Jyoti cnc project report

jyoti cnc automation pvt. ltd. rajkot.
report for those who completed techanical tranning in jyoti. for B.E. , B.Tech , M.Tech , M.E. & M.S. student.

1. REPORT ON INDURISTAL TRANNING
HELD AT
JYOTI CNC AUTOMATION PVT.LTD.
RAJKOT.

2. INDEX


I. Preface
II. Acknowledgment
III. declaration



1. Introduction
2. General information
2.11 Portfolio
2.12 Brief History & Development
2.13 Size of Unit
2.14 Organizational Structure
3. Foundry
4. Machining
5. Assembly

4. PREFACE


Practical training is also very important aspect in technical course. There is so many times vast
differences between theoretical knowledge and actual practical implication.


Thus practical training helps individuals of know he actual uses and impaction of what he has
gained from theoretical knowledge. The theoretical knowledge and classroom discussion is not
enough for a technical student now, for the knowledge of practical viewpoints, problems,
opportunities and situation of industrial units practical studies is necessary.


So as the students of 6
th
sem. B.TechWe also a get a valuable opportunities to learn the
practically of the theories, which learn.


We have tried to collect all the necessary information and had tried to prepare this report
with the best ofour knowledge and ability.

5. ACKNOWLEDGMENT


The visit/training industry is a part of our study as implied by Rajasthan
TechnicalUniversity.

We are heartilygrateful to all the executives of JYOTI CNC AUTOMATION PVT. LTD. for
developing their valuable time and providing usnecessary information regarding company and its
management.

Our special thanks to Mr. VINCENT DABHI who have made a great effort for making the
training program smooth and easy going.

We must also convey our special thanks to the sir and the director for giving us this wider
horizon of sphere of knowledge and finding time for reading and commenting a portion of the
manuscript.

THANK YOU.

6. DICLARATION

We the undersigned, DADHANIA MANTHAN , the students of S.S. COLLEGE OF
ENGINEERING hereby declare that this report is our own work carried out under supervision
and guidance of managers.

This report has not submitted to any university or institute for examination by any one.



DATE:-……………………….
PLACE:-……………………..


Sign of student,

…………………………
(DADHANIA MANTHAN )

7. INTRODUCTION

Jyoti is the brainchild of legendary Mr. P.G. Jadeja & Mr. S.L. Jadeja. Establish in 1989.
Driven by the vision to build the company “A temple of technology “throughteamwork, the
company has grown manifold from manufacturing gear boxes for machines. Later on jyoti has
rightly identified sift from conventional machines to highly sophisticated cnc machines in the
presence of manufactures.

Jyoti was the first company to manufacturing cnc machines in the Gujarat. It was not an end.
There are many first attached with jyoti since then jyoti driven by technology and innovation
keeps including new fire power in its arsenal by introducing machines like CNC turning center,
Vertical Machining Centers, Oval turning center i- Sect and first Indian machines like vmc
40/70 Linear with innovative linear technology.

After the opening of the Indian economy, there were great challenges present for
Indian companies but jyoti converted all challenges to the excellent opportunities. Jyoti has even
decided to compete at the global level and taken concrete steps by exporting cnc machines. It has
also established various distribution continents around the globe.

Jyoti is passing through the trajectory of rapid growth by achieving over 100% growth rate
since its inception. Export penetration and inclination has helped jyoti to establish the goodwill
among the foreign buyers and distributors.

Company’s expanding footprints ensures its global presence with exports operations in
countries like Italy, Russia, Argentina, Brazil and rest of South America, Tanzania and some
African countries, Middle East and other Asian countries like Malaysia .

8. GENERAL
INFORMATION

9. 1. Portfolio

Name of the company:Jyoticnc Automation Pvt. Ltd.

Chairman : ShriP.G. Jadeja

Working hours : 8:00 hrs.And overtime total
11:30hrs.

No. of members :1240

Accounting year : 1
st
April to 31
st
March

Land area : 1) 36,000 sq. mt.
2) 3,00,000 sq. mt.

Contact :MATODA,RAJKOT(GUJ.)(INDIA)
[phone],
0281 287082
[phone]
[email protected]
www.jyoti.co.in

10. 2.BRIEF HISTORY
& DEVELOPMENT


JYOTI CNC Pvt. Ltd. is promoted by an industrial entrepreneurs group having a track
record of achievement the character of group by its products and services, a priceless
performance asset, achieved its success not by an accident, but by sheet hard work declaration
and foresight, by the people who work with it.

