Internship Training at HMT Ltd

INTERNSHIP TRAINING AT HMT LTD
CHAPTER-1
INTRODUCTION
Fulcrum of INDIAN Industrial Development HMT synonymous with excellence in precision engineering is
a multiproduct company established in 1953. Built on a strong foundation of technical knowledge acquired
from leaders in machine tools such as Overlooking, Manurhin, Glidemeister, Liebherr, Rino Beraradi, Fritz
werner, Pegard, Waldrich coburg etc. HMT's Machine Tools expertise has been developed to such an extent
that HMT can design and develop any kind machine.
Having established as a machine tool manufacturer, HMT diversified into other product lines. From simple
lathes to heavy duty lathes and along with CNC machine to flexible manufacturing system, leading to
factory automation HMT's broad range purpose machines and CNC machines, meeting the application
needs to every engineering industries. Pioneering the concept of CNC technology technique in India HMT
has the destination of being the first company to successfully manufacture its own CNC systems in
association with Siemens.
● HMT Machines Tools Limited

● HMT Bearings Limited.
● HMT International Limited.
Today HMT is well positioned at the fore front of the precision engineering field. Its manufacturing plants
employee highly skilled forces strongly supported by (R&D) Research and development. Today over 7, 80,
000 machine tools manufactured by HMT are in used in India and abroad .
In tune with changing business environment. HMT limited restructured into holding company Tractors as its
core business and the following subsidiaries are,
PRAGA Machine tools limited
The machine tools, Bangalore unit.
The machine tool division at HMT Bangalore was the oldest manufacturing unit of the company and it is the
Mother unit of HMT.
The successful technology absorption in all product groups through collaborations with world-renowned
manufactures and further strengthened by continuous in house R&D
DEPARTMENT MECHANICAL ENGINEERING. AIT, BANGALORE. Page 1

1.1 Introduction About The Internship

An internship is the on-the-job training for many professional jobs, more often taken up by college and
university students during this undergraduate or master degree in their free time to supplement their formal
education and expose them to the world of work. Internship offers various occasion in interns during
internship programs to expand familiarity in their choose area of work, to find out what they have an
importance in an exacting in specific line of business, develop professional network links, build
interpersonal skill or get some credit points if it’s a sandwich course they are in Internship leads to the
intern’s individual development through challenging occupational coursework.
1.2 Manufacturing Range
The Indian machine tools industry manufactures almost the complete range of metal cutting & forming
tools. Customized in nature, the products from the Indian basket comprise conventional machine tools as
well as Computer Numerical Controlled machines (CNC). There are other variants offered by Indian
manufactures too, including special purpose machines, Robotics, handling systems & TPM friendly
machines & provide further value additions at lower & lower cost to meet specific requirements of users.
Based on perception of the current trends and demands, CNC segment could be the driver of growth for the
machine tool industry in India.
1.3 Current Trends
A slowdown in the Indian company since mid-1999 had its fallout on prospects of Indian machine tool
manufactures. The Indian machine tools industry is facing lack of adequate business opportunities that has
stemmed from sluggish in the home market of all user industries.
1.4 Export Performance
In the view of an imminent slowdown in the Indian economy, most Indian machine tool manufacturers
focused on potential overseas marketers for business opportunities. Indian machine tools are currently
exported to over 50 countries major one being USA, Italy, Brazil, Germany & the Middle eastern countries
Lathes And Automates, Presses, Electro discharge machines from Indian basket are generally favored in
overseas markets primarily due to their cost competitiveness as compared to that available elsewhere. The
visions of Indian machine tool industry are now step out and establish a relative presence in other potential
markets. World over market leaders have been those who have looked to increase their presence beyond
their national frontiers.

1.5 Industry Structure
Machine tool industry in India comprises about 450 manufactures with 150 units in the organized sector.
Ten major companies of the industry contribute almost 70% of production of India. And over three quarters
of total machines total production in the country comes out of ISO certified companies. Many machines tool
manufacturers have also obtained CE marketing Certification, in keeping with the requirements of the
European markets. The industry has an installed capacity of over Rs. 10000 million & employees a
workforce totaling 65,000 skilled and unskilled. Bangalore is considered as hub for the Indian machine
industry. The city for instance house HMT Machines Tools LTD, a company that manufactures nearly 32%
of the total industry’s output.
Machines tool industry in India is scattered all over the country. The hub of manufacturing activities
however is concentrated in places like Bangalore, Jalandhar & Ludhiana in Punjab, Pune in Maharastra.
1.6 Machine Tools
Machines tools industry is in a position to export general purpose & a standard machine tool to even
industrially advanced countries. During last four decades, the machine tool industry in India has established
a sound base & there are around 160 machine tool manufactures in the organized sectors as also 400 units in
the small ancillary sector.
The industry however lacks in engineering capability to undertake very high precision CMC machines.
Some companies have taken manufacture of CMC machines, but there is an upgrade R&D in this field.
Indian machine tools are manufactured to the international standard of quality, precision & reliability.
A number of collaborations have also been approved for bringing in the latest technology in the field of
modern machines tools and the industry is now exporting conventional as well as CMC high tech machine
tools. In the field of R&D, central manufacture technology institute, Bangalore has been doing research for
more appropriate designed machine tools.
Corporate Vision
To Be a Manufacturing Solution Provider of international Repute, Offering Best of

