Internship Report MEIL

Submitted by: Guduru Sudeep

Internship at: MEIL (Megha Engineering and Infrastructure Ltd.)
Internship Duration: March 10 – April 10
Department: Mechanical Workshop

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Introduction
As part of the academic curriculum for the Bachelor of Technology (B.Tech) program, internships
play a crucial role in bridging the gap between theoretical learning and practical industrial exposure.
They offer students the opportunity to gain hands-on experience, understand real-world applications
of their studies, and develop a professional work ethic.
I had the opportunity to undertake my internship at Megha Engineering and Infrastructures Limited
(MEIL), a prominent player in the infrastructure and engineering sector. My internship was
conducted in the Mechanical Workshop department, where I was exposed to various machining
processes, tools, and equipment used in fabrication and component manufacturing.
The internship duration was from March 10 to April 10, during which I worked under the guidance
of skilled supervisors and engineers. The main objective of this internship was to gain practical
knowledge of machines such as lathes, milling machines, CNC machines, and other workshop tools,
and to understand their role in industrial operations.
This report highlights my learnings, the tasks I performed, and how this experience contributed to
my academic and professional growth.

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Company Profile
Megha Engineering and Infrastructures Limited (MEIL) is a leading Indian infrastructure company
established in 1989. Headquartered in Hyderabad, Telangana, MEIL has emerged as one of the most
trusted names in the engineering and infrastructure sector. The company specializes in executing
complex and large-scale projects across various domains such as irrigation, drinking water supply,
power, hydrocarbons, transportation, manufacturing, and industrial infrastructure.
With operations spread across India and in several countries abroad, MEIL is known for its high
standards of engineering, efficient project management, and commitment to timely delivery. The
organization’s vast portfolio includes the construction of dams, canals, roads, bridges, tunnels, oil &
gas pipelines, and industrial plants.
The Mechanical Workshop division plays a crucial role in supporting the company's infrastructure
projects. It is equipped with advanced machinery such as lathes, milling machines, CNC machines,
welding units, and fabrication tools. This department is responsible for the manufacturing, repair, and
maintenance of various mechanical components used in MEIL’s projects.
MEIL’s commitment to innovation, quality, and sustainability has made it a major contributor to
India’s infrastructure growth, earning it numerous awards and recognition over the years.

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Objectives of the Internship

The primary objective of this internship was to gain practical exposure to the industrial environment
and understand the functioning of a mechanical workshop in a real-world setting. Specifically, the
goals included:

Understanding Workshop Operations:

To observe and learn the day-to-day operations involved in a mechanical workshop, including safety
practices, workflow, and equipment handling.

Hands-On Experience with Machines:

To acquire practical knowledge and operating experience with key machines such as lathe machines,
milling machines, CNCs, drilling machines, and welding units.

Application of Academic Knowledge:

To apply theoretical concepts learned during the B.Tech curriculum in real-time scenarios,
particularly related to manufacturing processes, engineering drawings, and machine operations.

Skill Development:
To enhance technical skills, including precision measuring, tool usage, machining techniques, and
problem-solving in mechanical processes.

Professional Exposure:
To understand the work culture, discipline, and expectations in a professional engineering setup and
improve communication and teamwork abilities.

Project Involvement:
To assist in ongoing fabrication or repair projects, gaining insights into production planning, material
handling, and quality control.

This internship was designed to bridge the gap between classroom learning and industrial
application, preparing me for future roles in the mechanical and manufacturing sectors.

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Machines Observed and Worked On

Lathe Machine – Experience and Learning
During my internship at MEIL's Mechanical Workshop, I had the opportunity to work closely with
lathe machines, which are fundamental to any machining or fabrication setup. A lathe machine is
used to perform various operations such as turning, facing, threading, knurling, drilling, and parting,
primarily on cylindrical workpieces.

Key Observations and Tasks Performed:

Understanding Lathe Components: I became familiar with the main parts of a lathe machine,
including the headstock, tailstock, carriage, chuck, tool post, lead screw, and bed.

Basic Operations: I observed and assisted in carrying out turning and facing operations on mild
steel and aluminium workpieces. These tasks helped in understanding how different cutting tools are
used based on material type and operation.

Tool Setup and Centering: I learned how to properly mount and center the workpiece in the chuck
and align the cutting tool for accurate machining.

Safety Practices: I was trained to follow standard safety measures such as wearing PPE, checking
for proper tool clamping, and keeping safe distances during machining operations.

Surface Finishing: I also observed how changes in feed rate, speed, and tool angle affect the surface
finish of the machined part.

Precision Measurement: Tools like vernier calipers and micrometers were used to check
dimensions, tolerances, and quality of the final product.

Learning Outcome:
Working with lathe machines gave me a strong practical foundation in machining operations. It
enhanced my understanding of metal cutting principles, machining parameters, and the importance of
precision in mechanical component manufacturing.

