CERTIFICATE

This is to certify that the “Internship report” submitted by A.SUDHAKAR(Reg. No.: 20114038) is
work done by her and submitted during 2023– 2024academic year, in partial fulfillment of the
requirements for the award of the degree of BACHELOR OF ENGINEERING in
MECHANICAL ENGINEERING , at SAKTHI AUTO COMPONENT LIMITED,
ERODE.

College Internship Coordinator Department Internship Coordinator

Dr. S. KARTHICK Mr.N.S.MOHAN, M.E,
. Assistant professor, Mechanical engineering

Head of the Department

Department of Mechanical engineering
Dr.M.PANDIAN, P.hD.

i
 ACKNOWLEDGEMENT

First I would like to thank Mr.Nassar, HR, Head, of SAKTHI AUTO

COMPONENT LIMITED, ERODE for giving me the opportunity to do an internship
within the organization.

I also would like all the people that worked along with me SAKTHI AUTO
COMPONENT LIMITED, ERODE with their patience and openness they created an
enjoyable working environment.

It is indeed with a great sense of pleasure and immense sense of gratitude that I
acknowledge the help of these individuals.

I am highly thankful to the Principal , Dr.V.VENKATACHALAM or the

facilities provided to accomplish this internship.

I would like to thank my Head of the Department Dr. M.PANDIAN for his
constructive criticism throughout my internship.

I would like to thank Dr.S.KARTHICK , college internship coordinator

Mr.N.S.MOHAN internship coordinator Department of MECHANICAL
ENGINEERING for his support and advices to get and complete internship in
above said organization.

I am extremely great full to my department staff members and friends who helped
me in successful completion of this internship.

ii
 ABSTRACT
Computer numerical control (CNC) is a manufacturing method that automates the control, movement and
precision of machine tools through the use of preprogrammed computer software, which is embedded inside the
tools. CNC is commonly used in manufacturing for machining metal and plastic parts. Mills, lathes, routers, drills,
grinders, water jets and lasers are common cutting tools whose operations can also be automated with CNC. It can
also be used to control nonmachine tools, such as welding, electronic assembly and filament-winding machines.

Organisation Information:

Sakthi auto component limited is one of the few facilities in the country with in-house machining
facility, machining 95% of the components produced. SACL caters to the needs of Global
Automobile and truck manufacturers by supplying safety critical components like Steering
knuckles and Rotors to more than 3 Million Vehicles per annum. The top customers for SACL
are Maruti Suzuki, General Motors, Hyundai, Honda Siel Cars, Ford, Fiat, Toyota, Volkswagen,
Renault, Mahindra & Mahindra, Tafe, Haldex and Volvo.

Key parts of the report:

Under each division we further provide specific industry solutions on focused domains with cutting
edge technologies.

Benefits of the Company/Institution through our report:

Under each division we further provide specific industry solution on focused domains with
cutting edge technologies. We emphasize on building relationships with our clients by delivering
projects on time and within budget.

iii
 INDEX

S.no CONTENTS Page no

1. Introduction……………………………………………………………………....1

2. Part programming………………………………………..……………………....3

3. Vertical turning lathe……………………………………………………………..5

4. Vertical machining center……………..…………………………………………7

5. Measuring equipments….……………………………………………………….8

6. Quality checking process……….………………………………….…………....11

7. Defects on flywheel………………………………………….…………………..12

8. Tool setup..............................................................................................................13

9. Conclusion……………………………………………………………………….15

iv
 Learning Objectives/Internship Objectives

 Internships are generally thought of to be reserved for college students looking to gain
experience in a particular field. However, a wide array of people can benefit from
Training Internships in order to receive real world experience and develop their skills.

 An objective for this position should emphasize the skills you already possess in the area
and your interest in learning more

 Internships are utilized in a number of different career fields, including architecture,

engineering, healthcare, economics, advertising and many more.

 Some internship is used to allow individuals to perform scientific research while others
are specifically designed to allow people to gain first-hand experience working.