Products & Services With Contemporary Technologies for Customers’ ultimate delight.
Corporate Mission:
To be a key source of :Technology for Excellence" in the field of metal cutting /

metal forming.
To provide 'High quality cost competitive solution' for entire manufacturing Industry
on 'One stop shop' basis.
To provide sustained support to all of strategic sectors.
To exceed customers’ expectations through continuous innovation.
To provide leadership & direction in the manufacturing sector for the overall
industrial growth of nation.
1.6 Machine Tool Division:
The unit was initially planned for manufacturing milling machine. To begin with foreign designed
capabilities HMT's self designed machines were introduced. Today range includes various type of milling
machines, these over wide spindle speeds and feeds. With high contents mechatronics, milling machine
with prefined program up to 40 steps have been introduced. In 1967 manufacturing of broaching
machines was taken up as import substitution. Available in horizontal and vertical versions, these
ruggedly constructed machines have infinitely variable cutting speeds with dead constant speeds ensuring
optimum tool life and fine surface finish.
Due to the latest technologies to the countries fast developing industrial base, in 1976 the unit introduced the
state of numerically controlled machine offering unlimited option in manufacturing concept.
The unit has designed a wide range of both Horizontal and Vertical CNC machine center to meet the
accuracy standards, providing the high flexibility and productivity with enough muscle to remove large
quantities of material with low rpm for light metal alloys.
High processing speeds are ensured through CNC systems that have a powerful graphics and user friendly
features. The unit also manufacture moving column type special purpose machines which can perform
milling, drilling, tapping, boring, and reaming operations with linear motion bearing for high position
accuracy with the X Y and Z axis.

CHAPTER -2
PATTERN SHOP
Fig 2.1: pattern shop
A pattern may be defined as replica model of desired casting which, when packed with a suitable modelling
material produces activity called mould. This cavity when filled with molten metal produces the desired
casting after solidification of poured metal the pattern will be given some close allowances.
The most commonly used pattern material in the industry are,
● Wood (e.g.: teak, deodar etc...)

● Metal (e.g.: aluminum, cast iron, bronze etc...)
● Thermal
● Rubber
● Epoxy resin
Mahogany wood is the most commonly used material for patterns, primarily because it is soft, light and easy
to work , but also once properly cured it is about as suitable as any wood available, not subject warping or
curling.
Once the pattern is built the foundry does not want it changing shape. The downside is that it wears out fast
and is prone to moisture attack due to high cost of wood and metal, the patterns are made using thermo cline
and complicated patterns can also make easily with a low cost, but for the high production, patterns used are
wood and metal.
CHAPTER-3
FOUNDRYSHOP
fig 3.1: Foundry shop
 Foundry shop is the place where the metal castings is prepared by melting and pouring the molten
metal into moulds. The most common metals processed are Aluminum and cast-iron. In this process,
parts of desired shapes and sizes can be formed.
 The foundry sand is used to make moulds and cores via a pattern. Green sand consist of high quality
silica sand about 10% betonies clay (as the binder), 2 to 5% water and about 5% sea
coal(carbonaceous mold addictive to improve casting finish ). The type of metal being cast
determines which addictives and what graduation of sand is used.
 The basic tests measure the following parameters: Wet tensile strength, mould ability, moisture
content, permeability, green compression, compatibility, loss on ignition, volatiles content, grain size
and distribution, dust (dead clay) content, and active clay content, impact strength. Each of these
tests lead you to obtain specific.
3.1 Melting Department
 IN HMT electric arc induction furnace is used, which melts the metal at the temperature 1800 degree
Celsius. An electric arc introduction (EAF) is a furnace that heats changes material by means of an
electric arc.
 The material used to produce cast iron are pig iron (contains 2% to 6% of carbon) and wrought iron
(very low carbon less than 0.08%).