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Lathe Machines in the Workshop

During my internship at MEIL's Mechanical Workshop, I had the opportunity to work with two
primary types of lathes: manual lathes and CNC lathes. Each type offers unique advantages and is
suited to different kinds of machining operations. Below is an in-depth look at the manual lathes.

Manual Lathes (HMT Lathes)

The workshop is equipped with four high-precision manual lathes from the HMT series. These
machines are known for their precise operations and are widely used when the job demands accuracy
and a high degree of craftsmanship. Key features of these lathes include:

Variety in Bed Lengths:

The manual lathes are available in different bed lengths of 1.5 meters, 2 meters, and 3 meters. This
variety allows the workshop to handle a range of workpiece sizes and complex machining tasks.

Chuck Diameter:
All HMT manual lathes come with a consistent chuck diameter of 400 mm. This larger chuck size is
particularly useful for securing bigger workpieces, ensuring stability and precision during machining.

Operational Mechanism:
Being manual, these lathes rely on gear systems for various operations. The gears control the speed
and feed, requiring the operator’s expertise to achieve the desired machining quality. This gear-based
control system, though requiring more skill, contributes to the fine precision and accuracy of the
operations.

Cost and Value:

HMT lathes are considered a significant investment due to their precision and the quality of work
they produce. Their higher cost is justified by their ability to produce parts that meet stringent
dimensional tolerances and surface finish requirements. These attributes make them indispensable
for tasks where accuracy is critical.
Key features of the HMT lathes include:
Heavy-duty build for high-precision work.
Manual gear systems for speed control.
High-quality finish on the machined components.
Suitable for operations like turning, facing, threading, and grooving.

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Manual Lathes (Samrat Lathes)

The workshop houses three Samrat lathes with bed lengths of 4.5 ft, 6 ft, and 9 ft. These machines
are gear-driven, allowing manual control over spindle speed and feed rate, and are suitable for
working on medium-sized cylindrical workpieces.

Key Features:
Bed Lengths: 4.5 ft, 6 ft, and 9 ft
Operation Type: Fully manual, gear-operated
Material Handled: Mild steel, aluminum, and similar metals
Use: Suitable for rough and semi-finish machining jobs

Operations Performed are:

Turning:
Used to reduce the diameter of a workpiece to the desired size.
I assisted in setting the tool, adjusting the speed, and controlling the feed manually.
Facing:
Machining the end of the workpiece to make it flat and smooth.
This operation helped in preparing a clean starting surface.
Grooving:
Creating a narrow cavity or recess on the outer surface.
Used in preparing parts for snap rings or design-specific functions.
Parting (Cutting Off):
Used to cut the finished part off from the remaining stock material.
Required careful tool alignment and steady feed control.
Drilling (using tailstock):
A drill bit was mounted in the tailstock to create holes along the center axis.
This operation helped me understand tailstock alignment and pressure application.
Chamfering:
Smoothing or beveling the sharp edges of the workpiece.
Done after turning or facing to improve safety and part aesthetics.

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Some Pictures of Lathes Machines

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Manual Lathes (Panther Lathes)

In addition to Samrat lathes, the MEIL mechanical workshop is equipped with Panther series lathes,
which are designed for heavy-duty and large-scale machining operations. These machines are ideal
for working on oversized or heavy components that require strong torque and stability during the
cutting process.

There are two Panther lathes in the workshop:

- One with a 1.5-meter bed length and a chuck diameter of 400 mm
- One with a 5-meter bed length and a chuck diameter of 1 meter

These lathes are gear-driven with 4 gear settings, allowing the operator to control spindle speeds
efficiently based on the size and material of the workpiece. The maximum rotational speed is
approximately 80 RPM, which is suitable for large jobs that require more torque and stability rather
than speed.

Key Features:
- Bed Lengths: 1.5 m and 5 m
- Chuck Diameters: 400 mm and 1000 mm
- RPM: Max speed ~80 RPM
- Gears: 4 gear levels for speed and torque adjustments
- Purpose: Designed specifically for large, heavy, and high-load jobs

Operations Performed:
- Turning Large-Diameter Shafts: Used to reduce and shape large-diameter cylindrical components.

- Facing and Grooving: Applied to the face and outer surface of oversized workpieces for leveling or
creating slots.

- Bore Machining: These lathes are suitable for deep bore operations due to their length and chuck
capacity.

- Heavy Stock Removal: Used when machining tough materials or thick sections that require high
torque and rigidity.

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Proeba Lathe – Extra Heavy-Duty Machining

The MEIL Mechanical Workshop is also equipped with a Proeba lathe, which is a special-purpose,
extra heavy-duty lathe used for handling very large and heavy components. This machine is
especially valuable in industries where large shafts, drums, or cylindrical components need to be
machined with high accuracy and stability.

The Proeba lathe in the workshop has the following specifications:

Bed Length: 8 meters
Chuck Diameter: 1 meter
Application: Heavy and long components requiring slow-speed, high-power cutting

Key Features:
Large Bed: The 8-meter bed allows machining of long components such as turbine shafts, rollers,
and industrial rods.

