Other major factors that affect the cost are the thickness of the plate, the starting point and
the cutting length. Using these factors, a general formula is derived which is then used for
the calculation of machining cost.
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3D machining processes
In this type of machining process, the tool moves in x, y and z direction as well hence the
machining is also done in the direction of depth. For calculating the machining cost of this
type of process, first, standard software is chosen, like WorkNC and on it, the step file of
the part is uploaded. Using various rough and fine cuts the machining time of the part is
then estimated. This machining time is then multiplied by a certain factor to give the
machining cost. The material cost can also be added to this cost if the vendor provides
end- to-end solutions.
New software Introduction:
Fig.5 General structure of NC system.
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Geometric Modelling:
● Geometric Modelling describes the shape of an object.
● Commonly used methods are surface modelling and solid modelling.
● In surface modelling, an object is represented with a set of surface patches. The most
popular surface patches are planes, ruled surfaces, paraboloid, bicubic surfaces, B-
spline surfaces, Non-uniform Rational B-spline (NURB) surfaces, Coons surfaces, etc.
● In solid modelling, an object surface is generally described with either a boundary

representation (B-rep) or by constructive solid geometry (CSG).
● In B-rep, an object is represented by a set of vertices, edges, and faces. In CSG, the
object is constructed from primitives of closed surfaces (such as spheres, cubes, prisms
and cones) with set theory and Euler operators.
● Different surface representations result in different approaches to tool path generation.
Surface Analysis:
● Surface Analysis investigates the intrinsic shape and properties of an object surface,
such as surface curvature and continuity.
● These features are commonly visualized with the aid of a colour raster device based on
a color-coded map.
Heuristic Planning:
● Heuristic Planning defines preliminary parameters and operation sequences based on
surface analysis and machining requirements.
● For instance, it determines the shape and size of tools to be used, and the number of
roughing and finishing processes.
Tool Path Generation and Simulation/Verification:

● It is the core of the new approach. The goal is to generate “error-free” tool paths.
● Here “error-free” means that the generated tool paths guarantee that the machined
surface is within the predefined tolerance. Geometric simulation and verification can be
used to detect errors in tool paths.
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● Because of the risk of human error, tool paths should be simulated, verified and
corrected before actual machining.
The Mechanistic Model of Cutting:
● They are the models of the interaction between the cutting tool and the workpiece.
● Machining efficiency and surface quality depend on factors such as the spindle speed,
federate, tool deflection, tool wear, etc.
Comparison:
● It determines the differences between the design surface and the machined surface.
● An NC program is acceptable whenever the overall error of the machined surface is

within the predefined tolerance.
Visual Output Display:

● It provides graphic descriptions of the designed and machined surfaces, machining
errors, tool paths, etc.
● These features are very helpful to NC programmers.
Machining Cost:
● It is critical for a commercial NC system.
● The cost is directly proportional to the machining time.
Post Processor:
● It creates the NC instruction for an individual type of CNC milling machine and
downloads it to the machine to produce workpieces.
WORKNC CAM software is the premier automatic CNC software for surface or solid
models in mould, die, and tooling businesses for 2 to 5-axis CNC programming.
WORKNC is used by all Western, Japanese, and Korean automotive makers and well-
known OEMs from a range of other industries.
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Figure 6 Stock Model
The Software was used to study and determine conventional machining time for
components. The software determines the optimal toolpath and using that it generates the
machining time.
Fig. 7 Model after completion of toolpath
Figure 4 shows the stock model that will be used for machining it is created using the extreme
dimensions of the part in the form of a rectangular block. Figure 5 shows the model after
completion of the toolpath. The yellow lines indicate the toolpaths and also indicate where the
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machining operation is carried out. After execution of the toolpath, the final machined part
can
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be seen on the software.
Calculating Machining Time