 Scrap metal is delivered to a scrap bay in presence of some additives for good properties, located on
top of furnace and left for heating.
 The molten metal is taken out from the furnace and poured into the ladle (which is a vessel used to
transport and pour out molten metal's) and molten metal is transferred to the molds.
 when this process is being carried out the copper coils are regularly cooled with coolant (water) so
that the coils do not melt due to high temperature generated in the coils.
 The foundry of HMT has three furnaces, two having capacity of 3Tonnes and one of 1.5 Tons.
 Specifications of 1.5 ton capacity furnace.
 Line voltage 11000 volts
 Primary voltage 440 volts
 Power voltage 440KW
 Frequency 50Hz
 Melting power 1 ton /hour
 Power factor 0.9
 After melting process is complete, the molten metal is carried quickly to the molds to prevent
solidification.
 The inversion of induction furnace is carried out by hydraulic lifts fled below the whole apparatus.

CHAPTER-4
MOULDING AND CORE MAKING
fig 4.1: Moulding and core making
In HMT due to complex structure of components (such as gear box) are produced with the master pattern.
Here the core is first made with the help of master pattern and allowed to bake. The core is made with the
help of sand such as,
● Rigid coated sand in shell core machining.

● Air setting sand or no bake sand.
● Green sand.
Here the gear box is made with NO BAKE SAND and which is prepared by mixing different constituents.
Here the prepared core is allowed to solidify. Smaller core is baked with the help of shell core machine,
which has a box containing rigid coated sand. When allowed to operate the front assembly rotates and the
box move upward from the sand falls in the die, here the die can be changed. Now the core is put in the
cope, drag and molten metal is poured after which pattern can be easily obtained.

CHAPTER-5
FETTLING
Fig 5.1: Fettling
Fettling is the process by which the pattern is obtained to desired finish by various processes, before fettling
the casting obtained is subjected to removal of projections chips, core, runner, riser etc. by the following
process.
● Decoding
● Chipping
● Shot blasting (for heavy pattern)
● Wheel abrasion (for small pattern)
● Decoding : This is the process of removal of fused sand.
● Chipping : This is the process of removal the runner, riser etc....
● Shot blasting: This is a strip (A metal or other surface) by directing a high speed stream of steel
particles as it.
● Wheel abrasion is removal of small metal strip using wheel abrasion apparatus.

CHAPTER-6
PLANNING
Fig 6.1 Planning
This section consists essentially of planners mounted on one side of section. In this section job planning is
one of the basic operations done for machining large flat surface.
6.1 HTC PRODUCTION

● It is the shop which gives the shape to the largest casting which comes out from the foundry after
being painted rough. In this sections various operations are performed by the help of planners,
boring and planning-boring machine.
● Different type of operation is done by using different machines including various measuring devices.
This section also includes in itself a high technology section in which advanced machines are placed
to machine crucial parts generally guide way headstock components etc. It accommodates a tool
preset device which is used to set the tool of all the machines and CNC machines. It is used to
measure the length and diameter of tool with the help of leases.
● Machine used in this section are : KTM machines (1982 England made)
● Wald rich co burg (Germany made)
● VM4 (vertical machining center 4-axis machine)
● HM4 (Horizontal machining center 4-axis machine

The CNC floor type horizontal boring and milling machine is the major machinery under constant. Model
name UTX 160 CNC, This machine is assembled in HMT Hyderabad; it can be used for almost all types of
milling, boring, drilling jobs. T-slots and clamps are used for holding the job. In case of irregular job shapes,
certain fixtures are used. The basic process of controlling CNC machines are the same.
1. The basic part programs for various operations will be stored in the system.
2. Depending on the tool used the tool offsets are specified.
3. Job should be aligned to the respective axises, and then the work offset is specified.
4. The maximum feed rate and rpm of the spindle is already set, we can control these feature from the
machine.
5. When the machine is turned on, it should be first set at the reference point.
6. Job option –for manual control of machine.
Single block potion-only single block of the part program will be handled.
7. The program is specified in cycles, when the all the cycles get completed, so does the job.
6.2 Electronics involved in a CNC system
1. A-B Processor in the CNC System uses a micro-programmed processor to perform all the function of a
conventional NC including interpolation. The process has a 16 bit word and up to 32k words of memory
capacity.
2. Memory power supply-since the processer use semiconductors memory, stand by battery power for the
memory is provided. Additional stand by battery power is available as an option.
3. Main power supply-the main power supply of 7300 CNC system is a switching type supply that
minimizes heat dissipation in the system cabinet. It has a typical efficiency of 75% and provided +Vdc, +or-
15 Vdcnd +24Vdc as output voltages. It requires a 115 Vac or 50/60 Hz single phase power.
4. Tape Reader –the tape rider, the basic input medium is used to load software program in to the processer
and also to read part programs. Either EIA RS-224 or EIA RS 258 (ASCII) tape formal can be used with the
system.