1 Meter Chuck: Provides the grip strength and diameter support to handle large and heavy
workpieces.

Heavy Frame: Built to absorb vibration and handle high cutting loads, which ensures better surface
finish and accuracy.

Low-Speed, High-Torque Operation: Ideal for roughing and finishing heavy parts where slow RPM
and high cutting power are needed.

Operations Performed:
Turning of Long Shafts: Used to shape and reduce the diameter of long and thick materials.

Facing of Large Ends: Flatting the end face of large parts for mounting or further processing.

Boring and Internal Cutting: On large pipes or cylindrical components that require internal
modifications.

Thread Cutting on Large Diameters: Performed when strong threaded connections are required on
heavy parts.
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CNC LATHES
CNC Lathes – Precision and Automated Machining
The MEIL Mechanical Workshop is equipped with two CNC (Computer Numerical Control) lathe
machines, which are used for automated, high-precision machining. These machines operate based
on programmed instructions, allowing for consistent and repeatable machining of components with
minimal manual intervention.

CNC Lathe Specifications:

Small CNC Lathe:
Chuck Diameter: 250 mm
Bed Length: 400 mm
Purpose: Ideal for machining small and medium-sized components with high accuracy.

Large CNC Lathe:

Chuck Diameter: 500 mm
Bed Length: 600 mm
Purpose: Used for larger and more complex parts requiring powerful cutting and more space.

Key Features of Both Machines:

Hydraulic Chucks: For automatic and firm clamping of the workpiece, ensuring safety and precision.

X and Y Axis Movement: Enables multi-directional tool movement for complex operations.

Tool Turret: Each CNC lathe is equipped with an 8-tool turret, allowing automatic tool change during
operations.

Computer-Controlled Interface: Uses G-code and M-code programming for executing precise
machining cycles.

Operations Performed on CNC Lathes:

Turning:
Automatically reduces the diameter of a rotating workpiece to the programmed dimension.

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Facing:
Creates a smooth flat surface at the end of the part.

Drilling:
Performed using turret-mounted drill bits aligned on the X or Y axis.

Grooving:
Cuts narrow grooves or recesses into the surface of the component with high accuracy.

Thread Cutting:
Produces external or internal threads with consistency across multiple parts.

Chamfering and Filleting:

Used to smoothen sharp edges or add finishing touches to the part.

Contour Machining:
Enables machining of complex profiles and shapes with a combination of tool paths.

CNC Controls
CNC Control Systems – FANUC and Siemens
During my internship at the MEIL Mechanical Workshop, I was introduced to two widely used CNC
control systems: FANUC and Siemens. These systems are the interface between the machine
operator and the CNC machine, allowing programming, monitoring, and execution of machining
operations with precision and automation.

1. FANUC CNC Control System:

FANUC (Factory Automation Numerical Control) is one of the most popular and reliable CNC
control systems used worldwide, especially in lathe and milling machines.

Key Features:
User-Friendly Interface: Simple layout, easy to navigate, especially for beginners.

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G-Code Programming: Uses standard ISO G-codes for programming.

High Accuracy and Speed: Suitable for high-speed precision machining.

Tool Management: Supports multiple tools, offsets, and tool life management.
Diagnostics: Built-in troubleshooting and diagnostic features for machine errors.

HNK Vertical Turning Lathe (VTL) – High-Precision Vertical Machining (CNC)

The MEIL Mechanical Workshop is equipped with an advanced HNK Vertical Turning Lathe (VTL),
which is used for machining large and heavy components in a vertical orientation. Unlike
conventional horizontal lathes, a vertical lathe holds the workpiece vertically, allowing gravity to
assist in stabilizing and supporting heavy parts.

Machine Specifications:
Chuck Diameter: 300 mm

Max Height Capacity: 2.5 meters

Drilling Capacity: Up to 60 mm

Tool Changer: Equipped with ATC (Automatic Tool Changer)

Application: Ideal for tall, heavy components requiring vertical machining

Key Features:
Vertical Orientation: The workpiece is mounted vertically on the rotating chuck, which is efficient
for machining large, tall, or heavy cylindrical parts.

Automatic Tool Changer (ATC): Allows multiple tools to be changed automatically, improving
machining speed and reducing manual intervention.

High Drilling Capability: Can drill holes up to 60 mm in diameter with precision.

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Stability and Accuracy: Its design ensures strong support for heavy loads, reducing vibrations and
improving accuracy.

Operations Performed:
Vertical Turning:
Machining the outer diameter of large, vertically held components.

Facing (Vertical Face Turning):

Smoothing and leveling the top face of the part.

Drilling:
Precision drilling up to 60 mm in diameter, especially on large flanges or discs.

Boring:
Enlarging pre-drilled holes in large components for exact fitment.

Grooving and Recessing:

Creating slots or grooves on the face or outer diameter of the component.

Threading:
Internal or external threads on tall components, depending on the setup.