Initially, the model is uploaded to the software in the form of a step file. Then a bounding box
is created to get the extreme dimensions of our model. Then we select the NC machine that we
want to use and the material we would be using for our part. Then a rough-cut toolpath is
selected for the machining process and a finishing toolpath is also added. After execution of
the tool path and machining time are generated.
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PROJECT 1
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1. Design and Development of test rig:
Objectives-
● To Design a test rig to hold blades and other components like a generator, flywheel,
and E-CVT.
● To prepare so that it will withstand load and can perform all the required tests.
● To Design a fully functioning E-CVT with all electronics parts ready.
● To design a Flywheel for respective power output.
● To design a belt pulley system.
Theory-
● This project includes quite a new idea of using CVT in windmills instead of
traditional gearboxes.
● The main idea behind using CVT and flywheel is that windmills should
generate power even at low wind speeds.
● Also new blades called UNITRON –UE22plus are used to increase efficiency.
Fig. 1.1 UNITRON –UE22plus.
● A single test rig contains a set of 3 such types of blades together which are
connected to the E-CVT via a Belt and pulley system.
● The actuation of CVT is done with the help of a servo motor and Arduino.
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Fig. 1.2 Windmill blade selection
Phase one- Designing and Analyzing:
● Designing a structure that will hold the total upper structure with blades and other
components such as E-CVT, Flywheel, and generator.
● It is taken care that two sets of rotors must fit in between two ends and should
withstand force due to their weight. (75 mm X 75 mm BOX pipes are chosen.)
Fig. 1.3 Structure.
● Ensuring mechanical strength of crucial components.

The main force acting on the hub and the circular knuckle is the self-weight of the
rotors (20 kg each) as these are the parts of the wind turbine, more factor of safety
used. The reason is we need more life of parts with less maintenance.
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Fig. 1.4. Knuckle Fig. 1.5 Circular Hub
Fig. 1.6 Circular plate holding 9 blades.
Phase Two - Making Production Drawings:
● Production Drawings are as per the manufacturing process. like if parts are going to
be manufactured by the laser cut / Water jet process the vendor requires the .DXF file
with a scale of 1:1 is compulsory. For example, below sheet is of size 1550 mm X 480
mm so need to create a custom sheet.
Fig. 1.7 DXF file for laser cutting. Fig. 1.8 For drilling.
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● But for the same sheet size, making it by laser cutting rather than cutting it and then
drilling holes on the M1TR machine takes less cost and mainly less time.
● For parts to be manufactured by the lathe process all diameter dimensions with width
should be given. The same goes for the milling manufacturing process.
Fig. 1.9 HUB Drawings for lathe. Fig. 1.10 Drawing for milling.
Conclusion-
● I was able to learn/ improve my command over software like Solidworks and
Ansys since this task was allotted to me at the start of my internship.
● It gave me a chance to interact with different people, for ask about the
checkpoints that they follow.
● Learned the importance of GD&T.
● It improved my visualization and inspection power while checking the parts.
● This project helped me to know about how manufacturing happens in industry.
● Learned about the different manufacturing processes in-depth.
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PROJECT 2
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2. Manufacturing of cylindrical fuel tank:
Objectives:
● To make changes in design which will result in ease of manufacturing.
● To make Material procurement sheets as per requirements.
● To make a manufacturing process flow sheet for tracking the project.
● To make Production Drawings.
● To make Dimension Check sheet after manufacturing of parts.
Introduction-
● This project is of EtherealX company, this company is a space research startup

company based in Bangalore.
● They have their design ready and need manufacturing assistance from our
company. the parts mainly consist of two cylindrical tanks, their tank stands, some
plumbing lines to connect, and a big stand on which the whole tank assembly is
to be set up.
Fig. 2.1 Fuel Tank setup.
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Phase One- Design Changes:
● Main concern is about the cylinders because of their sizes.
Fig 2.2 LOX Tank size.
Fig 2.3 RP Tank size.
● The first manufacturing process that comes into mind after considering the size is
rolling the 25 mm sheet circularly and then welding, The Second manufacturing
process is taking OEM pipe of standard sizes near the required diameter and using
the Turning operation to get the required size.
● Manufacturing by the rolling operation is cost-effective as compared to the turning
operation, but taking into consideration the strength factor, manufacturing by
turning operation is a good choice.
● But considering the pressure inside the cylinders (up to 100 Bars) and requirements
we decided to go with the turning operation.
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Fig. 2.4 Difference between seamless and welded pipe.
● Each tank has a flange which is a lid that closes from the top, it has two Holders,
which are there for lifting purposes. Initially, these two holders and flange are to be
manufactured from a single plate but it adds up to more material cost, Extra
machining, more wastage of raw materials more time, and more money.
● So instead of manufacturing it from a single block flange is made up of a separate
block and just two holders were made from the small materials and both of them are
welded together at the end.
Fig 2.5 RP Flane design change.
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Phase Two- Finalizing Manufacturing Process with Production Drawings and
Material Procurement:
Raw material is SS 304 for all parts except the tank stand has MS. Extra 5 mm tolerances
are given for all raw materials.
Fig 2.6 LOX Tank raw material sheet.
Fig 2.7 LOX Tank Manufacturing track sheet.
● Most parts were done on the lathe machine only, with 24mm ID holes on the
periphery. but for accuracy purposes, the holes were manufactured using VMC
machining.
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Fig 2.8 LOX Flange. Fig 2.9 Side Holders
Final Phase: Dimension Check Sheet -