5. CRT-The CRT can display up to 1024 characters of alphanumeric data. Information displayed will be in
position of each axis, the selected spindle speed, the feed rate in inches per minute, the tool number or turret
position, plus several blocks of the part-program above to be executed.
6. Manual data input keyboard-The MDI keyboard enables data to the entered manually in to the system, to
change next block of data to be executed, or to manually control machines.
7. Contact monitors-The contact monitors will handle DC Inputs from the control panel switches and AC or
DC inputs from the machine tool.
8. Servo Area-The interpolation program continuously generates the command to be executed which is
algebraically summed with the feedback accumulator to determine the actual axis position.

CHAPTER-7
ROUNDS AND NON-ROUNDS
● Rounds section:
This section is concerned with round job construction and working. This section involves operation like
grinding, slotting, drilling, etc..Following are the list machines and operation concerned with them.
Internal grinding machines : Concerned with grinding of outer surface of job. It uses magnet chuck and
shows only horizontal motion of the table.
Cylindrical grinding machines: This machine is used to grind cylindrical jobs with motion of grinding itself.
This job is held in the jaw of chuck.
Slater: This is machine concerned with slot cutting. It uses carbide tip and shows the vertical motion
concerned with this section are Lathes, Radial drilling machines etc..
● Non Rounds-Section:
All the non-rounds jobs that are to be used in machines are machined here.
● Machines used in this section.

● Horizontal milling machines.
● Vertical milling machines.
7.1 Boring and Marking
1.Boring: Boring is the operation of enlarging an already drilled hole. The hole is pre-drilled as in casting
only.
Machine used: Horizontal boring machine vertical boring machine, jog boring.
2.Marking: Marking out or layout is process of transferring a design or pattern to work piece, as the first
step in the manufacturing process. Marking consists of transferring the dimension from the plan to the work
piece in preparation of the next step, machining or manufacture

7.2 GEAR SECTION
fig 7.1: Gear section
Hobbing is a machining process for gear sprockets on a hobbling machine, which is a special type of
milling machine. The teeth or splines are progressively cut into the work piece by a series of cuts made by
cutting tool called a Hob.
All the gears that are used in machine tool division are made in this section.
Processes involved in the manufacture of a gear are:
1.Design is prepared
2. Design is released to foundry shop
3.The casting is prepared and released for material cutting
4.The job piece than under goes turning
5.Gear hobbing is done and followed by fitting
6.Inspection is done
7.Job piece is then sent for heat treatment where carburizing and annealing is done

8.After heat treatment again turning is done
9.Radial drilling is done
11.Internal boring and grinding is done to make the bore
12.Then cylindrical grinding is done
14.Gear tooth grinding is done
15.At lost gear tooth chamfering is done
16.Inspection is dine

CHAPTER-8
SPINDLES
fig: 8.1 Spindles
In machine tools, a spindle is a rotating axis of the machine, which often has a shaft at its heart. The shaft
itself is called a spindle, but also, in shop-floor practice, the word often is used metonymically to refer to
the entire rotary unit, including not only the shaft itself, but its bearings and anything attached to it ( chuck
etc.)
A machine tool may have several spindles, such as the headstock and tailstock spindles on a bench lathe.
The main spindle is usually the biggest one. References to "the spindle" without further qualification imply
the main spindle. Some machine tools that specialize in high-volume mass production have a group of 4, 6,
or even more main spindles. These are called multispindle machines. For example gang drill and
many screw machines are multispindle machines. Although a bench lathe has more than one spindle
(counting the tailstock), it is not called a multispindle machine; it has one main spindle.
This section in concerned with the manufacturing of small cylindrical parts or spindles which may be hallow
solid, shell type etc. According to machine requirement the job concerned are large in size as compared to
the section. This section manufactures all the head related to the jobs.