 Utilizing internships is a great way to build your resume and develop skills that can be
emphasized in your resume for future jobs. When you are applying for a Training
Internship, make sure to highlight any special skills or talents that can make you stand
apart from the rest of the applicants so that you have an improved chance of landing the
position.

v
 WEEKLY OVERVIEW OF INTERNSHIP ACTIVITIES

DATE DAY NAME OF THE TOPIC/MODULE COMPLETED

1st WEEK

18/05/23 Thursday Introduction of computer numerical control

19/05/23 Friday Introduction to Part programming
20/05/23 Saturday Introduction to sensors and actuators and motors

DATE DAY NAME OF THE TOPIC/MODULE COMPLETED

2nd WEEK

22/05/23 Monday Introduction flywheel dimensions and tolerances

23/05/23 Tuesday Operation of vertical turning lathe for facing in flywheel
24/05/23 Wednesday Operation of vertical turning lathe for boring
25/05/23 Thursday Measuring practice using vernier caliper, plug
gauge ,comparator and micrometer
26/05/23 Friday Working practice of gear hobbing in flywheel
27/05/23 Saturday Working practice of ring gear attachment on flywheel

DATE DAY NAME OF THE TOPIC/MODULE COMPLETED

29/05/23 Monday Introduction to vertical machining centre
30/05/23 Tuesday Introduction to canned cycle and tapping cycle in cnc for
internal thread cutting and boring
3rd WEEK

31/05/23 Wednesday Measurement of roughness using comparator

01/06/23 Thursday Understanding significance of roughness and dowel pin in

flywheel
02/06/23 Friday Working practice of hydraulic press for dowel pin and ring
gear attachment
03/06/23 Saturday vi Introduction to quality checking process
 DATE DAY NAME OF THE TOPIC/MODULE COMPLETED
4th WEEK

05/06/23 Monday Introduction to various defects occurs while machining

06/06/23 Tuesday Changing parameters in cnc as per the defect
07/06/23 Wednesday Studying reasons and causes of various alarms in CNC
08/06/23 Thursday Torque testing of flywheel
09/06/23 Friday Hardness testing with the help of ultrasonic testing
10/06/23 Saturday

DATE DAY NAME OF THE TOPIC/MODULE COMPLETED

5th WEEK

12/06/23 Monday Introduction to dynamic balancing of flywheel

13/06/23 Tuesday Working practice of schunk auto balancing machine
14/06/23 Wednesday Understanding the working of CMM
15/06/23 Thursday Checking quality of fully manufactured flywheel

16/06/23 Friday Checking quality of fully manufactured flywheel

vii
 1. INTRODUCTION
Computer numerical control (CNC) is a manufacturing method that automates the control,
movement and precision of machine tools through the use of preprogrammed computer
software, which is embedded inside the tools. CNC is commonly used in manufacturing for
machining metal and plastic parts. Mills, lathes, routers, drills, grinders, water jets and lasers
are common cutting tools whose operations can also be automated with CNC. It can also be
used to control nonmachine tools, such as welding, electronic assembly and filament-winding
machines.

Working method

With CNC, each object to be manufactured gets a custom computer program, usually written
in an international standard language called G-code, stored in and executed by the machine
control unit (MCU), a microcomputer attached to the machine. The M-code language is also
used in conjunction with G-code in CNC operations. While G-code controls the movement
and functioning of the machine, M-code controls the operation's external movements. The
program also contains the instructions and parameters the machine tool follows, such as the
feed rate of materials and the positioning and speed of the tool's components. Early in the
process, engineers create a computer-aided design (CAD) drawing of the part to be
manufactured and then translate the drawing into G-code. The program is loaded onto the
MCU, and a machine operator performs a test run without the raw material in place to ensure
proper positioning and performance. This step is important because incorrect speed or
positioning can damage both the machine and the part. When everything is ready, the CNC
machine runs its program and completes jobs with precision as instructed. The jobs could
involve anything from creating something from scratch to cutting a workpiece or printing
anything.

Components of CNC

The main components of CNC are:

Input Devices:

These are the devices which are used to input the part program in the CNC machine. There
are three commonly used input devices and these are punch tape reader, magnetic tape reader
and computer via RS-232-C communication.

Machine Control Unit (MCU):

It is the heart of the CNC machine. It performs all the controlling action of the CNC
machine.

Machine Tool:

A CNC machine tool always has a slide table and a spindle to control of the position and
speed. The machine table is controlled in X and Y axis direction and the spindle is controlled

1
in the Z axis direction.Depending upon the operation to be performed,the tool can be selected
from tool turret.Major type of tools used in milling operation are shown in the second picture.

