1

Acknowledgements

List of Tables

Executive summary
1. An overview of the company LTT

1.1 Team

1.2 Quality

1.3 Focus of the company

1.4 Orientation in the company

1.5 Processes

2. Project Details

2.1 Project Title

2.2 Objective of the project

2.3 Tasks assigned

2.4 Project requirements

3. Engineering training objectives

3.1 Objectives of object

3.2 Goals of engineering in LTT

4. Mould base and components

4.1 Components of Mould base

4.1.1 Cavity Plate

4.1.2 Core Plate

4.1.3 Ejector Box

4.1.4 Ejector plate4.1.5 Ejector back plate

4.1.6 Ejector Guide pillar

4.1.7 Guide pillar

2

4.1.8 Return pins

4.1.9 Support pillars

4.2 Materials used for production of mould bases

4.2.1 Mild steel (M.s)

4.2.2 EN 8

4.3 Applications

5. Strategy

5.1 Design

5.2 Planning and, manufacturing

5.3 Inspection and quality check

5.4 Assembly and Dispatch

6. Achievements

7. Conceptual Framework

8. Limitations

9. Conclusion

Appendix

Bibliography

Glossary
3

ACKNOWLEDGEMENT

I am highly indebted to LAKSHMI TOOL TECH PVT LTD for their guidance and constant
supervision from the first day to the final day of practice school. I generously thank Mr. C.
MADAN MOHAN (Company Guide) and Mr. B. VISHNU BHASKAR REDDY (University
Guide) for their improbable support during the practice school period.

I would also like to thank Dr. Y. V.Hanumantha Rao, Associate Director, Industrial Practice
School for giving me the opportunity to experience engineering from a practical aspect.

I would also like to thank Mr. M. Vijay Kumar, Department Guide, KL University for his
valuable guidance and support during the practice school program.

I would like to thank my institution and my faculty members and employees of company for
helping me to run the practice school program successfully.
4

LIST OF FIGURES
4.1 Engineering training objectives

5.1 CAVITY PLATE

5.2 CORE PLATE

5.3 EJECTOR BOX

5.4 EJECTOR PLATE AND EJECTOR BACK PLATE AFTER ASSEMBLY

5.5 SPEARS

5.6 EJECTOR GUIDE PILLAR

5.7 GUIDE PILLAR

5.8 RETURN PIN

5.9 SUPPORT PILLAR

5.10 MOULD BASE WITH ALL COMPONENTS ASSEMBLED

5

EXECUTIVE SUMMARY

This report includes the project which deals with FRONT HOUSING MOULD BASE. The project
is done using conventional and CNC machines. At first the design of the mould base is to be
studied. Then the design aspect of the mould base was studied to find any flaws in design. Then
the design is sent to the manufacturing unit and required design is manufactured manufactured
using CNC and conventional machines and then the components are to be assembled.

It also describes the objectives of the practice school program, various tasks assigned by the
company, strategies employed to complete assigned tasks. achievements during the program.

Result:
Thus this project is comprising the study on front housing mould base using the CNC machines
the process of manufacturing is done by CNC programming which comprises of G-codes and M-
codes.
6

2. AN OVERVIEW OF THE COMPANY LTT

LAKSHMI TOOL TECH started by the group of young engineers who are having a vast
experience in Tool room. In addition, 2005. They deliver our products with quality as per
requirement, with committed delivery schedules, at reasonable price. to this they are certified with
ISO 9001-

They make mould base and die sets as per pour standards and Non-standards as per the customer
requirement i.e. with pocket finishing in core and cavity plate. cooling boles, Ejector Pin Holes,
Lifters slots side Core provisions etc.

The standard moulds base will be C 45 materials. However, they will supply in EN 24, EN 31, EN
8 and EN 9, P20 material and in EN 8, S.G iron casting also, as per the customer requirement.

They are manufacturing mould bases ranging from 160*160 to 2500*1600 with the thickness of
core cavity up to 200/400. They are also doing core/cavity profiles with 1.5mm.