8.1 Types And Usage Of The Spindles
1. Wheel spindle for K130
2. Main spindle for G9
3. Fine boring machine spindle
4. Work head spindle for K130
5. Hob head spindle 55
6. Cutter spindle for Z5
8.2 Inspection Department
This department is responsible for inspection and servicing of the machines. This department is concerned
with the inspection of various components and machines being manufactured. The inspection is carried out
in various stages, beginning from the inspection of individual components at different stages of
manufacturing followed by the inspection of the whole machine while included final runs etc…..Inspection
of incoming material is also handled.
8.3 Inspection Of Instruments
● Direct reading instruments: In this method the value of a quantity is obtained directly by
comparing the unknown with the standard (EX: vernier types)
● Indirect reading instruments: In this method several parameters ( to which the quantity to be
measured is linked with ) are measured then value is determined by mathematical relationship.
● Measuring instruments: These are usually specified by their metrological properties such as range
of measurements, scale graduation value, scale spacing, sensitivity and reading accuracy. (ex: Dial
indicator, Dial test indicator and Dial comparatorm also available.
8.4 Material Testing
Material testing is a well established technique used to determine the physical and mechanical properties of
raw materials and components for steel, composite material and ceramics.

8.5 Material Testing Machines
● Universal testing machine: It is also known as a universal tester, materials testing machine or
materials test frame, is used to test the tensile strength and compressive strength of materials.
● Hardness tester: Its is the measuring the permanent depth of indentation.
UNIVERSAL TESTING MACHINE
Fig 8.2: Universal Testing Machine
Its components are oil pump, hydraulic press, main piston, fixed cross head and movable cross head. It has
range according to the load applied.
● 0-1 tons
● 0-4 tons
● 0-10 tons
It is used generally to determine:
● Proportional and elastic limit
● Yield point
● Ultimate tensile strength
● Percentage reduction and reduction in area.

Working:
It is generally used to perform tensile test which is widely used in the design of material for structure and
other purpose. Here, test piece is pulled out at a constant rate by gradually increasing the axial pull,
till the rupture takes place. Firstly the specimen is held in jaws of machine and the load is applied
gradually by hydraulic press which is measured from the pressure developed inside the cylinder. The
function of oil pump is supplied oil under the pressure to the hydraulic cylinder. The load taken from
the load scale the test is carried out on a specimen having uniform cross-section throughout gauge
length.
8.6 Brinell Hardness Test
Fig.8.3 : Brinell Hardness Test
Hardness is measured by this machine in HBN. In steel diamond are used to take impression, load applied
on the specimen to take the impression is given by the formula 30D2. Where, D=Dia.of diamond ball
(2.5mm max) Impressions formed on the specimen are of round shape.

8.7 Rockwell Hardness Test
Fig, 8.4 : Rockwell Hardness Test
Hardness measured by this machine in HRC max load applied in this machine is 150kg.Impressions are of
pyramid shape. It is performed when quick and direct reading is desirable in this test.
● Hot water tank

● Low temperature blocking
8.8 Inspection Department
This department is responsible for inspection and servicing of the machines. This department is concerned
with the inspection of various components and machines being manufactured. The inspection is carried out
in various stages, beginning from the inspection of individual components at different stages of
manufacturing followed by the inspection of the whole machine while included final runs etc…..Inspection
of incoming material is also handled.
8.8.1 Inspection Instruments
● Direct reading instruments:

In this method the value of a quantity is obtained directly by comparing the unknown with the standard (EX:
vernier types)
● Indirect reading instruments:
In this method several parameters ( to which the quantity to be measured is linked with ) are measured then
value is determined by mathematical relationship.
● Measuring instruments:
These are usually specified by their metrological properties such as range of measurements, scale graduation
value, scale spacing, sensitivity and reading accuracy.(ex: Dial indicator, Dial test indicator and Dial
comparatorm also available.

CHAPTER-9
HEAT TREATMENT:
fig.9.1:Heat Treatment
Heat treating (or heat treatment) is a group of industrial and metalworking processes used to alter
the physical, and sometimes chemical, properties of a material. The most common application
is metallurgical. Heat treatments are also used in the manufacture of many other materials, such as glass.
Heat treatment involves the use of heating or chilling, normally to extreme temperatures, to achieve a
desired result such as hardening or softening of a material. Heat treatment techniques
include annealing, case hardening, precipitation strengthening, tempering, normalizing and quenching. It is
noteworthy that while the term heat treatment applies only to processes where the heating and cooling are
done for the specific purpose of altering properties intentionally, heating and cooling often occur
incidentally during other manufacturing processes such as hot forming or welding.
9.1 Types Of Heat Treament

o Natural bath tank
o Quenching bath tank
o Carburizing bath tank
o Preheated furnaces
o Stress reliving furnace
o Rust removing tank
o Washing tank