Driving System:

The driving system of a CNC machine consists of amplifier circuits, drive motors and ball
lead screw. The MCU feeds the signals (i.e. of position and speed) of each axis to the
amplifier circuits. The control signals are than augmented (increased) to actuate the drive
motors. And the actuated drive motors rotate the ball lead screw to position the machine
table.

Feedback System:

This system consists of transducers that acts like sensors. It is also called as measuring
system. It contains position and speed transducers that continuously monitor the position and
speed of the cutting tool located at any instant. The MCU receives the signals from these
transducers and it uses the difference between the reference signals and feedback signals to
generate the control signals for correcting the position and speed errors.

Display Unit:

A monitor is used to display the programs, commands and other useful data of CNC
machine.

Advantages
Numerical control enables machines to produce items more quickly and with better surface finishes
without the need for manual machining or extensive human participation.

The following are some benefits of CNC systems:

Cost reduction.
CNC machines are cost-effective and bring down the cost of production due to precision manufacturing.
Energy consumption is decreased as a result of increased production efficiency, scalability and less
material waste, which also lowers operating expenses. The weight of potential financial obligations
related to worker safety is also lessened, which helps with cost-cutting.
Waste reduction.
The software used to run various kinds of CNC machines results in little to no waste during the
manufacturing process due to simulations and repeated optimizations.
Improved worker safety.
CNC machines minimize the chance of accidents and guarantee worker safety because there is less
need for human interaction. Most modern CNC machines are self-sufficient and can be handled
remotely by people for software upgrades, design changes or other preventative maintenance.
Human error reduction.
Since human error is eliminated in the manufacturing process with CNC, it is thought to offer greater
precision, complexity, speed, flexibility and repeatability. This ultimately results in fewer defects in the
manufactured products.
Contour machining.

2
CNC provides capabilities such as contour machining, which enables milling of contoured shapes,
including those produced in 3D printing and designs.
Faster MCU programming.
Some CNC systems are integrated with CAD software and computer-aided manufacturing software,
which can speed the process of programming the MCU.
Improved operational intelligence.
Integration with enterprise resource planning software and related applications, such as enterprise asset
management software, can facilitate operational and business intelligence processes and help improve
plant performance and maintenance.
No bottlenecks.
With the higher level of automation used, CNC systems reduce production and manufacturing
bottlenecks and improve the outcome.
Along with the wonderful benefits that CNC machines offer, they do tend to be more expensive, require
more maintenance than other production methods and compel companies to hire a skilled CNC
programmer.

3
 2.PART PROGRAMMING
CNC part programming involves a series of coded instructions that are required to produce a part. The
program controls the machine tool movements and controls auxiliary functions including spindle,
coolant, and rotation. The instructions may include numbers, letters, and symbols arranged in functional
format blocks.CNC part programming uses a program input device such as a keyboard, diskette drivers,
pouched tase reader or serial ports among others. The program describes work that should be done on a
part in the format required by CNC software.Programming is the point at which all the machining data
is compiled and translated so that the control system can understand and implement the
instructions.Machining data can be employed as;
 Machine sequence process, from tool start up to cutting depth, and tool path among others.
 Cutting conditions, feed rate, spindle speed, coolant, among others.
 Selection of cutting tools

G-codes
G-codes are used to command specific movements of the machine, such as machine moves or
drilling functions. The majority of G-Code programs start with a percent (%) symbol on the first
line, then followed by an “O” with a numerical name for the program (i.e. “O0001”) on the
second line, then another percent (%) symbol on the last line of the program. The format for a
G-code is the letter G followed by two to three digits; for example G01. G-codes differ slightly
between a mill and lathe application, for example:

[G00 Rapid Motion Positioning]

[G01 Linear Interpolation Motion]
[G02 Circular Interpolation Motion-Clockwise]
[G03 Circular Interpolation Motion-Counter Clockwise]
[G04 Dwell (Group 00) Mill]
[G10 Set offsets (Group 00) Mill]
[G12 Circular Pocketing-Clockwise]
[G13 Circular Pocketing-Counter Clockwise]

4
M-codes
[Code Miscellaneous Functions (M-Code)][citation needed]. M-codes are miscellaneous
machine commands that do not command axis motion. The format for an M-code is the letter M
followed by two to three digits; for example:

[M01 Operational stop]

