PREFACE

Training in an industry is a dynamic tool to get feeling of practical aspect of whatever has been learnt by us in the books. It greatly enhances knowledge with the practical experience. Training in such great and well-managed company is a great opportunity for the trainer as apart from the basic training. Also we get a change to be familiar with certain other aspects of industry relations etc. Our main objective of undergoing industrial training is to acquire practical knowledge. Training enables us to get a clear-cut view of the subject that we have read. Both theory and practical are essential. Hence we can say, The theory is blind without practical and practical without theory. In fact, both are complementary to each other. As a part of three years of Degree with Industrial Engineering, I have undergone for Six Weak Industrial Training after the Fourth Semester. I am proud of receiving my Industrial Training in Tool Room at Oriental Engineering Works Pvt. Ltd Yamuna nagar, Haryana that is one of the top heaviest engineering industries of the country.

ACKNOWLEDGEMENT

During my training of two months as Oriental, whatever I learnt is going to be of great practical importance in my future. For this I would like to express my gratitude to Mr.Sanjay Verma (Incharge of Tool Room) so that under his guidance I successfully completed my training. I would also like to thanks the whole staff of Tool Room whos friendly and cooperative behaviour help me lot in learning various techniques and gave me a never before experience in such reputed firm. I would like to convey my sincere thanks and gratitude to our respectable Director And H.O.D. Mech. Deptt. I convey my heartiest thanks to all those officers and employees of Oriental who have given me their full co-operation and devoted their valuable time for rendering me their needy services, guidelines during the course of imparting me practical training and with whose sincere and precious helps, I have been able to complete my practical training successful.

ORIENTAL PROFILE

ORIENTAL ENGINEERING WORKS PVT. LTD. It was established in 1933 at Lahore (now in Pakistan) and began with the manufacture of Cold Start Horizontal Diesel Engines. The company was shifted to its present premises after the partition of India. Later, the company stated the manufacture of Hydraulic Equipment and is presently manufacturing High Pressure Cylinders, Pumps and Hydraulic Systems up to 700 Bar (10,000psi).

Oriental Engineering Works Pvt. Ltd is also representing:

Jigs and M/s Roemheld GmbH,Germany for Hydraulic Work Holding / Elements for Fixtures for CNC Machining Centres.

Elements,

M/s Hilma-Roemheld GmbH, Germany for Quick Die Clamping / Changing Hydro-Mechanical, Mechanical and Hydraulic Vices.

M/s Plarad GmbH, Germany for Hydraulic / Electric / Pneumatic Torque Wrenches, Manual Torque Multipliers etc. It has been awarded the coveted Star Export House status.

Oriental Engineering has followed a systematic policy of up gradation in design and manufacturing. It now offers a complete range of 700 Bar(10,000psi) product range for Hydraulic Jacks, Cylinders, Pumps, Power Packs, Systems, Valves & Tools, Hydraulic, Systems including Cylinder & Power Packs for Construction, Mining, Hydro-electric Projects, Tunneling , Underground Metros etc. It is engaged in a big way in offering CUSTOM DESIGN EQUIPMENT.

We also entered in the field of manufacture of VACCUM PISTON DEWATERING RECIPROCATING PUMPS with sound proof canopies.

The Products are being exported to a large number of European Countries, USA and Canada, Australia, UK., Russia, Middle East, East Africa, South Africa, South East Asia and New Zealand.

We started the export of our Hydraulic Jacks in an organized manner in the year 1990. Our initial order from Sydney, Australia was for about US $ 1,500. In just about four months from the first supply, we made a quantum jump to the order from the same company of about US $ 30,000. We are now exporting our Hydraulic Jacks to the USA, West Europe through Germany, Australia, Middle East, etc. We have perhaps the largest capacity in the World for the manufacture of jacks of the capacity 500 tonnes and above. We supplied 4 Nos. 1500 tonnes capacity each to Bauer International GmbH, Germany for one of their projects in Abu Dhabi. We have made strides in our designs and processes over the period of time like all progressive manufacturers. We shall be the FIRST in India in the field of Hydraulics to get the coveted CE Certification (by TUV Cert Germany) - this certification in on way - all has since been tested and approved by TUV. Further, though not an ISO 14000 certified Company, we are a totally Pollution free Unit - Water, Air and handling of hazardous waste. We are proud of the fact that we are in no way lacking behind any one else in the world in terms of quality in the design, manufacture and performance. We impart after sales service in any part of the world where our equipment is being used. All our outlets have trained personnel.

