REPORT ON HMT AJMER

1. i
A
SEMINAR REPORT
ON
HMT (HINDUSTAN MACHINING TOOLS)
AJMER
(45 DAYS)
Submitted in partial fulfillment of the requirements
of the Degree of
Bachelor of Technology in Mechanical Engg. Of
Rajasthan Technical University, Kota
SubmittedTo: SubmittedBy:
PinkyMourya JasimAshraf
HOD, ME 12EJEME044
MECHANICAL DEPARTMENT
JAIPUR ENGINEERING COLLEGE, KUKAS
RAJASTHAN TECHNICAL UNIVERSITY, KOTA
(AUGUST-2015)
(2015-2016)

2. ii
COMPANY CERTIFICATE

3. iii
STUDENT’S DECLARATION
I hereby, certify that the work, which is being presented in the Seminar Report, entitled
“DATA COLLECTION OF ASSEMBLY OF GRINDING MACHINE AT HMT” in
partial fulfillment of the requirement for the award of Degree of B.Tech in Mechanical
Engineering, submitted in the Department of Mechanical Engineering of JAIPUR
ENGINEERING COLLEGE, KUKAS, Affiliated to Rajasthan Technical University (RTU),
Kota, Rajasthan, is an authentic record of my work under the supervision of Mr. Prashant
Kumar.
The results embodied in this report have not been submitted by me or anybody else to any
other University or Institute for the award of Degree.
JASIM ASHRAF
12EJEME046
CERTIFICATE
This is to certify that the above statement made by the Student is correct to the best of our
knowledge.
Prashant Kumar PinkyMouriya
Seminar Co-ordinator HOD, MECHANICAL

4. iv
ACKNOWLEDGEMENT
A research work owes its success from commencement to completion, to the people in love
with researchers at various stages. Let me in this page express my gratitude to all those who
helped me in various stage of this study.
It comes out to be a great pleasure and experience to me to have practical training for the
fulfillment in the Bachelor of Technology. I would express appreciation to all who assisted to
me in one or another way.
I am thankful to my facilitator Mr.Prashant Kumar for his continuous guidance & support.
I would like to thank him for giving me excellent suggestion and affectionate, encouraging
through development of seminar and for devoting his precious time.
I would like to express my grateful thanks to guide all the teachers. As their cooperation and
knowledge proved as a foundation of inspiration to me at all time I worked. Also I would like
to thank all faculty members and to the entire staff of Mechanical Engineering Department of
Jaipur Engineering College, Kukas, Jaipur for their valuable help throughout the work for
boosting me for creative thinking and helping me to think practically.
I am also thankful to all my colleagues for their co-operation and support.
JASIM ASHRAF

5. v
PREFACE
For an engineering student it’s very necessary that theoretical knowledge he should be
equally exposed to practical aspects of it. One could have the best practical knowledge only
through the renowned companies. That’s way I under taken practical training at ‘HMT
MACHINE TOOLS LIMITED, AJMER’ for 45 working days. These 45 days of training
period is compulsory of our syllabus, as prescribed by ‘’RAJASTHAN TECHNICAL
UNIVERSITY, KOTA’’ under the multipoint entry and credit system.
The H.M.T. Ajmer has its own design & development in which new designs are being
development to cover requirements of small scale as well as specialized industries such as
Ball & Roller Bearing Industry.
It has a well-developed machining and inspecting facilities and a most modern Tools room
where Jigs and fixture and tools are manufacture to very standards comparable with the best
in world.
The Unit is well equipped with modern machine shops having 200 nos. of different types of
precision machines, such as, CNC Machining Centers, CNC Lathes, High precision Jig
Boring Machines, High Precision Cylindrical Grinders and Slide way Grinders, besides well
equipped Heat Treatment Shop, Measuring Centre, Material Testing Laboratory, CAD
Centre for Design & Development and Foundry. Unit has also captive power generation
Capacity of 1850 KVA to meet power shortage.

6. vi
ABSTRACT
Practical training is a way to implement theoretical to practical use. To become a successful
engineer it is necessary to have a sound practical knowledge because it is the only way by
which one can learn and acquire proficiency and skill to work efficiency at different
industries/places. It is a proven fact that bookish knowledge is not sufficient because the
things are not as ideal in practical field as they should be.
In India a huge amount of public money is invested in government undertakings. A country
like ours, which is based on mixed economy, attaches great importance to public sector like
defense, chemicals, fertilizers, petroleum, electronics etc. There acceptability to public
depends upon the way in which they manage and control their finance and gives a profitable
system on after discharging their social responsibilities and that in terms which depends upon
quality of production of good produced by them and productivity.
It is matter of great pleasure that our college authorities have recommended a practical
training of 45 days to supplement our theoretical knowledge acquire in the college.
In HMT MACHINE TOOLS LIMITED, AJMER which is one of the examples to
understand the manufacturing process and productivity.