Our major Customers are listed as

1. MINDA INDUSTRIES

2. TAFE MINDA CORP

3. SUNKIST MOULDERS

4. VARROC

5. GODREJ

6. SEMCO

7. STOVERCRAFTS PVT LTD

8. MINDA VALEO

9. AUTOLITE INDUSTRIES LTD

10. ROLLOMO TOOLS AND DIES

11. AUTOMOTIVE ANCILLARY LTD

12.ALPHA CRAFT

13.ENDURENCE TECH PVT LTD

14.KRISHNA MARUTHI GROUPS LTD

7

15.SRS DIE CASTERS PVT LTD

16.LAKSHMI DESIGNERS

17.CRP INDIA LTD

18.ASK AUTOMOTIVE PVT LTD

19.ORIENT FANS

20.OSWAL ELECTRICALS

21.MAHAVEER DIECATSERS

22.CIPET

23. KARTHIKEYA MOULD AND DIES

24.HOSCO INDIA PVT LTD

25.AMTEK PUNE

26.CR TOOLS

27.SUPER WOOTO LTD

28.MENON ALKO

29. VENTURE AUTO

30.FASTEK INNOVATIVE TOOL

31.EXEL DIE CASTERS

32.CHAMUNDI DIE CASTERS

33.SHAPERS INDIA PVT LTD

34.GRAND MASTERS MOULD LTD

35.MANAS AUTO

36.APARNA DIES AND MOULDS

37.ESTECHTAB-RAYADH

38.MSSL TOOLING (FZE) SHARJAH

8

LTT is manufacturing industry of Mould bases and dies which is located at Andhra Pradesh
Industrial Estate (APIE), Bangalore, Hyderabad. It has 3plants located in Hyderabad at different
places.

Unit: This is tool room for manufacturing of mould bases and assembly of a product.

Unit2: Mould bases and dies are manufactured and assembled here.

Unit3: This unit is manufacturing of Precision Machining and Sub-assemblies and parts with
simultaneous 4Axis CNC machining facility.

We are allotted in Unit 1. in this unit manufacturing of mould bases for given work order is done.

The following are the departments involved in this unit

1. Marketing

2. Designing

3. Planning

4. Manufacturing

5. Quality control

Work order issued by the manufacturing department is sent for design department. Here necessary
design modifications are done. The planning is done by planning department, where they estimate
the project cost, job flow and B-O-M sheets and raw materials required. After that it will undergo
respective processes. The 2D drawings sent from planning department to the employees.

Following are the processes which the job undergoes

1. CNC machining
2. Jig and Horizontal boring
3. Fitting
4. Heat treatment
5. Grinding
6. Quality check
7. Polishing
8. Final assembly
9

After returning from heat treatment, it is tested with hardness tester to verify hardness and compare
with customer requirement. Quality check is done for machined component and rework is done if
required.

This completes the entire process, from receiving of customer order to dispatch of product in mould
bases.

Team:
They have an efficient team of engineers who have been in the industry for years. They have
trained to handle our latest machinery that they keep updating from time to time.

Quality:
They make uncompromising efforts to check the quality of our machines as it is of prime concern
to us. Our quality check managers make sure that straight quality checks are conducted at every
state of production. This ensures that our products meet the relevant standards of quality. They
have latest testing methods to ensure that only best of our products reach the customers. Strict
checking makes sure that not a single product is releases without the approval of our quality check
department. The continuous changes in the demands of the industry and the trust of our customers
motivate us to excel in our endeavors.

Focus of the Company:

They strive to regularly enhance and update our products by unending development activities. This
commitment has been a major force behind phenomenal growth and success. As the industry is
facing fast changes by the way of new advancements happening in technology and design every
day. Our efforts are directed to remain in tune with these developments in the industry and
incorporate them in our product range.
10

Technology and Machines used

CNC machinery
CVC lathe
Boring
Lathe
Drilling
Grinding
Milling machines
This company used advanced software for designing and cam programming. There aa Engineering
department in the company. They mainly use the software include AutoCAD, PRO ENGINEER.
This company runs on both conventional and non- conventional machines. Highly sophisticated
machinery is used for manufacturing. Conventional machines include surface grinding, boring,
radial drilling, cylindrical grinding and milling machines.
CNC machines are also used in non-conventional machining. They are used in order to increase
production by increasing the machining time and decreasing the non- operational time. CNC
machinery includes drilling, milling, boring and routing.

PROCESSES:
Every job order undergoes the following process
1. Marketing: Deals with sales and services between customer and company.
2. Design validation: Design team makes 2D & 3D drawings with Auto CAD design software.
3. Procurement of material: The required material will be chosen by the customer and is ordered
for manufacturing of their product with required specifications.
4. Manufacturing: There are different types of operations. Such as
Roughening: The initial raw material is shaped to the required dimension with tolerance.
Drilling: Necessary holes are made using job cards.
11

Milling: This operation is done in CNC machines to get the required profile.
Surface grinding: Required surface finish is obtained in this process.

