1. Govt. Engineering College Bikaner
(An Autonomous Institution of Govt. of
Rajasthan)
A
PRESENTATION
ON VOCATIONAL TRAINING AT
INDO DANISH TOOL ROOM ,
JAMSHEDPUR
By :
By
Dept. of Mechanical Engineering
Gaurav Gunjan
B. Tech. (Final Year)
Dept. of Mechanical Engineering1
2. ABOUT IDTR:-
• Indo Danish Tool Room, Jamshedpur was established in 1991 by
Government of India under the assistance of Govt. of Denmark.
• Their main objective is to provide consistent, reliable, quality service for
industrial growth based on its trained, skilled and innovative manpower
capabilities backed by the state of the art tool room facilities and
provide trained manpower (through long & short term training).
• They undertake Design and Manufacturing of Jigs, Fixtures, Gauges,
Die Casting Dies, Press Tooling and Plastic Moulds for the Automobile
and Engineering Sectors and machining of precision components.
MSME Tool Room and Training Centre, Jamshedpur (IDTR) is a
Government of India Society, Under Ministry of MSME
3. To impart long-term and short-term training to youngsters in the field
of Tool & Die making course with the latest technologies (and other
allied Engineering trades) both for fresher's and personnel already
engaged in this field.
To provide Consultancy Services primarily to Small scale Units in the
field of Tool Engineering aimed at improving the productivity of the
Small Scale Units
To design and manufacture Moulds, Tools, Dies, Jigs Fixtures etc of
high precision quality.
To provides common facility services in precision machining / heat
treatment and other technical engineering know-how in tooling to
Small Scale Industries in the Country.
4. DEPARTMENTS:-
Design & Manufacturing:
Design and manufacture of precision dies and tools, moulds, jigs & fixtures,
gauges etc. and their appropriate use and maintenance.
Tool manufacturing using latest technology.
Tool related innovations for improved product design using Rapid Prototyping
Technology.
Precision machining and Heat Treatment.
Consultancy & Others:
Product & Process Development.
Productivity/ Quality improvement.
Training Program/Course curriculum development for training institutes.
Execution of Turn-key projects.
Vacuum Heat Treatment.
Productivity/ Quality improvement.
Inspection and calibration facilities.
5. Partners:-
SIEMENS
IDTR offers following training program in collaboration with
SIEMENS:--
CNC COMMISSIONING & MAINTENANCE.
AC SERVO DRIVE COMMISSIONING & MAINTENANCE.
CNC PROGRAMMING & OPERATION (SinuTrain).
IGNOU, New Delhi
IDTR offers Certificate Course on Motorcycle Service and
Repairing in collaboration with IGNOU and Hero-Honda.
8. Computer Numerical Control
(CNC)
The idea of computer numerical control is to
position a computer right at the machine
tool.The introduction of CNC machines
radically changed the manufacturing industry.
Curves are as easy to cut as straight lines
complex 3-D structures are relatively easy to
produce, and the number of machining steps that
required human action have been
dramatically reduced.
9. Advantages:-
Reduces tooling costs
Reduces layout time
Increases machine and tool life
Reduces storage problems
Less setup time
Reduces actual machining time Allows rapid design
changes in part Less jigs and fixtures are needed
Avoids human errors
Complex geometry is produced as cheaply as simple
ones
10. 10
Hardware Configuration of CNC Mechanical Engineering Ken Youssefi
Machine Department
Machine Control Unit (MCU)
the brain of the NC machine.
The Data Processing Unit (DPU)
reads the part program.
The Control Loop Unit (CLU)
controls the machine tool operation.
11. NUMERICAL
DATA
(NC CODE)
NUMERICAL
MANUFACTURING CONTROLLER
OPERATOR
Drive Control
PROCESSED
PART
MACHINE UNIT
11
12. HOW CNC WORKS:-
• Controlled by G and M codes.
• These are number values and co-ordinates.
• Each number or code is assigned to a particular
operation.
• Typed in manually to CAD by machine operators.
• G&M codes are automatically generated by the
computer software.
13. ELECTRICAL DISCHARGE MACHINE - EDM
Die-sinking EDM systems, the electrode (cutting tool) and workpiece are held by
the machine tool. The power supply controls the electrical discharges and
movement of the electrode in relation to the workpiece. During operation the
workpiece is submerged in a bath of dielectric fluid (electrically nonconducting).