Quality:The company is certified for ISO 9001:2000 and ISO 14001 by TUV Cert-Germany. Majority of its products comply to ASME B30.1-1998 and ISO 10100-2001 and also CE marked. The accessories used, also conform to SAE J 517 for hydraulic hoses and EN 837-1 for pressure gauges.

INFRASTUCTURE

1.

Oriental Engg. Works has a sprawling works covering an area of about 25 hectares including covered production area of around 35,000 square meters. It has the capacity to handle jobs weighing upto 100 tonness (single piece).

2.

3.

Extensive facilities for hot & cold rolling, machining, welding, heat treatment and stringent quality controls to ensure strict compliance to international standards.

4.

More than 125 sophisticated machines and machine tools are installed in various production bays. Apart from these, more than 100 welding machines ( for various processes including SMAW, SAW, MIG, TIG and flash butt welding and under operation). Design department equipped with Pro-engineering facilities. Surface coating facilities/ Hard chrome plating / Zinc plating / Electroless nickel Hard anodizing, 7 Tank phosphating Powder painting. Metrology equipped with calibrating facilities of all measuring instruments, pressure gauges etc. Machine shop equipped with latest CNC machine.

5.

6. 7. 8.

9.

Chemical lab.Metallurgical & Sand testing laboratory including Salt spray test.

10. Foundry equipped with Cupola and Oil fired furnaces.

Products & Services

Garage Equipments High Pressure Hydraulic Cylinders Hydraulic Tools Jacks Pneumatic Tools

PRODUCT RANGE

Oriental Engineering has followed a systematic policy of up gradation in design and manufacturing The groups product range includes for:-

1.

Hydraulic Presses, Mechanical Presses & Press brake. Oriental has successfully commissioned around 100 presses built include a 3700 tonness hydraulic presses for defense and a 2500 press. tonnesss mechanical

2.

It now Offers Pumps, Power Packs, Systems, Valves & Tools, Hydraulic, Systems including Cylinder & Power Packs for Construction, Mining, Hydro-electric Projects, Tunnelling, Underground Metros etc. Cylinders (Single Acting Light Weight Aluminium Cylinders, Single Acting General Purpose Cylinders, Low Height Flat Cylinders, Single Acting Cylinders with Lock Nut, Double Acting Cylinders, Single Acting Hollow Plunger Cylinders, Double Acting Hollow Cylinders etc..)

3.

4. 5.

It now offers a complete range of 700 Bar(10,000psi) product range for Hydraulic Jacks It also entered in the field of manufacture of VACCUM PISTON DEWATERING RECIPROCATING PUMPS with sound proof canopies

Air Hydraulic Pumps Ultra-High Pressure Injectors are used to install and demount interference-fit parts such as bearings, couplers, wheels, hubs, propellers and so on. Works on the principal of injecting oil under ulta-high 2 pressure of 3000 kg /cm between mated surfaces. Low effort on handle allows one-man operation. Easy to use.

Air Hydraulic Pumps Air Hydraulic Pumps are designed for fast operation, greater versatility and durability. Ideal pump where Shop-Floor air is available at 7 bar. Carrying handles are of treadle design, which allows easy operation by hand and foot. Built in Relief Valve protects hydraulic system components regardless of air pressure. Assembly can be done to fit on larger reservoir (if required). Provides greater speed at low cost. It is recommended to attach a Filter-Lubricator unit at air inlet.

C-Clamps Used as a maintenance tool for pressing, clamping, crimping, punching applications and also for assembly. Operational in all positions. Single acting, spring return cylinder. Female half coupler & dust cap provided on all models.

Double Acting Cylinders Heavy duty oil return Jacks/Rams/Cylinders for quick retracing, horizontal, vertical and inverted operations. Suitable loads may be attached to the piston rod as well, if required. Double acting cylinders are designed to operate in both pushing and pulling directions under pressure Collar threads and base mounting holes enable easy fixturing. Hard chrome plated steel piston rod.

 Safety valve in retract side of cylinder helps to prevent damage in case of accidental overpressurization. Female half coupler & dust cap provided on all models. Swivel saddle with 3-5 swivel angel available on request for 50 tonnes & above hydraulic cylinders. Please contact nearest dealer for cylinders with capacities & strokes not mentioned in the data sheets. All variations are possible on request, subject to confirmation from the dealer.