Tapping: Tapping & Threading is done to the holes as per the drawings.
5. Quality check: The machined job is checked for quality and is also verified after each & every
operation.
6. Heat treatment: All the machined parts are undergoing this operation to gain hardness. This
process is carried out through various mediums like vacuum, water gas (air).
7. Polishing: The component is polished to obtain fine finishing.
8. Assembly: All the machined parts are assembled in the assembly section.
9. Dispatch: After the assembly final product is delivered to the customer.
12

3. PROJECT DETAILS
Project title:
The practice school proposed project title is "FRONT HOUSING MOULD BASE", in LTT.

Objective of the project:

The main objective of the product is to manufacture the job according to the customer design for
the efficiency of the product.
1. Our main objective of the product is to how we can apply the theoretical knowledge as practical
knowledge in the company.
2. We are exposed to industrial exposure.
3. To involve the task orientation, team work, goal orientation and managing the interpersonal
relationships.
4. To gain a deeper understanding of the professional work, culture, organizational
targets, delivery results, work pressure etc. of an organization.
5. To understand the organizational distribution of work.
6. To develop the qualities required for an engineer.
7. To enhance professional attitude, communication skills and leadership qualities.
8. To gain more knowledge about upgrading technology.
9. To understand the practical problems that arises the industry and learns different ways to solve
them.
10. To have a smooth transition from academics to professional world.
11. To develop interpersonal and intrapersonal skills.

Tasks assigned:
1. To get an overview of industry and get accustomed to its environment.
2. To blind with manufacturing and design department and start working with
them.
3. To gain knowledge about mould base and its components and how they are machined for
required sizes and shapes.
4. To learn in detail about injection molding machine and its technical specifications.
5. To know about different types of raw materials and their specifications.
13

6. To solve the practical problems that arises in the shop floor.

7. To know about design specifications of mold base. Study the design sent by the customer.
8. Converting the 3D design to 2D design.
9. Drawing the part diagrams of the components of the design.
10. Representation of the dimensions in the design.
11.Scheduling and allotting the material and for the commencing of the process. 12. The
manufacturing of the product is commenced according to the design.
13. Inspection of the product after it is manufactured
14. The components are assembled and distribution to the distributors.

Project requirements:
For successfully completion of the project in LTT there are some prerequisites like:
1. Sound knowledge on Auto CAD.
2. Proficiency in manufacturing subjects like manufacturing processes I & II. computer integrated
manufacturing.
3. Sound knowledge on PRO-E
4. Good proficiency in using M.S. Office.
5. Knowledge and experience in the tool room as the manufacturing is done using traditional &
CNC machines.
6. Knowledge on G-Codes & M-Codes for making CNC program for any required design.
7. Knowledge and experience in assembling of components to make a mould base.
14

4. Engineering Training Objectives

1. To be a part of professional atmosphere and understand the work culture.

2. To have a smooth transition from academic to professional life.
3. To develop communication skills and confidence by frequent interactions with the employees
in the company.
4. To understand the importance of time and acquire ability to complete time bound tasks.
5. To bring a new lease of life by putting theoretical knowledge into practice.
6. To get an exposed to industry related problems & solve them.
7. To understand group dynamics and group decision making.
8. To emergence as a team player and prospect full team leader. 9. To identify strengths and
weakness and to do the needful to develop strengths & deal with weakness.
10. To have a well-defined plan for future.

Objectives of OJET (ON-JOB ENGINEER TRAINING)

1. To focus on setting challenging organizational targets in consultation with company guide and
technical guide at the beginning of practice school program and work towards achieving these
targets.
2. To gain a deeper understanding of the professional work, culture, organizational targets,
delivering results, work pressure, etc. of an organization.
3. To develop corporate work culture.
4. To learn the aspects of project scheduling and management of work.
5. To understand the organizational distribution of work.
6. To involve in task orientation, team work, goal orientation and managing the interpersonal
relationships.
7. To develop the qualities required for an engineer.
15

Goals of Engineering Training in LTT

1. To focus on the organizational structure and how it functions.
2. To understand the projects that the organization undertakes.
3. To get the tasks of a particular ongoing project assigned by the company guide.
4. To contribute to the company in getting the assigned work done.
5. To get technical information from the staff.
6. To assist the company in improvising their technological outlook.
7. To enhance the qualities of team spirit and team building.
8. To improvise that trait of lateral thinking.
9. To understand the concepts of designing and implementation.
16

MOULD BASE AND COMPONENTS

A mould base is an assembly of a group of components, which perform different functions. These
parts are manufactured by a series of machining processes. The quality of these components is to
a large extent determined by the performance of these machining processes.

