1. 2014
HEAVY INDUSTRIES
TAXILA
SUBMITTED BY:
SHEHRYAR ALI
SESSION:
16TH
JULY-16TH
AUGUST
INSTITUTION:
UNIVERSITY OF ENGINEERING
AND TECHNOLOGY
(UET),TAXILA.
[INTERNSHIP REPORT]

2. INTRODUCTION:-
HIT is one of the largest industries for manufacturing of TANK’s, APC’s and guns.HIT is
completely operated under the supervision of Pakistan army.
This industry has carried out mass production on a large scale. The industry has many sub-
factories which are producing different components of tank or other products.
Some of the sub-factories are:
(1) DESCOM
(2) HRFT
(3) APC
(4) M-SERIES
(5) TF
(6) AARDIC
My internship was in DESCOM and all the shops I visited during the session are as under with
all the details :
CNC LATHE MACHINE SHOP
SHOP # 2
ABOUT:
CNC is abbreviated as “Computer Numerical Control”. It is E45 CNC lathe machine. It is
the 1945’s 1st
model.

3. CHUCKS:
This machine has 2 chucks; collet chuck and 3-jaw chuck. It has a tool turret on which 12
tools can be mounted at a time; 6 live tools and 6 dead tools. The difference between live and
dead tools is that dead tools cannot rotate about its axis.
PROGRAMMING:
This machine uses shop turn programming in which further 2 types are used; g-code
programming and m-code programming.
SYSTEMS:
This machine uses 2 systems; WCS (World co-ordinate system) and MCS (Machine co-
ordinate system).
COORDINATES:
This machine uses 3 co-ordinates; z-axis (used for length), x-axis (used for diameter) and
c-axis (used for milling operations).
LIMITATIONS:
This machine has some limits i.e. 6300 rpm maximum limit, 220 mm limit in diameter
and 310 mm limit in length. But this machine has a specific feature that it can simulate the
desired part before any operation, 3D model can be viewed before process.

4. SPECIFICATIONS OF CNC LATHE E-45:
Working Range:
1) Swing over head:
Maximum 430mm in diameter.
2) Maximum turning diameter:
220mm
3) Maximum turning length:
310mm
4) Distance between centers(spindle nose-tailstock live center):
687mm
Travels:
5) Travel x:
160mm
6) Travel z:
310mm
Main spindle – Clamping system:
7) Maximum size of chuck:
160mm in diameter
Tool System:
8) Revolver type tool turret with direction logic, optional with driven tool:
9) Tool holding fixtures according to DIN 69880:
VDI 30
Tail Stock:
10) Travel (manually):
460mm
11) Quill travel:
120mm
12) Quill diameter:
60mm

5. Coolant Device:
13) Tank capacity:
230 liters
Chip Conveyor:
14) 10-pole plug for assembly chip conveyor included in basic machine:
Color:
15) Light grey:
Electrical Connection:
16) Power supply:
[V] 3/PE 400~
17) Maximum voltage function:
[V] +5/-15
18) Frequency:
[Hz] 50/60
Operating Conditions:
19) Require ambient temperature:
[Centigrade] +10 to +35
Dimensions/Weight:
20) Height to turning axis above floor:
1152mm
21) Tool height:
1940mm

6. FARO GAUGE:
It is made in Switzerland and is a portable machine used to measure very precise dimensions
where vernier caliper and screw gauge fails.
Features:
It has the following features;
 Dimensions
 Reports
 Tools
 3D Caliper
 Gauge setup
It has a small prob at the front which when touch any surface make it a reference and measures
all dimensions from that reference point. The prob can be changed to any size by adjusting it in
the gauge setup first.
Reverse Engineering:
Reverse engineering can be done by using Faro gauge that means that a part/job can be
converted to drawing.
A scanner is attached in front of prob, rays are thrown and a picture is transformed which
is sent to a computer. This is called as reverse engineering.
Software is used that refines the shape from Faro gauge to computer so that pro-E
software could read it.
Manufacturing and Machining Operations:
There are almost 156 machines in shop 2 including milling machines, lathe machines, drilling
machines and so on.
An over-view of these machines is as follows.