● The important dimensions were marked which were to be checked after manufacturing.
● This also helped how precise the manufacturing was done.
● After manufacturing the dimension check should be done with the help of a CMM
machine.
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Fig. 2.10 Final Dimension check sheet
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Final Product after manufacturing -
Fig. 2.11 During manufacturing
Fig. 2.12 Assembly of tank and plumbing line flange.
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Conclusion-
● This project helped me to gain knowledge about the different types of

manufacturing processes, especially for large parts.
● I learned to prepare the production drawing as per industry standards.
● I learned how to develop innovative ideas when a particular problem is given.
● I also developed the quality of facing challenges and improving upon them.
● This project proved to be highly beneficial for the company
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PROJECT 3
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3. Manufacturing of Fuel Injectors:
Introduction -
● For the same company EtherealX these parts were to be manufactured. total of 5
sets were manufactured.
Fig. 3.1 Total assembly of fuel injector.
● LOX article (Blue colored part shown in the above figure) injects the primary
fluid (Shown in green colored below image) through the slots and the holes, RP
article (Black colored part shown in the above figure) injects the secondary
fluids (Red colored in below image) with the help of the gap of 0.95 mm
between the two articles.
● These injectors are to be made for prototyping; this part will be connecting to
the total fuel tank assembly of previous project, with help of flanges. And has
total width of 280 mm by 232.19 mm
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Fig 3.2 Fuel flow directions
Phase one - Understanding the design (Simplifying it for manufacturing ease)-
● Two main parts of the injector are lox and RP. LOX injector part has slot
patterns and tapered holes at the bottom from where fuel is going to be
injected.
● As the whole project was a prototype, all 5 injectors differ in no. of slots and
outer diameter by just 0.1 mm.
● The parts are first divided into further parts for ease of manufacture and cost
savings.
Fig. 3.3 Divided assemblies in exploded views.

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● As all the parts are circular so manufacturing method is chosen as lathe, but during
the manufacturing process the parts are to be made with the SS304 material which
is strong is almost impossible to manufacture the groove using a lathe one reason is
the material another reason being the shape of the groove. Due to taper angle tool
was braking every time.
Fig. 3.4 Groove dimension.
● So, for manufacturing the groove the VMC machine is used. Due to problems in the
lathe operations. which has increased the cost and due to the problem of the groove the
timeline got delayed by 2 days, but we recovered the 2 days during the welding and
final assembly process.
● After these important tolerances were noted and the important details also.
Fig. 3.5 Most important tolerance.

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● The gap is 0.95 mm which is the most important tolerance to be considered during
manufacturing. it is basically for the secondary fluid.
● The main slots were manufactured using EDM wire-cut due to their small dimensions.
● For that firstly a small hole of 0.6 mm diameter is created using an EDM Drill to pass
the wire for slot cutting but if observed slots are at a particular angle to rotate the body
indexing tool is required.
● There are 5 injectors, injectors with an even number of slots were easy to manufacture
for example to make the holes for 14 slots we just have to make 7 concentric holes on
opposite ends of the cylinder.
● But the injectors with odd number of slots are tricky cause we have to make that
number of holes with particular angles in between them for example for 9 and 13 slot
injectors total of 9 and 13 holes were created by rotating 9 and 13 times respectively.
● Considering the above points indexing fixture is designed for 13 13-slot injectors, a
fixture with 13 faces was designed for each face to resemble the 13 holes to
manufacture.
● The next two figures explain how the manufacturing is done for both of the injectors.
Fig 3.6 For 14 slots rotating 7 times
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Fig. 3.7 for 9 slots rotating 9 times
Fig. 3.8 EDM Drilling and the indexing fixture used.