COMPONENTS OF A MOULD BASE:

The components of mould base are:
Cavity plate
Core plate
Ejector plate
Ejector back plate
Ejector box
Ejector guide pillar
Guide pillar
Guide bush
Ejector guide bush
Return pin
Support pillars

CAVITY PLATE:
This is the fixed part of the mould base in which core plate is fixed.
The fixed cavity also comprises of Cavity insert
Plunger bush
Cooling ring
Guide pillars
17

CORE PLATE:
➤ This is the moving part of the die in which core insert is fixed

➤ The core plate also comprises of

* Core insert
* Core pins
* Guide bushes
* Cooling manifold

EJECTOR PLATE:
➤ Ejector plate helps in the ejection of the casted component by pushing the ejector back plate
forward.

➤ Ejector plate also helps in stopping the ejector pins from dismantling with the ejector back
plate.

➤ Rails and support blocks helps in supporting the ejector plate and ejector black plate.
18

EJECTOR BACK PLATE:

➤ Ejector back plate consists of all ejector pins in it so that when the plate is pushed all the ejector
pins move and ejection of the casted component is done

➤ Ejector back plate is mounted on ejector guide pillars which guides the plate to move freely.

GUIDE PILLAR

RETURN PIN
19

MATERIALS USED FOR PROFUCTION OF MOULD BASES:

➤ MILD STEEL (M.S)

➤EN 8

➤C 45 (CAST IRON)

MILD STEEL (M.S):

Mild steel, also called plain-carbon steel, is the most common form of steel because its price is
relatively low while it provides material properties that are acceptable for many applications, more
so than iron. The density is 7.85 gm/cm3 and its Young's modulus is 210,000 MP.

COMPOSITION:
➤ Carbon: 0.2% max

➤ Manganese: 1.65%

➤ Copper: 0.6%

➤ Silicon: 0.6%

EN 8:
EN 8 is an unalloyed medium carbon steel with good tensile strength. It is normally supplied in
cold drawn or as rolled. Tensile properties can vary but are usually between 500-800 N/mm2.

COMPOSITION:
➤ Carbon: 0.4%

➤ Silicon: 0.25%

➤ Manganese: 0.8%

➤ Sulphur: 0.05%

➤ Phosphorus: 0.05%
20

C 45 (CAST IRON):
C 45 is a medium carbon steel is used when greater strength and hardness is desired than in the "as
rolled" condition. Extreme size accuracy, straightness and concentricity combine to minimize wear
in high speed applications. Turned ground and polished.

COMPOSITION:
➤ CARBON: 0.5%

➤ SILICON: 0.35%

➤ MANGANESE: 0.8%

➤ SULPHUR: 0.025%

➤ PHOSPHORUS: 0.025%

➤ CHROMIUM: 0.04%

EN 8 materials is used in the Casting, Core cavity and Ejector box. And C 45 (or) MILD STEEL
is used for to make the Ejector plates.

NOTE:
Among C45 and MILD STEEL most of the percentage, C45 material is to be used; this s because
MILD STEEL material had low strength rather than C45 material.
21

QUOTATION:
Quotation is to be given by the customer as per their requirement aspects of the product. After then
coding is to be given for that quotation. After then pattern is to be prepared.

PATTERN:
Pattern is to be made for the product as per requirement of the customer. Our company producer
for the pattern is DECCAN PATTERNS. The pattern is to be making with thermacole with the
ball diameter of 20. The thermacole used is a high graded thermacole. After then casting process
is to be done.

CASTING
Casting is a manufacturing process by which a liquid material is usually poured into a mold, which
contains a hollow cavity of the desired shape, and then allowed to solidify. The solidified part is
also known as a casting, which is ejected or broken out of the mold to complete the process. Casting
materials are usually metals or various cold setting materials that cure after mixing two or more
components together; examples are epoxy, concrete, plaster and clay. Casting is most often used
for making complex shapes that would be otherwise difficult or uneconomical to make by other
methods.
During 1st stage, material in molten state is a highly nonlinear viscous fluid.
1. It flows through mold passages and is subject to rapid cooling from mold wall, on one hand, and
internal shear heating, on the other.
2. Melt then undergoes solidification under high packing and holding pressure.
3. Mold is opened, part is ejected, and machine is reset for next cycle to begin.
4. Forward stroke of plunger to facilitate flow of molten material from the heating cylinder through
nozzle and into mold. Gradual increase in pressure.
5. as soon as cavity is filled, pressure increases rapidly, and packing occurs.
6. During packing part, flow of material continues, at a slower rate, to account for any loss in
volume of material due to partial solidification and shrinkage.