7. 1) Lathe Machine:
There are about 64 lathe machines including engine lathes, universal engine
lathes, turret lathes, drum type turret lathes, precise centre lathe and numerical control lathe.
Facing, threading, turning, taper turning, boring operations can be done on these lathes. Only that
threading operation cannot be done on turret lathe because it does not have a lead screw.
Engine lathes include simple lathes, precise engine lathes as well as universal
engine lathe. The difference is that the bed moves in universal engine lathe. Bolts with hexagon
heads, spring holder, and joint ring can be made on these machines. Precision engine lathe is also
an engine lathe but is used for small jobs for precision and accuracy.
Turret lathe is different from engine lathes that threading operation cannot be
done on turret lathes and multiple tools can be held by its tool post. Seal rings are made on turret
lathe made of steel and cast iron.
Numerical control lathe is also a type of engine lathe but with a numeric
machine by which a programme is fed in the machine and the operation is done according to the
programme.
Copy lathe is a lathe that copies a template known as a copy template. To make a
specific contour or a curve such as in exhaust valve of an engine, a specific copy template is
made with same contours and curves and a prob is moved over it. Whenever the prob takes a
curve, the tool post also moves with it, hence making that specific shape.
Drum type turret lathe is also a turret lathe but its tool post is circular like a
drum.
2) Milling machine:
There are 14 milling machines including universal milling machines, vertical and
horizontal milling machines, vertical knee type milling machine, and spline milling machine.

8. The difference between lathe and milling machine is that in lathe machine single
point operations are done while in milling machines surface contact operations are done.
In Universal milling machines the bed moves.
Vertical and horizontal milling machines have different directions of
operations only.
Spline milling machines just do operations on splines present on shafts and other
components.
3) Radial Drilling Machines:
There are about 5 radial drilling machines. It is used for heavy jobs and for heavy drills such
as drill in gudgeon pin. It is also used for accurate drill and also for centre accuracy.
4) Honing machines:
There are 2 honing machines; vertical and horizontal.
Vertical honing is used for cylinders. Its maximum diameter is 150mm and maximum depth is
400mm. It has a fixture with oil stones used for cutting and fining the internal sides of cylinder
and is made in a way that 1 oil stone is followed by a support and so on. It also has expansion
pressure honing tool. It has a hydraulic and stroke system. It uses diesel as a coolant. Maximum
delta of 10 can be achieved on this machine.
5) Amri-Boring Machines:
There are 2 amri-boring machines used for bores in the pistons of tanks. It has
hydraulic system and 2 pistons can be operated at a time.
6) Grinding Machines:
There are about 24 grinding machines including internal and external grinding,
angular grinding, spline grinding, cutter grinding, gear teeth grinding machine and rotary table
grinding machine.
Angular grinding is different from others in that it can be done at any angle.
Rotary table grinding is different in the sense that it has a table that rotates.
Spline grinding only grinds the splines.
All these grinding operations have just 1 purpose that is to increase finishing of a
component.
Gear teeth grinding machine only grinds the teeth of gears. It has a grinding
wheel at the same angle that of pressure angle of teeth.