JYOTI CNC Pvt. Ltd. established as a small scale industry at the Gondal road in 1988. The
chair man of the company named P.G. JADEJA started the business with his two brothers of rs.
30,000 by taking loan.



YEAR MILESTONE
1988 Jyoti established
1989 Introduced trouble free gear boxes for small
lathes
1992 Designed all geared lathes
1994 Designed several special purpose machines
which helped textile industry to bring
substantial price reduction in component
manufacturing
1996 Designed twine spindle (chucker) type
machine. The first in Rajkot
1997 Designed and manufactured first cnc turning
center in Gujarat
2000 Achieved the international standard for
quality management system an iso
9001-1994 certificate from TUV
Designed and manufacture first cnc
turn mill center an participation in
INTEC’ 2000 at Coimbatore

11. 2001 Designed and manufacture “SECT” the
first Indian machine for non circular
turning applications.
Designed and manufacture “VMC 40
LINEAR” the first Indian machine
having linear motors introduced to get
higher dynamics for faster production
rates.
2002 Participated in ENGIMACH 02’
organized in Ahmedabad. honored with
the best “THE BEST INNOVATIVE
TECHNOLOGY DISPLAY” award
at show
Participated in “TAGMA” in Mumbai
(www.tagmaindia.org)
Participated in national manufacturing
technological show (NMTS) at
Bangalore.
2003 Participation at EMO-2003
Achievement of iso 9001-2000
certification from TUV
2004 Achieved CMT-PMT award for “the best
innovative designed “IMTEX 2004
Mumbai
2005 Honored with the CII “Best
Entrepreneurship of the year” award for
2004-2005
2006 BLACK PEARI award for display and
demonstration of best innovative technology at
ENGIMACH 2006
2007 Take over “HURON” at France which is 140
years old.

12. 3. SIZE OF UNIT

On the basis of size, nature, capital investment and production capacity industries can be
divided into three major groups,

Small scale industry
Medium scale industry
Large scale industry

Jyoti pvt. Ltd. can be placed under the large scale group as the capital invested in the
machinery.



4. OrganizationalStructure

The superior-subordinate relationship is defined by organizational structure. Which are formal
documents, which indicate the chain of command and the title have been assigned to the
managers and the other personnel? These structures are somewhat like “ROAD MAPS” as they
guide to official relationship. Organizational structure indicates the people’s location or the
position in the hierarchy and their relationship within the formal organization. They aid in
determining which of the basic type of organizational authority structure a particular enterprise
has adopted.

13. FOUNDRY

Foundry means pouring molten metal in to a refractory mold with a cavity of the shape
tobe made, and allowing it to solidify.
When solidified, the desired metal object I taken from the refractory mold either by
breaking the mold or taking the mold part.
The solidified object is called casting.
This process is also called founding.
As a production process, casting is usually carried out in a foundry.
A foundry is a factory equipped for making moulds, melting and handling metal in
molten form, performing the casting process, and cleaning the finished the casting.
The workers wdo perform the casting operation are called foundrmen.


PATTERN SHOP

Pattern making stepwise
Pattern methoding
Pattern designing
Core designing
Pattern raw material designing
Core raw material designing
Pattern drawing preparation
Core raw material preparation
Inspection of raw material
Machining of pattern raw material
Machining of core raw material
Pattern screwing and assembling
Core screwing and assembling
Final inspection

14. Pattern mounting and methoding
Final inspection
Pattern mounting and methoding

Sand preparation

 Coastal sand is taken in use for preparing the mould.
 Some important properties of molding sand for obtaining good mould and casting are:-
 Strength
 Permeability
 Thermal stability
 Collapsibility
 Reusability

 Constituents of moulding sand:-

 Silica sand
 Binder
 Additives
 Water

 Silica sand:-

 Silica sand (SiO2) contains water for a long time and is suitable for a wide
working range.
 It helps to patching and finishing operation of the mould.
 It is very cheap as compared to other sand .
 Mostly used for cast iron and non ferrous metal casting

15.  Binders:-

 The purpose of adding a binder to the moulding sand is to impart it sufficient
strength and cohesiveness so as to unable it to retain it shape after the mould has
been rammed and the pattern withdrawn.
 However it produce and adverse effect on the permeability of the sand mould.

