A

APPRENTICESHIP TRAINING
POOJA INDUSTRIES KOLHAPUR

SUBMITTED TO

SHIVAJI UNIVERSITY, KOLHAPUR

For the Partial Fulfilment of the degree of

MASTER OF COMMERCE

SUBMITTED BY

MR. DIGVIJAY SANDIP GURAV

(B.COM)

Under the Guidance of

DR. ANIL SURYVANSHI

(M.com, M.B.A., P.H.D.)

THE NEW COLLEGE, KOLHAPUR

2024-25

1
 Department Of Commerce

THE NEW COLLEGE, KOLHAPUR

COLLEGE CERTIFICATE

This is to certify that Mr. Digvijay Sandip Gurav has submitted

his internship report on APPRENTICESHIP TRAINING IN
POOJA INDUSTRIES. He has
completed Internship project report under the Guidance of
DR. ANIL SURYVANSHI in Partial Fulfilment of the
MASTER OF COMMERCE (M.COM) Degree of Shivaji
University, Kolhapur, for the academic year 2024- 25.

DR. A. N. YADAV DR. V.M. PATIL

(H.O.D)
(PRINCIPAL)

Date:

Place:

2
 Department Of Commerce

THE NEW COLLEGE, KOLHAPUR

GUIDE CERTIFICATE

This is to certify that Mr. Digvijay Sandip Gurav has submitted

his internship report on MACHINE OPREATOR. He has
completed Internship project report under the Guidance of
DR. ANIL SURYAVANSHI, in Partial Fulfilment of the
MASTER OF COMMERCE (M.COM) Degree of Shivaji
University, Kolhapur, for the academic year 2024- 25.

EXTERNAL INTERNAL

NARENDRA DESHMUKH DR. ANIL SURYAWANSHI

Date:

Place :

3
 DECLARATION

I hereby declare that the Project A STUDY ON MACHINE

OPERATOR IN POOJA INDUSTRIES Has Completed
and written by me has not previously formed the basis for the
award of any Degree or Diploma or other similar title of this
or any other University or Examining body.

Place:

Date:

Student Signature

Mr. DIGVIJAY SANDIP GURAV.

4
 ACKNOWLEDGEMENTS

I would like to express my special thanks of gratitude to my

teacher Dr. Anil Suryavanshi for their able guidance and
support in completing my project. I would also like to extend
my gratitude to the principal Sir Dr. V. M. PATIL for
providingme all the facility that was required.

Place:

Date:

Student signature

Mr. DIGVIJAY SANDIP GURAV

5
 INDEX
SR/No Name Of Chapter Page No
1. Introduction 7
2. Compony Overview 8
3. Objective 9
4. Internship Activities
4.1 Week 1 10-12
4.2 Week 2 13-16
4.3 Week 3 17-23
4.4 Week 4 24-26
5. Experiences 27

6. Conclusion 28-29

7. Progress Report 30-31

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1. Introduction

Vertical machining has been in its most basic form for

over 150 years. However, this is still one of the latest
forms of machining technology (the oldest are lathes /
lathes). The "milling" process includes a rotating cutter
or drill bit and a movable work table to which the
workpiece is attached.
The knife is attached and rotated in a housing called a . Due
to the sharpness of the tool and the strength of the table
pushing the material into the knife, the material is deformed
and is properly cut or shaved. The force axis can be directed
up / down (called the Z axis) left / right (called the X axis) or
from front to back (called the Y axis).
VMCs can be equipped with many adjustments. For example,
there are many approach angles, as well as rotary and other
positioning devices on the work table. Later versions of the
VMC project added power and hydraulic feeding devices to
make the system more automated, and finally computerized
controls were added to allow greater automation of work,
repeatability, tool selection / change and contour control.
These new CNC machines took the "milling machine" to a
new level of efficiency and therefore the term was born.

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2. Company Overview

We are pleased to introduce ourselves as a precision

engineering unit being in existence since 2007 and

being managed by a team of experienced and dedicated

engineers and skilled personnel's. We are

involved in the manufacture of highly precision

components, accessories etc. Apart from this, we are also

involved in Development of import substitution items,

Reverse Engineering & Prototype development.