9. 7) Hobbing Machines:
There are about 3 hobbing machines. This machine makes external gears e.g. spur
gears, helical gears. It cannot make gears with a step. This operation makes it different from the
gear shaping machine that makes internal gears as well as can make gears with a step.
8) Bevel Gear Generator:
There are about 6 bevel gear generator machines that make straight as well as
helical bevel gears. When the gears are manufactured, they are tested on a bevel gear tester
which is at 90 degrees. To make a helical bevel gear as well as straight bevel gear, the cutting
tool and the job must at some angle. Bevel itself means that whose cross-section changes
through-out the length.
9) Broaching machine:
There is 1 broaching machine that has a tool known as broach and it is available in
different sizes. It is used for inner operations and is used for mass production. It makes internal
cuts and splines. The broach tool has external cuts over it is forced through the job that makes
internal cuts and splines.
10) Demagnetizer:
It demagnetizes a component. When a component is manufactured, it has some
magnetic properties in it. The component is moved through a magnetic field which is created by
an electric current.
TOOL MFR AND MAINT BRANCH
SHOP # 4
ABOUT:
This shop manufactures cutting tools and maintains them when any tool is damaged.
Following are the machines upon which these tools are manufactured.

10. 1) Relieving Lathe:
N
A metal-cutting machine tool of the lathe group for machining the back surfaces of the
teeth of multi-blade cutting tools (for example, form cutters and tap borers) to impart to them a
curved (“relieved”) shape. The tool is a form tool whose shape is a mirror image of the shape of
the piece to be worked; it is mounted on a slide rest, and the work piece is mounted on pointed
journals (directly or on a mandrel). The work piece is rotated by the lathe spindle. The slide rest
and form tool are moved transversely by a rotating cam, which also returns the slide rest to its
initial position when the form tool reaches the tooth space of the tool being machined.
2) Tool Milling Machine:
Milling is the machining process of using rotary cutters to remove material from a work
piece advancing (or feeding) in a direction at an angle with the axis of the tool. It covers a wide

11. variety of different operations and machines, on scales from small individual parts to large,
heavy-duty gang milling operations. It is one of the most commonly used processes in industry
and machine shops today for machining parts to precise sizes and shapes.
3) Jig Boring Machine:
In machining, boring is the process of enlarging a hole that has already been drilled (or
cast), by means of a single-point cutting tool (or of a boring head containing several such tools),
for example as in boring a gun barrel or an engine cylinder.
The dimensions between the piece and the tool bit can be changed about two axes to cut
both vertically and horizontally into the internal surface. The cutting tool is usually single point,
made of M2 and M3 high-speed steel or P10 and P01 carbide. A tapered hole can also be made
by swiveling the head.
4) Thread Grinding Machine:
Threading is the process of creating a screw thread. More screw threads are produced
each year than any other machine element.
During thread grinding, the part and the tool perform several types of motion relative to
one another. The tool rotates about its axis (principal motion); the part rotates (circular feed); the
wheel or part moves during each rotation in a straight line a distance equal to the thread pitch
(traverse feed); and the wheel moves laterally relative to the part (lateral feed). Thread-grinding
machines use single-thread wheels that operate in one direction (the most precise method but one
that is not very productive) or in both directions.

12. 5) 3D CMM:
A coordinate measuring machine is a device for measuring the physical geometrical
characteristics of an object. This machine may be manually controlled by an operator or it may
be computer controlled. Measurements are defined by a probe attached to the third moving axis
of this machine. Probes may be mechanical, optical, laser, or white light, amongst others. A
machine which takes readings in six degrees of freedom and displays these readings in
mathematical form is known as a CMM. The typical 3 "bridge" CMM is composed of three axes,
an X, Y and Z. These axes are orthogonal to each other in a typical three dimensional coordinate
system. Each axis has a scale system that indicates the location of that axis. The machine will
read the input from the touch probe, as directed by the operator or programmer. The machine
then uses the X, Y, Z coordinates of each of these points to determine size and position with
micrometer precision typically.
6) CNC Wire Cut:

13. CNC wire cut also known as CNC wire cut EDM which is working base on electro
sparking principle. If there is a load, the wire EDM will move slowly towards the electrical
conductive work piece. The wire will be energize and create electrical spark between the wire
cut CNC machine and work piece. The electrical spark created between the wire and work piece
will erode some small amount of work piece and flush away by the deionizer water to form the
spark gap between the wire and the work piece. The electrical sparking process will stop if
reach the required depth. The spark gap size can be controlled as small as 0.0127mm.
If there is no load the machine will run only one cycle until the required depth and stop.
SURFACE TREATMENT
SHOP # 6
Purpose:
The surface treatment shop is an electroplating shop. Electroplating is the process of
depositing coating by means of electrolysis.
Purpose of Electroplating:
 To improve appearance of job.
 Prevention from corrosion.
 Reflection and decoration.
 Reclamation of under-sized components.
 Prevention from carburizing and nitriding.
 To increase solderability.
 To increase electrical conductivity.
Processes Carried Out At Surface Treatment Shop:
 Zinc plating
 Cadmium plating.
 Copper plating.
 Tin plating.
 Aluminum anodizing.
 Silver plating.

14.  Copper oxidation.
 Chromium plating.
 Phosphating.
 Ferrous oxidation.
 Tin + lead plating.
General Principle of Electroplating;
In compound solution, ions charged with electric current whether negative or positive and
moves to opposite poles and continue discharged and make deposit thickness on the component
surface. Hydrogen and oxygen comes out at the surface of the solution which shows the current
flowing. Time for this process is given according to deposit thickness.
Machinery Equipment and Process of Surface Treatment:
East Hall:
Key:
a) Number of baths.
b) Main chemicals.
c) Main process.
d) Function.
e) Main components to be plated.
f) Time of deposition and time of bath.
1) Zinc plating:
a) Number of plating tanks = 4
b) Zinc oxide, sodium cyanide, sodium hydroxide.
c) Degrease, pickle, plating, passivation.
d) Corrosion resistance.
e) Clamp, spring, torsion bar, pipe etc.
f) Time = 20~30 min at room temperature.
2) Cadmium plating:
a) Number of plating tanks = 1
b) Cadmium sulphate, sodium cyanide, sodium hydroxide.
c) Degrease, pickle, plating, passivation.
d) Preventing from rust and seepage.
e) Nut and washers
f) Time = 20~30 min at room temperature.
3) Copper plating:
a) Number of plating tanks = 2
b) Copper cyanide, sodium cyanide.

15. c) Degrease, pickle, plating.
d) Preventing from carborizing and rust.
e) Gears, shafts, nuts.
f) Time = 1.5~2 hurs.
4) Tin Plating:
a) Number of plating tanks = 1
b) Sodium stagnate, sodium hydroxide, sodium acetate.
c) Degrease, pickle, plating.
d) Solder ability, preventing from nitriding.
e) Cylinder liners, thimbals, connectors.
f) Time = 40~50 minutes.
5) Aluminum Anodizing:
a) Number of plating tanks = 1
b) Sulphuric acid.
c) Etching, bright, oxidation, coloring.
d) Surface hard and coloring of aluminum components.
e) Telescope body.
f) Time = 20~30 minutes.
6) Silver Plating:
a) Number of plating tanks = 1
b) Silver chloride, potassium cyanide.
c) Degrease, mercury dip, plating, passivation.
d) Increase the conductivity.
e) Rotary ring, connector.
f) Time = 20~30 minutes.
7) Copper Oxidation:
a) Number of plating tanks = 1
b) Potassium per sulphate, sodium hydroxide.
c) Degrease, pickle, plating, oxidizing.
d) Preventing from reflection.
e) Screw, washer, nuts.
f) Time = 5~10 minutes.
West hall:
1) Chrome plating:
a) Number of plating tanks = 6
b) Chronic acid, sulphuric acid.
c) Degrease, pickle, plating.
d) Reclamation of under-sized components.
e) Gudgeon pin, shafts, bearings, seats etc.