Double Acting Hollow Cylinders Hollow piston rod design allows for both pull & push forces. A hollow saddle fitted to the rod is supplied as standard interchangeable threaded hollow saddles are available as optional extras. Larger central holes can be made on request. Hard chrome plated steel piston rod. These cylinder are oil return.They are suitable for quick retracing and for horizontal, vertical and inverted operations. Collar threads and base mounting holes enable easy fixturing (except YS 250100, YS300200, YS350200, YS500200). Relief valve prevents damage in case of over-pressurisation. Stop ring provided on all models. Female half coupler & dust cap provided on all models.

Hydraulic Oil Maximum pump volumetric efficiency. Maximum internal heat transfer. Prevents pump cavitation. Additives prevent rust, oxidation and sludge. High viscosity index.

 Maximum film protective lubricity. The 20 liters can have a screwed re-useable top pullout funnel with inbuilt filter. Easy pouring. The pullout funnel can be pushed back for safe closing during storage

Hydraulic Power Packs Petrol Engine Driven/Diesel Engine OEW offers a range of Engine/ Air Driven Hydraulic Power Packs. Pumps are available in two stage models. All Pumps come equipped with Pressure Relief Valves for safety. Tank : Steel fabricated. All Tanks are electrostatic powder coated. All Power Pack components suitably fitted for out door duty. Extra Relief Valve provided in reservoir to prevent over loading. Return Line Filter provided in only Double Acting Cylinder type Power Packs

Pressure Gauges Pressure gauge is always recommended to safeguard against overloading of the hydraulic system. 2 Calibrated to read in kg/cm and psi. Fast and easy installation. Pressure gauges calibrated to read directly in tones can be provided on request

DIVISION OF ORIENTAL ENGG. WORKS PVT. LTD;ORIENTAL has been divided into four divisions as follows:1. MACHINE BUILDING DIVISION (MBD) Machine building division is very important division of ORIENTAL and it manufactures sugar mill machinery. Press components and other Steel plant machinery. It is sub-divided into following shops:a) FABRICATION SHOP-I,II b) MACHINE SHOP-I,II c) ASSEMBLY SHOP d) QUALITY SHOP 2. FOUNDRY GROUP (FG) Foundry group is the third important group of ORIENTAL and it is responsible for casting of large castings for the big industries.

3.

TUBE SHOP Tube shop deals with tube manipulation and fabrication of tubing system

used in economizers and super-heaters.

4.

CONTAINER SHOP Container shop manufactures chlorine, ammonia and other gases containers.

FABRICATION SHOP

Fabrication shop is one of the constituents of the machine-building department. Almost all sort of fabrication work are done here. In this shop thick sheets of mild steel are cut, welded and bent according to the required design. For the cutting of plates and sheets CNC gas cutting techniques are made use of. Then different cut parts are joined together with the help of welding.

Some of the welding techniques adopted in Oriental are:-

Gas Metal Arc Welding (GMAW) Submerged Arc Welding (SAW) Shielded Metal Arc Welding(SMAW) Semi Saw Plasma Arc Welding

Brief description of these welding techniques is given in the following pages. The bending of sheets is preferred in hydraulic presses. For bending, a specific type and size of the die is kept under the plate to be bent and then hydraulic pressure is applied above the plate. Extent of bending depends upon the radius of curvature of arc formed by bend plate. Gauging is used for cutting sheets.

WELDING TECHNIQUES
1. Shielding Metal Arc Welding (SMAW)

Principle:It is arc welding process in which coalescence if the metal is produced by heat from an electric arc. That is maintained between tip of a covered electrode and surface of base metal in joint being welded. The principal function of covering on electrode is to provide arc stability and to shield molten metal from oxidation with gases created as coating down from heat of the arc. For generating arc there should be some difference between electrode and workpiece. For better results length of the arc should be as small as possible.

Advantage:Auxiliary gas shielding or granular flux is not required any more.

Limitation:Due to high temperature are characteristics may change.

2.

Submerged Arc Welding(SAW) It produces the coalescence of metal by hating them with arc between

base metal electrode and work-piece. The arc and molten metal are submerged in a blanket of granular fusible flux. The main role of the flux is to control the chemical and mechanical properties of final weld. In the welding end of a continuous bare wire electrode is inserted into the mould of

flux that covers area to be welded. An arc is initiated using one of the arc initiation methods. A wire feeding mechanism begins to feed electrode wire. Additional flux is fed along with electrode. Heat evolved by electric arc melts some of flux creating a pool of molten metal beneath layer of molten slag. The flux blanket on the top surface of weld pool prevents the atmospheric gases to mix.