[M02 End of Program]
[M03 Start Spindle – Clockwise]
[M04 Start Spindle – Counter Clockwise]
[M05 Stop Spindle]
[M06 Tool Change]
[M07 Coolant on mist coolant]
[M08 Flood coolant on]
[M09 Coolant off]
[M10 Chuck open]
[M11 Chuck close]
[M12 Spindle up]
[M13 BOTH M03&M08 Spindle clockwise rotation & flood coolant]
[M14 BOTH M04&M08 Spindle counter clockwise rotation & flood coolant]
[M16 Special tool call]
[M19 Spindle orientate]
[M29 DNC mode ]
[M30 Program reset & rewind]
[M38 Door open]
[M39 Door close]
[M40 Spindle gear at middle]
[M41 Low gear select]
[M42 High gear select]
[M53 Retract Spindle] (raises tool spindle above current position to allow operator to do
whatever they would need to do)
[M68 Hydraulic chuck close]
[M69 Hydraulic chuck open]
[M78 Tailstock advancing]
[M79 Tailstock reversing]

5
Example of part programming
%
O0001
G20 G40 G80 G90 G94 G54(Inch, Cutter Comp. Cancel, Deactivate all canned cycles, moves axes to
machine coordinate, feed per min., origin coordinate system)
M06 T01 (Tool change to tool 1)
G43 H01 (Tool length comp. in a positive direction, length compensation for the tool)
M03 S1200 (Spindle turns CW at 1200RPM)
G00 X0. Y0. (Rapid Traverse to X=0. Y=0.)
G00 Z.5 (Rapid Traverse to z=.5)
G00 X1. Y-.75 (Rapid traverse to X1. Y-.75)
G01 Z-.1 F10 (Plunge into part at Z-.25 at 10in per min.)
G03 X.875 Y-.5 I.1875 J-.75 (CCW arc cut to X.875 Y-.5 with radius origin at I.625 J-.75)
G03 X.5 Y-.75 I0.0 J0.0 (CCW arc cut to X.5 Y-.75 with radius origin at I0.0 J0.0)
G03 X.75 Y-.9375 I0.0 J0.0(CCW arc cut to X.75 Y-.9375 with radius origin at I0.0 J0.0)
G02 X1. Y-1.25 I.75 J-1.25 (CW arc cut to X1. Y-1.25 with radius origin at I.75 J-1.25)
G02 X.75 Y-1.5625 I0.0 J0.0 (CW arc cut to X.75 Y-1.5625 with same radius origin as the previous
arc)
G02 X.5 Y-1.25 I0.0 J0.0 (CW arc cut to X.5 Y-1.25 with same radius origin as the previous arc)
G00 Z.5 (Rapid traverse to z.5)
M05 (spindle stops)
G00 X0.0 Y0.0 (Mill returns to origin)
M30 (Program End)
%

6
 3.VERTICAL TURNING LATHE

Vertical turning lathes are large, ram-type machines, also called vertical boring mills (VBMs).
These lathes are not high-production machines, but they are ideal for heavy-duty and high-power
cutting of medium and large parts.

 An important advantage of the VTL machine is the ease in which large heavy workpieces can be
set and held in place for machining. An advantage for any shop using VTL is that gravity is an
important factor in holding these parts. Generally only a minimum of hard clamping is required.

7
 vertical turning lathe

 Vertical turning lathes that use the main spindle to load and unload themselves are finding
increasing acceptance as multitasking capabilities make them efficient processing centers for
producing chucked parts.
 Vertical turning lathes give foundries with machine shops as well as those that outsource
machining the ability to cut bigger and heavier castings.
 An indexable tool turret head distinguishes traditional VTLs from VBMs
 Aside from turret head or ram head, VTL machine design uses a rotating table to support the
workpiece and use a bridge-type construction that carries the X-axis. A ram traverses the X-axis
guides and delivers the cutter.
 In terms of productivity, vertical turning centers typically improve cycle times because shops
can be more aggressive with their cuts

4.VERTICAL MACHINING CENTER

8
 Vertical machining center

Vertical machining technology is one of the most productive tools in the CNC machine shop. It has
various tools in the changer and other options that enhance and customize productivity. CNC vertical
machining centers are flexible multi-functional tools that help machine holes and other properties in
components with a flat surface. It operates in a vertical direction using a spindle that works at a steep
angle.
A CNC Vertical Machining Center offers different styles of automatic tool changers as well. The
most common style is the umbrella-style. This is where the tool holders are loaded into the carousel
vertically. The other style is a drum or side-mount style. The tools are loaded in horizontally in this
type. This allows for greater part height in the work area and can help accommodate a rotary table,
fixture or any additional work holding devices mounted to the table
Ring gear attachment
One of the critical components that sits on the Engine Flywheel and engages with the pinion of starter
motor to crank the engine upon Starting. Ring gear transfers starting torque from starter to engine
crankshaft.