7. After packing, injection plunger is withdrawn and pressure in mold cavity begins to drop.
8. At this stage, next charge of material is fed into the heating cylinder in preparation for next shot.
Cooling starts from 1st rapid filling of cavity and continues during packing and then following
withdrawal of the plunger, with the resulting removal of pressure from the mold and nozzle area.
Upon pressure removal, gate of mold may still be relatively fluid.
22

Because of pressure drop, there is a chance for reverse flow of material from mold until material
adjacent to the gate solidifies and the sealing point is reached.
Reverse flow is minimized by proper design of gates such that quicker sealing action takes place
upon plunger withdrawal.
Following the sealing point, there is a continuous drop in pressure as material in cavity continues
to cool and solidifies in readiness for ejection.
Length of sealed cooling stage depends on:
1. wall thickness of part
2. material used
3. mold temperature
Because of low thermal conductivity of polymers, cooling time is usually the longest period in the
molding cycle.
During this stage:
1. mold is opened
2. part is ejected,
3. Mold is then closed again in readiness for next cycle to begin.
Rapid movements may cause:
1. Undue strain on the equipment
2. Damage the edges of the cavities.
Adequate time must be allowed for mold ejection.
23

MILLING
Milling is the machining process of using rotary cutters to remove material from a work piece
feeding in a direction at an angle with the axis of the tool. It covers a wide variety of different
operations and machines, on scales from small individual parts to large, heavy-duty gang milling
operations. It is one of the most commonly used processes in industry and machine shops today
for machining parts to precise sizes and shapes.
Milling can be done with a wide range of machine tools. The original class of machine tools for
milling was the milling machine (often called a mill). After the advent of computer numerical
control (CNC), milling machines evolved into machining centers (milling machines with
automatic tool changers, tool magazines or carousels,
CNC control, coolant systems, and enclosures), generally classified as vertical machining centers
(VMCs) and horizontal machining centers (HMCs). The integration of milling into turning
environments and of turning into milling environments, begun with live tooling for lathes and the
occasional use of mills for turning operations, led to a new class of machine tools, multitasking
machines (MTMs).
24

STRATEGY
The strategy involved is to know how to start the basic engineering after a project was specified.
In order to do so we need a detailed study of the specifications understanding the process and
equipment.
In order to start the project, we had a brain storming sessions with our company guide B. VISHNU
BHASKAR REDDY to clarify our doubts regarding the project and to have a clear idea about it.
Our strategy mainly has the following steps.
DESIGN
PLANNING
MANUFACTURING
QUALITY CHECK
ASSEMBLY

DESIGN:
First the design given by the customer is studied and rectified for any errors in it. > After then the
design is changed from 3D view to 2D view by using PRO-E software.
The PRO-E model is converting to the .dwg format then the 3D is converting in to 2D.
In AUTO CAD the detailing is done according to the standards and with the symbols, detailing is
done according to the ISO standards.
Then we can get the require part of diagrams with dimensions.
Now the design department can make all views of the component which can be easily understand
by the workers in the company by using the AUTO CAD software.
The design is given a work order number for the purpose of manufacturing.
A print of the design of the component is taken and sent to manufacturing department.
OUR PROJECT (FRONT HOUSING MOULD BASE) CONSISTS OF MAINLY 4
COMPONENTS
They are
1. CAVITY PLATE
2. CORE PLATE
3. EJECTOR BOX
4. EJECTOR PLATES
25

The part diagrams of the FRONT HOUSING MOULD BASE are shown as below

CAVITY PLATE:
The plate used to fit the cavity insert, the cavity insert will have gap of the details to fill the plastic
material and form plastic component Cavity plate usually of mild steel material cavity insert
usually of hot die steel (through hardened) P20 direct use without hardening after cavity
machining.

PLANNING AND MANUFACTURING:

For our project the work order is given as 5074/5077.
Then the part diagrams are sent to the manufacturing unit.
The manufacturing department will bring the required material for the project according to the
customer need.
In manufacturing the product, we have to use the material EN8, C45 & MS.
Then the supervisor of the manufacturing department will allot the work to the different machines
according to their availability and the sequence of operations.
Every work piece should have to be rough before starting manufacturing to remove the rust and
excess material on the faces of the work piece.
For the roughening of the material company uses the CNC machining process using the CNC
machine.
26

CNC machining process:

On the CNC machine, for machining the product we have given the program with G-Codes and
M-Codes as follows. By that program only the machine will work as per requirements or
measurements. This machining also called as vertical machining. The program is:

PROGRAM O0002N1000

O0002;
#100-00;
#101-141.5;
G00 G90 G17 G80 G54;
G90 Z50.00;
M3 S1200;
G90 G54 X00.00 Y200.00;
G00 G90 Z10.00;
N1000 G90 G01 Z #100 F1000;
G01 G90 G41 Y-1275 D2 F2000;
X-345.00, R 40.00;
Y-275.00. R 40.00;
X-345. R-40.00;
Y-275.00. R 40.00;
X00.00:
G01 G40 Y200.00;
#100=#100+0.20;
IF (#100 LT #101] GO TO 1000;
GOO G90 Z150;
M5;
MO9;
M30:
%
27

The codes used in the CNC program are:

GOO: Rapid linear positioning
G90: Absolute programming
G17: XY Plane section
G80: Canned cycle cancel
G54: Work coordinate system 1 selection
G01: Linear feed interpolation
G41: Cutter composition left
G40: Cutter composition cancel
By giving this program in CNC machine we got the product roughening surface as per the
requirement.
8. After roughening face milling, pocketing and some other difficult shapes are done on the CNC
machines.
9. After finishing the work on CNC machine the work is sent to the JIG Boring for making the
holes like runner holes. These are important holes also called as 117 holes with tolerance of 0.02.
10. After Jig Boring machining, the horizontal machining process is to be done. The total side
work for the component is made on that machine only. Like clamping. holes etc. The machine
used here is Horizontal boring machine or also called as Edge boring machine.
11. Then the work piece is finally sent for drilling operations for drilling the holes like cooling
holes, lifting holes etc... then the tapping is done for the holes like lifting holes.
12.Ejector box is to be prepared and one sided grinding is required. 13.PT-6 and PT-7 which are
called as ejector plate and ejector back plate.

EJECTOR PLATE & EJECTOR BACK PLATE:

Raw material used is C 45 or MS (Mild steel), most of the percentage C 45 only used. This is
because C 45 had more strength than the mild steel. It will come to the company with the stock.
And it has to be block up by machining. It will come at a stock of thickness of absolutely 1mm to
the company. So that these plates are keep under grinding process, CNC and Zig boring process,
drilling operation, tapping the holes and making screw locking holes. After then the plates exposed
to edge boring operation. Finally, the plates are to exposed to finishing grinding.

INSPECTION AND QUALITY CHECK:

Finally, the manufactured components are sent to the inspection department whether to check all
the operations are done according to the design and then the components undergo for the quality
check whether the dimensions are obtained in the required tolerance limits.
28

HEAT TREATMENT:
Heat treatment is a controlled process used to alter the microstructure of materials such as metals
and alloys to impart properties which benefit the working life of a component, for example
increased surface hardness, temperature resistance, ductility and strength.

ASSEMBLY AND DISPATCH:

After the quality check the material is sent to the assembly department. There the final assembly
of the components is done. Then it is dispatched to the customer.
29

ACHIEVEMENTS
We are able to complete any of the works assigned to us effectively by the company so that the
project guide and the employees are satisfied with our work.
We are successful in creating an impression to the company employees that we can perform any
works assigned to us with content within time in the company.
The project guide is showing interest to help in learning new things.
We are able to mingle freely with the employee and also employees are willing to help us learn
new things.
The employees are willing to make us a part of their work for any new tenders to be bid by the
company.
30

CONCEPTUAL FRAMEWORK
The academic subjects like AUTOCAD, strength of materials and advanced strength of materials
were useful in understanding the design concepts of solar
dryer. Design of machine elements concepts and approach had helped us a lot while studying the
drawings and interacting with manufacturers.
The CSS classes and training on preparing the reports, email etiquettes and format for presentations
had helped us for preparing reports and charts asked.
The CSS training sessions helped me in communication in a better way with the employees at the
company.
31

LIMITATIONS
The design that was sent by the customer sometimes might have errors in design this might take
some considerable time for correct design.
The profit that company receives on each mould base is low and so renovation of the present.
Machine is not good option from cost effectiveness point of view.
Many countries no longer teach pupil or students how to use manually operated lathes or
Milling machines etc... people or students no longer develop the detailed skills required by the
engineers of the past. These include mathematical and engineering skills.
Fewer workers are required to operate CNC machines compared to manually operated machines.
Investment in CNC machine can lead to unemployment.
The CNC machine operator only needs basic training and skills, enough to supervise several
machines. In years gone by, engineers need years of training to operate Centre lathes, milling
machines and other manually operated machines. This means many of the old skills are been lost.
Using the technology in manufacturing can bring a company to a point where it relies fully on the
technology for the operations to function smoothly. In these cases, a breakdown or other downtime
for production machinery can bring operations to a standstill. Workers performing manual jobs
can experience downtime themselves, but individual workers can always be temporarily replaced
to keep things moving. When a critical pieced of manufacturing technology fails, the company
begins to lose money right away, since integral machinery cannot be easily replaced or bypassed
while it is being repaired. Downtime can cause a manufacture to miss shipment deadlines for the
customers, potentially causing it to lose a few accounts.
Need to keep stocks of raw materials. Cash also investment in work progress.
Time lost switching between components may need to be reset and may cause a rift in production
and its quality.
32