We are equipped with the state of art manufacturing and

inspection facilities and have put in place

established manufacturing and quality control processes in

place to ensure production of high quality
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products to desired standards. We are the registered vendor
for HAL, BEL, LRDE etc. Ours is an ISO 9001-

2008 certified company.

We have 5 Axis marching & CNC Turning facility. Our

strength is lies in batch production. Presently we are

undertaking machining of components batch as small as

one off, two off etc.

Enclosed please find along with this letter the following for
your kind consideration.

Brief Company Profile.

List of Machineries along with their capacities.

List of inspection and measuring instruments.

List of Manpower.

List of proposed machineries and Equipments.

It is our intension to be associated with you on a long term

basis for the manufacture of precision

components, accessories, jigs & fixtures etc., we are also

willing to develop some of the import

substitution items and components required by you.

We request you to please visit our unit at your earliest

convenience and view our facilities and capabilities.

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3. Objectives of the Internship
When I started my internship at Pooja Industries Office, I
had some goals in mind. First, I wanted to understand how
CNC/VMC machines work.
Second, I wanted to get better at talking to people and
solving problems. I wanted to learn micrometer, vernier,
all type of gauges which can use for measurements our
service. This meant learning how to handle complaints and
answer questions nicely.
Next, I was interested in how the company gets more
people to use their service. I wanted to know how they
advertise to get more works. This meant learning about
marketing and how to make customers happy.
Lastly, I wanted to learn from the people who have been
working with our industry. I wanted to listen to their
advice and learn from their experiences. I wanted to
become better at what I do and get ready for my future
career.
Overall, I wanted to learn a lot and become better at
different things during my internship at Pooja Industries
Office. I wanted to help the company and also learn as
much as I could to prepare for my future.

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 4. Internship Activities
4.1 Week 1
CNC VMC: Fundamentals of the process
VMCs are primarily used (though not exclusively) as metal cutting
machines that remove steel, aluminum or other hard materials - thus
forming a raw block of material into a precisely formed or
"machined" surface.

VMC can be used not only for cutting, but also for drilling, carving,
engraving, threading, countersinking, chamfering and many other
applications. Due to their versatility and relatively low cost, these are
extremely popular machines that can be found in workshops around
the world. In fact, there is a good chance that the machine works just
a few kilometers from where you are now.

All VMC consoles use common components, which are as follows:

Rotary spindle - A spindle that is perpendicular to the work surface or

table can accommodate various cutting tools (or mills, as they are
sometimes called). The spindle cartridge is mounted in a housing that
moved up and down - this direction of movement is called the Z axis.

Table - The table is a platform on which workpieces can be mounted

- directly or by means of various devices, such as milled aluminum
plates or hard clamping vices. The table has left and right movement,
which we call the X axis, and from front to back, which is called the
Y axis. These two motion axes, in conjunction with the Z axis, allow
virtually unlimited contouring on the planes of motion.

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Conclusion:
In my first week of learning at the internship, I started
exploring how CNC machine works. I found out about
the different kinds of wires, spindles, tools that connect
CNC machines need for this. I also learned about the
types of tools used in different kind of jobs.

I got to practice talking with customers, learning the

best ways to connect with them.

The main lesson was understanding what customers

think about our service and how to make them happy by
solving their issues fast.