o NAOH bath tank

o Hot water tank
o Low temperature blocking
9.2 Types Of Heat Treatment Process
Annealing:-
Annealing consists of heating a metal to a specific temperature and then cooling at a rate that will produce
a refined microstructure, either fully or partially separating the constituents. The rate of cooling is generally
slow. Annealing is most often used to soften a metal for cold working to improve machinability or to
enhance properties like electrical conductivity.
Normalizing:-
Normalizing is a technique used to provide uniformity in grain size and composition (equiaxing)
throughout an alloy. The term is often used for ferrous alloys that have been austenized and then cooled in
open air. Normalizing not only produces pearlite, but also martensite and sometimes bainite, which gives
harder and stronger steel, but with less ductility for the same composition than full annealing.
Stress relieving:-
Stress relieving is a technique to remove or reduce the internal stresses created in a metal. These stresses
may be caused in a number of ways, ranging from cold working to non-uniform cooling. Stress relieving is
usually accomplished by heating a metal below the lower critical temperature and then cooling
uniformly. Stress relieving is commonly used on items like air tanks, boilers and other pressure vessels to
remove all stresses created during the welding process.
Quenching:-
Quenching is a process of cooling a metal at a rapid rate. This is most often done to produce a martensite
transformation. In ferrous alloys, this will often produce a harder metal, while non-ferrous alloys will
usually become softer than normal.
Aging:-
Some metals are classified as precipitation hardening metals. When a precipitation hardening alloy is
quenched, its alloying elements will be trapped in solution, resulting in a soft metal. Aging a "solutionized"
metal will allow the alloying elements to diffuse through the microstructure and form intermetallic particles.
These intermetallic particles will nucleate and fall out of solution and act as a reinforcing phase, thereby

increasing the strength of the alloy. Alloys may age "naturally" meaning that the precipitates form at room
temperature, or they may age "artificially" when precipitates only form at elevated temperatures. In some
applications, naturally aging alloys may be stored in a freezer to prevent hardening until after further
operations - assembly of rivets, for example, may be easier with a softer part.
Tempering:-
Untempered martensitic steel, while very hard, is too brittle to be useful for most applications. A method
for alleviating this problem is called tempering. Most applications require that quenched parts be tempered.
Tempering consists of heating steel below the lower critical temperature, (often from 400 to 1105 ˚F or 205
to 595 ˚C, depending on the desired results), to impart some toughness. Higher tempering temperatures
(may be up to 1,300 ˚F or 700 ˚C, depending on the alloy and application) are sometimes used to impart
further ductility, although some yield strength is lost.
Flame hardening:-
Flame hardening is used to harden only a portion of a metal. Unlike differential hardening, where the entire
piece is heated and then cooled at different rates, in flame hardening, only a portion of the metal is heated
before quenching. This is usually easier than differential hardening, but often produces an extremely brittle
zone between the heated metal and the unheated metal, as cooling at the edge of this heat-affected zone is
extremely rapid.
Case hardening :-
Case hardening is a thermo chemical diffusion process in which an alloying element, most commonly
carbon or nitrogen, diffuses into the surface of a monolithic metal. The resulting interstitial solid solution is
harder than the base material, which improves wear resistance without sacrificing toughness.[21]
Decarburization:-
The heating of steel is sometimes used as a method to alter the carbon content. When steel is heated in an
oxidizing environment, the oxygen combines with the iron to form an iron-oxide layer, which protects the
steel from decarburization. When the steel turns to austenite, however, the oxygen combines with iron to
form slag, which provides no protection from decarburization. The formation of slag and scale actually
increases decarburization, because the iron oxide keeps oxygen in contact with the decarburization zone
even after the steel is moved into an oxygen-free environment, such as the coals of a forge. Thus, the carbon
atoms begin combining with the surrounding scale and slag to form both carbon monoxide and carbon
dioxide, which is released into the air.

9.3 Ball Screw
:-
fig.9.2: Ball screw
A ball screw is a mechanical linear actuator that translates rotational motion to linear motion with
little friction. A threaded shaft provides a helical raceway for ball bearings which act as a precision screw.
As well as being able to apply or withstand high thrust loads, they can do so with minimum internal friction.
They are made to close tolerances and are therefore suitable for use in situations in which high precision is
necessary. The ball assembly acts as the nut while the threaded shaft is the screw. In contrast to
conventional leadscrews, ball screws tend to be rather bulky, due to the need to have a mechanism to re-
circulate the balls.
9.4 Lathes Operations

The general operations done with the lathe are grooving, turning, cutting, sanding and etc. if anyone wants
to operate the lathe machine then he must first know about the feeds, cutting speed, depth of the cut and
usage of tool should be considered. Each lathe operation has got its own factors that need to be considered
before doing the work. The factors should be used properly so that one can avoid from mishandling and
mishaps while performing any kind of lathe operation. With every cut desired the speed, depth and feed of
the lathe machine is changed for precision.