CONCLUSION
Thus this report gives clear information about the work we had performed at LTT till the Mid
Term. The strategies we had employed in doing the tasks and how the Concepts we learnt in
classroom are useful to us in performing the tasks in the company.
It speaks in length about the different verticals in various tasks assigned to us during the Practice
School Program. It also speaks about the extent to which the company people are good enough to
make us learn and get trained in spite of their busy calendar.
The report thus concludes with the overview of the work that had been performed at LTT.
33

APPENDIX:
G CODES
G-Codes simple definition
GOO Rapid traverse
G01 Linear interpolation with federate
G02 Circular interpolation (clockwise)
G03 Circular interpolation (counter clockwise)
G2/G3 Helical interpolation
G04 Dwell time in milliseconds
G05 Spline definition
G06 Spline interpolation
G07 Tangential circular interpolation / Helix interpolation/Polygon interpolation/
GOS Ramping function at block transition / Look ahead "off"
G09 No ramping function at block transition / Look ahead "on"
G10 Stop dynamic block preprocessing
G11 Stop interpolation during block preprocessing
G12 Circular interpolation (cw) with radius
G13 Circular interpolation (ccw) with radius
G14 Polar coordinate programming, absolute
G15 Polar coordinate programming, relative
G16 Definition of the pole point of the polar coordinate system
G17 Selection of the X, Y plane
G18 Selection of the Z, X plane
G19 Selection of the Y, Z plane
G20 Selection of a freely definable plane
621 Parallel axes "on"
G22 Parallel axes "off"
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G24 Safe zone programming: lower limit values

G25 Safe zone programming, upper limit values
G26 Safe zone programming "off"
G27 Safe zone programming "on"
G33 Thread cutting with constant pitch
G34 Thread cutting with dynamic pitch
G35 Oscillation configuration
G38 Mirror imaging "on"
G39 Mirror imaging "off"
G40 Path compensations "off"
G41 Path compensation left of the work piece contour
G42 Path compensation right of the work piece contour
G43 Path compensation left of the work piece contour with altered approach
G44 Path compensation right of the work piece contour with altered approach
G50 Scaling
G51 Part rotation; programming in degrees
G52 Part rotation; programming in radians
G53 Zero offset off
G54 Zero offset #1
G55 Zero offset #2
G56 Zero offset #3
057 Zero offset #4
G5S Zero offset #5
G59 Zero offset #6
G63 Feed/spindle override not active
G66 Feed/spindle override active
G70 Inch format active
35

G71 Metric format active

G72 Interpolation with precision stop "off"
G73 Interpolation with precision stop "on"
G74 Move to home position
G75 Curvature function activation
G76 Curvature acceleration limit
G78 Normalcy function "on" (rotational axis orientation)
G79 Normalcy function "off"
G80-G89 for milling applications:
G80 Canned cycle "off"
G81 Drilling to final depth canned cycle
G82 Spot facing with dwell time canned cycle
G83 Deep hole drilling canned cycle
G84 Tapping or Thread cutting with balanced chuck canned cycle
G85 Reaming canned cycle
G86 Boring canned cycle
G87 Reaming with measuring stop canned cycle
G88 Boring with spindle stop canned cycle
GS9 Boring with intermediate stop canned cycle
GS1-G88 for cylindrical grinding applications:
GS1 Reciprocation without plunge
G82 Incremental face grinding
G83 Incremental plunge grinding
GS4 Multi-pass face grinding
G85 Multi-pass diameter grinding
G$6 Shoulder grinding
G87 Shoulder grinding with face plunge
36