7. vii
TABLE OF CONTENTS
Chapter No. Page No.
1. Certificate ii
2. Student declaration iii
3. Acknowledgement iv
4. Preface v
5. Abstract vi
1. INTRODUCTION (1-6)
1.1. Introduction of HMT Ltd
1.2. HMT network
1.3. Brief history of HMT Ltd
1.4. Product & service
2. DEPARTMENTSOF HMT & SAFETYMEASURES (7-9)
2.1. Human resource dept.
2.2. Manufacturing and assembly dept.
2.3. Service and inspection dept.
2.4. Material dept.
2.5. Planning dept.
2.6. Design dept.
2.7. Foundry dept.
2.8. Finance dept.
2.9. Sales dept.
3. VARIOUS SHOPS OF HMT (10-20)
3.1. Pattern shop
3.2. Foundry shop
3.3. Manufacturing shop
3.4. Round section
3.5. Medium machine shop (m.m.s)
3.6. Heavy parts section
4. HEAT TREATMENT (21-23)
4.1. Hardening operation
4.2. Stabilizing operation
4.3. Stress relieving operation
4.4. Nitriding operation

8. viii
4.5. Annealing operation
4.6. Blackening
5. PRODUCTS OF HMT (24-28)
5.1. Hydraulic cylindrical grinder m/c g17/22
5.2. Cnc double disc grinder m/c 22
5.3. Tooling
5.4. Description
5.5. Cnc double grinding disc m/c
6. Conclusion 29
7. Reference 30

9. ix
LIST OF FIGURES
Fig. No Name of Figure Page No.
1.1 Marketing network 2
3.1 Furnace 13
3.2 Knee type milling machine 17
3.3 Cnc trainmaster machine 18
5.1 Hydraulic cylinder grinder g17/22 24
5.2 Cncgds 15/22 27

10. 1
CHAPTER 1
INTRODUCTION
1.1 INTRODUCTIONOF H.M.T
The H.M.T. Ajmer previously called as Machine Tools Corporation of India Ltd.,
which was incorporated in January. 1967 to set-up a Grinding Machine Tools Plant at
Ajmer to specialize in the Manufactures, development and Marketing of high
precision and sophisticated grinding machine tools, which are urgently required for
our rapidly development national economy. It was installed as a branch of H.M.T.
under the technical collaboration with TOS Hitivar, Czechoslovakia.
Commencing its production with a small by highly versatile universal tool post
Grinder. "MTC" Model (ITG-15a) in the year 1970. The factory has been able to
progressively tools like Universal Tools & Cutter Grinder "MTC" Model (GTC - 28),
Crankshaft Grinding "MTC" Model (GCS-500), Vertical Surface Grinder "MTC"
Model (GVS-30), Internal Grinder "MTC" Model (GIF-80) and Center less Grinding
Machine. However it has started the production of centre lathe of various sized also.
The H.M.T. Ajmer has its own design & development in which new designs are being
development to cover requirements of small scale as well as specialized industries
such as Ball & Roller Bearing Industry.
It has a well-developed machining and inspecting facilities and a most modern Tools
room where Jigs and fixture and tools are manufacture to very standards comparable
with the best in world.

11. 2
1.2 MARKETING NETWORKS
Fig. 1.1 Marketing Network
1.3 BRIEF HISTORY OF H.M.T.
When India achieved independence in 1947 there was hardly any industrial base in
the Country. Right from that period, HMT has played an important role in providing
the much needed industrial base as well as sustaining a launching pad for the growth
and development of the Country.
1.4 BACKGROUND HISTORYOF HMT LIMITED:
When India achieved independence in 1947, there was hardly any industrial base in
the country. Right from the prior H.M.T. has played an important role in providing