Factors that usually effect SAW:-

Chemical composition and final deposits of weld. Type of metal to be welded. Position in which weld is to be made. Volume of welding to be performed.

3. Gas Tungsten Arc Welding (GTAW) It is technique that uses an arc between a tungsten electrode and weld pool. The process is adopted with/without shielding gas. Shielding gas is fed through torch to protect electrode, molten weld metal and shielding weld metal from oxidation. The arc is produced by the passage of current through conducting gas. The arc is established between the tip of electrode and work. Heat generated by arc melts the joining surfaces. Filler wire is added to leading edge to fill the joint.

4. Co2 Gas Welding/Metal Active Gas Welding (MGAW) MGAW is so called because Co2 is an active gas. MS wire electrode is fed automatically in the welding torch and Co2 gas is allowed to pass through the torch pipes. It acts as a shielding gas because it protects the weld pool from oxidation by atmospheric gases. If instead of Co2 we use helium/argon welding technique is called MIG.

5. Plasma Arc Welding (PAW) It is an arc welding process that produces coalescence of metals by heating with a constricted arc between electrodes and constricted nozzle. It uses a non consumable electrode. PAW torch has a nozzle that creates a gas in the chamber surrounding the electrode. The arc heats the gas fed into chamber to a particular temperature. It becomes ionized and conducts electricity. The ionized gas is called plasma. It raises the gas temperature up to 30,000 degree F. It is very expensive technique. Principle:The gas is directed through the torch to surround the electrode. It bears ionized un arc to form plasma. For most operations auxiliary shielding gas is used. The arc construction nozzle is specified by nozzle diameter and throat length.

Disadvantage:-

Major disadvantage of PAW is the relatively high expenses of equipment. Also there are more control variables, more complex and expensive operator training.

ASSEMBLY SHOP

Study of CNC MACHINING (Turning & Milling) &PROGRAMMING CNC : Computer and Numeric Control Conventionally, an operator decides and adjusts various machines parameters like feed , depth of cut etc depending on type of job , and controls the slide movements by hand. In a CNC Machine functions and slide movements are controlled by motors using computer programs. For a CNC machine control unit (MCU) decides cutting speed, feed, depth of cut, tool selection , coolant on off and tool paths. The MCU issues commands in form of numeric data to motors that position slides and tool accordingly. Overview A numerical control, or NC, system controls many machine functions and movements which were traditionally performed by skilled machinists. Numerical control developed out of the need to meet the requirements of high production rates, uniformity and consistent part quality. Programmed instructions are converted into output signals which in turn control machine operations such as spindle speeds, tool selection, tool movement, and cutting fluid flow By integrating a computer processor, computer numerical control, or CNC as it is now known, allows part machining programs to be edited

and stored in the computer memory as well as permitting diagnostics and quality control functions during the actual machining.

All CNC machining begins with a part program, which is a sequential instructions or coded commands that direct the specific machine functions.The part program may be manually generated or, more commonly, generated by computer aided part programming systems.

Basic CNC Principles All computer controlled machines are able to accurately and repeatedly control motion in various directions. Each of these directions of motion is called an axis. Depending on the machine type there are commonly two to five axes. Additionally, a CNC axis may be either a linear axis in which movement is in a straight line, or a rotary axis with motion following a circular path. Motion control - the heart of CNC The most basic function of any CNC machine is automatic, precise, and consistent motion control. Rather than applying completely mechanical devices to cause motion as is required on most conventional machine tools, CNC machines allow motion control in a revolutionary manner. All forms of CNC equipment have two or more directions of motion, called axes. These axes can be precisely and automatically positioned along their lengths of travel. The two most common axis types are linear (driven along a straight path) and rotary (driven along a circular path). Each axis consists of a mechanical component, such as a slide that moves, a servo drive motor that powers the mechanical movement, and a ball screw to transfer the power

from the servo drive motor to the mechanical component. These components, along with the computer controls that govern them, are referred to as an axis drive system Using a vertical mill machining center as an example, there are typically three linear axes of motion. Each is given an alphabetic designation or address. The machine table motion side to side is called the X axis. Table movement in and out is the Y axis, while head movement up and down the column is the Z axis. If a rotary table is added to the machine table, then the fourth axis is designated the b axis. Work Positioning The method of accurate work positioning in relation to the cutting tool is called the rectangular coordinate system. On the vertical mill, the horizontal base line is designated the X axis, while the vertical base line is designated the Y axis. The Z axis is at a right angle, perpendicular to both the X and Y axes. Increments for all base lines are specified in linear measurements, for most machines the smallest increment is one ten-thousandth of an inch (.0001). If the machine is graduated in metric the smallest increment is usually one thousandth of a millimeter (.001mm). The rectangular coordinate system allows the mathematical plotting of points in space. These points or locations are called coordinates. The coordinates in turn relate to the tool center and dictate the tool path through the work.