G88 Shoulder grinding with diameter plunge

G90 Absolute programming
G91 Incremental programming
G92 Position preset
G93 Constant tool circumference velocity "on" (grinding wheel)
G94 Feed in mm/min (or inch/min)
G95 Feed per revolution (mm/rev or inch/rev)
G96 Constant cutting speed "on"
G97 Constant cutting speed "off"
G98 Positioning axis signal to PLC
G99 Axis offset
G100 Polar transformation "off"
G101 Polar transformation "on"
G102 Cylinder barrel transformation "on"; Cartesian coordinate system
G103 Cylinder barrel transformation "on," with real-time-radius compensation (RRC)
G104 Cylinder barrel transformation with center line migration (CLM) and RRC
G105 Polar transformation "on" with polar axis selections
G106 Cylinder barrel transformation "on" polar-/cylinder-coordinates
G107 Cylinder barrel transformation "on" polar-/cylinder-coordinates with RRC
G10S Cylinder barrel transformation polar/cylinder-coordinates with CLM and RRC
G109 Axis transformation programming of the tool depth
G110 Power control axis selection/channel 1
G111 Power control pre-selection V1, F1, T1/channel 1 (Voltage, Frequency, Time)
G112 Power control pre-selection V2, F2, T2/channel 1
G113 Power control pre-selection V3, F3, T3/channel 1
G114 Power control pre-selection T4/channel 1
G115 Power control pre-selection T5/channel 1
37

G116 Power control pre-selection T6/pulsing output

G117 Power control pre-selection T7/pulsing output
G120 Axis transformation; orientation changing of the linear interpolation rotary axis
G121 Axis transformation; orientation change in a plane
G125 Electronic gear box; plain teeth
G126 Electronic gear box; helical gearing, axial
G127 Electronic gear box; helical gearing, tangential
G128 Electronic gear box; helical gearing, diagonal
G130 Axis transformation; programming of the type of the orientation change
G131 Axis transformation; programming of the type of the orientation change
G132 Axis transformation; programming of the type of the orientation change
G133 Zero lag thread cutting "on"
G223 Angled wheel transformation "on" but angled wheel moves after others
G265 Distance regulation - axis selection
G270 Turning finishing cycle
G271 Stock removal in turning
G272 Stock removal in facing
G274 Peck finishing cycle
G275 Outer diameter / internal diameter turning cycle
G276 Multiple pass threading cycle
G310 Power control axes selection/channel 3
0311 Power control pre-selection V1, F1, T1/channel 3
6312 Power control pre-selection V2, F2, T2/channel 3
G313 Power control pre-selection V3, F3, T3/channel 3
G314 Power control pre-selection T4/channel 3
G315 Power control pre-selection T5/channel 3
G316 Power control pre-selection T6/pulsing output/Channel 3 G317 Power control pre-
selection T7/pulsing output/Channel 3
38

Note that some of the above G-codes are not standard. Specific control features, such as laser
power control, enable those optional codes.
M codes simple definition
M00 Unconditional stop
M01 Conditional stop
M02 End of program
M03 Spindle clockwise
M04 Spindle counterclockwise
M05 Spindle stop
M06 Tool change
M19 Spindle orientation
M20 Start oscillation
M21 End oscillation
M30 End of program
M40 Automatic spindle gear range selection
M41 Spindle gear transmission step 1
M42 Spindle gear transmission: step 2
M43 Spindle gear transmission step 3
M44 Spindle gear transmission step 4
M45 Spindle gear transmission step 5
M46 Spindle gear transmission step 6
M70 Spline definition, beginning and end curve 0
M71 Spline definition, beginning tangential, end curve 0
M72 Spline definition, beginning curve 0, end tangential
M73 Spline definition, beginning and end tangential
M80 Delete rest of distance using probe function, from axis measuring input
M81 Drive On application block
M101-M108 Turn off fast output byte bit
39

M109 Turn off all (8) bits in the fast output byte
M111-M118 Turn on fast output byte bit
M121-M128 Pulsate (on/off) fast output byte bit
M140 Distance regulation "on"
M141 Distance regulation "off"
M150 Delete rest of distance using probe function, for a probe input
M151-M158 Digital input byte 1 is the active probe input
M159 PLC cannot define the bit mask for the probe inputs
M160 PLC can define the bit mask for the probe inputs
M161-M168 Digital input byte 2 is the active probe input
M170 Continue the block processing look ahead of the part program
M171 Stop the block processing look ahead of the probe input part program segment
M200 Activate the hand wheel operation in the automatic mode
M201-M208 Select the axis for the hand wheel operation
M209 Activate the hand wheel operation in the automatic mode
M210 Deactivate the hand wheel input while in the automatic mode
M211 Deactivate this hand wheel feature and also remove the hand wheel offset
M213 Spindle 2 clockwise
M214 Spindle 2 counterclockwise
M215 Spindle 2 stop
M280 Switchable spindle/rotary axis, rotary axis on, first combination
M281 Switchable spindle/rotary axis, rotary axis on, second combination
M290 Switchable spindle/rotary axis, spindle enabled, first combination
M291 Switchable spindle/rotary axis, spindle enabled, second combination
40

PHOTOS
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