16. f) Time = 0.15~1.0 hours.
g) Temperature = 55~60 centigrade.
h)
2) Nickel plating:
a) Number of plating tanks = 1
b) Nickel sulphate, magnesium sulphate.
c) Polish, degrease, plating.
d) Reflection and decoration.
e) Reflectors, models.
f) Time = 30~45 minutes at room temperature.
3) Phosphating:
a) Number of plating tanks = 1
b) Granodine No-111
c) Degrease, pickle, phosphate, seal.
d) Under coating for painting.
e) Covers, housing support, wheel idler etc.
f) Time = 40~60 minutes.
g) Temperature = 96~99 centigrade.
4) Fe-Oxidation:
a) Number of plating tanks = 2
b) Sodium hydroxide, sodium nitrate.
c) Degrease, pickle, oxidation seal.
d) Corrosion resistance without size disturbs.
e) Guns, bridge block, gauge.
f) Time = 40`501 minutes.
g) Temperature = 137~150 centigrade.
Process Detail:
East Hall:
1) Zinc plating:
Purpose: for protection from corrosion and for decoration.
Composition of bath: Zinc oxide, sodium cyanide, sodium hydroxide.
Bath Size: 2000x800x1000mm
Process Flow: degreasing, pickling, zinc plating, passivation.
Loading capacity: 50 DM2

17. Usage: clamps, springs, torsion bars, pipes etc.
2) Copper Plating;
Purpose: from corrosion resistance, electrical conduction, prevention from carburizing
and jam.
Composition of Bath: copper cyanide, sodium cyanide.
Bath Size: 1500x900x1000mm
Process flow: degreasing, pickling, copper plating.
Loading capacity: 30DM2
Usage: gears, shafts, nuts.
3) Silver plating:
Purpose: to increase electrical conductivity and soldering ability.
Composition of Bath: silver chloride, potassium cyanide.
Bath size: 400x300x300mm
Process flow: degreasing, dip in mercury, silver plating, passivation.
Loading capacity: 0.02 DM2
Usage: rotary rings, connectors, thimbals etc.
4) Copper oxidation:
Purpose: protection from light and decoration.
Composition of bath: potassium persulphate, sodium hydroxide.
Process flow: degreasing, pickling, copper plating, oxidation.
Usage: screw washers, nuts etc.
West Hall:
1) Aluminum anodizing:
Purpose: for corrosion resistance, decoration, prevention from reflection and surface
hardness.
Composition of bath: sulphuric acid.
Bath size: 600x600x800mm

18. Process flow: etching, brightening, anodizing, coloring.
Loading capacity: 0.5DM2
Usage: housing, telescope body etc.
2) Tin + lead plating
Purpose: to protect from whether effects, acidic effect of engine oil and to cushion the
shell from hard rotating shaft.
Composition of bath: fluoboric acid, lead fluoborate, tin fluoboarate.
Bath size: 600x600x800mm
Process flow: stripping, degreasing, pickling, tin +lead plating.
Loading capacity: 0.5 DM2
Usage: inserts, bearing shells etc.
3) Nickel plating:
Purpose: for decoration, corrosion resistance and reflection.
Composition of bath: nickel sulphate, magnesium sulphate.
Bath size: 1200x800x800mm
Process flow: polishing, degreasing, nickel plating, polishing.
Loading capacity: 50DM2
Usage: reflectors etc
4) Ferrous oxidation:
Purpose: for corrosion resistance.
Composition of bath: sodium nitrite, sodium hydroxide.
Bath size: 1500x800x1000mm
Process flow: degreasing, pickling, oxidizing, sealing.
Loading capacity: 60kg
Usage: gun parts, breech block, cam shafts.
5) Chromium plating:
6) Phosphating:
7) Cadmium plating:
8) Tin plating:

19. HEAT TREATMENT PROCESS
SHOP-8
Manufacturing of springs:
Varieties = 375
Inner diameter = 1.2~100mm
Outer diameter = 1.8~120mm
Length = 2~1000mm
Machinery equipment statement:
1) Box type electric resistance furnace = 8
2) Well type gas carburizing resistance furnace = 3
3) Well type tempering resistance furnace = 3
4) Salt bath furnaces = 7
5) High frequency induction heating equipment = 2
6) Bevel gear quenching press = 1
7) Quenching tanks = 8
8) Sub-zero treatment equipment = 3
9) Hydraulic press = 1
10) Shot blasting machine = 2
11) Sand blasting = 1
12) Hermatic drying box = 1
13) Floor type grinding = 3
14) Engine lathe = 1
15) Spring coiling machine = 1
16) Gas nitriding furnace = 2
17) Spring compression and tension tester = 3
18) Spring fatigue tester = 1
19) Bench drill = 1
20) Double column inclinable press = 1
21) Deep well type resistance furnace = 1
22) Hardness tester = 9
23) Fire pin impact tester = 1

20. 24) Lead bath furnace = 1
25) Magnetic flow detector = 1
26) Vertical polishing machine = 1
27) Metallurgical microscope = 1
28) High temperature atmospheric control resistance furnace=1
Available Capabilities:
1) Annealing/Normalizing:
 Full annealing/normalizing
 Stress relief annealing
 Isothermal annealing
 Process annealing
2) Hardening:
 Free hardening
 Press hardening
 Deep well hardening
3) Tempering:
 Low tempering
 High tempering
4) Salt bath treatment:
 Low temperature salt bath treatment
 Medium temperature salt bath treatment
 High temperature salt bath treatment
 Nitrate temperature salt bath treatment
5) Case hardening
 Bright carburizing
 Gas carburizing
 Gas carbo nitriding
 Induction hardening
 Flame hardening

21. 6) Sub-zero treatment
 Upto 120 centigrade
7) Spring manufacturing:
 up to 10mm wire diameter
8) De-scaling:
 Shot blasting
 Sand blasting
Processes involving manufacturing of springs:
Following are the processes by which springs are manufactured;
1) Wounding of wire on mandrel of an engine lathe.
2) Diameter is then tempered up to 300~350 centigrade.
3) Cutting of wire
4) Grinding
5) Rectification
 Straightness
 Pitch variation
 Length
6) Again tempering
7) Inspection
8) Surface treatment
FORGING PROCESS
SHOP#12

22. Forging:
The working of metal into required shape after heating performed by means of hammer
blow or under the pressure of press is termed as forging. The various kinds of machine parts of
different shapes and sizes are manufactured by forging processes.
Forging Presses:
1) Drawing down process:
In this process, length of blank is increased and diameter of blank is reduced.
2) Upsetting process:
In this process, diameter of blank is increased and length is reduced.
3) Trimming Process:
A process by which extra material which flashed out of the component/fins is
removed by trimming die called trimming process.
4) Bending process:
5) Heating process:
6) Materials:
Common materials are used for forging of components are as under;
38 Crsi.A3, Steel-10, steel-40, steel-35, steel-41, steel-15,
20Cr2Ni4A, 18Cr2Ni4A.
7) Optical pyrometer:
An instrument used for measuring of high degree heat.
8) Tools:
 Tongs
 Hand hammer
 Horn
 Anvil
 Punch
 Chisel
 Swages
 Forging dies
 Saddle support
 Mandrel
9) Anvil:
Used for hand forging, heated metal is shaped on anvil.
10) Swages:
Used to smooth round rods or round surfaces.
11) Fullers:
These are forming tools which come in different shapes and sizes and can be
manipulated to make grooves and hollows.