9.5 Types of Lathe Operation

The working of the lathe machine changes with every operation and cut desired. There are a lot of
operations used for using the lathe machine. Some of the common lathe operations are:
fig.9.3: Types of Lathe Operations
Facing :-
This is usually the first step of any lathe operation on the lathe machine. The metal is cut from the end to
make it fit in the right angle of the axis and remove the marks.
Tapering:-
Tapering is to cut the metal to nearly a cone shape with the help of the compound slide. This is something in
between the parallel turning and facing off. If one is willing to change the angle then they can adjust the
compound slide as they like.
Parallel Turning:-
This operation is adopted in order to cut the metal parallel to the axis. Parallel turning is done to decrease
the diameter of the metal.
Parting:- The part is removed so that it faces the ends. For this the parting tool is involved in slowly to
make perform the operation. For to make the cut deeper the parting tool is pulled out and transferred to the
side for the cut and to prevent the tool from breaking.
Lathe Cutting Tools:-
There are several lathe cutting tools that help in cutting with the lathe machine. The commonly used tools
Carbide tip tools
● Grooving tool
● Cut-Off blade
● Parting blades
● Boring bar
9.6 Heavy Duty Lathe-45 Assembly
fig.9.4: Lathe-45 Assembly
Lathe machine is used to removal of the material with required shape and size and different operation to be
performed. L-45 Assembly is one of the department in HMT that assembles all the relevant parts of Lathe-
45 machine it involves in assembly.
Salient features of L-45 lathe:
● Designed to provide flexible, accurate, high performance and cost effective machining such as
OD/ID turning, profile turning, facing, and thread cutting.
● Machine can also be offered with a gap piece to accommodate large dia. components.
● Infinitely variable spindle speeds in four ranges-automatic selection.
● All gears in main drive and feed drives of alloy steel, case hardened and ground.
● Various types of lathes are there, L-50, L-60, L-70.
● The lathe bed length varies as per requirements of customers. The length of the bed usually of 2m,
3m, 4m, 5m, 6m, 7m, 11m, and etc.. are presently manufacturing in this HMT.

9.7 Specifications
L45 L5 L6
0 0 L70
Height of 450 500 600 700
Mm
canters
Swing over Mm 900 100 115
Bed 0 0 1350
Swing over Mm 570 670 870 1000

cross slide
Distance 2000/3000/4000/5000/7000
mm
between
centres
Bar Mm 110
passage/spin
dle bore
Spindle Kw 18.5(opt. 80) 18.5
power(100%
)
Speed range Rp/m 21 from 4.5-450 forward
6 from 9-450 reverse
Feed range Mm/rev 77 from 0.1-6.4
longitudinal

9.8 Radial Drilling Machine Assembly
RD Assembly in one of the department in HMT that assembles all the relevant part of the radial drilling
machine it involves in assembly of gear drives control systems. Radial drilling machine is intended for
drilling a medium to large and heavy work piece.
Fig.9.5: Radial Drilling Machine
The main components of RD machine are

1. BED
2. Column
3. Sleeve
4. Arm
5. Drill head
6. Motor {Three phase squirrel/large induction motor}

Salient features:
● Massive and rigid construction.

● Light centering of spindle.
● Precise depth release
● Electro hydraulic clamping provided for drill head, arm and sleeve.
THE HINDUSTAN RADIAL DRILLING MACHINE. TYPE- RM65

Specifications : In inches
Drilling Capacity : in steel 2” in cast iron 2-3/8”
Drilling rough bores : in steel 3-9/16” in cast iron 4-5/16”
Boring with supported bar : in steel 4-3/4” in cast iron 5-1/2”
Trepanning in steel 7-7/8” : in cast iron 9-1/16”
Tapping whit worth : in steel 1-3/4” in cast iron 2-1/2”
Tapping Metric fine thread: in steel 56 in cast iron 70
Drilling depth : 12-13/16”
12 Spindle speeds : 40 - 1700RPM 50 – 2100 RPM
6 Spindle feeds : .005” /Rev to 050” /Rev
Spindle diameter : 81.1
Drilling pressure : 1650 kg
Drill power : 4.8/6 horse power
Arm elevating motor power: 3 HP
Coolant pump motor power: .15 HP
Standard Box table : 600 mm x 500 mm x 500 mm