Learning Outcome:
Operating and observing the HNK Vertical Turning Lathe helped me understand how vertical
machining works, particularly for components that are too large or heavy for horizontal setups. I
learned the significance of:
Proper work holding in vertical orientation.
Tool path management using ATC.
Drilling and boring on large, thick materials.
Safety measures for handling tall, rotating parts.

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Manual Vertical Lathe Machines (VTLs)

In addition to CNC vertical lathes, the MEIL Mechanical Workshop is equipped with two manual
vertical lathe machines used for machining large and medium-sized components. These machines
operate manually, requiring skilled operators to control feed rates, cutting depth, and tool
movements.

1.Large Manual VTL

Chuck Diameter: 3 meters.
Jaw Type: 4-jaw chuck.
Movement: Manual control both X and Y directions.
Applications: Very large heavy machining of large diameter parts.

2. Medium Manual VTL

Chuck Diameter: 1.5m meters.
Cutting Depth: 10 mm in a single pass.
Jaw Type: 4-jaw chuck.
Movement: Manual control in both X and Y directions.
Spindle Speed (RPM): 117 RPM.
Application: Medium machining of large-diameter parts.

3. Small Manual VTL

Chuck Diameter: 1 meter.
Max Machining Range: Up to 600 mm diameter jobs.
RPM: 150 RPM.
Jaw Type: 4-jaw chuck.
Application: Small-scale machining operations for balanced components.

Operations Performed on Manual VTLs:

Turning:
Reducing the outer diameter of large and medium components manually with precision.

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Facing:
Creating smooth and flat surfaces on the top face of the workpiece.

Grooving:
Making external and internal grooves or recesses using manual feed controls.

Drilling:
Performing vertical drilling operations with the help of a fixed drill bit and rotating job setup.

Boring:
Enlarging or refining holes previously drilled, often used for fitting shafts or bearings.

Thread Cutting (Optional):

In some cases, manual thread cutting can also be performed depending on tooling and job
requirements.

Learning Outcome:
Working on manual vertical lathes taught me how to handle heavy machining with manual controls,
accurately adjust feed and depth of cut, and monitor the cutting process without computer assistance.
I gained hands-on understanding of:
4-jaw chuck alignment.

Proper job setup for vertical machining.

Tool angle and feed adjustment.

Safe handling of heavy rotating parts.

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DRILLING MACHINES
Drilling Machines – Precision Hole-Making Equipment
The MEIL Mechanical Workshop is equipped with five different types of drilling machines, each
serving specific purposes based on the size, accuracy, and positioning of the holes to be drilled.
These machines are essential for performing accurate hole-making operations on various metal
components.

1. Radial Drilling Machines (2 Units):

Radial drilling machines are used for drilling large and heavy workpieces that cannot be easily
moved. The radial arm allows the drill head to be positioned over the workpiece without
repositioning it.

Key Features:
Large arm movement for wide coverage.

Adjustable drill head on vertical and horizontal axes.

Suitable for large plates, structures, and assemblies.

Applications:

Drilling holes on heavy components.

Tapping, reaming, and boring operations.

Ideal for jobs where the position of holes varies widely.

2. Batliboi Drilling Machines (2 Units):

Batliboi drilling machines are high-quality, medium-duty machines known for their precision and
reliability. These machines are generally pillar-type or bench-type, suitable for medium-sized
components.

Key Features:

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Robust and durable structure.

High spindle speed control.

Good for medium precision drilling tasks.

Applications:

General-purpose drilling.

Precision drilling on shafts, flanges, and smaller components.

Used in toolrooms and light fabrication works.

3. Kitchen & Walker Drilling Machine (1 Unit):

This is a heavy-duty vertical drilling machine, widely used for its stability and ability to handle
tougher materials.

Key Features:
Rigid frame suitable for heavy drilling loads.

Vertical movement of the drill spindle.

Durable for continuous and long-term operations.

Applications:
Deep hole drilling.

Large-diameter hole making in solid materials.

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Heavy industrial components.

Operations Performed on Drilling Machines:

Drilling: Creating round holes of various diameters in metal workpieces.

Tapping: Cutting internal threads into holes for bolts/screws.

Reaming: Sizing and finishing drilled holes for precision fits.

Countersinking: Creating a conical seat around a hole for screw heads.

Boring: Enlarging existing holes with better accuracy.

Learning Outcome:
Through hands-on practice on various drilling machines, I learned about:

-Tool and workpiece setup.

-Feed rate and RPM adjustment.

-Safety protocols during vertical drilling.

-Selection of the right machine for different job types.

This section of my internship helped strengthen my understanding of precision hole-making

techniques and the role of drilling machines in fabrication and assembly.