CNC Machines- Advantages Disadvantages

Advantages: High Repeatability and Precision e.g. Aircraft parts Volume of production is very high Complex contours/surfaces need to be machined. E.g. Turbines Flexibility in job change, automatic tool settings, less scrap More safe, higher productivity, better quality Less paper work, faster prototype production, reduction in lead times

Disadvantages: Costly setup, skilled operators Computers, programming knowledge required Maintenance is difficult

Types of Machine Lathes for metal and plastics Used to produce 3D product shapes and moulds for plastic products. Milling machine for mould making and surface milling Used to produce dies for die cutting printed products.

CNC Lathe: Automated version of a manual lathe. Programmed to change tools automatically.

Used for turning and boring wood, metal and plastic.

CNC Milling Machine: Has 3 to 5 axes. Used for wood, metal and plastic. Used to make 3D prototypes, moulds, cutting dies, printing plates and signs.

How CNC Works Controlled by G and M codes. These are number values and co-ordinates. Each number or code is assigned to a particular operation. Typed in manually to CAD by machine operators. G&M codes are automatically generated by the computer software.

Features of CNC Machinery The tool or material moves. Tools can operate in 1-5 axes. Larger machines have a machine control unit (MCU) which manages operations. Movement is controlled by a motors (actuators). Feedback is provided by sensors (transducers) Tool magazines are used to change tools automatically.

Tools: Most are made from high speed steel (HSS), tungsten carbide or ceramics. Tools are designed to direct waste away from the material. Some tools need coolant such as oil to protect the tool and work.

Tool Paths, Cutting and Plotting Motions Tool paths describes the route the cutting tool takes. Motion can be described as point to point, straight cutting or contouring. Speeds are the rate at which the tool operates e.g. rpm. Feeds are the rate at which the cutting tool and work piece move in relation to each other. Feeds and speeds are determined by cutting depth, material and quality of finish needed. e.g. harder materials need slower feeds and speeds. Rouging cuts remove larger amounts of material than finishing cuts. Rapid traversing allows the tool or work piece to move rapidly when no machining is taking place.

CNC Programming Basics CNC instructions are called part program commands. When running, a part program is interpreted one command line at a time until all lines are completed.

Commands, which are also referred to as blocks, are made up of words which each begin with a letter address and end with a numerical value.

Each letter address relates to a specific machine function. G and M letter addresses are two of the most common. A G letter specifies certain machine preparations such as inch or metric modes, or absolutes versus incremental modes. A M letter specifies miscellaneous machine functions and work like on/off switches for coolant flow, tool changing, or spindle rotation. Other letter addresses are used to direct a wide variety of other machine commands.

CNC programming:Important things to know: Coordinate System Units, incremental or absolute positioning Coordinates: X,Y,Z, RX,RY,RZ Feed rate and spindle speed Coolant Control: On/Off, Flood, Mist Tool Control: Tool and tool parameters Programming consists of a series of instructions in form of letter codes Preparatory Codes: G codes- Initial machining setup and establishing operating conditions N codes- specify program line number to executed by the MCU

Axis Codes: X,Y,Z - Used to specify motion of the slide along X, Y, Z direction

Feed and Speed Codes: F and S- Specify feed and spindle speed Tool codes: T specify tool number

Miscellaneous codes M codes For coolant control and other activities

Programming Key Letters:

O - Program number (Used for program identification) N - Sequence number (Used for line identification) G - Preparatory function X - X axis designation Y - Y axis designation Z - Z axis designation R - Radius designation F Feed rate designation S - Spindle speed designation H - Tool length offset designation D - Tool radius offset designation T - Tool Designation