12. 3
the much needed industrial base as well as a launching pad for the growth &
development of the country.
HMT was conceived by the Government of India in 1949, and was incorporated in
1953, with the objective of producing a limited range of machine tools, required for
building an industrial edifice for the country.
HMT Limited was established in 1953 in technical collaboration with M/s Orleikon
of Switzerland. Over the years, new products have been added to its manufacturing
range. It has technical collaboration with over 30 leading International Engineering
Companies for manufacture of various products HMT’s diversified product range
includes Machine Tools, Watches, Tractors, Printing Machine Press, Di-Casting and
Plastic Injection, Moulding Machines, Food Processing Machinery, CNC Systems,
Bal Screws etc.
This Unit was established as Machine Tool Corporation of India limited in January
1964 keeping in view the Government Policy of differing new industries in under
developed areas of the country and achieving self-reliance in production of Grinding
Machine Tools which were imported.
This Unit was started 1970-71 with a production of Rs. 8.64 Lack faces with
difficulty in procurement of quality Machine Tool Casings a captive Foundry Plant
was installed in 193 with a capital of about Rs.2 Crore.
Unit was subsequently merged with HMT Ltd. On 1st April 1975 as sixth Machine
Tool Plant with this merger; the Unit got backup support of HMT. The basic plant
was established with the collaboration of the Czechoslovakian firms, M/s Skoda
Export, Praha and German firmWMW, then in East Germany.
Today, HMT is a Multi-Product, Multi Technology Engineering Complex with
strengths comprising of:
 16 Manufacturing Units / 22 Product Division
 Assets Worth over US$ 250 Million
 ISO-9000 accreditation
 The widest range of machine tools, ranging from General- Purpose lathes to CNC
turning machine centers.
 Source of qualified and experienced Manpower.
1.5 HMT CORPORATE MISSION:
 To establish ourselves as one of the Worlds companies in the engineering field
having strong international competitiveness.
 To achieve market leadership in India through ensuring customer satisfaction by
supplying internationally competitive products and services.

13. 4
 To achieve sustained growth in the earnings of the group on behalf of
shareholders.
 To produce and market engineering goods and services of world class excellence
for satisfying the aspiration of the stake holders through total performance
leadership, consistent with the national socio-economic needs and priorities.
1.6 PROFILE:
The Unit was established at Ajmer as "MACHINE TOOL CORPORATION OF
INDIA LIMITED." a Government of India Undertaking in January, 1967 with the
collaboration of Czechoslovakian M/s. Skoda export and M/s.WMW, GDR. Then the
East Germany, for the purpose of making India self-reliant in manufacture of
precision Grinding Machines. This Unit was merging with M/s. HMT Limited in
1975.
From 1.4.2000 as per the Turnaround Plan, approved by the Govt. of India, it became
a Unit of HMT MACHINE TOOLS LTD., which is wholly owned Subsidiary of
Nation's prestigious Company, HMT LIMITED. This Unit is situated over 178 acres
of land, out of which 68 acres are for factory campus and 116 acres for a beautiful
Township comprising 136 quarters for housing its employees with Community
Centre, Club, playground, etc.
The Unit is well equipped with modern machine shops having 200 nos. of different
types of precision machines, such as, CNC Machining Centers, CNC Lathes, High
precision Jig Boring Machines, High Precision Cylindrical Grinders and Slide way
Grinders, besides well equipped Heat Treatment Shop, Measuring Centre, Material
Testing Laboratory, CAD Centre for Design & Development and Foundry. Unit has
also captive power generation Capacity of 1850 KVA to meet power shortage.
Ajmer Unit is capable to meet the requirement of all types of Grinding Machine Tools
for Indian as well as world market including CNC, tooled-up machines & special
purpose machines tailor made to customer’s requirement.
The Unit has highly skilled and dedicated Work Force and has strength of qualified &
experienced Engineering personnel to fulfill requirement of Business operations to
the satisfaction of customers.
1.7 Unit Business
 Hydraulic Groups for Defense Wide range of CNC, Manufacture of Machine
Tools
 Conventional General Purpose & Special purpose Grinding Machines
(Cylindrical, Centre less, Internal, Dupls. Horizontal & Vertical, and Tool &
Cutter).