23. 12) Tongs:
It is used to hold the hot metal pieces which are manufactured in many shapes and
sizes. There are 3 types of tongs;
 Straight up tong
 Curved up tong
 Pick up tong
13) Hand hammer:
It is used in hand forging. There are 3 types;
 Cross pin hammer
 Sledge hammer
 Ball pin hammer
14) Chisel:
It is used to cut metal. 2 types are used;
 Hot chisel
 Cold chisel
15) Types of forging:
 Free forging
 Open type forging
 Die forging
16) Measuring instruments:
 Steel rules
 Inside calipers
 Outside calipers
 Vernier calipers
17) Machines used in forging shop:
a) Pneumatic hammer:
It is used for medium and heavy forging.
 Maximum weight forged on 250kg hammer=9kg
 Maximum weight forged on 750kg hammer=40~45kg
 Maximum diameter forged on 750kg hammer=1000mm
 Maximum diameter forged on 250kg hammer=345mm
 Maximum weight forged on 250kg hammer=1kg
 Maximum weight forged on 750kg hammer=8kg
b) Press:
 Double disc friction screw press used for forging of small and large
components.
 Open type inclined able press is used for trimming of forged components.

24. 18) Heating:
Heating of steel is very important and main operation in forging practice. If a
piece of steel is heated, it becomes softer and its tensile strength is reduced and at
the same time its plasticity and malleability is increased. The structural
transformations which occur in metals on heating their mechanical and physical
properties also change.
19) Safety measurements:
 Keep shop clean
 Metal scraps should be placed in scrap box
 Never use compress air to clean the machine of chips
 Keep hand tools in good condition
20) Pre-heated temperature of forging dies:
 250~300 centigrade
21) Machinery and equipment:
1) Pneumatic hammer 250kg
2) Chamber type gas heating furnace
3) Pneumatic hammer 750kg
4) Chamber type gas heating furnace
5) Chamber type gas heating furnace
6) Double disc friction screw 300ton
7) Open type double column press 80ton
8) Porous type end heating furnace
9) Box type resistance furnace
10) Box type resistance furnace
11) Brinell hardness tester
12) Floor type grinding machine
13) ARC welding machine
14) Track pin heating machine
15) Black smith furnace
16) Surface plate
17) Shot blasting machine
18) Electric single beam crane
19) Power hacksaw machine
20) Single column hydraulic press 90ton
21) Rockwell hardness tester
22) Hydraulic shear machine
23) Power hacksaw machine
24) Battery car

25. FOUNDRY PROCESS
SHOP # 10
SAND MULLER:
A sand Muller is a machine that mixes and restores the "ready-to-use" texture of molding
sand. Green sand is mostly prepared in the foundry shop.
MOLDING:
Patterns are used for molding. Without the pattern, molding cannot be done. 2 types of
patterns are used;
 Wooden patterns; by which hand molding is done.
 Metallic patterns which comes in 2 pieces.
The sand from sand Muller is then hand molded in their respective patterns.
BAKING:
The mold is then baked in an oven for 4 hours at almost 400 degree centigrade.

26. MOLD CLOSING:
This is done in a pattern that has a riser from which the molten metal rises. Its purpose is
to cover the shrinkage. A basic formula is that if 1kg casting needs to be done, then a rise of 3kg
must be used.
FURNACES:
There are 3 furnaces;
 Cupola furnace
 Induction furnace
 Pit furnace for gases
COPPER COIL:
This is a machine used to melt the metal. Copper is a very good conductor of electricity.
Current is induced in copper coils that generate heat and the metal is melted.
CASTING:
There are 4 casting processes in forging shop;
 Vacuum casting which manufactures rods made of aluminum and brass. There is
a vacuum pump that sucks the molten metal in a die and a solid rod emerges out.
 Centrifugal casting that manufactures rings.
 Investment casting that uses paraffin wax and a core made of urea to make the
products.
 Die casting
ELECTRIC RESISTANCE FURNACE:
It heats the metal under a temperature of 800 degree centigrade.
WAX INJECTOR:
It is a Chinese machine that automatically injects wax in a die according to its
requirements. It makes wax patterns.