 Additives:-

 Additives are those materials which are added to the moulding sand to improve
upon some of existing properties of the impart certain new properties to it

 Commonly used additives are:-

 Coal dust
 Sea coal
 Cereals or corn flour
 Silica flour
 Wood flour
 Pitch
 Dextrin and molasses
 Fuel oil


 Water

 The clay contend added to foundry and sand will not give the required strength
and bond until a suitable quantity of water is added to it.
 This quantity of water varies from 2 to 8 percent according to different
requirements.

16.  Mould Classifications:-

 Sand moulds
 Green sand moulds
 Dry sand moulds
 Skin sand moulds
 Cement sand moulds
 Sodium silicate
 Metal moulds
 Plaster moulds

 Mould Making

 First the coastel sand is dried in a sand drier.
 Sand drier dries the sand by heating at high temperature.
 Then it is send to the bucket alivator for cooling.
 The dry sand is lifted and send to the mould mixture.
 Mould is prepared by adding rasin and catalyst it to it.


 Furnace :-

 In all the casting processes, the metal must be heated to the molten state to be
poured into the mould.
 Heating and melting is done in the furnace.
 Various types of furnace used in the foundry are:-

 Cupolas
 Direct fuel-fired furnace
 Crucible furnace
 Electric-Arc furnace
 Induction furnace

 The raw material or scrap is collected in the furnace and it is heated and melted at
high temperature.
 Jyoti has installed electric furnace which has capacity of heating metals at high
temperature.

17.  The electric furnace has the capacity of 11KV and and can melt 3 tonnes of raw
material in 1 hour by giving temperature of 1200 C to 1400 C.
 The carbon is added to the melted metal in different proportions to get a good quality
of casting.




 Sand Casting operations:-

 A mechanical drawing of the part is used to generate a designing for the pattern.
 Patterns have been to mounted on plates equipped with pins for alignment.
 Core boxes produce core halves which are pasted together.
 The cope half of the mould is assembled by securing the cope pattern plate to the
flask with aligning pins, and attaching inserts to form the spare and risers.
 The flask is rammed with the plate and inserts are removed.
 The drag half is produced in similar manner, with the pattern inserted.
 A bottom board is placed below the drag and aligned with pin.
 The pattern, flask, and bottom are inverted, and the pattern is withdrawn, leaving the
appropriate imprint.
 The core is set in place within the drag cavity.
 The mould is closed by placing the cope on the top of the drag and securing the
assembly with the pins.
 The flask are then subjected to pressure to conteract buoyant forces in the liquid,
which might lift the cope.
 After the metal solidifies, the casting is removed from the mould.
 The sprue and rises are cut off and the casting is cleaned.

18. MACHINING

In Unit-2 , is machining shop.There is various machining process like milling , grinding ,
threading , turning , boring , slotting , etc. done.
For the various machinig process , various machines used which are listed below ,
1. VMC-640
2. HMC-560
3. DX-100
4. DX-150
5. DX-200
6. DX-250
7. DX-300
8. DX-350
9. TC-01
10. TC-02
11. TMC-250
12. TMC-250A
13. TMC-350
14. ATM-160
15. HMC-560
16. Slide way Grinding Machine
17. Horizontal Boring Machine

 INRODUCTION ABOUT VMC -640:-

 Different type maching process which are performed by VMC-640 as boring ,
milling , threading , feeding , slotting .
 VMC-640 is four axis machine X,Y,Z,A .
 Maximum feed :- 20,000 to 40,0000 .
 R.P.M. :- 10,000 may be for special purpose .
 Automatic Tool Changer (ATC) :- 20 tools max.
 Motors used :- Three motors for its X,Y,Z axes .
 Bed & Spindle
 Rotary Table :- Its move about 360 degree
 For VMC , vertical axis is consider as a Z axis.
 In VMC X,Y axis moves and Z axis can be up & down , not moved.

19.  In Z axis spindle rotate in clockwise & anticlockwise direction.
 TANK:-
 Coolant tank,slideway lubrication tank, clean coolen tank (optional).
 For auto operation VMC used Siemens system which is based on computer rised
programme.
Various functions of the switches which is used in programming
machining process enlisted as below,