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12
 4.2 Week 2:
After joining in 2nd week I’m learning about CNC
vertical machining center model : BMV60
SPECIFICATIONS.
Machine Capacity.
Table Size : 1250 X 600 mm
T- Slot Dimension : 5 X 18 X 100 mm
Max. Load on table : 1200 kgs
Travel X / Y / Z axes 1050 / 610 / 610 mm
respectively.
Distance From spindle face to table top : 850mm,
Coolant through, Chip Conveyor,
System controller : FANUC
With UCAM make 5th Axes with Pneumatic
Tail Stock.
2. In that day I also learn about the standard features of
this machine. And the feature is
 AC servo drives
 AC variable speed spindle motor
 Hardened and ground ball screws
 Feedback through the absolute encoder
 Automatic tool clamping-unclamping
 Centralized automatic lubrication
 Spindle taper air blow
 Telescopic covers with wipers
 Full machine guard
 RS 232 serial/ USB interface
 Leveling pads.
 Maintenance tool kit
 Electronic counterbalance
 Air gun, 3 Tier lamp, Air nozzle
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 Compact footprint.
 Superior aesthetics
 High metal removal rate
 Easy coolant and chip management
 Powerful spindle with various power & torque option
 Rear chip disposal
 Chip conveyor in lieu of coolant tank with chip tray
 2/ 3 axis with linear glass scale feedback
 16/25/ 40 bar coolant through spindle
 Provision for 4th and 5th axis rotary table
 4th axis rotary table
 Voltage stabilizer
 Ultra isolation transformer
 Increased daylight area through column raiser block
 Spindle mounted probe
 Table mounted probe
 Hard part probing
 Edge finder
 Automatic front door
 Ball screw type auto pallet changer with twin pallets
 Higher Spindle Power
 Ring coolant around the spindle
 Spindle RPM 4800
 Higher spindle RPM with chiller unit

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 #1 Drill Bits
Drill bits have a conical cutting point and a shaft with one or more flutes-the helical grooves
that run down the exterior of the tool.

Drill Bit

CNC machining drill bits typically come in three varieties-center, twist, and ejector drills-
with each type having different important functions.

You should use center drill bits to precisely create small spots on the workpiece, which can
then be drilled properly using a twist drill. In contrast, ejector drills are better suited for deep
hole drilling.

#2 End Mill
End mills are similar to drill bits but are much more versatile in the operations they perform.
They typically have up to eight sharp flutes on their ends and sides, allowing them to remove
large amounts of materials within a short period. An end mill should be your go-to tool if
you want to cut straight down into a material without requiring a pre-drilled hole (or spot).

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End Mill

End mills come in many varieties, with the roughing end mill type being the most common.
Roughing end mills have up to eight flutes, just like the regular end mills. However, the
flutes in the roughing end mills are serrated, allowing you to remove larger amounts of
materials compared to the regular end mills.

Roughing End Mill

#3 Face Mill
More often than not, the starting material (or workpiece) used in CNC milling machines
requires some sort of preparation before you can perform major milling operations.

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Face mills are specialty cutting tools that allow you to make flat sections of the workpiece
before detailed cutting operations are carried out. This tool features a solid body with
multiple interchangeable cutter inserts that can be swapped as needed.

Face Mill

You might want to consider using a “side and face cutter” for more demanding complex
operations. For instance, side and face cutters allow you to cut a groove or slot in a
workpiece while also cutting the sidewalls of the workpiece.

Side and Face Cutter

#4 Reamers

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Let’s say you need to create a 1/2” hole in a workpiece. You can proceed to use a 1/2” drill
bit, right? Wrong! Do this, and you can expect to have an oversized hole when you’re done
drilling your workpiece.

An ideal way to create this hole is to start with a smaller drill bit, say 31/64”, before
widening the hole to 1/2” using a reamer. Reamers allow you to expand the size of existing
holes while achieving dimensional accuracy and tight tolerances.

Reamers

#5 Gear Cutters
As the name suggests, gear cutters are used to make gears for manufacturing industries. You
can use it to fabricate a wide variety of gears, including spur, bevel, worm, screw, and helical
gears.

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Gear Cutter

#6 Hollow Mill
Hollow mills are pipe-shaped cutting tools with three or more that enclose and revolve
around a cylindrical workpiece. This cutting tool allows you to create a consistent pre-thread
diameter quickly and efficiently. You can also use them in drill press work for finishing
projections that must be in a given position.

Hollow Mill

#7 Thread Mill
As the name suggests, thread mills are CNC cutting tools used for cutting threads. They are
similar to taps in the purpose they serve. But unlike taps that cut only internal threads, CNC
machines fitted with thread mills can cut both internal and external threads.

You should opt for thread mills if you’re looking to penetrate hard metals or asymmetrical
parts.