14. 5
 Unit's product CNC Double Disc Grinder displayed in IMTEX'1988 at New Delhi
was conferred upon CMTI-Trust award for the best innovative design of the year.
 CNC Turning Centers.
 CNC Training Machines (Lathe & Machining Centre).
 Reconditioning/Refurbishing of Machine Tools.
 All types of Grinding Machines.
 Other Machine Tools
 Conversion of old machines into CNC machines & retrofitting of CNC control on
conventional machines.
 Unit got National award for excellence in indigenization of Defense Stores in the
category of Mechanical Engineering for the year 1993-94. This award was for
development and supply of Hydraulic Unit for 7-72 tanks.
 Hydraulic Lifts for Tractors.
 High Precision Components/operations on job work basis for Automobile
Industry and BHEL. Jigs & Fixtures
 Wiping Cylinders for Bank Note Press Supply

15. 6
1.8 PRODUCT & SERVICES
YEAR UNITS/DIVISION LOCATION STATE
1953
1961
1962
1963
1965
1967
1971
1971
1972
1972
1973
1975
1975
1975
1978
1981
1981
1982
1983
1985
1986
1991
Machine Tools I
Machine Tools II
Watch Factory I
Machine Tools III
Machine Tools IV
Machine Tools V
Tractor Division
Die Casting Division
Printing Machine Division
Watch Factory II
Precision Machine Division
Machine Tools VI
HMT (International) Ltd.
Watch Factory III
Watch Factory IV
HMT Bearing Ltd.
Quartz Analog Watches
Watch Factory V
Stepper Motor Division
Ball Screw Division
CNC System Division
Central Re-Conditioning
Bangalore
Bangalore
Bangalore
Pinjore
Kalamessery
Hyderabad
Pinjore
Bangalore
Kalamessery
Bangalore
Bangalore
Ajmer
Bangalore
Sri Nagar
Tumkur
Hyderabad
Bangalore
Ranibagh
Tumkur
Bangalore
Bangalore
Bangalore
Karnataka
Karnataka
Karnataka
Haryana
Kerala
Andhra Pradesh
Haryana
Karnataka
Kerala
Karnataka
Karnataka
Rajasthan
Karnataka
Jammu & Kashmir
Karnataka
Andhra Pradesh
Karnataka
Uttar Pradesh
Karnataka
Karnataka
Karnataka
Karnataka
Table 1.1: Division of HMT

16. 7
CHAPTER 2
VARIOUS DEPARTMENTS OF HMT LTD.
2.1Human ResourceDepartment:
Headed by Joint General Manager (HRM) this department is setup with an aim of
conservation and proper utilization of human resources and is also responsible for
maintaining the cordial relations between employees and management. The other
important functions of this department are performance appraisal and different welfare
activities for the employee.
2.2Manufacturing and Assembly Department:
Headed by JGM (manufacturing). HMT Ajmer’s manufacturing environment is highly
advanced; this department also looks after utilizing only the latest production techniques
in all phases of manufacturing maintenance. This assembly of machine is done stages,
much as sub assembly. Group assembly and final assembly of individual components.
There subassemblies after inspection pass on group assembly, which consists of head
stock assembly, saddle, gearbox, tail stock assemblies etc. this group then reaches to the
final assembly to be fitted on the bed. Electrical are also inter faced and the machine is
ready for final testing and printing of plant and equipment.
2.3Service & Inspection Department:
Headed by DGM. This department is responsible for inspection & Servicing of the
M/C’s. This department is concerned with the inspection of various components and
machines being manufactured. The inspection is carried out in various stages, beginning
from the inspection of individual components at different stages of manufacturing
followed by the inspection of the whole machine while included final runs etc. Inspection
of incoming material is also handled.
2.4Materials Department:
Headed by JGM. It is responsible for all kinds of purchases made by unit. This
department also maintains a Central store and looks after appropriate levels.
2.5 Planning Department:
Headed by JGM(EQ). The main functions of the planning department are as under: -
 Time calculations for each operation. Job card booking of workers in shifts.
 To prepare monthly progress reports for the production activities carried out in shop.
 To calculate manpower and machines available, accordingly new machines are ordered
and component.
 Counting of products and components.