1. RESET: - Machine reset by using this switch.
2. SINGLE BLOCK:- By using this switch, only one block is processed or on operation.
3. CYCLE STOP / START: - It is used to stop or start the cycle. Cycle can be defined on the
based of the operation which is completed.
4. AUTO PRO: - Which is defined programme for particular job that saved in system.
5. M01:- It is the code of the programme. In the programme wherever, M01 is used that means
programme or machining process is stopped after that step.
6. DRY: - It is used to inform all the data of the job.
7. MDA: - It is used to add manually programme.
8. JOG: - When the cycle is stopped and after that the axes of the job required to move , then
without JOG axes cannot move. First of all , it gives JOG command then it can be possible
the movement of the axes.
9. REFRRENCE POINT:- It is used for the reference.
10. VAR: - There is the four vertical key as VAR,1 ,10 , 100 . 1:- it is used to move job 1 micron
in any direction.Function of 10 & 100 keys is also same as key 1.
11. M/C on
12. ARM JOG
13. SPEED SWITCH: - By using switch , the speed of machine operated manually.It is usually
100 %.
14. FEED SWITCH: - It is used for feed rate.
15. EMERGENCY SWITCH : - It is used to stop the machine in emergency condition.

20. All the switches that mentioned as above which is used in Siemens
programming system.

 TOOL USED IN VMC:-
 Ø 63 mm cutter
 Ø 25 mm cutter
 Ø 13 mm drill
 Ø 10 mm mill
 Ø 6.8 mm drill
 Ø 6.8 mm long drill
 Ø 8.6 mm drill
 Ø 4 mm drill
 Ø 4.2 mm drill
 16 mm insert cutter
 Ø 8 mm mill
 16 mm champer cutter
 Ø 8,10,5 mm lap (thread)
 54 mm degree cutter
 104 mm boring bar
 80 mm finish cutter
 Tool holder in which insert is mounted
 Material used in insert cutter is carbide .Properties of this material is pure brittle.

 INTRODUCTION TO THE HMC -560

 in HMC-560,there is a four axes X,Y,Z and B.
 axis B is considered as a movement of pallet
 twopalletes used in it.
 HMC used for big components.
 In HMC two palletes are used for save the time to change the job.
 Its has accuracy about 10 micron
 Tools heavy and capacity of the tools is 40
 Magazine is provided in back side of the machine and also saprated from working
area or chamber.
 Used boring bar in two finish boring bar and two rough boring bar.
 Tools of the HMC-560 is same as the tools of VMC-540

21.  DX - 250, 200, 350

 By this machine only turning may be possible.
 There are two axes used as X and Z.
 Z axis is consider as a spindle axis and it is horizontal axis.
 In this machine turret has a capacity to carrying 8 tools.
 Coolant system of the CNC machine.
 There is the different maintained coolant nozzle and injector used for that.
 Coolant system is also joined with the turret and also mountained on the machine
body or top of the job which is controlleble by the programme.
If any m.s. job has been rejected after the various machining processes
then for further use of it can be coated by Crome which is the coating
material. After the coating all the machining process has been done.

 General formula to find out rpm and feed:-

 For drilling : for carbide,


 For HSS :-



 For milling :- for carbide,


 For HSS :-

 For cutter :-number of insert cutter

15)

22. ASSEMBLY

 In assembly workshop there is the all part of the machines assembled by dividing
according to various machining process.
 We are in turning side , in which all of the DX series machines developed , like wise
DX 50 , DX 100 , DX 150 , DX 200 , DX 250 , DX 300 , DX 350 .
 All above machines developed according to requirement of the customer.
 As example requirement of customer is standard machine with chip conveyer four nos
boring holders , 2nos axial tool holders , set of sleeve , tool shank size (25 * 25 ) ,
without tail stock .
 For all DX series four motors used in which may be induction or servo motors
 Turning process
 Technical specifications for turning machine DX-200
 Capacity :- DX-200

 Swing over bed :- 500mm
 Max. turning length :- 500mm
 Std. turning dia. :- 200mm
 Max. turning dia. :-350mm


 Slides
 X-axis travel :- 200mm
 Logitudinal(Z-axis travel) :- 500mm
 Rapid feed(X-Z axis travel) :- 24 m/min

 Main spindle

 Spindle motor power(30min per count)kw :- 12/9
 Spindle bore :- 70mm
 Spindle nose :- A26
 Max. bar capacity :-52mm
 Spindle speed range(rpm) :-50-4000 rpm
 full power speed range :-750-3250 rpm

23.  Turret (servo)


 Number of station :- 8
 Max. boring bar dia. :- 40 mm
 Tool size (cross sectional) :- 25*25 mm

 Tailstock
 Quill dia. :- 85 mm
 Quill stroke :- 120 mm
 Thrust (adjustabl) :- 500 kgf(max)
 Accuracy ( as per VDI/DGQ 3441)
 Positioning uncertainty (p) mm :- 0.007 mm
 Repeatability ( ps medium ) :- 0.005 mm
 Other
 weight (approx) :- 3900 kg
 dimension (l*w*h)( approx ) :-2690*1635*1485 mm