M - Miscellaneous function

Explanation of commonly used G codes G00 Preparatory code to control final position of the tool and not concerned with the path that is followed in arriving at the final destination. G01 Tool is required to move in a straight line connecting current position and final position. Used for tool movement without any machining- point to point control. (linear interpolation) G02 Tool path followed is along an arc specified by I, J and K codes. ( circular interpolation)

Table of Important G codes G00 Rapid Transverse G01 Linear Interpolation G02 Circular Interpolation, CW G03 Circular Interpolation, CCW G17 XY Plane,G18 XZ Plane,G19 YZ Plane G20/G70 Inch units G21/G71 Metric Units G40 Cutter compensation cancel G41 Cutter compensation left G42 Cutter compensation right G43 Tool length compensation (plus) G43 Tool length compensation (plus) G44 Tool length compensation (minus) G80 Cancel canned cycles G81 Drilling cycle G82 Counter boring cycle

G83 Deep hole drilling cycle G90 Absolute positioning G91 Incremental positioning Table of Important M codes: M00 Program stop M01 Optional program stop M02 Program end M03 Spindle on clockwise M04 Spindle on counterclockwise M05 Spindle stop M06 Tool change M08 Coolant on M09 Coolant off M10 Clamps on M11 Clamps off M30 Program stop, reset to start

Program Command Parameters:Optimum machine programming requires consideration of certain machine operating parameters including: Positioning control Compensations Special machine features Positioning control is the ability to program tool and machine slide movement simultaneously along two or more axes. Positioning may be for point-to-point movement or for contouring movement along a continuous path. Contouring requires tool movement along multiple axes simultaneously. This movement is referred to as Interpolation which is the process of calculating intermediate values between specific points along a programmed path and outputting those values as a precise motion. Interpolation may be linear having just a start and end point along a straight line, or circular which requires an end point, a center and a direction around the arc.

Rules for programming Block Format N135 G01 X1.0 Y1.0 Z0.125 F5 Sample Block Restrictions on CNC blocks Each may contain only one tool move Each may contain any number of non-tool move G-codes Each may contain only one feed rate Each may contain only one specified tool or spindle speed The block numbers should be sequential Both the program start flag and the program number must be independent of all other commands (on separate lines) The data within a block should follow the sequence shown in the above sample block

CAD/CAM Two computer-based systems which impact the use of CNC technology are computer aided design and computer aided manufacturing. A computer aided design, or CAD, system uses computers to graphically create product designs and models. These designs can be reviewed, revised, and refined for optimum end use and application. Once finalized, the CAD design is then exported to a computer aided manufacturing, or CAM, system. CAM systems assist in all phases of manufacturing a product, including process planning, production planning, machining, scheduling, management and quality control.

PLANNING AND SELECTION OF ASSEBLY Now in any organisation basically there are three levels of management Top level Middle level Bottom level

So in the top level of management managers and higher authorities set up a project in an organisation. After discussion there is selection of best method for achievement of the goal. So it is set up for the next level of the organisation.

Now in the next level, executive engineers and other staff members read this method properly and after removing any difficulties, it is implemented.

So workers of organisation work as per scheduling and requirement of the project. For this so many supervisors are provided to workers to ask any difficult during working or carrying out the project.

 Now selection of any assembly is done by BOM (bill of material). In BOM specification of every part is given. With this diagram of each component is also sent by that industry which gives the order of assemblies to such companies.
By

the study of BOM, it become easy to make decisions that which

kind of assembly shop is available or kind of assembly be done and what parts has to be purchased for the require product. After proper studying of BOM decisions are made for the required assembly.

A layout of assembly;

Fabrication Machining Assembly Quality Dispatch

Firstly some parts which required welding etc send to fabrication shop as per requirement. Then machining is done of some parts to remove the sharp edges. After that finally machined parts assembled to required positions. Quality is checked by the comparing the final product with standard and then dispatched to the industry. During assembly of pins in the cradle, chamfering is done. It can be done by two ways by filler and grinder. By grinder it can be done faster than the

filler. It is done to make the radius of pin equal to that part where it is going to attach. Because if there is any tolerance left, it may make the assembly loose. Thats why proper oiling is done of the pins and bolts are clamped tightly. It is done by so many workers so work rate of each worker is checked out. Incentives are given as per there working hours. By this time study we can also calculate the time taken by each assembly and no of workers also.

CONCLUSION

Hence it is a modern approach to carry out a process in short time to keeping the material nearly at the same temperature at which we are taking from the furnace. It is very rapid process by the help of which productivity can be increased and also the efficiency of product.