Taper Angles and Their Importance In Drilling Machines:

Taper is a gradual decrease in diameter from one end to the other, and it plays a critical role in
holding the tools firmly in the machine spindle without slipping. There are several standard tapers
used in the workshop:

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a. Morse Taper (MT):

Most commonly used in lathe tailstocks and drilling machines

Ensures self-holding fit due to friction

Comes in sizes MT1 to MT7

Typical taper angle: approx. 1.49°

Morse Taper Taper per foot Common Use

MT1 - MT2 0.04998 in/ft Small tools and drill presses
MT3 - MT4 0.602 in/ft Medium-duty lathes/drills
MT5 – MT4 0.631 in/ft Heavy-duty machines

R8 Taper:
Used in milling machines

Allows tool changes without removing the collet

Taper angle: approx. 16.85°

Importance of Taper Accuracy:

Ensures proper tool alignment.

Provides maximum contact surface between tool and spindle.

Prevents tool slippage and ensures machining accuracy.

Helps in easy removal and mounting of tools.

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Some Pictures of Different Tools Used in Drilling Machines

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Conventional Milling Machines

Conventional Milling Machines
During my internship at MEIL Mechanical Workshop, I had the opportunity to observe and learn
about three conventional milling machines used for various machining operations. These machines
are manually operated, gear-driven, and capable of producing precise components by removing
material from the surface of the workpiece using rotating cutters.

1. HMT Milling Machine

Chuck Diameter: 100 mm

Bed Size: 1 meter

Cutter Type: Keyway cutter (Keymax)

Movement: Manual feed in X and Y directions

Drive: Gear-operated

Features: High precision, durable, and one of the costliest among the three

Highlights:

The HMT milling machine is known for its precision and build quality.

Commonly used for keyway cutting, face milling, and slotting.

Its rigid bed and accurate feed mechanism allow for close tolerance work.

2. Huron Milling Machine

Chuck Diameter: 100 mm

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Bed Size: 2 meters

RPM Range: 70 to 1400

Drive Type: Manual gear system

Features: Suitable for larger workpieces due to extended bed

Highlights:

Offers a wider speed range for different cutting requirements.

Ideal for surface milling, contour cutting, and slotting of long parts.

Known for stable operation at both high and low speeds.

3. General Milling Machine (Conventional)

Chuck Diameter: 100 mm

Bed Size: 2.5 meters

RPM Range: 40 to 1600

Drive Type: Gear operated

Features: Longest bed among the three for machining large parts

Highlights:

Best suited for large and lengthy components that require extended travel.

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Can handle face milling, drilling, and shaping of bulky parts.

Common Operations Performed:

Face Milling:

Removing a layer from the surface of a workpiece to create a flat, smooth surface.

Keyway Cutting:

Creating slots in shafts or components to fit keys for mechanical power transmission.

Slot Milling:

Producing grooves or channels using specific cutters.

Side Milling:

Cutting on the sides of a workpiece using a side cutter.

Drilling:

Using the milling setup for vertical drilling applications.

Profile Milling:

Creating complex contours and shapes using multiple passes.

Learning Outcome:
Working with manual milling machines helped me understand:

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The importance of RPM and feed rate selection

How to align workpieces and cutters correctly

The difference in accuracy and capacity between different machine sizes

Manual control of axes for precision machining

This exposure enhanced my knowledge of traditional machining techniques and their relevance even
in modern workshops.

CNC Milling Machines

CNC Vertical Milling Machines
CNC (Computer Numerical Control) milling machines are widely used in the MEIL Mechanical
Workshop for precision machining, complex profiling, and efficient material removal. These
machines are equipped with Automatic Tool Changers (ATC) and advanced control systems for high
productivity and accuracy.

There are three major CNC vertical milling machines in the workshop, each with unique features
suited for different job sizes and complexities.

1. Hartford CNC Milling Machine

Company: Hartford

Bed Length: 4 meters

Machining Capability: Can perform both vertical and horizontal cutting

3D Machining: Yes, capable of creating 3D profiles and contours

ATC (Automatic Tool Changer): Holds up to 50 tools

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Applications: Ideal for long and complex 3D parts like molds, dies, and large components

Special Feature: Multi-directional cutting (vertical & horizontal)

2. BFW CNC Milling Machine

Company: BFW (Bharat Fritz Werner)

Bed Length: 1200 mm

Control System: Fanuc Control

ATC Capacity: 20 tools

Machining Position: Vertical only

Coolant System: Yes, used during all machining operations to reduce heat and improve finish

Applications: Suitable for medium-sized parts, slots, holes, and pocket milling with high precision

3. CNC Vertical Milling Machine – 3

Bed Length: 6 meters

ATC Capacity: 70 tools

Machining Position: Vertical and horizontal

Coolant System: Enabled

Applications: Designed for extra-large components with detailed profiles and long features

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Operations Performed on CNC Vertical Milling Machines:

Face Milling:

Smoothing large surfaces of the workpiece using a face mill cutter.

Profile Milling:

Creating complex 2D and 3D shapes as per programmed CAD data.

Pocket Milling:

Removing material from closed cavities in the component.

Slot Milling:

Machining straight or curved slots on the workpiece.

Drilling and Tapping:

Automated and precise hole creation and thread tapping using different tools.

Contour Milling:

Following intricate paths and curves on 3D components.