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Thread Mill

#8 Slab Mill
Slab mills, also known as slab cutters or plain mills, are used to cut flat surfaces. These
cutters typically only have teeth on their periphery and are ideal for creating wide and narrow
cuts quickly.

Slab Mill

#9 Fly Cutter
Fly cutters are single-point rotary tools that make broad or shallow cuts and produce a
smooth surface finish. Compared to most face mills, fly cutters are inexpensive and offer a
better surface finish. It should be your go-to tool for plane surfacing operations.

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Fly cutter

Now let’s take a look at some of the materials used to make these tools

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Conclusion:
In week two, I learned about joining different types of
Tools that used in CNC Machine for Developing
job.
Conclusion. CNC machining is an electromechanical
process that manipulates tools around three to five axes,
with high precision and accuracy, cutting away excess
material to produce parts and components.

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4.3 Week 3
Understanding the Industrial Business
In the third week, I learned about the actual business of
it
I also learned what actually process happen between an
customer and a Machine operator
Knowing About the Different types of machine:
o CNC Vertical Lathes — Available in a wide
variety of sizes, these tools can make fast, precise
cuts and hold extremely tight tolerances. They can
be found combined with machining centers for
single setup milling and turning.
o CNC Vertical Machining Centers — The most
common piece of CNC equipment, these complex
tools are the easiest CNC mills to program and a
key component of many machine shops. Best for
short runs and small sizes, these systems can come
fully equipped with an assortment of tools and tool
changers, magazines, and carousels. They also
offer coolant and fluid systems and specialty
enclosures.
o CNC 5-Axis Machines — Among the most
advanced milling machine centers, these tools can
be manipulated across five axes to produce three-
dimensional parts with high levels of complexity,
precision, and speed for even the most difficult
designs.
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 CNC
Description Image
machine
Translates programs consisting of
specific numbers and letters to move
the spindle (or workpiece) to
various locations and depths. Can
either be a Vertical Milling Center
(VMC) or a Horizontal Milling
Center, depending on the orientation
of the spindle. Many use G-code.
Mill Functions include: face milling,
shoulder milling, tapping, drilling
and some even offer turning. Today,
CNC mills can have 3 to 6 axes.
Most CNC mills require placing the
workpiece on or in them and must
be at least as big as the workpiece,
but new 3-axis machines are being
produced that are much smaller.
Cuts workpieces while they are
rotated. Makes fast, precision cuts,
generally using indexable tools and
drills. Effective for complicated
programs designed to make parts
that would be unfeasible to make on
Lath manual lathes. Similar control
specifications to CNC mills and can
often read. G-code Generally have
two axes (X and Z), but newer
models have more axes, allowing
for more advanced jobs to be
machined.
Involves cutting a material using a
plasma torch. Commonly used to cut
steel and other metals, but can be
used on a variety of materials. In
this process, gas (such as comprassed
air) is blown at high speed out of a
Plasma nozzle; at the same time, an
CNC plasma cutting
cutter electrical arc is formed through that
gas from the nozzle to the surface
being cut, turning some of that gas
to plasma. The plasma is sufficiently
hot to melt the material being cut
and moves sufficiently fast to blow
molten metal away from the cut.
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 (EDM), also known as spark
machining, spark eroding, burning,
die sinking, or wire erosion, is a
manufacturing process in which the
desired shape is obtained using
electrical discharges (sparks).
Material is removed from the
workpiece by a series of rapidly
recurring current discharges
between two electrodes, separated
by a and subject to an electric. One
of the electrodes is called the tool
electrode, or simply the "tool" or Master at
"electrode", while the other is called the top, badge die workpiece at bottom, oil
the workpiece electrode, or jets at left (oil has been drained). Initial flat
"workpiece". stamping will be "dapped" to give a curved
surface.
Type of used in mass production.
Considered to be highly efficient by
increasing productivity through
automation. Can efficiently cut
materials into small pieces while
simultaneously utilizing a
diversified set of tooling. Multi-
spindle machines have multiple
Multi-
spindles on a drum that rotates on a
spindle
horizontal or vertical axis. The drum
machine
contains a drill head which consists
of several spindles that are mounted
on and driven by. There are two
types of attachments for these drill
heads, fixed or adjustable,
depending on whether the center
distance of the drilling spindle needs
to be varied.
Also known as wire cutting EDM,
wire burning EDM, or traveling
wire EDM, this process uses to
machine or remove material from
any electrically conductive material,
using a traveling wire electrode. The
Wire wire electrode usually consists of -
EDM or -coated brass material. Wire
EDM allows for near 90-degree
corners and applies very little
pressure on the material. Since the
wire is eroded in this process, a wire
EDM machine feeds fresh wire from
a spool while chopping up the used
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 wire and leaving it in a bin for
recycling,
Also called cavity type EDM or
volume EDM, a sinker EDM
consists of an electrode and
workpiece submerged in oil or
another dielectric fluid. The
electrode and workpiece are
connected to a suitable power
supply, which generates an
electrical potential between the two
Sinker parts. As the electrode approaches
EDM the workpiece, dielectric breakdown
occurs in the fluid forming a plasma
channel and small spark jumps.
Production dies and molds are often
made with sinker EDM. Some
materials, such as soft ferrite
materials and epoxy-rich bonded
magnetic materials are not
compatible with sinker EDM as they
are not electrically conductive.
Also known as a "waterjet", is a tool
capable of slicing into metal or
other materials (such asgranite) by
using a jet of water at high velocity
and pressure, or a mixture of water
and an abrasive substance, such as
sand. It is often used during the
fabrication or manufacture of parts
Water jet for machinery and other devices.
cutter Waterjet is the preferred method
when the materials being cut are
sensitive to the high temperatures
water jet
generated by other methods. It has
found applications in a diverse cutting machine for all materials
number of industries from mining to
aerospace where it is used for
operations such as cutting, shaping,
craving, and reaming.
Used to rapidly punch holes and cut
Punch
thin materials. Such as sheet metal,
press
plywood, thin bar stock, and tubing.

