SUMMER TRAINING REPORT

CERTIFICATE
This is to certify that Mr. ANKIT BHATT Student of Mechanical Engineering from., UTTARAKHAND has undergone practical training at INSTRUMENTS RESEARCH AND DEVELOPMENT ESTABLISHMENT, DEHRADUN for a period of 30 Days from 13th June 2011 to 25th July 2011 at Photonics Division. He was associated with study of CAM and FOLLOWER DESIGN. I wish him all success in future.

Sc E Project Guide.

CD (PR) IRDE.

ACKNOWLEDGEMENT

First of all, I am grateful to Mr. S.S.Sundaram, Director IRDE, Dehradun for providing me this opportunity by giving me permission to undergo practical training at this esteemed organisation. I express my deep gratitude to Mr. J.K.Bajpai, Sc. 'G', Chief Designer of the Opto-Mechanical Engineering Division for providing me with facilities available at PR to carry out this project and Mr. Amit Kumar Sharma Sc. 'B' for guiding and encouraging me throughout my project work. Last but not the least I am also thankful to all Scientists, Technicians and others who directly or indirectly helped me during the tenure of my Project semester.

Place: IRDE, DEHRADUN Date- 6th July 2011

KRISHANK KUMAR MALWA B.Tech. 3rd Year Mechanical Engineering COT PANTNAGAR, UTTARAKHAND

ABSTRACT

With the advances of new technology in the field of engineering, especially in manufacturing, it becomes uttermost to produce component of high accuracy and precision. For most of components, accuracy becomes inevitable aspect and so we need machines which can match with these requirements. In this report, besides some conventional lathe and milling machines I have laid special attention on high accuracy machines like SPDT, NC machine, CNC machines. These machines are capable of producing components of accuracy up to nanometer. Moreover as CNC and NC machines are operated by programs, so with these machines we can obtain increased flexibility, excellent reliability, high production rate and production of complex part. Various methods used in chemical lab for the finishing of some component, are also discussed, at the same time different instruments used for inspecting this high accuracy have been introduced.

CONTENTS
1. Introduction to I.R.D.E 1.1. IRDE Vision 1.2. Quality Policy 1.3. Major Area of Activity 1.4. Infrastructure

Machine Shop

Machining is a term used to describe a variety of material removal processes in which a cutting tool removes unwanted material from a workpiece to produce the desired shape. The workpiece is typically cut from a larger piece of stock, which is available in a variety of standard shapes, such as flat sheets, solid bars, hollow tubes, and shaped beams. Machining can also be performed on an existing part, such as a casting or forging.

Material removal processes:

Mechanical
o

Single-point cutting

Turning Planing and shaping

o Multi-point cutting
o

Milling Drilling Broaching Sawing

Abrasive machining

Grinding Honing Lapping Ultrasonic machining Abrasive jet machining

FOUNDARY SHOP
Foundry Engineering deals with the process of making casting in moulds prepared by patterns. The whole process of producing castings may be classified into five stages. 1. Pattern making

2. 3. 4. 5.

Moulding & core making Melting Casting Cleaning of casting

Pattern: It is defined as the model of the product, which is to be cast. Different kinds of pattern material are: a) b) c) d) e) Wood Metal Plastics Plasters Waxes

Types of pattern: 1. 2. 3. 4. 5. Single piece pattern Double piece or split pattern Cope & drag pattern Match plate pattern Skeleton pattern

TYPES OF SAND USED a) Green Sand b) Parting Sand c) Core Sand

MECHANICAL INSPECTION LAB

Facilities:
Co-ordinate MM Vision system Micro height gauge Bore gauge Dial gauge Gauge blocks Bevel protactor Depth micrometer Vernier micrometer

VISION SYSTEM (HAWK 7)

SPECIFICATION:
Make Stage travel

Magnification
Resolution Accuracy Angular resolution Software

Vision Engineering HAWK 7 200x150 mm Eyepiece 10x Objective 50x 0.4 m

(3+L/50) m 1min Quadra Check 5000

MEASUREMENT CAPABILITIES:
Linear & angular dimensions Inspection of miniature components PCD of holes Noncontact measurement Geometrical parameters Thread parameters

CMM (CO-ORDINATE MEASURING MACHINE)

SPECIFICATION:

Make Type Measuring Range Resolution Accuracy Software Probing System Minimum Probe Dia.

Carl-Zeiss Moving Bridge Type 700x700x600 0 .1m (2+ L/300) m CALYPSO HOLOS NT VAST-XT Probe 3mm

CAPABILITIES:
Linear & angular dimensions Geometrical parameters 2D &3D profile measurement Digitizing Interface with CAD files Scanning through VAST-XT Probe

MICRO HEIGHT GUAGE

SPECIFICATION:
Make Measuring Range Resolution Mitutoyo 0-900 mm .001 mm

 Accuracy Minimum Probe Dia.