Chamfering and Deburring:

Cleaning up edges and adding angled cuts for part finishing.

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Learning Outcome:
Through working with these CNC vertical milling machines, I gained hands-on experience in:

Tool setup and tool changes using ATC

Understanding the Fanuc control interface

Importance of coolant usage during high-speed machining

Creating and editing G-code and M-code

Achieving precision and consistency in complex components

These machines demonstrated the efficiency and capabilities of CNC systems in handling jobs that
would be time-consuming or impossible on manual machines.

Conventional Boring and Jig Boring Machines

Conventional Horizontal & Jig Boring Machines
Boring machines are essential in precision engineering where enlarging and finishing of pre-drilled
holes is required. At MEIL Mechanical Workshop, three conventional boring machines are used for
different job types based on their configuration, orientation, and accuracy requirements. These
machines provide high precision and surface finish for critical components.

1. Collet Horizontal Boring Machine

Bed Length: 1.6 meters

Spindle Diameter: 250 mm

Chuck Type: Fixed, does not move vertically

Chuck Rotation: 360°

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Movement: X and Y directions

RPM Range: 8 to 950

Cutting Orientation: Horizontal only

Applications: Suitable for medium-to-large components requiring precise horizontal hole boring.

Key Features:

High rigidity for heavy cuts.

Chuck rotation allows flexible positioning of the workpiece.

Stable for long-duration machining.

2. PAMA Horizontal Boring Machine

Bed Length: 2.5 meters

Chuck Rotation: 360°

Chuck Removability: Yes, chuck can be removed

Movement: X and Y directions

RPM Range: 8 to 950

Cutting Orientation: Horizontal only

Applications: Suitable for heavy and long components, and machining large bores or inner diameters.

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Key Features:

High capacity and flexibility due to removable chuck.

Used for deep boring, slotting, and facing.

Excellent surface finish and dimensional accuracy.

3. Societe Genevoise Jig Boring Machine

Type: Vertical boring machine (Jig Boring)

Bed Length: 2 meters

Movement: X, Y, and Z directions

Applications: Designed for ultra-precise boring, finishing, and positioning holes in jigs and fixtures

Orientation: Vertical

Key Features:

Jig boring allows micron-level accuracy.

Capable of fine tolerance work, ideal for tool rooms.

Precision movement in all 3 axes.

Operations Performed on Boring Machines:

Boring:

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Enlarging existing holes with fine accuracy and better surface finish.

Facing:

Machining the flat face of a component, usually done on horizontal boring machines.

Grooving/Slotting:

Creating internal grooves or keyways in components.

Drilling:

Initial hole creation in case of jig boring, later enlarged by boring tools.

Counterboring & Reaming:

Finishing operations to ensure uniform and accurate hole sizes.

Learning Outcome:
Working with these boring machines taught me:

The difference between horizontal and jig boring.

Importance of chuck alignment and spindle rigidity.

How machine movement in multiple axes enhances versatility.

Real-world usage of boring machines for precision hole creation and enlargement.

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These machines are a critical part of large-scale industrial machining and contribute significantly to
component quality and fitment accuracy.

Slot Cutting Machines

Slot Cutting Machines
Slot cutting machines are used to machine slots or keyways into various components, which are
essential in power transmission systems and mechanical assemblies. In the MEIL Mechanical
Workshop, three slot cutting machines are employed to handle different sizes of workpieces.

1. Large Slotting Machine (Heavy-Duty)

Purpose: Used for large and heavy jobs

Capabilities: Can cut deep and wide keyways or slots in large components like gears, pulleys, or
couplings

Features: Heavy frame, adjustable stroke length, and rigid cutting tool setup for consistent
performance

2. Medium Slotting Machine

Purpose: Suitable for medium-sized components

Applications: Often used in general fabrication for shafts, sprockets, and internal features

Features: Balanced size and flexibility, capable of handling moderately heavy parts with ease

3. Small Slotting Machine

Purpose: Designed for small and precise jobs

Applications: Ideal for keyways in small shafts, bushes, or sleeves

Features: High accuracy, shorter stroke, and smooth feed control

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Operations Performed:
Keyway Cutting:

Creating precise slots for inserting keys used in shafts and couplings

Internal Slotting:

Machining slots inside cylindrical components

External Grooving:

Cutting surface-level grooves on external surfaces

Form Slotting:

Shaping non-standard or custom slot profiles

Learning Outcome:
Through hands-on experience with slot cutting machines, I learned:

The importance of accurate alignment for proper slot positioning

How to adjust stroke and depth based on the job requirement

The difference between light and heavy-duty slotting setups

Slotting machines continue to be a reliable solution for machining precise internal and external slots
in a wide range of components.

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Different Types of Tools Used

The performance and precision of any machining process heavily depend on the type of cutting tools
used. At MEIL Mechanical Workshop, a variety of specialized tools are employed to perform drilling
and milling operations efficiently and accurately.