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● The LOX articles follow 1.5-inch BSP threading, while the RP-1 articles use 1-inch
BSP threading. It's essential that the inner walls of these articles have a surface finish
of 0.8 Ra.
Phase Two - Material Dimensions Sheet and Production Drawings -

● After finalizing the manufacturing process and understanding design details the
material dimensions sheets were prepared.
Fig. 3.9 Material dimensions sheet
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● Production drawings were prepared with all details included.
Fig. 3.10 RP injector Drawing.
w
Fig. 3.11 LOX injector injector detailed drawings.
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● Final BOM which will help in assembly and the component details.
Fig. 3.12 BOM for assembly.
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Phase Three - Final Product after manufacturing:
Fig. 3.13 Final product after assembly and welding.
Conclusion-
● This project helped me to gain knowledge about the different types of

manufacturing processes. especially the EDM process which is novel to me.
● Got good knowledge about the different problems that may arise during
manufacturing and how to tackle them and follow your timeline.
● Learned how to handle the project.
● Got an idea about the designing parts that are to be manufactured by welding
(because the tolerance changes due to welding heat contraction and expansion).
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PROJECT 4
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4. Manual preparation for Instant quote website:(On going)
Introduction:
The company is working on a new feature in the website the “: INSTANT QUOTE”
which will allow users to upload a CAD file of whichever part they want to
manufacture and instantly it will provide them with the quotation according to the
manufacturing process they chose.
So, to ease of customer, I was given the task of preparing the manual for every type of
machining process which will help the user to use the page properly.
Objective:
● To collect data about the machining process.
● Types of material that should be used for machining.
● To-do list preparation.
● Different types of operations that can be performed using that machining process.
● Tolerance for that machining process.
Phase one: Machining process explained-
● The first step is to include about machining process. This step includes the basic
information about the machining process and its types different new features etc
● For an example of CNC Milling, add the types of CNC milling
Fig. 4.1 Types of milling according to cutting plane.

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Fig 4.2 Types of milling according to axis.
● The next step is to add the material that should be used.

● After those tolerances that van achieved by that machining process for example CNC
turning
Fig 4.3 Tolerances for CNC turning.
● Next step is to add the different types of machines and their specifications cause the
charges differ according to the machines also.
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BANSILAL RAMNATH AGARWAL CHARITABLE TRUST’S

VISHWAKARMA INSTITUTE OF TECHNOLOGY

AN INTERNSHIP PROJECT REPORT

Aniket Nitin Devadkar

IN THE PARTIAL FULFILMENT OF THE DEGREE OF

VISHWAKARMA INSTITUTE OF TECHNOLOGY, PUNE

PUNE) UNDER THE GUIDANCE OF

PROF. Ramakrishna Bharsakde,

AND MR. Mahesh Takey

Vishwakarma Institute of Technology

Mr. Mahesh Takay Prof. Ramkrishna Bharsakde

Company Guide, College Guide,

CAD AND CART, Pune Mechanical Engineering Department

Prof Dr. Dattatray Hulwan.

Mechanical Engineering Department Mechanical Engineering Department

Project Report 2|Page

Project Report 3|Page

Figure 1 : Cad and cart.com.................................................................8

Fig. 1 Cad and cart.com

Fig. 2 On Demand Manufacturing.

Responsibilities at Cad and Cart as Project Intern

Fig. 3 Additive Manufacturing Process.

Manufacturing Cost in Additive Manufacturing

Subtractive Manufacturing Process

Fig. 4 Subtractive Manufacturing Process

Cost Calculation in Subtractive Manufacturing

In subtractive manufacturing processes, the costing pattern is different according to

New software Introduction:

Fig.5 General structure of NC system.

● Commonly used methods are surface modelling and solid modelling.

● In solid modelling, an object surface is generally described with either a boundary

● Different surface representations result in different approaches to tool path generation.

Tool Path Generation and Simulation/Verification:

The Mechanistic Model of Cutting:

● An NC program is acceptable whenever the overall error of the machined surface is

Visual Output Display:

● These features are very helpful to NC programmers.

● It is critical for a commercial NC system.

● The cost is directly proportional to the machining time.

Fig. 7 Model after completion of toolpath

Calculating Machining Time

Fig. 1.1 UNITRON –UE22plus.

Phase one- Designing and Analyzing:

Fig. 1.3 Structure.

● Ensuring mechanical strength of crucial components.

Fig. 1.6 Circular plate holding 9 blades.

Phase Two - Making Production Drawings:

● This project is of EtherealX company, this company is a space research startup

Fig. 2.1 Fuel Tank setup.

● Main concern is about the cylinders because of their sizes.

Fig 2.2 LOX Tank size.

Fig 2.3 RP Tank size.

Fig 2.5 RP Flane design change.

Fig 2.6 LOX Tank raw material sheet.

Fig 2.7 LOX Tank Manufacturing track sheet.

Final Phase: Dimension Check Sheet -

Fig. 2.11 During manufacturing

Fig. 2.12 Assembly of tank and plumbing line flange.

● This project helped me to gain knowledge about the different types of