17. 8
 Prepare machines and sectional layouts
2.6 DesignDepartment:
 Headed by JGM. Its functions are: -
 Design & development of products.
 Vendor development for new items.
 Drawing of component, group assembly, special assembly etc. along with master part
list (BOM) for machines.
 Deciding the type of material required for each component grade such as casting alloy
etc.
 Testing & trials of machines.
 Marketing of special purpose machine.
2.7 Foundry Department:
Headed by JGM Foundry. This department is administratively under HMT Ajmer, but
functionally under executive director.
2.8 Finance Department:
Headed by AGM Finance. The functions of this department include maintenance of all
accounts of the Company. The balance sheet is finally prepared which is sent to the head
office for the preparation of combined balance sheet. The costing section of this dept. is
responsible for the computing of each product of that the selling price may be determined
accordingly.
2.9Sales Department:
Is headed by JGM (Sales). This dept. is divided into 3 sections viz. Sales, Spares and
Reconditioning. These functions of sales sections are the execution of sales order and to
bid for contracts through tenders. The function of service section is to provide after sales
& also looks after customer’s complaints and supply of spares.
2.10 Security Department:
This is headed by Junior Security officer. Main function of this dept. is preventions of
theft, sabotage and maintenance of industrial security within the HMT compound
including Township.
2.11 Quality Assurance Department:
Dy. General Manager heads this department. This department also looks after the
feedback received from marketing division so as to make improvement accordingly.

18. 9
2.12 SAFETYMEASURES
 Do not wear loose garments they got caught leading to accidents.
 Either roll up your uniform releases or bottom up the cuffs.
 Always wear uniform and shoes they are for your safety.
 Long and unruly hair is always dangerous particularly when working near rewbeing
parts or machines or cutters.
 Ring, bracelets and watches can get caught in the machinery. Do not wear them when
on duty.
 Be calm and patient while working. A disturbed mind will invite trouble and haste
makes waste.
 While walking watch your steps.
 Be watchful of blind corners, you may be caught in the wrong way.
 Do not ailment the attention of others or do not have you alleviated by other while
working.
 Don't carry to many tools/instruments.
 Put the work area clean dry clip free and free of obstructions.
 Watch out for jobs, brass, rods, etc. which protrude form for vice and machines it my
hit you resulting in accident.
 Use personal protective equipment and safety drives.
 Do not touch/operate equipment unless you are authorized.
 Do not leave on the machine.
 Lubricate the Machine as is required.
 Do not clean the machine parts with hearts, bars use cloth, cotton, wash brush
 Do not repair or try to adjust or repair any equipment when in motion.
 Ensure all machine controls of the machine are accessible to you.
 Do not attempt to change the speed of the machine when in motion.
 Don’t keep unwanted instruments/tools on the machine bed.
 Use the right tools for the right join the right way.
 Use the proper speed.
 Use the proper feed.
 Use the proper depth of cut
 Do not use broke or blunt or damaged tools.
 Do not walk or work under suspended loads.
 Do not blow air from your mount to clean the components.
 Keep yourself at a safe distance from the cutting tool in motion.
 Don’t touch with pressure the job when it is hot or in motion.
 Switch off machine immediately in anything goes wrong.

19. 10
CHAPTER 3
VARIOUS SHOPS AT HMT LTD., AJMER
3.1PATTERN SHOP
A pattern may be defined as a replica model of the desired casting which, when
packed in a suitable molding material, produces a cavity called mould. The molten
metal solidifies in the mould cavity to get the desired casting.
The important considerations to be made while making a pattern:-
 Appearance and surface finish of the casting to be produced.
 Number of casting to be made from the same pattern.
 Facility & ease in molding
 Method of withdrawal of the pattern from the mould.
3.1.1 MATERIAL OF PATTERN:-
1. Wood
2. Plastic
3. Rubber
4. Wax
5. Plaster of Paris
3.1.2 PATTERN ALLOWANCE:-
A sand casting pattern is similar in shape to cast the product (but not exactly
same).A sand mould cavity is negative replica of the pattern and is produced by
packing sand around the pattern. When the pattern is prepared certain allowance
is given on the size of casting.
3.1.2.1 TYPES OF PATTERN ALLOWANCE:
• Shrinkage or contraction allowance:-
To compensate the solid phase contraction of the casting. The
pattern dimensions are increased by a certain amount depending on
the cast metal and type of mould.
Ranges:-
Aluminum = 13mm/m
Copper =16mm/m
Grey iron =20mm/m
• Machining or finishing allowance:-

20. 11
It is a provided on surface that are machined later. It includes
adding material to pattern surface along the directions of its
normal.
Ranges:-
Small aluminum die cast parts =1mm to 20mm
Large grey iron cast parts > 20mm
• Draft or tapper allowance:-
To facilitate the removal of the pattern from the weak brittle
moulding sand, the pattern should have some degree of taper called
draft. The amount of draft needed depends on the method of
moulding and drawing of the pattern, the material the pattern is
made from.
Range:-
Small external faces = 0.5degree
3.2 FOUNDARYSHOP
In a foundry shop casting of different jobs is prepared by using the moulding box,
pattern and moulding materials-
3.2.1 Moulding material
• Green sand
• Dry sand
• Semi Bake sand
• Bake sand
• No bake sand
3.2.2 Binding material
Part – A Binding
Part – B Chemical
Part – C Setting
3.2.3 Preparation of Sand–
All of first fresh silica sand and bake sand are mixed in definite ratio (50&50%)
in the muller. Some binding material and some other material are also mixed in
the sand. This mixture is known as mouldingsand.