Drilling Operation Tools:

CD Tool (Center Drill Tool):

Used to create a starter hole or center mark before actual drilling to ensure accuracy and prevent drill
bit deviation.

Drill Bits (Various Lengths):

Available in different lengths and diameters, these are the primary tools for creating holes in
workpieces.

Shorter bits provide better stability; longer bits are used for deeper holes.

Chamfer Tool:

Used for chamfering, i.e., to bevel the edges of drilled holes to remove sharp edges and help in
fastener insertion.

Reamer Tool:

Used for finishing and sizing drilled holes with high precision and smooth surface finish.

Bore Tool:

Applied for enlarging and truing up existing holes to achieve greater accuracy and alignment.

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Tap Tool:

Used for thread cutting inside drilled holes to create internal screw threads.

Milling Operation Tools:

Insert Tool (for Roughing):

Designed with replaceable inserts for heavy material removal during the roughing stage.

Provides good durability and cost-efficiency.

T-Max Cutter:

A large face milling cutter used for roughing and finishing flat surfaces.

Ensures uniform surface finish over large areas.

End Mill Cutters:

Primarily used for finishing operations, contouring, slotting, and pocketing.

Comes in different sizes and flute designs for versatility.

Learning Outcome:
Understanding and working with these tools allowed me to:

Choose the right tool for each stage of machining.

Maintain accuracy, surface finish, and efficiency in operations.

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Get hands-on knowledge of tool mounting, alignment, and usage techniques.

Proper tool selection and application are critical for achieving desired machining results and
extending tool life.

Different Types of Measuring Instruments

Measuring Instruments
Precision in mechanical machining depends heavily on accurate measurements. MEIL Mechanical
Workshop is equipped with a wide range of measuring and inspection instruments to ensure
dimensional accuracy, surface finish, and tolerance limits in all machined components.

1. Vernier Calipers
Types:
Plain Vernier

Dial Vernier

Digital Vernier

Measuring Range:
0–150 mm

0–200 mm

0–300 mm

0–450 mm

0–600 mm

0–1 meter

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0–2 meters

Purpose: For external and internal measurements, step measurements, and depth measurements.

2. Micrometers
Types:
Plain Micrometer

Digital Micrometer

Measuring Range:
25–50 mm

0–100 mm

100–200 mm

300–400 mm

400–500 mm

Up to 1000 mm

Purpose: For highly accurate external diameter and thickness measurements.

3. Inside Micrometers
Measuring Range:
0–500 mm

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0–1000 mm

50–1500 mm

Purpose: For internal diameter measurement of bores and cavities.

4. Depth Measuring Instruments

Depth Vernier Calipers:
Types: Plain & Digital

Range: 150 mm, 200 mm, 450 mm, 600 mm

Depth Micrometers:

Range: 0–25 mm, 50 mm, 100 mm

Purpose: Accurate depth measurement of slots, holes, and recesses.

5. Bore Gauges
Measuring Range:

18 mm, 35 mm, 60 mm, 150 mm

Purpose: For checking internal diameters of holes and bores with high precision.

6. Dial Gauges
Types:
Pleasure Dial

Pippy Dial

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Purpose: Measuring small displacements, alignment errors, and runout in rotating shafts.

7. Height Gauges
Measuring Range:

0–600 mm

Purpose: Vertical measurement and precise marking on components.

8. Slip Gauges
Measuring Range:

From 1.0001 mm to 100 mm

Purpose: Standard reference blocks for calibrating other instruments or gauging equipment.

9. Other Measuring Tools:

Measuring Tape: For quick large-scale measurements.

Spirit Level: Ensures component and machine bed leveling.

Protractor & Bevel Protractor: Used for measuring angles.

Groove Micrometer: Special tool for measuring inside grooves.

Pitch Gauge: Measures screw thread pitch.

Radius Gauge: Measures internal and external radii.

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Marking Block: Assists in layout marking and precision height marking.

Learning Outcome:
Using these measuring instruments during the internship helped me:

Understand the importance of precise measurement in machining

Learn calibration techniques and tool handling

Ensure tolerance and fitment accuracy of all machined parts

These instruments play a critical role in maintaining the quality control and precision engineering
standards of MEIL's mechanical workshop.

Different Materials Used

Materials Used in the Workshop
In machining and fabrication processes, the choice of material plays a key role in determining the
strength, durability, corrosion resistance, and machinability of a component. The MEIL Mechanical
Workshop uses a wide variety of metals and alloys to suit different engineering applications.

1. Mild Steel (MS) / Magnet Steel

Grades Used: 1, 4, 9, 10, 11, 14, 19, 24, 29, 31, 34

Properties:

Good machinability and weldability.

Moderate strength and hardness.

Cost-effective for general fabrication.

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Applications: Shafts, brackets, structural parts, and machine bases

2. HCSC (High Carbon Steel Cast)

Properties:

Very high hardness and strength.

Susceptible to corrosion.

Requires special tooling for machining.