(Die-Sinking EDM is also called Sinker, Ram-Type, Conventional, Plunge or
Vertical EDM)
MECHANICAL ENGINEERING DEPARTMENT Ken Youssefi 13
14. EDM – DIE-SINKING (PLUNGE)
• During normal operation the electrode never touches
the workpiece but is separated by a small spark gap.
• The electrode (plunger) can be a complex shape, and can be moved
in X, Y, and Z axes, as well as rotated, enabling more complex
shapes with accuracy better than one mil.
• The spark discharges are pulsed on and off at a high frequency cycle
and can repeat 250,000 times per second. Each discharge melts or
vaporizes a small area of the workpiece surface.
• The amount of material removed from the workpiece with
each pulse is directly proportional to the energy it
contains.
• Plunge EDM is best used in tool and
die manufacturing, or creating
extremely accurate molds for injection-
molding plastic parts.
15. EDM
The EDM process can be used on any material that is
an electrical conductor
The EDM process does not involve mechanical
energy, therefore, materials with high hardness and
strength can easily be machined.
Applications include producing die cavity for large
components, deep small holes, complicated internal
cavities
16. EDM – DIE-SINKING (PLUNGE)
• During normal operation the electrode never touches the
workpiece but is separated by a small spark gap.
• The electrode (plunger) can be a complex shape, and can be moved
in X, Y, and Z axes, as well as rotated, enabling more complex
shapes with accuracy better than one mil.
• The spark discharges are pulsed on and off at a high frequency cycle
and can repeat 250,000 times per second. Each discharge melts or
vaporizes a small area of the workpiece surface.
• The amount of material removed from the workpiece with
each pulse is directly proportional to the energy it
contains.
• Plunge EDM is best used in tool and
die manufacturing, or creating
extremely accurate molds for injection-
molding plastic parts.
17. FLOW OF COMPUTER-AIDED
CNC PROCESSING
• Develop or obtain the 3D geometric model of the part,
using CAD.
• Decide which machining operations and cutter-path
directions are required (computer assisted).
• Choose the tooling required (computer assisted).
• Run CAM software to generate the CNC part program.
• Verify and edit program.
• Download the part program to the appropriate machine.
• Verify the program on the actual machine and edit if
necessary.
• Run the program and produce the part.
18. CNC MACHINES
Machining Centers, equipped with automatic tool changers, are
capable of changing 90 or more tools. Can perform milling, drilling,
tapping, boring… on many faces.
MECHANICAL ENGINEERING DEPARTMENT Ken Youssefi 18
19. TOOLS:--
• Most are made from
high speed steel (HSS),
tungsten carbide or ceramics.
• Tools are designed to direct waste away from the
material.
• Some tools need coolant such as oil to protect the
tool and work.
20. TOOL PATHS, CUTTING
AND PLOTTING MOTIONS
• Tool paths describes the route the cutting tool takes.
• Motion can be described as point to point, straight cutting or
contouring.
• Speeds are the rate at which the tool operates e.g. rpm.
• Feeds are the rate at which the cutting tool and work piece
move in relation to each other.
• Feeds and speeds are determined by cutting depth, material
and quality of finish needed. e.g. harder materials need
slower feeds and speeds.
• Rouging cuts remove larger amounts of material than
finishing cuts.
• Rapid traversing allows the tool or work piece to move
rapidly when no machining is taking place.
21. CNC Programming Basics
• Each letter address relates to a specific machine function. “G”
and “M” letter addresses are two of the most common. A “G”
letter specifies certain machine preparations such as inch or
metric modes, or absolutes versus incremental modes.
• A “M” letter specifies miscellaneous machine functions and
work like on/off switches for coolant flow, tool changing, or
spindle rotation. Other letter addresses are used to direct a
wide variety of other machine commands.
23. BASIC CNC PRINCIPLES
• Using a vertical mill
machining center as an
example, there are typically
three linear axes of motion.
Each is given an alphabetic
designation or address.
The machine table motion
side to side is called the “X”
axis. Table movement in
and out is the “Y” axis,
while head movement up
and down the column is the
“Z” axis.