Learning Experience
I have done my organization study in Hindustan machine tool limited Bangalore.
During in this study I had a good experience in this organization. It was a great knowledge based and
excellent training program. All the staff members of the organization were co-operative and friendly in their
approach. Whenever I visited to all the functional department. In every department weather it is lower level
or higher level the concerned, staff given me all the necessary information whatever I required to learn.
Overall it’s been good experience. In the plant I had gone through various departments with interacting
between the head of department then there only just I noticed some of the aspects, which are required to me.
Initially I started working upon the production process and how the products are manufactured from raw
materials; the chain of converting raw material into consumer hand products is very interesting. My
experience on the factory has much more impact on me because for the first time i had worked with the
practical aspects and soon I come to realize practical aspects are not easy to learn. I have got the practical
oriented of the functions of the various departments of the company. I was able to analyze the performance
of the company, and I also understood the application of theoretical concepts into business decision in the
organization and I understood delegation of authority, responsibility, co-ordination and tem work in the
organization.

CHAPTER-10
CONCLUSION
Hence we conclude our report successfully completing internship of duration of 30 days in HMT machine
tools limited and we thank respected people head of various department who allotted their time and guided
us through different process happening and sharing their knowledge with us which helped us in bridging the
gap between the college education and industrial requirement and gained lot of new information about
various machine and there working.

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● HMT Machines Tools Limited

PRAGA Machine tools limited

The machine tools, Bangalore unit.

DEPARTMENT MECHANICAL ENGINEERING. AIT, BANGALORE. Page 1

1.1 Introduction About The Internship

1.2 Manufacturing Range

1.3 Current Trends

1.4 Export Performance

DEPARTMENT MECHANICAL ENGINEERING. AIT, BANGALORE. Page 2

1.5 Industry Structure

1.6 Machine Tools

To Be a Manufacturing Solution Provider of international Repute, Offering Best of

To be a key source of :Technology for Excellence" in the field of metal cutting /

DEPARTMENT MECHANICAL ENGINEERING. AIT, BANGALORE. Page 3

1.6 Machine Tool Division:

DEPARTMENT MECHANICAL ENGINEERING. AIT, BANGALORE. Page 4

Fig 2.1: pattern shop

The most commonly used pattern material in the industry are,

● Wood (e.g.: teak, deodar etc...)

fig 3.1: Foundry shop

3.1 Melting Department

DEPARTMENT MECHANICAL ENGINEERING. AIT, BANGALORE. Page 6

DEPARTMENT MECHANICAL ENGINEERING. AIT, BANGALORE. Page 7

MOULDING AND CORE MAKING

fig 4.1: Moulding and core making

● Rigid coated sand in shell core machining.

DEPARTMENT MECHANICAL ENGINEERING. AIT, BANGALORE. Page 8

Fig 5.1: Fettling

DEPARTMENT MECHANICAL ENGINEERING. AIT, BANGALORE. Page 9

Fig 6.1 Planning

6.1 HTC PRODUCTION

DEPARTMENT MECHANICAL ENGINEERING. AIT, BANGALORE. Page 10

2. Depending on the tool used the tool offsets are specified.

6. Job option –for manual control of machine.

6.2 Electronics involved in a CNC system

DEPARTMENT MECHANICAL ENGINEERING. AIT, BANGALORE. Page 11

DEPARTMENT MECHANICAL ENGINEERING. AIT, BANGALORE. Page 12

ROUNDS AND NON-ROUNDS

● Machines used in this section.

7.1 Boring and Marking

DEPARTMENT MECHANICAL ENGINEERING. AIT, BANGALORE. Page 13

7.2 GEAR SECTION

fig 7.1: Gear section

Processes involved in the manufacture of a gear are:

2. Design is released to foundry shop

3.The casting is prepared and released for material cutting

4.The job piece than under goes turning

5.Gear hobbing is done and followed by fitting

DEPARTMENT MECHANICAL ENGINEERING. AIT, BANGALORE. Page 14

8.After heat treatment again turning is done

9.Radial drilling is done

11.Internal boring and grinding is done to make the bore

12.Then cylindrical grinding is done

14.Gear tooth grinding is done

15.At lost gear tooth chamfering is done

DEPARTMENT MECHANICAL ENGINEERING. AIT, BANGALORE. Page 15

fig: 8.1 Spindles

DEPARTMENT MECHANICAL ENGINEERING. AIT, BANGALORE. Page 16

8.1 Types And Usage Of The Spindles

1. Wheel spindle for K130

2. Main spindle for G9

3. Fine boring machine spindle