Applications: Components requiring high wear resistance like tool bodies, guides, and heavy-duty
machine parts

3. Stainless Steel (SS)

Grades Used:

202: High hardness and corrosion resistance

304: Most commonly used, good corrosion resistance and machinability

316: Premium quality, high corrosion resistance, used for special environments (marine, chemical)

Applications: Fittings, shafts, food-grade equipment, high-temperature parts

4. Brass
Properties:

Good corrosion resistance

Easy to machine

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Appealing finish

Applications: Bushes, valve bodies, decorative fittings

5. Copper
Properties:

Excellent electrical and thermal conductivity

Soft and ductile

Applications: Electrical parts, heat exchangers, connectors

6. Cast Iron
Properties:

High compressive strength

Good vibration damping

Brittle compared to steel

Applications: Machine beds, housings, blocks, and pulleys

Learning Outcome:
Understanding the properties and applications of each material helped me:

Select suitable material based on job requirements

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Learn how material hardness, corrosion resistance, and machinability affect tool choice and
machining method

Handle and identify different materials during practical work.

Skills Acquired and Learning Outcomes

During the one-month internship at MEIL Mechanical Workshop from March 10 to April 10, I was
exposed to a wide range of machines, tools, materials, and real-time industrial practices. This hands-
on experience significantly enhanced both my technical and professional skill set.

Technical Skills:
Machining Knowledge:

Gained practical exposure to lathe, milling, drilling, boring, slotting, and grinding machines, both
manual and CNC types.

Understood the operation, parts, and working principles of conventional and CNC machines.

CNC Programming Basics:

Learned about CNC control systems including FANUC and Siemens.

Understood tool setting, coordinate systems, and ATC (Automatic Tool Changer) functions.

Measuring and Inspection:

Used various measuring tools like vernier calipers, micrometers, bore gauges, height gauges, slip
gauges, etc.

Understood the importance of precision, tolerance, and quality control.

Material Identification:

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Learned about different metals and alloys used in fabrication and machining, including their
properties and applications.

Tool Selection and Usage:

Developed the ability to select the right tools for drilling, milling, and turning operations based on
material and finish required.

Soft Skills & Industrial Etiquette:

Team Collaboration: Worked alongside experienced operators and engineers, improving teamwork
and communication.

Discipline and Safety: Understood the importance of PPE, workshop safety rules, and machine
handling protocols.

Problem Solving: Encountered real-time challenges and observed how quick thinking and precision
are applied in machining tasks.

Documentation & Observation: Maintained a daily log of observations, machine specifications, and
operations performed.

Contribution and Participation

During my one-month internship at MEIL Mechanical Workshop, I actively engaged in various
activities and tasks that enhanced my learning and also added value to the workflow of the
workshop.

1. Daily Observation and Machine Handling

Actively observed and participated in the operation of conventional and CNC machines such as
lathes, milling machines, drilling, boring, and slotting machines.

Assisted machine operators in setting up jobs, loading/unloading components, and basic tool changes
under supervision.

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2. Material Handling and Identification

Helped in identifying materials based on grades and applications like MS, SS, HCSC, Brass, Copper,
Cast Iron, etc.

Participated in organizing and labeling materials used for machining processes.

3. Measuring and Quality Checks

Performed basic measurement checks using vernier calipers, micrometers, bore gauges, and height
gauges.

Contributed to maintaining dimensional accuracy by re-checking sample pieces alongside

supervisors.

4. CNC Machine Observation

Closely observed CNC programming, particularly tool path setup, coordinate entry, and tool
changing in ATC.

Understood the working of FANUC and Siemens control panels and participated in minor data
entries under guidance.

5. Workshop Etiquette and Team Work

Maintained workplace cleanliness and followed safety protocols strictly.

Supported senior technicians in routine machine maintenance and cleaning tasks.

Actively communicated with team members, operators, and instructors to clarify doubts and improve
understanding.

Learning Approach:
My contributions were focused on being proactive, asking questions, and assisting wherever
possible. I ensured I made the most of the hands-on opportunity by staying involved and showing
enthusiasm throughout the training.

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Conclusion
The internship at MEIL Mechanical Workshop from March 10 to April 10 was a highly enriching and
practical experience that significantly contributed to my technical growth and understanding of real-
time manufacturing processes. Through hands-on exposure to both conventional and CNC machines,
I gained a deeper insight into the working of lathes, milling machines, drilling machines, boring
machines, slotting machines, and vertical turning lathes.
I also developed a solid understanding of industrial materials, cutting tools, tool angles, and
measurement instruments, and how they are applied in various machining operations. Observing and
learning about modern control systems like FANUC and Siemens further broadened my knowledge
of automation in mechanical industries.
This internship has helped me bridge the gap between theoretical knowledge and practical
application. It has strengthened my interest in the field of manufacturing and machining and has laid
a strong foundation for my future endeavors in the mechanical engineering domain.
I am grateful to MEIL for providing such an opportunity and to the workshop supervisors and
technicians who guided me throughout this learning journey.

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