The f ollowing are the some of Machinery Operational

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11
2. Cutting Data
Tables on the following pages provide basic speed, feed
and cutting data for some of the materials
commonly used for prototypes. Use the tool
manufacturer’s data instead whenever it is available.
Mill Cutting Speeds (SFM) surface ft/min
Material HSS Carbide
Aluminum 600 800
Brass 175 175
Delrin 400 800
Polycarbonate 300 500
Stainless Steel (303) 80 300
Steel (4140) 70 350
Table 5: Milling Speed Data (SFM)
Drill Cutting Speeds (SFM) surface ft/min
Material Drilling C--‐Sink Reamer Tap
Aluminum 300 200 150 100
Brass 120 90 66 100
Delrin 150 100 75 100
Polycarbonate 240 160 120 100
Stainless Steel (303) 50 35 25 35

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Steel (4140) 90 60 45 35
Table 6: Drill Cycles Speed Data (SFM)
Cutting Feeds (IPR) in/rev
Operation Tool Diameter Range (in)
<.125 .125--‐.25 .25--‐.5 .5--‐1. >1.
Milling
Aluminum .002 .002 .005 .006 .007
Brass .001 .002 .002 .004 .005
Delrin .002 .002 .005 .006 .007
Polycarbonate .001 .003 .006 .008 .009
Stainless Steel (303) .0005 .001 .002 .003 .004
Steel (4140) .0005 .0005 .001 .002 .003
Drilling .002 .004 .005 .010 .015
Reaming .005 .007 .009 .012 .015

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3. LIST OF MAN POWERS

21
4. PROGRAMING FORMAT

22
 Conclusion :
In week three, I gained insights into the actual business
processes of Job developing on cnc/vmc machine and
the interactions between me and seniors.

I learned about the code language and measurement.

Additionally, I learned about the G -Codes of machines
the informative chart table of g code are following,

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 4.4 Week 4

Journey through Practical Learning in CNC

Operations

In this week what I learn theoretically in all 3 weeks I

have done it practically

4.4.1 OVERVIEW OF CNC SETUP & OPERATION:

CNC MACHINE SETUP AND OPREATION FOLLOWS THE PROCESS SHOWN IN FIGURE:

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25
1. Pre--‐Start
Before starting the machine, check to ensure oil and coolant
levels are full. Check the machine
maintenance manual if you are unsure about how to service it.
Ensure the work area is clear of any
loose tools or equipment. If the machine requires an air
supply, ensure the compressor is on and
pressure meets the machine requirements.