 Controller

 the CNC system offered with the DX series machine is the latest system sinomerzk
802dsl digital control system is also available as option
 simulataneous 4 axes control
 10.4’’ TFT color screen
 Real time simulation PLC ladder display for diagnostics spindle load meter
 Background editing
 1 MB memory
 auto referencing
 oriented spindle stop
 inch/ matric switchable
 online help
 multiple repetitive cycles
 thread cutting cycles
 constant surface speed control
 rigid tapping
 pitch error compensation
 tool nose radius compenstion

24.  backlash compenstion
 direct drawing dimention
 G-code compatibility
 RS-232C serial interface port
 Inbuilt calculator
 Electronic handwheel
 PCMCIA carel slot

 Standard features

 Ac spindle drive
 Ac servo digital drive
 L.M guide ways
 Hyd. Chucking
 8 station bi-directional servo turret
 Auto and manual coolant system
 Centraised and programmable lub. System
 Laser calibrated axis of highly precise Positioning accuracy and repeatability

 Productivity improvement option

 Chip conveyor (rear or side)
 Bar feeder
 Bar puller
 Programmable tail stoke
 Part catcher
 Auto door
 Automatic tool setting
 Hyd. Collet chuck
 Fully tooled up solution to meet Customer needs
 Live quill ( built in revolving center)
 Two speed gear box

25.  DX-200 CNC turning center
 Overview
 In today’s competive market, you need to produce world class products quickly ,
accurately and with the minimum of the non-productive time
 You can find a range of high technology CNC lathes that deliver the fastest throughout
you need in DX series manufactured by jyoti. This machines are a result of
continuousdevelopments and innovation we have made in the field of machine tool
ever since we started manufacturing CNC lathes compiling and considering the
customer feedbacks and incorporative our own innovations. DX-200 with its unique
feature delivers optimum performance to match demand of various work piece size
application.

 Rigid structure

 The rigid bed and single piece 30 deg slant saddle are made out of high grade cast iron
for stability and least distortion enabling heavy cuts and faster production with
virtually no vibration it means higher surface finish even on hard matirials.
 Step up stucture concept enables consistent performance because of widely space
quideways even it bigger diameter.

 Spindle

 main spindle is manufactured in house using world class machiniry and assembled in a
dust free controlled temperature environment. Spindle is housed in a cartiidge with 3
super precision angular contaet bearings in the front and angular contact bearing at
rear and this arrangment takes care of radius as well as axis loads.

 Head Stock

 Made out of closed grain FG300 casting and provided with fins for better hear
dissipation.

26.  3-Point Leveling System

 Due to high rigidity of the base design and 3 point leveling , twisting of bed is
eliminated . This feature in 200 allows machine to be installed or relocated quickly
easily.

 Tail Stock

 A manually moveable tailstock with hydraulicallyaccreted quill is a standard feature of
the machine. Programmable tailstock with hydraulic movement is offered as an option.

 High Speed Servo Turret

 DX-200 machine is equipped with high speed and high precision bi- directional servo
turret with clamping system archived by 3 piece coupling. tool change time in just 0.5
sec.

 AutomaticTool Setting

 Programmable for confident unmanned running .allows the machine to set accurate
tool data and even defact in process tool wear or breakages.
 CNC system used in turning process

 Siemens 808 DT
 Siemen 802 DSL
 Siemens 810 D
 Fanus 0i mate TD
 Fanus 0i TD plus alpha drives

 Various turret used in CNC
 JST 63
 JST 80
 JST 125
 BTP 63

27.  BTP 80
 BTP 100
 BTP 125
 8 stn
 12 stn
 Live tool turret

 Tail stock

 Prog. Tail stock
 Pro. Quill
 Servo T.S.
 Revolving Centre
 Live center
 Collate chuck
 Customize fixture
 Others………….
 Chip conveyor(Std.)
 Chip tray
 Chip conveyor(Scraper type)

 Others

 Tool eye
 Work piece measuring system
 Gearbox
 Part catcher
 Bar feeder
 Auto door
 Tower light
 Tool load monitoring
 Customized color
 Customized cutting tool

 Various Test

 Squareness test
 Coolant trail
 Geometrical test
 Laser calibration
 Ballbar test
 Spindle vibration
 Cutting trail

28.  Practical test
 Final inspection
 Pre dispatched inspection