(2+ L/600) mm 3mm

CAPABILITIES:
Height Measurement Circle Measurement ( Bore/Shaft) Width Measurement Perpendicularity, Straightness, Inclination

3 PIN BORE GUAGE

SPECIFICATION:
Make Measuring Range Resolution Mitutoyo 6-12, 12-20, 20-50, 50-100 .001 mm

DIAL GUAGE

SPECIFICATION:
Make Measuring Range Resolution Mitutoyo 0-12 .001 mm

DIGITAL VERNIER

SPECIFICATION:

 Make Measuring Range Resolution

Mitutoyo 0-150, 0-300 mm 0.01 mm

DIGITAL MICROMETER

SPECIFICATION:
Make Measuring Range Resolution Mitutoyo 0-25, 50-75,75-100 mm 0.001 mm

DEPTH MICROMETER

SPECIFICATION:
Make Measuring Range Resolution Mitutoyo 0-300 mm 0 .001 mm

DIGITAL HEIGHT GUAUGE

SPECIFICATION:
Make Measuring Range Resolution Mitutoyo 0-900 mm 0.0001 mm

BEVEL PROTACTOR

SPECIFICATION:
Make Measuring Range Resolution Mitutoyo -360 to +360 mm 2min

JIG BORING MACHINE

A jig boring machine gets its name from the fact that it is so often used to drill and bore holes needed for drill jigs. It is designed for locating and boring holes on jigs, fixtures, dies, gauges and other precision parts to an accuracy of +/- 0.0025mm. It is precision tool room machine intended for laying out, centering, drilling, reaming and finishing boring holes machining form contours, milling boss face surface etc. Jig borers are very accurate vertical type boring machines, designed for use in making jigs and fixtures they are used as co-ordinate measuring machines for inspection and precision layout operations. It resembles a vertical milling but it is constructed with greater precision and is equipped with an accurate measuring device for controlling table movements this machine also designed to be operated by numerical control.

CHEMICAL LAB
1. ANODISING:
Hard anodising produces harder coatings than the normal 'decorative' process, but the exact shade depends upon coating thickness and anodising conditions (which we can control), as well as alloy, thermal history, degree of hot or cold work, etc., over which we have no control. Excellent thermal conductivity Good malleability and ductility Imparts a surface as hard as some gemstones Increase in the surface hardness upto 1000 V.P.N Excellent lubricating properties especially for continuously moving parts. Excellent corrosion and abrasion resistance. Enhancement of working life CORROSION RESISTANCE: The hard anodising process coats the metal with a layer of aluminium oxide, which is chemically inert under neutral or mild acidic conditions of exposure; it therefore offers a means of protection of the metal surface in a wide range of environments. Because the oxide coating is derived in part from the metal itself, the constituents of the particular alloy have an effect upon the nature of the coating and upon its corrosion resistance (e.g. Al-Cu alloys) will give a useful measure of protection.

TEMPERATURE RESISTANCE: The anodizing process applies to the metal surface a coating of aluminium oxide. The nature of the process is such that adhesion of the oxide to the substrate can be taken for granted, unlike ceramic and other coatings which are dependent upon cleanliness and other factors. The melting point of aluminium oxide is over 2000C, which is far above that of the metal itself, and it is largely unaffected by temperatures within the useful range of the metal. Sealing, dyeing and Ano-lube treatments do not share the properties of the oxide itself and trials should be carried out to establish their suitability at elevated temperature.Coatings are unaffected by sub-zero temperatures except insofar as differential contraction between oxide and metal may give rise to a greater tendency to crazing; this effect is dependent upon alloy, process conditions and the physical shape of the workpiece, so trials should be carried out to determine suitability. ELECTRICAL INSULATION: The coating produced by the anodising process is composed of aluminium oxide, a material having exceptional dielectric strength. The coating has excellent adhesion to the substrate, high resistance to mechanical damage and extremes of temperature making anodising aluminium the preferred choice of a number of electrical applications. WEAR RESISTANCE - HARDNESS TESTING: The coating produced by the hard anodising process is chemically akin to many gemstones and shares their property of extreme hardness and resistance to abrasion. The hardness of anodised coatings is specified in British Standards using the Vickers Micro Hardness Test in which the hardness is measured on a section through the film giving micro hardness values of 250 to 600; depending on the aluminium alloy, the process and the sealing. The matrix of aluminium oxide itself has a micro hardness of around 1,100 Vickers. The indentation method of the Vickers Test really indicates the crushability of the brittle and porous anodic film whereas the property often expected by customers is abrasion resistance.

APPLICATIONS: Pneumatic Cylinder Tubes, Pneumatic Valve Spools, Pump Components, Automotive Hydraulic Components, Pulleys, both Vee and Timing types, Plasma etching equipment, Drugs Machinery, Food Handling Machinery, Plastics Machinery, Pistons, Cylinders, Actuators, Engine Blocks, Solenoid Valves Aluminum Castings and many many more.