intro of me

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SUMMER TRAINING REPORT


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CERTIFICATE

This is to certify that Mr. ANKIT BHATT Student of Mechanical Engineering from

UTTARAKHAND has undergone practical training at INSTRUMENTS RESEARCHAND DEVELOPMEN

ESTABLISHMENT, DEHRADUN for a period of 30 Days from 13th June 2011 to 25th July 2011 at Photoni

Division. He was associated with study of CAM and FOLLOWER DESIGN.

I wish him all success in future.

Sc E CD (PR)

Project Guide. IRDE.


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ACKNOWLEDGEMENT

First of all, I am grateful to Mr. S.S.Sundaram, Director IRDE, Dehradun for providing me th

opportunity by giving me permission to undergo practical training at this esteemed organisation.

I express my deep gratitude to Mr. J.K.Bajpai, Sc. 'G', Chief Designer of the Opto-Mechanic

Engineering Division for providing me with facilities available at PR to carry out this project and Mr. Am

Kumar Sharma Sc. 'B' for guiding and encouraging me throughout my project work.

Last but not the least I am also thankful to all Scientists, Technicians and others who directly or indirectl

helped me during the tenure of my Project semester.

Place: IRDE, DEHRADUN KRISHANK KUMAR MALWA

Date- 6th

July 2011 B.Tech. 3rd

Year

Mechanical Engineering

COT PANTNAGAR, UTTARAKHAND


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ABSTRACT

With the advances of new technology in the field of engineering, especially in manufacturing, it becomes uttermo

to produce component of high accuracy and precision. For most of components, accuracy becomes inevitab

aspect and so we need machines which can match with these requirements. In this report, besides som

conventional lathe and milling machines I have laid special attention on high accuracy machines like SPDT, N

machine, CNC machines. These machines are capable of producing components of accuracy up to nanomete

Moreover as CNC and NC machines are operated by programs, so with these machines we can obtain increase

flexibility, excellent reliability, high production rate and production of complex part. Various methods used

chemical lab for the finishing of some component, are also discussed, at the same time different instruments use

for inspecting this high accuracy have been introduced.


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CONTENTS

1. Introduction to I.R.D.E

1.1. IRDE Vision

1.2. Quality Policy

1.3. Major Area of Activity

1.4. Infrastructure


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Machine Shop

Machining is a term used to describe a variety of material removal processes in which a cutting tool remov

unwanted material from a workpiece to produce the desired shape. The workpiece is typically cut from a larg

piece of stock, which is available in a variety of standard shapes, such as flat sheets, solid bars, hollow tubes, an

shaped beams. Machining can also be performed on an existing part, such as a casting or forging.

Material removal processes:

Mechanical

o Single-point cutting

Turning Planing and shaping

o Multi-point cutting

Milling Drilling

Broaching Sawing

o Abrasive machining

Grinding Honing

Lapping Ultrasonic machining Abrasive jet machining

FOUNDARY SHOP

Foundry Engineering deals with the process of making casting in moulds prepared by patterns. The whole proce

of producing castings may be classified into five stages.

1. Pattern making
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2. Moulding & core making

3. Melting

4. Casting

5. Cleaning of casting

Pattern: It is defined as the model of the product, which is to be cast. Different kinds of pattern material are:

a) Wood

b) Metal

c) Plastics

d) Plasterse) Waxes

Types of pattern:

1. Single piece pattern2. Double piece or split pattern

3. Cope & drag pattern

4. Match plate pattern

5. Skeleton pattern

TYPES OF SAND USED

a) Green Sand

b) Parting Sandc) Core Sand


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MECHANICAL INSPECTION LAB

Measurement capabilities:

Linear & angular dimensions

Geometrical parameters

Thread parameters

2D &3D data generation

Digitizing of unknown profile

Interface with CAD files

Facilities:

Co-ordinate MM

Vision system

Micro height gauge

Bore gauge

Dial gauge

Gauge blocks

Bevel protactor

Depth micrometer

Vernier micrometer

VISION SYSTEM (HAWK 7)

SPECIFICATION :

Make Vision EngineeringHAWK 7

Stage travel 200x150 mm

Magnification Eyepiece 10x

Objective 50x

Resolution 0.4 m

Accuracy (3+L/50) m

Angular resolution 1min

Software Quadra Check 5000


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MEASUREMENT CAPABILITIES:


Inspection of miniature components

PCD of holes

Noncontact measurement


Thread parameters

CMM (CO-ORDINATE MEASURING MACHINE)

SPECIFICATION:

Make Carl-Zeiss

Type Moving Bridge Type

Measuring Range 700x700x600

Resolution 0 .1m

Accuracy (2+ L/300) m

Software CALYPSO

HOLOS NT

Probing System VAST-XT Probe

Minimum Probe Dia. 3mm

CAPABILITIES:



2D &3D profile measurement

Digitizing

Interface with CAD files

Scanning through VAST-XT Probe

MICRO HEIGHT GUAGE

SPECIFICATION:

Make Mitutoyo

Measuring Range 0-900 mm

Resolution .001 mm


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Accuracy (2+ L/600) mm

Minimum Probe Dia. 3mm

CAPABILITIES:

Height Measurement

Circle Measurement ( Bore/Shaft)

Width Measurement Perpendicularity, Straightness, Inclination

3 PIN BORE GUAGE

SPECIFICATION:

Make Mitutoyo Measuring Range 6-12, 12-20, 20-50, 50-100

Resolution .001 mm

DIAL GUAGE

SPECIFICATION:

Make Mitutoyo

Measuring Range 0-12

Resolution .001 mm

DIGITAL VERNIER

SPECIFICATION:


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Make Mitutoyo

Measuring Range 0-150, 0-300 mm

Resolution 0.01 mm

DIGITAL MICROMETER

SPECIFICATION:

Make Mitutoyo

Measuring Range 0-25, 50-75,75-100 mm

Resolution 0.001 mm

DEPTH MICROMETER

SPECIFICATION:

Make Mitutoyo Measuring Range 0-300 mm

Resolution 0 .001 mm


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DIGITAL HEIGHT GUAUGE

SPECIFICATION:

Make Mitutoyo

Measuring Range 0-900 mm

Resolution 0.0001 mm

BEVEL PROTACTOR

SPECIFICATION:

Make Mitutoyo

Measuring Range -360 to +360 mm

Resolution 2min


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JIG BORING MACHINE

A jig boring machine gets its name from the fact that it is so often used to drill and bore holes needed for drill jig

It is designed for locating and boring holes on jigs, fixtures, dies, gauges and other precision parts to an accuracy

+/- 0.0025mm. It is precision tool room machine intended for laying out, centering, drilling, reaming and finishinboring holes machining form contours, milling boss face surface etc.

Jig borers are very accurate vertical type boring machines, designed for use in making jigs and fixtures they ar

used as co-ordinate measuring machines for inspection and precision layout operations. It resembles a vertic

milling but it is constructed with greater precision and is equipped with an accurate measuring device f

controlling table movements this machine also designed to be operated by numerical control.

CHEMICAL LAB

1. ANODISING:

Hard anodising produces harder coatings than the normal 'decorative' process, but the exact shade depends upo

coating thickness and anodising conditions (which we can control), as well as alloy, thermal history, degree of ho

or cold work, etc., over which we have no control.

Excellent thermal conductivity

Good malleability and ductility

Imparts a surface as hard as some gemstones

Increase in the surface hardness upto 1000 V.P.N

Excellent lubricating properties especially for continuously moving parts. Excellent corrosion and abrasion resistance.

Enhancement of working life

CORROSION RESISTANCE:

The hard anodising process coats the metal with a layer of aluminium oxide, which is chemically inert und

neutral or mild acidic conditions of exposure; it therefore offers a means of protection of the metal surface in

wide range of environments. Because the oxide coating is derived in part from the metal itself, the constituents

the particular alloy have an effect upon the nature of the coating and upon its corrosion resistance (e.g. Al-C

alloys) will give a useful measure of protection.


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TEMPERATURE RESISTANCE:

The anodizing process applies to the metal surface a coating of aluminium oxide. The nature of the process is such

that adhesion of the oxide to the substrate can be taken for granted, unlike ceramic and other coatings which are

dependent upon cleanliness and other factors. The melting point of aluminium oxide is over 2000C, which is far

above that of the metal itself, and it is largely unaffected by temperatures within the useful range of the metal.

Sealing, dyeing and Ano-lube treatments do not share the properties of the oxide itself and trials should be carried

out to establish their suitability at elevated temperature.Coatings are unaffected by sub-zero temperatures exceptinsofar as differential contraction between oxide and metal may give rise to a greater tendency to crazing; this

effect is dependent upon alloy, process conditions and the physical shape of the workpiece, so trials should be

carried out to determine suitability.

ELECTRICAL INSULATION:

The coating produced by the anodising process is composed of aluminium oxide, a material having exceptional

dielectric strength. The coating has excellent adhesion to the substrate, high resistance to mechanical damage and

extremes of temperature making anodising aluminium the preferred choice of a number of electrical applications.

WEAR RESISTANCE - HARDNESS TESTING:

The coating produced by the hard anodising process is chemically akin to many gemstones and shares their

property of extreme hardness and resistance to abrasion. The hardness of anodised coatings is specified in British

Standards using the Vickers Micro Hardness Test in which the hardness is measured on a section through the film

giving micro hardness values of 250 to 600; depending on the aluminium alloy, the process and the sealing.

The matrix of aluminium oxide itself has a micro hardness of around 1,100 Vickers. The indentation method of thVickers Test really indicates the crushability of the brittle and porous anodic film whereas the property often

expected by customers is abrasion resistance.

APPLICATIONS:

Pneumatic Cylinder Tubes, Pneumatic Valve Spools, Pump Components, Automotive Hydraulic Components,

Pulleys, both Vee and Timing types, Plasma etching equipment, Drugs Machinery, Food Handling Machinery,

Plastics Machinery, Pistons, Cylinders, Actuators, Engine Blocks, Solenoid Valves Aluminum Castings and many

many more.


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