MACHINE SHOP

Machine shop is the main work station of the organization. Here various machining operations are carried out to produce different parts of hydraulic and mechanical presses. There are two division of machine shop a) Machine shop-I :- Heavy Work Division b) Machine shop-II:- Light Word Division

Various Machine Employed at Machine Shop-I

1. 2. 3. 4. 5. 6. 7. 8.

SACEM CNC Horizontal Boring Machine. WELDRICH COBURG plano-miller SWIFT LATHE H.M.T Radial Drilling Machine SKODA Horizontal Boring Machine HAURISTI Horizontal boring machine WMW UNION Horizontal boring machine SKODA Horizontal boring machine

HB-9 P-4 L-14 RD-4 HB-1 HB-8 HB-5 HB-3

PROCEDURE OF WORK:Every department or every work station works under planning department of ORIENTAL. So the Machine-I planning Department prepare the design of the press and any other job, to be manufactured. It prepares the drawing and route card, which are directly obtained through the computers installed at shop floor directly linked with the planning department. Route card is document at which the whole process to be carried out and is printed in sequence i.e. operations to be performed on the machine tool and after completion of work on job on one machine then at which machine tool to be transferred and sequence of job on one machine to be performed on that machine tool and operation observed.

FOUNDRY SHOP

Foundry shop is the main work station of the organization. Here various types of difficult castings are to be cast, as required by the client. There is only one division of casting in the Oriental

Pattern: - Pattern is the same or the original shape of the substance which we have to cast.

Mould:- Whereas mould is the replica of the pattern which is used for giving the proper shape to the casting as required and these moulds are made from the sand.

Types of Sand used:-

There are two types of sand used in Oriental for casting. 1. 2. Cement Sand Phenolic Sand

1.

Cement Sand:- Cement sand contains two or three things i.e. river Sand, cement and molasses. These three things are mixed in fixed proportion so that sand does not loose its adhesive nature. In Cement Sand there is 85% to 90% is river sand, 8% molasses and 4% cement. In this mixture molasses act as binder, which binds the sand properly and its adhesive nature. Cement sand is used only for filling the vacant area around the mould. After the proper ramming of the cement, sand baked so that it does not fatal by gaining moisture. Phenolic Sand:- Phenolic sand is also the mixture of three things i.e. silica sand, resin and catalyst. The composition of Phenolic Sand is 90% to 93% Silica Sand and 2% to 3% Catalyst. Here resin acts as chemical which increases the properties of the sand and catalyst is used as binder or hardener which helps in setting the sand. Silica sand is coarse sand, so there is no need of baking it. After mixing all the things for making the mixture of Phenolic sand, it is taken to the patterns where it is properly rammed. After that it would be left for some time so that it becomes as hard as stone.

2.

Types of Materials Used for Making Patterns

1.

Mostly the patterns used in Oriental are made from thermo coal sheets. These thermo coal sheets are cut in the shapes as per drawing given to pattern making man. Pattern making man cut the big blocks of thermo

coal in the pieces as per dimensions given in the drawing with the help of cutters and element wire (Element wire is that wire which is used in heaters. This wire becomes hot and cuts the thermo coal sheets very smoothly without damaging the material).
2.

Wooden patterns are also used for making the moulds .Wooden patterns are used when more finishing is required. Metal patterns are also used in castings. These patterns are used only for taking the prints on the mould.

3.

Direction for Moulding Work

On getting the patterns and moulding, understand the shape of casting clearly.

Discuss the position of risers and setting clearly with the supervisor. Check the mixture poured from the mill. Never use the set moulding and coarse sand. Ram the sand in the moulds very well. Always repair the moulds with the same sand, fix the repairing portion with nails. It is necessary to paint mould. Never use thinner for oily sand and never use water paint for silicate sand.

 Dry the core or mould of oil paint in the core oven or with the help of burner. Decide the thickness of mould and core assembly according to the drawing. Before closing the moulds provide passage for the release of the gases. Release the gases of core and moulds separately. Clean the mould with air and brush before closing it. Use thin sealing between mould boxes or between the cores before closing it. Place weight on the moulding boxes or tight them with the help of bolts.

Procedure for Making a Mould

Check clearly that the pattern is not wet from anywhere and it is not damaged from anywhere.

Always place the pattern on the plain surface.

The handles used on the patterns should not be loose and always be straight.

Ramming in the pockets and contours should be properly done. After facing sand provide proper vents in the cement sand. Always check there is no alignment in the mould and the ramming of upper box should be properly done.