9
Dowel pin assembly
The flywheel dowel pins ensure that the cover assembly is correctly centralized on the flywheel, and
prevent misalignment of the cover assembly on the flywheel which would cause clutch non-release
and vibration problems in the vehicle.

5.MEASURING EQUIPMENTS
Comparator

A mechanical comparator is a measuring instrument that is made up of mechanical means like gears,
levers, pinions & racks to get the magnification. These kinds of means are mainly used for
magnifying the means’ movement to enhance the precision of the instrument.

10
Air gauge

The air probe (also referred to as an air plug gage, air spindle or mandrel) consists of a precision
ground hardened steel body incorporating two or more air gage nozzles. Air is passed through the
probe body to the nozzles where a back pressure is produced by the surface of the workpiece. An air
gage readout (air comparator) senses the resulting back pressure and displays the size of the
workpiece.

As shown in the drawing, the nozzle tips are recessed a small amount below the body of the probe.
This feature makes the air gage measurement essentially non-contact, consequently wear does not
directly affect the accuracy of the gage measurement. Moreover, the flow of air purges the gaging
surface of contaminants making the measurements highly reliable

11
Screw gauge
Least count of micrometer screw gauge = (1 mm)/(100) = 0.01 mm. Micrometer screw gauge is
defined as an instrument that is used for measuring the diameter of thin wires, the thickness of small
sheets such as glass or plastics.

Vernier caliper
A vernier calliper is defined as a measuring device that is used for the measurement of linear
dimensions. It is also used for the measurement of diameters of round objects with the help of the

12
 measuring jaws.

6.QUALITY CHECKING PROCESS

Torque testing machine

The machine offered by us is used for fly wheel torque testing. Torque is applied by Hydraulic cylinder and
measured by torque transducer for the slippage of flywheel from the ring. Moreover, four models can be
loaded in the same machine with easy changeoverThere are two different approaches to measuring torque,
including reaction and in-line. The in-line method of torque testing measures the torque required to turn the
rotating part, while the reaction method measures the amount of force required to prevent the part from
rotating. Each of the two testing methods uses different specialized sensors. This is why it’s important to
consider the torque testing method, prior to purchasing your torque tester.

13
Auto dynamic balancing machine
The balancing machine pictured here is a fully-automatic flywheel balancing machine. A flywheel is
automatically chucked and balance cycle initiated automatically. When balance reading is determined, the
flywheel is rotated to the first correction location. The drill automatically positions over the flywheel and
the correction hole is drilled (repeat for additional hole locations). Disallowed drill locations are
programmed and will not drill in these locations. After correction, the audit balance spin occurs
automatically and a passed flywheel will be automatically lifted to load/unload position.
Defects on flywheel
Blow holes
Tiny gas bubbles are called porosities, but larger gas bubbles are called blowholes or blisters. Such defects
can be caused by air entrained in the melt, steam or smoke from the casting sand, or other gasses from the
melt or mould.
Sandrub

14
This defect is caused by the dust on flywheel.the dust accumulates on cutting portion and causes the poor
surface finish and tiny dents on flywheel.
Rust
Rust is an iron oxide, a usually reddish-brown oxide formed by the reaction of iron and oxygen in the
catalytic presence of water or air moisture. Rust consists of hydrous iron(III) oxides (Fe2O3·nH2O) and
iron(III) oxide-hydroxide (FeO(OH), Fe(OH)3), and is typically associated with the corrosion of refined
iron

7.Tool setup
Inserts for turning and boring

15
Drilling tool

Tapping tool

16
 8.CONCLUSION

I have studied the dimensions and tolerances of flywheel and basics of computer
numerical control and part programming for the machining job . Computer numerical control
(CNC) is a manufacturing method that automates the control, movement and precision of
machine tools through the use of preprogrammed computer software, which is embedded
inside the tools. CNC is commonly used in manufacturing for machining metal and plastic
parts . I have understood the practical knowledge of dynamic balancing which not only used
in flywheel and also clutch plates and other axis symmetrical child parts. and studied the
roughness indications and tolerancing.

17
18