27. CYCLONE SYSTEM:
It is a German machine that coats. It has 2 tanks; primary and secondary. It coats 11
layers; 3 layers are made by upper tank and 8 layers are made by lower tank.
OTHER MACHINES IN FOUNDRY SHOP:
 Infrared drying oven
 Silicon mold making
 Funnel and consumable cup
 Shake out
 Tilting machine
CNC MILLING MACHINE SHOP
SHOP K
It’s a 5-axis milling machine. It uses g-code and m-code for programming. It uses
27 no oil or machine oil as coolant. There is a tool device that measures exact length and

28. diameter of new tool. 2 buttons are present; one is on top for length and the other is on side that
is for diameter. For setting the origin, stylo is used. On the screen, there is a CN side and a
manual side. On CN side there is an rpm knob, feed knob and ripet knob. While on manual side,
there is a release knob for cutter and arrows for direction. It also has tool fixture.
Specifications:
CB Ferrari
A-17
Italy
CNC Control:
E520
SOFTWARE:
o ELEXA
o DAM
TABLE SIZE:
1250*560mm
POWER OF MOTOR:
10KW
TRAVEL:
o X-Axis (longitudinal) 1050mm
o Y-Axis (Transverse) 520mm
o Z-Axis (Vertical) 420mm
o C-Axis (Tilting of milling head) +90⁰ to -90⁰
o A-Axis (CNC Dividing head) 360⁰
Accuracy :
0.001mm
Tool Magazine Capacity:
19 tools

29. SP2
For 3D digitizing (Tracing)
Coolant:
“27” no of oil use as a Coolant
Capability:
o Simple milling.
o Grooving.
o Drilling.
o Boring.
o Reaming.
o Tapping Operation.
o Machine is capable of producing Complex jobs having internal & external contour.
o Pockets and Conical profile with high accuracy.
Controls:
o CN
o Manual
Cutters:
o Key way & anvil Cutter
o Single flute cutter
o End mill cutter
o Straight drill
o Taper shirk drill
Accuracy:
CNC milling machine is so accurate because its head is fix and does not have
play. It has motor systems instead of gear trains and also has hydraulic system and pressure
system that increases its efficiency.
Operation:
Oil is pressurized which suck the tool and is fixed in collet and it cannot be
released unless the same pressure of oil is achieved.

30. Parts Made On CNC Milling Machine:
1) 2nd
and 3rd
speed synchronizer body.
2) Lever
3) Gear shaft
4) Stop
5) Hook
6) Pusher
7) Lower extractor
8) Upper extractor
9) Cocking lever shaft
QUALITY CONTROL
QC (D)
ABOUT:
QC’s function is to manufacture parts according to the requirements. In house products
are the products that are manufactured in shops. Its material is purchased before the operation
e.g. springs.
Wender industries means products manufactured from the firms of Pakistan.
Strategies:
QC follows 3 strategies;
a) Dimension inspection; visual as well as radiographic(gamma rays).
b) 2 tests;
 Destructive test in which the material is destroyed.
 Non-destructive test involving gamma rays.
c) To check the fitness in its application.
Lab tests:
 Physical test in which hardness and tensile testing is done.

31.  Chemical test in which elements are checked in any job.
SUGGESTIONS FOR IMPROVEMENT
 There were lots of machines in the shops which can give output at a very
high production rate, so they should be active all the time and more good can
come out of them than only being used for almost one third time of a year.
 The internees should be taught some helpful softwares as well which are
related to their field and can be used in their jobs as new technology is more
based on the computer softwares for controlling the production.
 Internees can be trained to make a project on a software as it will be easier
for them than to be given a production project which is difficult.
 Some machines in some shops need to be cleaned and their parts to be
replaced for better output.(my observation)
 The apparatus which is not in use now a days should be taken out of shops
so that new apparatus can be installed.
Comments:
The environment was very good for learning all the kinds of operations
related to mechanical engineering. Staff was also very cooperative, if anyone
wants to learn something they were more than eager to go in all the details.
It was a good experience in a big industry and the knowledge we gain will
surely go a long way for us.