2. Start/Home
Turn power on the machine and control. The main breaker is
located at the back of the machine.
The machine power button is located in the upper--‐left
corner on the control face.

3. Load Tools
Load tools into the tool carousel in the order listed in the
CNC program tool list.
4 Set Tool Length Offsets
For each tool used, jog the machine to find and then set the
TLO.

5. Set Fixture Offset XY

Once the vise or other fixture is properly installed and aligned
on the machine, set the fixture offset
to locate the part XY datum.

6. Set Fixture Offset Z

Use a dial indicator and 1--‐2--‐3 block to find and set the
fixture offset Z.

26
7. Load CNC Program
Download the CNC program from your computer to the
machine control using RS--‐232
communications, USB flash memory, or floppy disk.

8. Run Program
Run the program, using extra caution until the program is
proven to be error--‐free.

9. Adjust Offsets as Required

Check the part features and adjust the CDC or TLO registers
as needed to ensure the part is within
design specifications.

10. Shut Down

Remove tools from the spindle, clean the work area, and
properly shut down the machine. Be sure
to clean the work area and leave the machine and tools in the
location and condition you found
them.

27
Conclusion:
In week four, I immersed myself in hands-on
experiences, applying the theoretical knowledge gained
in the previous three weeks.
The final aspect of my internship involved recovery,
where I had Developed a job myself.
What I learn about the measurement and the code
language of machines that I applied practically
starting of few days I had lot of mistakes but
slowly I am doing very well the seniors are very
good with me they helping me whenever I did the
mistakes.
After all that I learned very much in week three so
in that point I am very happy that I stayed in that
company and did it that very carefully.
Now I had very good knowledge in tools and G-
code language.

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5. Experiences
During my internship, I had conversation with my co
workers they guides me every step. They thought me
that every single part of machine that how to start
machine, how to develop a job. In that day I get
knowledge about safety, how to do job with caring.

From these experiences, I learned that it's essential for

a business to succeed.

In short, my time during the internship showed me how

important it is to take care of machines. Listening to the
seniors, fixing the problems, and developing the job
with care should always be our top priority.

29
 6. Conclusion:
In all that internship what I learned is in following
Highlight experience with machine operations and other
related duties.
Include technical skills such as CNC programming,
CAD/CAM software, and PLC programming.
List related certifications and educational qualifications.
Describe safety and quality control measures taken.
Highlight areas of expertise such as troubleshooting and
problem-solving.
Demonstrate knowledge of machine maintenance and repair.
Mention any awards or recognition received for outstanding
performance.

32
7. Progress Report:
Sr/No Date Progress Sign
1) 1/02/24 Introduction
2) 2/02/24 Basic about machine
3) 3/02/24 Tools
4) 5/02/24 Fundamentals of
Process
5) 6/02/24 Service
6) 7/02/24 Operations
7) 8/02/24 Learning of M-code
8) 9/02/24 Learning of G-code
9) 10/02/24 Learning of
Measurements
10) 12/02/24 Learning process of job
11) 13/02/24 Job Developing process
12) 14/02/24 Learning of tools
13) 15/02/24 Learning of features of
machine
14) 16/02/24 Reamers
15) 17/02/24 End mill
16) 19/02/24 Face mill
17) 20/02/24 Gear cutters
18) 21/02/24 Thread mill
19) 22/02/24 Slab mill
20) 23/02/24 Fly cutter
21) 24/02/24 Uses of lubricant oil
22) 26/02/24 Uses of cutting oil
23) 27/02/24 Cutting data
24) 28/02/24 Programing format
25) 29/02/24 Work offset
26) 1/03/24 Set-up operation
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27) 2/03/24 Safety guidance
28) 04/03/24 Efficiency
29) 05/03/24 Reflection
30) 06/03/24 Conclusion

32