 The height of the upper box should not less than 10 or it should be according to pouring basin.

STUDY OF TIME CONSUMPTION

Types of time consumption:1. 2. Manual Time Machining Time

1.

Manual Time: - Manual time is the time which is consumed during the manual activity. Manual time is classified as: Loading and Unloading Preparation Time study

 Setting Time Study

a.

Loading and Unloading This is the time which gets consumed during the loading and unloading

of the job from the machine. This involves operator involvement but it is beyond limits to get it under control unless and until whose system is computerized.

b. Preparation Time Study Preparation time study is the study of all activities, which starts just after unloading the finished job and halts before setting of the job in parallel and perpendicular with the machine. Activities include in PTS are:-

1. 2. 3. 4. 5.

Loading of the job Clamping of the job Search for the clamps Instructions from supervisor Getting route card

6. 7.

Setting tool on machine Getting tool from tool room

c.

Setting Time Study

Setting time study is carried out to record the time consumed during setting of the job in parallel and perpendicular with bed and tool of the machine, concentric with the chuck of the lathe and checking for circular run out on lathe. As the machining operation involve lease operator interventions and it has to work with the pace fed/set by the operator so to snatch time from this part is difficult rather impossible. Now we are left only manual activities.

Salient Features
1. PU Seals used by us are made up of special PU Compound with an approximate Shore A Hardness of 93. It has an embedded O Ring which allows leak free operation from No Load to the Rated Pressure .The Working Temperature Range is from -35 to +80C. The Surface Speeds can be achieved up to 0.5 meter per sec. Also provided is the Teflon Back up Rings to these seals to give a further strength to the Heel of the Seal. These seals are by far the best in the world for this type of Hydraulic Application. Polyurethane Seals do not leave any carbon black residue and so dont contaminate the oil at any stage. It is the residue from the seal which is the principle cause of the blockage of the Hydraulic System by contaminating the oil and thereby the poppet seats. It is these seals which give a very long working life compared to any other seal material like Leather or Rubber. As a matter of fact in the international markets

Rubber and Leather are outdated materials for Cylinder Application in Hydraulic Systems. PU seals are being used up to 200 tonness Hydraulic Jacks. Beyond 200 tonness, we use Canvas impregnated Twin set seal to the design of James Walker - U.K 2. The hoses are Thermoplastic with a Working Pressure of 700 Bar and Burst Pressure of 2800 Bar. The main advantages of Thermoplastic Hoses are that they do not disintegrate from the core unlike the Rubber Hoses. Once again the erosion of rubber from the core causes contamination of oil and thereby damages the system as explained above for the seals. Thermoplastic Hoses from Polyflex Germany have a factor of safety of 4:1. Very few manufacturers give this type of a factor of safety. 3. The overall surface finish in the Hydraulic Jacks / Cylinders is Ra 0.8 micron. We have the proud privilege of achieving as close as Ra 0.2 micron. We hereby confirm that the Tangee OEW Hydraulic Cylinders have a surface finish of the bore not worse than Ra 0.4 micron. This has an absolute direct bearing on the life of the seals and thereby the jacks. 4. We use a Special Hard Chrome Plating (HCP), which gives the surface hardness equivalent to HRC 65 as against HRC 55-58 of the usual Hard Chrome Plating Processes. 5. We are offering a WIKA GERMAN Pressure Gauge Duly calibrated to read directly in tonnesss. We have our own Calibration equipment whose calibration is traceable to the National Standard. 6. Tangee OEW Hydraulic Jacks have always carried with them the innovation / improvements in the design and the manufacturing process to compete in the international market. We, at The Oriental Engineering have the proud privilege of being the FIRST Company manufacturing Hydraulic Jacks in the WORLD to obtain ISO 9001 Certification and that too from TUV Cert, Germany. It was way back in Sept. 1993. All other players in the world market in the field of Hydraulic Jack manufacture followed suit. This proves the fact that we, at the Orientals have never lacked behind in our efforts to keep abreast with the developments in our field. Keeping in mind the international acceptance, we were the pioneers in India to using Pradiffa German Polyurethane Seals and also

Thermoplastic Hoses from Polyflex Germany. These hoses have a working pressure of 700 bar and the test pressure of 2800 bar. We are giving below a partial list for the Hydraulic Jacks of 300 tonness to 1500 tonness capacity exported by us from our Works: