report on industrial training at hmt machine tools, kalamassery

REPORT ON

INDUSTRIAL TRAINING

AT

HMT MACHINE TOOLS LTD, KALAMASSERY

Submitted by

VEDANT PRUSTY

Reg. No.: 120929210

DEPT.OF MECHATRONICS ENGINEERING

MANIPAL INSTITUTE OF TECHNOLOGY (A constituent institution of Manipal University)

January 2015

Report on Industrial Training at HMT Machine Tools, Kalamassery January 2015

2 Vedant Prusty Dept. of Mechatronics Engineering, MIT Manipal



CONTENTS

Chapter Page No.

________________________________________________________________________

i. Training Certificate…………………………………………………………02

ii. Contents……………………………………………………………………. 03

iii. Acknowledgement..…………………………………………………………04

1. Introduction…………………………………………………………………05

2. Objectives…………………………………………………………………...13

3. Plant Services Department………………………………………………….14

4. Foundry and Pattern Shop…………………………………………………..17

5. Planning Department………………………………………………………..22

6. NH Assembly……………………………………………………………….27

7. CNC Assembly……………………………………………………………...30

8. Quality Control……………………………………………………………...33

9. Heat Treatment………………………………………………...…………....37

10. High Technology Center………………………………………………...….41

11. Printing Machines Division…………………………………………………44

12. Heavy Parts………………………………………………………………….46

13. Conclusion ……………...…………………………………………………...49

iv. References………………….………………………………………………..51

Industrial Training Schedule………………………………………………...52

______________________________________________________



ACKNOWLEDGEMENT

"...the beauty of the destination is half veiled and the fragrance of success half dull until

the traces of all those enlightening the path are left to fly with the wind, spreading word of

thankfulness..."

I am grateful to my guide, Mr. K. Ramachandran Nair, Deputy Chief Engineer (TS) for

leading the path and encouraging me to widen my horizons. Thank You Sir for letting me

dig deep into and exploring the concepts and practices of machine tool manufacturing, and

production planning.

My gratitude to Mr. Gopi Mohan of the Training Center at HMT MTK for helping me

identify, select and decide over the subject and scope of this training. Despite his busy

schedule, he took out time to patiently guide and nurture us, making sure we had the best

all-round exposure to the industrial practices.

Without the companionship of Mr. Sarthak Prakash and Ms. Sruthy J. Kunnel, HMT and

Kalamassery would not have happened!

Thanks to Sarthak, we made it!

Thanks to Sruthy, we tried to make the fullest of our time here!

I run out of words while expressing my heartfelt gratitude and salutations to the kind couple,

Mr. and Mrs. T.G. Job of Peruva, Kottayam District. Their foster parenthood, care and love

added to the joy of learning and experiencing through this month.

This project would not have seen the light of day without the constant support of my family

– my parents and my sister.

Special thanks to Mr. B. Sarkar at HVF, Dr. Chandrasekhar Bhat and everyone at the Dept.

of Mechatronics Engineering, MIT Manipal for their help and support in realizing this

training.



1. INTRODUCTION

The machine tool industry constitutes the backbone of the industrial sector and is vital for

the growth of the Indian Economy. Even though the Indian machine tool industry is a small

segment of the engineering industry, it plays a very important role in the development and

technology upgradation of the engineering industry. The quality and cost of engineering

products depends on the quality of mother machine tools and their automation level. The

development of the machine tool industry is therefore of paramount importance for a

competitive and self-reliant industrial structure. This report discusses the 1 month Industrial

Training at HMT’s Machine Tool Division at Kalamassery, Kerala. The training was

completed in December-January 2015.

1.1 Company Profile

By end of the Second World War, the government of India confronted by a big problem of

disposing the colossal war waste. Ultimately, a committee was constituted to inquire into

the possibilities. The committee report of 1948 proposed the establishment of a government

owned machine tool industry. This was expected to fulfill two aspects. The first was being

utilization of the Rs.4000 million worth of metallic waste. The second was the

incorporation of a state owned infrastructure – manufacturing facility. The result was the

birth of THE HINDUSTAN MACHINE TOOLS LIMITED, which diversified in due

course of time to the present stature of the multi core, multi-location, and multi-unit, multi-

product industrial giant HMT Ltd.

The HMT Ltd was started as a single factory to produce Tool Room Lathe at Bangalore in

collaboration with M/s Oerlikon of Switzerland in 1953, with capacity to manufacture

around 400 machines per year. Since then different collaborations, continued in house

R&D and tremendous marketing efforts brought HMT, to present status.

The growth of HMT Ltd. was characterized by the forward and backward integration of

technology and product diversification. Thus the company that started with manufacturing

and selling lathes expanded its machine tools products range to evolve as the ultimate

solution in metal cutting. The product diversification efforts took the company to the

business of watches in 1962, tractor in 1971, die-casting on plastic machinery in 1971,

printing machinery in 1972, presses in 1972, lamps & lamp making machinery in 1976,



food processing machinery in 1980, CNC systems in 1986, ball screws in 1986 and

reconditioning in 1990.

The multi product activities made HMT Ltd. change its identity as Hindustan Machine

Tools Limited. Today HMT Ltd has 16 manufacturing units with 22 products divisions

spread through the length and breadth of India. A subsidiary viz., HMT (international) Ltd

undertakes the exports of the company. They are also export agents for general other Indian

companies.

HMT Ltd was restructured in 1992 to facilitate better administration of the multi product

business activities. Accordingly, the following business groups were established:

Machine tools business group, to concentrate on metal cutting machines

Industrial machinery business group to deal with printing machines, die-casting and

plastic injection molding machines food processing machines and metal forming

machines

Agricultural business group to concentrate on tractor

Engineering components business group to deal with casting and ball screws

Consumer product business group, to deal with watches and lamps

In addition to these business groups, the

company owns three subsidiaries as follows:

HMT (international) Ltd. which

undertakes overseas project &

exports

PRAGA Tools Ltd. which

manufacturers machine tools

HMT bearing Ltd which

manufacture precision bearing in collaboration with M/S Kozo Japan

As per the revival plan of this public sector industry a turnaround plan has introduced in

early days of this millennium and re-organized as HMT Ltd holding company including

tractor division and presently comprises of the following subsidiaries:

Fig. No. 1: The NH 22 High Speed Precision Lathe

is still the primary product of HMT



1. HMT Machine Tools Limited.

2. HMT Watches Limited

3. HMT Chinar Watches Limited

4. HMT Bearing Limited

5. HMT International Limited

6. PRAGA Tools Limited

1.1.1 HMT Machine Tools Limited

The HMT Machine Tools Limited is engaged in the manufacture and marketing of general

purpose machine tools, special purpose machine tools, computer numerically controlled

machine tools, precision machinery system, printing machines, metal forming passes, dies

casting and plastic injection molding machines, ferrous and non-ferrous casting.

The product range of HMT Machine Tools:-

BANGALORE:

Heavy duty lathes

Single and multi-spindle automates

Radial drilling machines

Multi spindle drills

Cylindrical & surface grinders

Laser cutting machines

CNC turn mill centers

CNC wire cut EDM

PINJORE:

FMS & FMC

Horizontal machining centers

Vertical machining centers

Milling machines

Broaching machines

KALAMASSERY:

CNC turning center

Turn mill center

Fig. No. 2: ECONO CNC 26 Flat Bed Lathe



Flexible turning cell

Copying lathes

Center lathes

Offset printing machines

Paper cutting machines

HYDERABAD:

Special purpose machines

Horizontal machining center

FMS

CNC horizontal boring machines

Bed type & floor types boring machines

AJMER:

Grinding machines

SPM grinders

CNC grinders

Facilities available in different machine tool units:

CNC ram type Plano miller

Horizontal machining centers



Horizontal jog boring machines

CNC turning centers

Turn mill centers

Slide way grinders

Cylindrical grinders

Internal grinders

Precision gear shapers

Precision gear hobbers

Gear grinders

Induction hardening machines

3D co-ordinate measuring machines

Fig. No. 3: STALLION 100S series Slat Bed Lathes



1.1.2. HMT Watches Limited

HMT Watch Limited manufactures and markets watches including hand wound / automatic

& quartz.

1.1.3. HMT Chinar Watches

HMT Chinar Watches limited is also one of the subsidiaries engaged in the manufacture

of chinar model watches located in Srinagar, Kashmir state.

1.1.4. HMT Bearing Limited

HMT Bearing Limited is one of the subsidiaries engaged in the manufacture of different

types of industrial bearing situated in Hyderabad.

1.1.5. HMT International Limited

HMT International is engaged in the export of HMT’s range of product worldwide HMT

(I) also market and backed up by a good sales & services network. It also under takes

Turkey project & technical services for developing countries.

1.1.6. Praga Tools Limited

Praga Tools Ltd is also a subsidiary of HMT Limited engaged in the manufacture of machine tools located in Hyderabad.

1.2 The Kalamassery complex of HMT Limited Kalamassery

The Kalamassery unit, the 4th machine tools unit was established in 1963 and started production in 1964. The unit originally manufactured only two types of center lathes viz.

H & LB, but later added special purpose lathes like copying and turret lathes. Model L. T-

20 was the first product to be indigenously developed by the unit (1968) and the

development of this product was a landmark in the history of the unit. The production of

this was later licensed to M/S Qetcos, Kerala, Matools, Philippines Ceylon Steel

Corporation Sri Lanka. The original center lathes H&LB were then replaced by a new

family of unified series of lathes, which was designed and developed by the unit,

incorporating the concepts of typification, standardization & unification.



Diversification of Kalamassery Unit and Birth of Printing Machine Division

During the period 1972-73,

Kalamassery unit diversified its

product range to include printing

machinery division (PMK). The

commercial entry of PMK was with

two types of letter presses viz. RTE &

RTAF under collaboration with M/S Nebiolo of Italy. Autoplaten, an

indigenous development came up

subsequently. During the ensuing

years, the printing machinery division came up with offset press viz. OMIR in collaboration

with M/S Nebiolo later indigenous offset press viz. SOM 136 was introduced to the market.

The first two-color machine from HMT was OMIR in collaboration with M/S Korning &

Baver of Germany. The latest development of PMK is the paper-cutting guillotine PG

92D3, in collaboration with M/S Divano Blinders of Italy.

THE CURRENT PRODUCT RANGE

Product Model

Offset printing machines SOM436

SOM425 (four colour)

SOM236

SOM231

SOM225 (double colour)

SOM136

SOM131

SOM125g (single colour)

Paper cutting machine PG-92D3

The Kalamassery units of HMT are famous for development activities. Their product have

always fetched award and prized at different trade fair & competitions. To name a few are

the prizes bagged in different IMTEX fairs by FC-25, SBC & SBCNC machines. The CNC

lathe model STC has won the VASVIK Industrial research award 1987 instituted by the

Fig. No. 4: SB CNC30

Fig. No. 5: VMC 1200M



Vindhalaxi Audyogik Samsadhan Vikas Kendra, (VASVIK) for outstanding advancement

of science and technology.

The machine tool products of this unit have been certified by RWTUV-(Reinisch West

Falischer Techniseruber Wachungs Verein) an international certification agency of high

repute as confirming to total quality management system. Both the division have been

awarded ISO 9001 certification by IROS. The manufacturing shop at MTK is supported

by various infrastructural facilities like high technology CNC machine centers, testing

facilities, foundry, heat treatment, computer system, CAD systems etc. Around 600 well

experienced personnel form the human resources of the unit keeping in line with the current

corporate trends.

Training Centre

The manufacturing shops at MTK are supported by various infrastructure facilities like,

high technology CNC machining center, testing facilities foundry, heat treatment,

computer system CAD system etc. around 800 well experienced personal form the human

resources of the unit keeping in line with the current corporate trends. This unit views HRD

as one of the primary concerns as a measure to increase productivity and enhance social

stranding. The company has a well-established training system by personnel of high

technical and management skills.

Fig. No. 6: PG 29 Guillotine



1.3 The Marketing Network of HMT Ltd

The machine tools marketing divisions with its headquarters at Bangalore and having wide

network of regional and divisional offices spread throughout India caters to the marketing

needs of this unit at the primary level. To co-ordinate the marketing activities at unit level

and co offer technical support to machine tool marketing, a strong sales and services team

is constituted at unit level. HMT’s major customer includes defense, railways, automobile

and other engineering industries in various sectors.

Fig. No. 7: HMC 1000 series

1.4 Quality policy

HMT MLT is committed to total customer satisfaction by the supply of quality products

and services through:

Continuous improvement of technology of product and processes.

Innovation and creativity.

Effective implementation of quality management system.

Monitoring the effective realization of quality objectives and periodical review of

its suitability.

This report is structured according to various divisions of the factory at HMT MTK. The

functions, scope, and work done at each division is described briefly under these headings.



2. OBJECTIVES

The Objectives of this training were as follows:

To study the planning, organization and setup of the Machine Tools Industry at

HMT Kalamassery.

To understand in detail the overall production mechanism and products of HMT

MTK.

To specifically study life cycle of products from casting, forging, machining,

assembly to final testing, inspection and shipping.

To spot possible areas of reduced efficiency in the production cycle and identify

their reasons.

To explore manufacturing and working of CNC, VMC and HMC, their electronics,

control and mechanics, along with use of G- Codes.



3. PLANT SERVICES DEPARTMENT

Plant services department is responsible for maintaining the machines and equipment of

the unit in optimum condition of performance so as to make them available for production.

The plat services department is responsible for the erection and commissioning of the

machines in the plant. The department is also responsible for the electrical power

distribution of the entire factory complex. The department looks after the internal transport

functions and housekeeping activities inside the factory.

3.1 Scope

Erection, commissioning, repair, maintenance, reconditioning, retrofitting and

preventive maintenance of all the machines and equipment used for production in

the MTD and PMD plants and training center.

Maintenance of the cranes, jib cranes, air compressors and a/c units in the MTD and

PMD plants.

Upkeep of R&M stores and spare parts planning.

Housekeeping activities in the shop floors.

Materials movement in the shop floors and maintenance of internal transport

vehicles and equipment.

Maintenance of power supply to the entire factory complex.

Maintenance of 66 kV sub-station, switchgear, power transformers, and the entire

distribution system.

Maintenance of supply distribution in colony, pump house.

Maintenance of internal telephone exchange and the communication system.

To arrange and co-ordinate contract works in connection with any of the above

activities.

3.2 Objectives

To maintain the plant, machines and equipment in optimum conditions of performance

ensuring availability for production. The plant services department sets its measurable

quality objectives for every year. These objectives ensure that the machines and equipment

are well maintained to meet the requirements of the customers. The quality objectives are



communicated to all the employees in the department by displaying them in the key areas

of the factory.

Chart No. 1: Process for Breakdown Maintenance



Chart No. 2: Process for Preventive Maintenance

NO

Prepare preventive

maintenance schedule

Intimate schedule to

chief of manufacturing

Get monthly plan for

preventive maintenance

Ensure

availability

of machine

Perform P.M as per

check list

After completion of PM,

Hand over machine to

production

Update P.M Schedule

Review in the fortnightly maintenance meeting for

process improvement and effectiveness

Review and

Reschedule Plan

Record Deviations,

If any

YES



4. FOUNDRY AND PATTERN SHOP

The foundry & pattern shop attached to the machine tool division, HMT, Kalamassery and

part of engineering components business group is geared to manufacture all cast iron &

spherical graphical iron required for machine tools and printing machinery division and can

also undertake job orders. Established in 1968 with polish design, it is a semi mechanized

foundry producing heavy duty gray & SG iron casting for machine tools and printing

machines using mains frequency induction furnaces for melting and resin bonded sand for

molding and core making.

4.1 Pattern Shop

A pattern is defined as anything used for forming an impression called mould in the sand.

Mould when filled with molten material on solidifying, forms a reproduction of the pattern

and is known as mould. It is slightly larger in size than casting. As the first stage in

preparing the casting, the pattern of the castings is prepared. Pattern of casting is prepared

at pattern shop with either of the materials given below:

Wood: - Wood is the most commonly used pattern material as it is cheap, easily

available and also easy to join and fabricate. But it has a large rate of moisture

absorption and also warping and wearing is high.

Metals: - Metals have the advantage that they do not warp, are very accurate and

have high strength. But shaping is slightly difficult and it is also subjected to rusting

and the costs are also high.

Plastics: - They are mostly thermosetting plastics. They are light in weight, have

very good surface, do not react with water or air and are not subjected to warping,

but cannot withstand high temperatures.

Plasters: - The most common example is gypsum cement. Repairs can’t be easily

done and it does not need skilled labor.

Wax: - Wax has very good surface finish, can be easily altered to any shape and is

very accurate. But it cannot withstand high temperatures.

Wood with metallic coating

Thermocol: single use patterns are made using thermocol



In the process of casting, a pattern is a replica of the object to be cast, used to prepare the

cavity into which molten material will be poured during the casting process. The pattern

needs to incorporate suitable shrinkage allowances depending on material flow and heat

transfer considerations. Pattern making is a skilled technique that was highly valued in the

different cultures practicing casting through the centuries.

In sand casting, the pattern is usually of wood, whereas it may be metal or other materials

in pressure or centrifugal casting. The patternmaker also decides where the sprues and risers

(inlet and outlet for molten material) will be placed with respect to the pattern. Parts of the

object which have holes or depressions are handled by inserting cores defining volumes

that the material will not flow into. Sometimes patterns may also accommodate chills, solid

pieces of the final material, to enable rapid cooling, resulting in martensitic hardening in

the neighborhood of the chill.

4.2 Sand Mould Making Procedure

The procedure of making a typical sand moulding starts by placing a bottom board first

either on the moulding platform or on the floor, making the surface even. The drag

mounding flask is kept upside down on the bottom board along with the drag part of the

pattern at the center of the flask on the board. There should be enough clearance between

the pattern and the walls of the flask Rest of the drag flask is completely filled with the

backup sand and uniformly rammed to compact the sand. The ramming of sand should be

done properly so as not to compact it too hard, which makes the escape of gases difficult,

nor too loose so that mould would not have enough strength. After the ramming is over, the

excess sand in the flask is completely scraped using a flat bar to the level of the flask edge.

The finished drag flask is now rolled over to the bottom board exposing the pattern. Using

a stick, the edges of the sand around the pattern is repaired and cope half of the pattern is

placed over the drag pattern, aligning it with the help of dowel pins. The cope flask on top

of the drag is located aligning again with the help of the pins. The dry parting sand is

sprinkled all over the drag and on the pattern.

A sprue pin for making the sprue passage is located at a small distance of from the pattern.

Also a riser pin if required is kept at an appropriate place and freshly prepared moulding

sand similar to that of the drag along with the backing sand is sprinkled. The sand is

thoroughly rammed, excess sand scraped and vent holes are made all over in the cope as in



the drag. The sprue pin and the riser pin are carefully withdrawn from the flask. Later the

pouring basin is cut near the top of the sprue. The cope is separated from the drag and any

loose sand one the cope and drag interface of the drag is blown off with the help of bellows.

Now the cope and the drag pattern halves are withdrawn by using the draw spikes and

rapping the pattern all around to slightly enlarge the mould cavity so that the mould wall

are not spoiled by the withdrawing pattern. The runner and the gates are cut in the mould

carefully without spoiling the mould. Any excess or loose sand found in the runners and

mould cavity is blown any using bellows. Now the facing sand in the form of a paste is

applied all over the mould cavity and the runners which would give the finishing casting a

good surface finish. A dry sand core is prepared using a core box. After suitable baking, it

is placed in the mould cavity. The cope is replaced on the drag taking care of the alignment

of the two by means of pins. The mould is now ready to pouring.

4.3 Moulding Procedure

The pig iron, MS scrap, Carbon, manganese and other constituent materials are melted in

the electric furnace. The molten metal is drawn into a ladder and transported using an

overhead crane. The molten metal is poured to the mould trough the cavity designed for the

same.

4.4 Forging

Forging is the operation where the metal is heated and then a force is applied to manipulate

the metal in such a way that the required final shape is obtained. This is the oldest of the

metal working processes known to mankind since the copper age. Forging is generally a

hot working operation through cold forging is used sometimes.

4.5 Fettling

The complete process of the cleaning of casting, called fettling, involves the removal of the

cores, gates and risers, cleaning of the casting surface and chipping of any of the

unnecessary projections on the surface. The dry sand cores can be removed simply by

knocking off with an iron bar, by means of a core vibrator, or by means of hydro blasting.

The method depends on the size, complexity and the core material used. The gates and

risers can be removed by hammering, chipping, hack sawing, abrasive cutoff or by flame

or cutting. Removal of gates and risers can be simplified by providing a reduced metal

sections at the casting joint, for brittle materials such as grey cast iron, the gates cab easily



be broken by hitting with a hammer. For steel and other similar materials sawing with any

metal cutting saw like hack saw or band saw would be more convenient. For large size

gates and risers we use flame or arc cutting to remove them. Similarly, abrasive cut off may

also be used for removal of gates. Most of the abrasive cut off can be carried out by portable

grinding machines with an angled grinding head.

For cleaning the sand particles sticking to the casting surface, sand blasting is normally

used. The casting is kept in a closed box and a jet of compressed air with a blast of sand

grains or steel grits is directed against the casting surface, which thoroughly cleans the

casting surface. T The shots used are either chilled cast iron grit or steel grit. Chilled iron

is less expensive but is likely to be lost quickly by fragmentation. In the operation, the

operator should be properly protected.



Chart No. 3: Foundry Process



5. PLANNING DEPARTMENT

The Production planning department is the most vital link between product design and

production department. This department provide necessary facilities and technical

knowhow for the manufacture of the product. Production requires optimum utilization of

natural resources, men, money, material and machines. But before starting the work of

actual production, Production planning has to be done in order to anticipate possible

difficulties and decide in advance how the production should be carried out in the best and

economic way. The principle of Production planning lies in the statement “First plan your

work, and then work for your plan”.

5.1 Objectives

In any business organization, production activities must be related to market demands as

indicated by the continuous stream of the customer’s orders. For maximum effectiveness

this must be done in such a way that customer’s demand is satisfied. But at the same time,

production should be carried out in an economic manner. The process of developing this

kind of relationship between market demand and production capability is the function of

production planning and control.

5.2 Role of Planning Department

The role of Production planning department comprises of:

Production Pre Planning (PPP) and Planning Estimation (PPE)

Production Planning Ordering (PPO) & Finished Part Section (FPS)

5.3 Functions and Responsibilities

1. PRODUCTION PRE PLANNING

Processing design documents

Identification of house manufacturing item, outside manufacturing item and

brought out parts

Preparation of preparation layouts



Identifying and intending actions for all special tooling

Implementation of design alterations

Manufacturing special tool data

Attending shop problems

Coordinating activities related to alteration requests

Preparation of documents related to assembly of products

All data entry in computer related to PPP

Verification and approval of materials warrant

Maintain all data and records related to the products

Arranging and ensuring all quality formats

2. PRODUCTION PLANNING ESTIMATION

Estimation of standard time for manufacturing and assembly operations

Preparation and implementation of alterations

Data entry of activities related to PPE function in the computer

Attending shop complaints regarding standard time

Authorization of special time in job cars

Arranging time study

3. PERFORMANCE MONITORING WING

Analyze the organization requirement

Design the structure report

Create appropriate database

Develop software for report

Prepare making list and dispatch of statements

4. COSTING SECTION

Arranging the data related standard labour, material and assembly cost

Assessment of rectification or rework expenses

Coordination of activities related to annual product costing

5. TIME RECORD

Monitoring and ensuring the regular flow of job card

Entering ticket numbers and actual hours on each job



Calculating the total standard hours for a job

Obtaining signature on job cards and idle cards

Acting as a link between PPD and shop floor.

Table No. 1: Process Model of Production Planning



Chart No. 4: Planning Process Flow Chart



Chart No. 5: Planning Process Flow Chart contd.



6. NH ASSEMBLY

The machine tool assembly department at Kalamassery assembles various components of

conventional lathe and CNC lathes. For convenience, the assembly department is

subdivided into NH assembly and CNC assembly. (NH Lathe stands for New Heavy Lathe).

NH assembly section assembles conventional lathe and CNC assembly section assembles

computer numerically controlled lathes. The most of the electrical components are ‘brought

out’ items and is assembled by electrical assembly section.

Procedure followed in NH Assembly

Scrapping - High points are removed for better contact. Blue paint is rubbed over

parts to find uneven surfaces. Scrapping is done for good quality contact in saddle,

keepers, cross slide, Legs, Apron- Split nut, Tail Stock Base, Compound Slide,

Accessories.

Saddle Assembly-This section includes the grooving for oil passage, installation of

distributor assembly and oil assembly and cross feed assembly.

Feed Base Assembly- Six shaft preassembles with gear core first taken here. This

is followed by friction cone assembly and shifter block assembly.

The machine is run for up to 3 hours to check for noise/friction defects. Assembly

of gears is oiled using a cam mechanism in running lathe.

Apron assembly -this include the pre assembly, the group assembly, the split nut

lead screw engagement, the reciprocating pump and lubrication. Also transmission

of feed drive to cross slide and the longitudinal movement on thread are

implemented there.

Hydraulics - lathe uses hydraulics to engage certain gears and also for braking and

gear shifting lapping and pump assembly, pipe bending, value body assembly,

distributor assembly and piping to machines.



Trail stock assembly- this includes sleeve clamping, roller assembly, top and bottom

clamping, hand wheel assembly, tail stock group assembly. Needle bearing is used

in roller assembly. The ABPO-464 balancing machine is used to check uniform

weight.

Swivel is assembled next

Headstock assembly- this involves head stock pre assembly , spindle balancing and

pulley balancing, brake assembly, clutch assembly and hydraulic checking ,

lubrication distributor piping and assembly, dial assembly, head stock control

assemblies and headstock group assembly.

Headstock inspection+ noise level is checked. Main spindle run out and headstock

lubrication are also checked as per ISO quality standards. Machines may be returned

to replace component if needed.

Final assembly- this takes 65 hours for complete assembly. It can be divided into

front work and top work.

Front work on bed includes saddle assembly, feed box assembly, lead screw,

bearing assembly, support assembly and rack assembly.

Top work involves head stock assembly, tail stock assembly and centre-

reading of cross slide assembly and swivel assembly.

Quadrant box assembly- Gears with different gear ratios are fitted at quadrant for

feeds as per requirement, AI key is used to shear if high loads occur.

Motor mounting- Depending on requirement pulley A -type, B type for A2-6 and

L/S AL-8 is used.

Machines- For maintaining accuracy of product as per quality standard.

Surface grinder, taper grinding, turning lathe and milling machine.

- Variants include



Bed length wise

Gap bed /Straight bed

Hardness

Centre height (NH-22, 26, 32)

Headstock

Motor speed

Protection assembly - this includes installing front covers, name plates, chip tray,

splash guard, wipers, side cover and hydraulic tank assembly.



7. CNC ASSEMBLY

The increasing demands the need for high accuracy, scrap reduction etc. have pulled for

development in the field of machining and manufacture. All these have led to the invention

and improvement of CNC machines which can undoubtedly be termed as one of milestones

of century.

HMT is famous for its world class CNC turning centres. It was in late 80's that HMT

Kalamassery started the production of CNC turning centres. The earlier models of machines

used Sinumerik and Hinumerik control systems and MCU whereas new generation CNC

idea Fanuc/Siemens control systems.

Assembly can be divided into:-

Group assembly

Pre final assembly

Final assembly

Group assembly

Place where assembly of headstock, tailstock, turret indexing unit, power rack, turcite

fixing etc. Is done. After the assembly of each part they are set to an extensive test and it is

passed on to pre final assembly only after inspection department certifies it. Units includes

STC-15, STC-20, STC -25/SBCNC-30, SBCNC-40/60/80, SHELL TURN, STALL 10

AND ECOCNC.

Pre-final assembly

It is the section where the assemblies of various components of CNC lathes like headstock

take place to the lathe bed. It is here that the alignment of ball screw is done. The assemblies

of saddle, cross slide etc. to the bed also take place here. Once the various parts are put

together, lathe is taken to final assembly.

Final assembly

As the lathe is brought from the pre assembly, the various electrical components required

are installed.



Bed- most of CNC turning centres are of slant bed type.

Headstock- CNC do not have shift gear incorporated. Main spindle is mounted on

angular contact bearings which could take both axial and radial loads.

Drives - It contain 3 servo motors- one for main spindle, one for saddle traverse

over the bed and the third one for cross slide/turret movement across the saddle.

Saddle- saddle is the portion which carries the turret and slides over the load. The

saddle is actually fixed to a ball nut.

Turret is that part which holds various tools and would position the required tool to

perform the cutting.

Sequence is as follows-

Unclamping- the turret make part unclamped from the curvic coupling. This

is actuated by piston cylinder arrangement enclosed with turret housing.

Rotation- It is actuated by means of a direction control valve- Solenoid

valve. This rotation is fed back to the controller by another encoder.

Creep - As the turret reaches desired angle, an opposite flow is given to

motor so as to reduce the speed.

Clamping- once the desired pain is attained the turret clamps back in to the

coupling and is ready for machining. For operations such as drilling, milling

a special C- axis motor is required and is fitted on consumer request.

Tailstock- Instead of a rotating, a rotation center is used to reduce heat generation.

Hydraulic systems- Many of the critical operations include full proof set ups are

hydraulic systems (owing to their flexibility and controllability)

Headstock- workpiece is clamped by means of piston cylinder arrangement.

Turret- turret clamping, indexing, creeping are controlled hydraulically.

Tailstock- it is controlled by Solenoid controlled valve. The plunger is

hydraulically controlled.



Gear box- It is actuated by hydraulic systems. Levels are shifted when piston

inside a cylinder pushes them.

Lubrication- ensuring sufficient lubrication to maintain smooth running for the

machine as well as to reduce vibrations, heat generation and errors. Other systems

include

Chip conveyor

Cabinet cooling

Oil refrigeration

Power supply

Axis alignment- it is done by giving the tool pre-defined test feed and then

comparing with actual position.



8. QUALITY CONTROL

Quality control in its simplest term refers to control of quality during the manufacture. Both

quality control and inspection are envisaged to assure the quality in entire area of

production process. Inspection is a function of determining the quality. When quality

becomes effective, the need for inspection decreases. Hence, the quality control determines

the cause of variation in the characteristics of products and gives solutions by which these

variations can be controlled. It is economical in its purpose, objective in its procedure,

dynamic in its operation and helpful in its treatment.

8.1 SCOPE

Objectives

The total quality management department sets its measurable quality objectives for every

year. These objectives ensure that requirements of the products are not only identified and

met with, but also constantly reviewed and improved.

The quality objectives are communicated to all the employees in the department by

displaying it in the key areas. The measurable objectives are set taking into consideration

of the following:

Reduce internal losses due to scrap rejection and rework.

Reduce external losses due to service cost.

Maximize the customer satisfaction



Purpose

To ensure the conformance of the incoming items or raw materials being used for

the production with the specified standards.

To ensure that the casting produced in the foundry department meet the design

standards.

To ensure documentation of the quality of the components and assembled units by

inspecting or testing.

To ensure the testing of end products for its conformation with the specification.

This is carried out by inspecting the performance of the end machine in a systematic

manner as specified in the working instruction manual.

To ensure the documentation of all inspection report.

To ensure the procurement of modern testing instruments and periodic calibration

of the existing testing facilities.

To ensure the quality of the manufacturing process of the major components in the

unit.

To ensure the systematic analysis of the feed backs on performance and reliability

reports of the products from inspection.

To ensure the systematic analysis of customer complaints for continual

improvement of the product quality

To ensure total customer satisfaction.

8.2 Measurement of Total Quality Management Effectiveness

Inspection

The effectiveness of the inspection process is measured through four parameters taken from

internal and customer feedback.

An average expected value per annum will be fixed by evaluating previous year’s records

and strategic measures will be planned to bring down it to a lower value than the expected.

The measurement parameters are:-

No. of NCR in assembly due to the manufacturing components

No of NCR in assembly due to brought out parts

Warranty cost due to failure of BOP items during the month in Rupees

Warranty cost due to failure of manufacturing items during the month in Rupees



Quality Control

The effectiveness of the quality control is measured with five parameters. The average

expected value per annum will be fixed by evaluating previous year’s record and strategic

measures will be planned to bring down it to a lower value than expected.

These parameters will be analyzed monthly in UQC meeting for necessary correction and

preventive measures are taken to ensure its effectiveness.

The measuring parameters are:-

Percentage loss of standard hours

Loss in rupees

Percentage loss in foundry product

Average warranty cost per machine

Average breakdown days per machine

8.3 Quality Policy

HMT MTL is committed to:

Maintain QUALITY LEADERSHIP in all products and services.

TOTAL CUSTOMER SATISFACTION through quality goods and services.

Commitment of management of CONTINUALLY IMPROVE the quality system.

To create a CULTURE among all employees towards TOTAL QUALITY

CONCEPT.

Total quality through PERFORMANCE LEADERSHIP.

Quality Objectives

The objectives of the quality management at HMT MTL at Kalamassery are:-

Total production for the year 2010-11 - 78 cores

Total sales for the year 2010-11 - 78 cores

Operational profit (PBDIT) - 250 lakhs

Internal losses (% of standard hours) - 0.6%

Total foundry rejection - 2.4%

Average warranty cost per month - Rs.900/-

8.4 ISO 9001 Accreditation



The HMT Ltd is accredited with ISO 9001 certification in 2001. Quality assurance offers

more scope for reducing costs, rework. Extra handling, rejections etc. and enhancing

competitiveness and profitability than other management techniques there by considerably

reducing warranty claims and premium pricing. Effective quality management system in a

company will help the company to acquire and maintain desired quality and optimum costs

through planned and efficient utilization of the technological and material resources

available to the company.

Chart No. 6: Quality Department Structure



9. HEAT TREATMENT

Heat Treatment is the controlled heating and cooling of metals to alter their physical and

mechanical properties without changing the product shape. Heat treatment is sometimes

done inadvertently due to manufacturing processes that either heat or cool the metal such

as welding or forming.

Heat Treatment is often associated with increasing the strength of material, but it can also

be used to alter certain manufacturability objectives such as improve machining, improve

formability, and restore ductility after a cold working operation. Thus it is a very enabling

manufacturing process that can not only help other manufacturing process, but can also

improve product performance by increasing strength or other desirable characteristics.

Fig. No. 8: Heat Treatment



The various components used for the manufacture of parts for machine tools and printing

machines are shown in Table 2 below.

Table No. 2: Components used for Machine Manufacturing

Sl. No. Material Analysis by ERC weight

1. Cast Iron 70%

2. Steel 20%

3. Non-ferrous alloys 5%

4. Non-metallics (Plastic, rubber, etc.) 5%

____________________________________________________________________

Cast Iron is comparatively low in cost and has the following properties:

Castablility

Machinability

Wear Resistance

Damping Characteristics

Dimensional Stability

Pressure tightness



Table No. 3: Process of Heat Treatment

BATH/FURNACE APPROX CONTENTS

1. Carburising Bath Sodium Cyanide 8 – 10%

Sodium Chloride, Barium Chloride

Temp 910 degrees C+-20

2. Hardening Bath NaCl, Barium Chloride,

Working Temp 850 degrees C +- 20

3. Annealing Bath Same as hardening bath

Working Temp 650 degrees C +-20

4. Quenching Bath Sodium Nitrite, Sodium Nitrate

Working Temp 180 degrees C +-20

Electroplating Section

BATH/FURNACE APPROX CONTENTS

1. Chromium Plating Bath Chromium acid 200gm/liter,

300gm/liter H2SO4,

Temp 45-50 degrees C

2. Blackening Bath NaOH, Sodium Nitrite,

Sodium Nitrate,

Temp 145 degrees C +- 10



Prepare Job for Hardening

Pre-heat at 450 degree C +-20

Heat treat at 650 degree C +-20 for 30 mins

Heat at 780/820/850 degree C for 30 mins

Quench in Quenching bath at 180 degree C +-20

Cool at room temp by quenching in water

Is hardness as per requirement? NO

Temper at 180 +-20 degree C in quenching bath

Cool to room temp by quenching in water

YES

Wash and dispatch job

Chart No. 7: Hardening Process



10. HIGH TECHNOLOGY CENTER

A machine tool is a power driven machine which can be used for the manufacture of

components of other machines. HMT Kalamassery unit is a machine tool factory. In the

High Technology Center there are 5 CNC machines.

VMC

HMC

HM4

VTC

VTC2

All these machines are working with the help of CNC control. Controlling a machine tool

by means of a prepared programme which consists of blocks or series of numbers is known

as Numeric control. It contain machine control unit and machine tool itself.

VMC 400

It can do drilling and milling operation. It can hold 12 tools in the magazine. The work

table movement in X and Y axis are 400 mm and z axis is 420 mm. System 802- Auto tool

change- pneumatic control.

HMC (Horizontal milling machine)

Spindle works horizontally. It table length of X axis 630mm, Y axis 560mm and Z axis

500mm. It can hold 60 tool. It has 4 axis X, Y, Z and B.

HM4 - its table capacity is x axis 1600 y axis 1200 and B axis 360 degrees. It can hold 60

tools in the magazine.

VTC 1 AND 2

Vertical Machining Centre with automatic tool changer. Its capacity is X axis 1150mm, Y

axis is 640mm and z axis is 500 mm. It can hold 30 tools.



10.1 Applications of CNCs

It includes both for machine tools as well as non-machine tools. CNC is widely used for

lathe, drill press, milling machine grinding unit, laser, sheet metal press, tube bending

machine.

Elements of a CNC

Part program

Machine control unit

Machine tool

Part program is a detailed set of commands

to be followed by the machine tool. Each

command specifies a position in the Cartesian coordinate system. Programmers should be

well versed with machine tools machining process.

Machine Control Unit (MCU) is a microcomputer that store the program and executes the

command into actions by the machine tool.

It consists of two main units the date processing unit (DPU) and control loop unit (CLU).

DPU software includes control system software, calculations algorithm, translation

software that converts path program into usable further, interpolation algorithm to achieve

smooth motion of cutter, editing of part program. CLU consists of the circuits for position

and velocity control loops, deceleration and backlash take up, function controls such as

spindle on/off.

Point to Point systems

That move the tools or the workpiece from one point to another and then the tool programs

the required task.

Continuous path systems

It provides continuous path such that the tool can perform while the tools are moving,

enabling the system to generate angular surfaces, two dimensions or three dimensional

contours. Velocity error is significant in affecting the position of the cutter.

Fig. No. 9: HINUMERIC 2100M CNC Control System



Interpolator

The input speed of 1in/sec in example 2 is converted into the velocity components by an

interpolator called the linear interpolator whose function is to provide the velocity signals

to X and Y directions.

Incremental and absolute systems

In incremental, sister distance is measured from one point to the next. An absolute system

is one which all the morning commands are referred from a reference point.

Open loop control

There is no feedback and uses motors for driving the lead screw. A motor is a device whose

output shaft rotates through a fixed angle in response to an input pulse.

Closed loop control

There is a force resisting the movement of the tool/work piece. Milling and turning are

typical examples. Servo motors and feedback devices are used to ensure that the desired

position is achieved.

Manual part programming

It first prepares the program manuscript in a standard format .Manuscripts are typed with a

device known as flexo writer. The punch type of prepared on the flexo writer.

Computer aided programming

Complex shaped component require calculation to produce the component done by

programming software contained in the computer. Program communicates through system

language which is based on words. Programming languages are:

APT, ADAPT, AUTOSPOT, COMPAT – 2, CLROMANCE, SPLIT.



11. PRINTING MACHINES DIVISION

The printing machine department of HMT Kalamassery is a leading manufacturer of offset

printing machines in India. PMK department is functioning very similar to that of MTK

manufacturing. The major components are cast with the help of foundry department. The

cast components are manufactured into printing machine components at PMK

manufacturing department.

11.1 Sections in PMK manufacturing

The PMK manufacturing is broadly divided into three sections, namely, small parts, heavy

parts and high technology center.

Small parts

The small parts are again sub-divided into rounds non rounds and CGR (cams, gears and

rollers). The round or symmetrical objects are machined rounds. The irregular parts are

machined in non-rounds cams, Gears and rollers require more accuracy, hence they are

machined in separate special purpose machines (SPM) in CGR.

Heavy Parts

As the name suggests, the

heavy parts deals with

machining of heavy parts

like:

1. Weld metal base – The

base is made by welding

together the beams in the

welding shop.

2. Side frame – Side frames are mechanized, drilled bored.

3. Cylinder Drums are machined, and grinded

Fig. No. 10: SOM 536



High Technology Center

In this section works which require high accuracy are done in certain special machines.

11.2 Machines Available at PMK Manufacturing

1) NH/CNC Lathes

2) Grinding Machines

3) Milling Machines

4) Drilling Machines

5) Rack cutting machine

6) Cam milling machine

7) Gear hobbing machines

8) Planning machines

9) Boring machine

10) Straight bevel conflux

generator

11) Engraving machines

Each unit is of single colour. A four color machine will have 4 units, one for each color,

ink first comes on to plate roller then transferred to blanket roller and then to impression

roller on which paper is being fed. Thus, the image is formed on the paper. After sheet is

passed through all the units, required image is formed.

Fig. No. 11: SOM 436



12. HEAVY PARTS

This section is in charge of manufacturing heavy parts like:

Headstock

Tailstock

Bed/Guideways

Marking

It is the first process in which dimensions are marked on the surface of the casted product,

so that machining can be done on it.

Many machining operations are carried out in heavy parts.

Planing Machine

It is used to machine the guideways.

Profile Milling Machine

Cutting tools are made in such a way that it is having the profile which is milled on the jobs

surface. This machine has 8 cutting tips they are carbide and replaceable.

CNC Plano Milling

This is a computer numerically controlled milling machine. It has 6 point Tools. Tool

Movement and changing are controlled by the computer. It has 3 axes, that is x, y, z axes

and a right angle unit that allow tool Movement in the perpendicular direction.

Groove Cutting

Groove is made using an ‘L’ shaped cutting tool which pushes. At first, a circular slot is

made using normal cutting tool. Then ‘L’ shaped tool is inserted and by push action, it is

made to go forward.



Grinding

Sideway grinding, surface

grinding, and internal grinding

etc. are used in Heavy Parts. The

grinding wheel is made of

aluminum oxide and diamond is

used to shape them.

Grinding is mainly done on

guideways and bed using surface

grinding wheels.

An Autocollimator is used to

check the convexity of the guideway.

Line Boring Machine

In very long holes, ordinary boring is not done and it causes bending and taper. In such

cases, a single point tool supported at many parts is inserted through workpiece.

Induction Hardening Machine

Many parts require hardness only at selected region; so hardening operation are done only

in those parts by principle of induction.

Other Functions

At heavy parts coolants are rarely used as cast Iron is self-lubricating due to presence of

carbon in it. In many machines, bore center, parallelism, etc. are obtained by use of dials.

This is called “dialing”

All objects in this section are carried by cranes.

Fig. No. 12: PSG 200 Surface Grinding Machine



Chart No. 8: Objective Measurement Chart



13. CONCLUSION

HMT Machine Tools Kalamassery is one of the last few profit generating facilities in

HMT’s core and original field – heavy machine tool manufacturing. Recently, HMT

Machine Tools at Kalamassery has made a foray into defence manufacturing by producing

directing gears, a ship-borne positioning mechanism, for sonars fitted on warships for

tracking enemy submarines.

HMT Machine Tools completed the project around September 2014 in collaboration with

the Naval Physical and Oceanographic Laboratory (NPOL), a DRDO lab that designs and

develops sonars and underwater surveillance and communication systems for the Indian

Navy, and Bharat Electronics Ltd (BEL), which manufactures the whole system. It has

already received orders for several of these modules. The contract for this was valued at

about Rs.16 crore. HMT MTK has not only re-entered the market, but has revitalized the

heavy machine manufacturing industry in India this decade. While it may not be in its

erstwhile glory days of thousands of employees, the facility is slowly but surely rising

quickly.

Fig. No. 13: The Main Manufacturing Facility at HMT Kalamassery



Perhaps one point that is a big boost to this company is the tremendous respect it has for

quality of service. From microscale precision right in the convexity of lathe beds, rigorous

testing of all equipment, and secured delivery and training services, HMT MTK is now

generating clientele in the public as well as private sectors.

My experience has been one of thrill as well as intense learning. The on-site exposure to

the traditional methods of manufacturing using lathes, cutting, drilling, milling and slotting

machines, using collimators for measurement, as well as hands on experience with modern

Computer Integrated Manufacturing using VMC and HMC lathes, multi-point cutting tools,

multi tool turret systems, etc. The exposure to areas like Production and Operations

management, Job Shop Scheduling, Aggregate Planning, etc. were a key aspect of the

training period.

At the end of it, I have had quite a bit to take back from this place, and recognize the

contribution it made in my understanding of the industry in engineering.



REFERENCES

All content in this report are based solely on company reports and documentation at HMT.

All procedures mentioned are HMT customized versions of standards available in open

source. Any images of machines are taken from the website of Hindustan Machine Tools

http://www.hmtmachinetools.com/.

The company profile and product range is readily available for further perusal at

http://www.hmtmachinetools.com/kalamassery-complex.htm.

Fig. No. 14: HMT Kalamassery

http://www.hmtmachinetools.com/

http://www.hmtmachinetools.com/kalamassery-complex.htm

report on industrial training at hmt machine tools, kalamassery

Documents

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