21. 12
3.2.4 Preparation of a mould –
Following element is used for preparing a mould.
• Pattern
• Moulding box
• Moulding sand
• Face plate
• Split plate
• Matching pins etc.
3.2.5 Procedure
A prepared pattern is placed on the face plate and moulding boxes also fixed.
Now moulding sand is filled in moulding boxes now this mould sand is pressed
by manually and also by machine for the good packing of moulding sand. This
process is known as reaming process.
After reaming process and complete moulding boxes are kept in oven. Here sand
packing takes place. So there no damage in cores and edges. Heating process done
at 220o C for 2 hours
3.2.6 Closing of boxes
After heating process cope and drag are clamped and some packing material also
used for good packing of boxes.
3.2.7 Pouring of metal
The melted metal is poured in the boxes through the sprue cup. The melted metal
fills in cavities through the runner and gate ways. When the cavity is filled by
melted metal. It comes out from riser. The shrinkage of melting metal in cavity is
filled by the metal which is in the riser. The moulding boxes are cooled in air for
one day and then opened and moulding job is come out.
3.2.8 Accessories
• Chills – Chills are provided in the moulding at the places where more
hardness is required in the casting. These are iron plates.
• Chaplet – Chaplet are provided in the gaps to maintain the gaps.
3.2.9 Induction Furnace
Induction Furnace is used for melting the metal. There is tilting head in furnace
for pour out the melting metal. To get more special properties following metal is
added.
• Ferro Manganese

22. 13
• Ferro Silicon
• Ferro chromium
• Carbon (as required
• To remove slag from the melting metal silica sand is mixed in the furnace.
• To get more fluidity of metal elino cline mixed in the melted metal.
Fig. 3.1 Furnace
3.3MANUFACTURING DEPARTMENT
In all the factories, manufacturing department is main department, because here
product or different parts of machine is prepared.
H.M.T. Ajmer also has a manufacturing dept. Which is divided in the following
sections?
1. Mfg. H.P. (Heavy Parts)

23. 14
2. Mfg. S.P. (Small Parts)
In manufacturing H.P. heavy parts of an m/s like machine bed, gear box main body
etc. are manufacture.
In manufacturing S.P. different small components and parts of an m/c like shaft,
spindle, gear, bushes, screw etc. are manufacture.
Following sections comes in the mfg. small parts DPT.
1. Non round section
2. Round Section
3. Spindle, shaft Section
4. Gear Section
5. Heat Section
6M.M.S. (Medium Machine Shop)
7. Special accessories & spindle Assembly
3.4ROUND SECTION
Here small rounded components are manufacture. Following m/c are used to
manufacture the round parts
Name of M/C No. Off Type
Capstan Lathe 1
Drum Turret Lathe 1 RTV50
Turret Lathe 2
Centre Lathe 6
Drilling m/c 1
Radial Drilling m/c 1
In growing m/c 2
Centre less Grinding m/c 1 GCL60
Cylindrical Grinding m/c 1 KI30 U
BUA31 Grinding m/c 1
Circular Dividing m/c 1
Linear Dividing m/c 1
K-130 Grinding m/c 1

24. 15
Horizontal Milling m/c 1
Vertical Milling m/c 1
Slotler m/c 1
3.4.1 CENTER LATHE LAB
Manufactured by Chamundi Machine Tools Limited
Versatile lathe equally adaptable to precision tools room work and high speed
production turning.
• Direct multiple V belt drive to spindle ensures smooth torsional vibration.
• Free high turning speeds
• Five inter
• Changeable tool holders with quic.
• Change tool post, interlocked feed levers, full overload
• Protection foot brake and many other feature facilitate fatigue
• Free, easy operation of the machine
MAIN DATA
LB 17
Centre height MM 170
Distance between centers MM 700 or 1000
Spindle nos/bore MM Americal type L 1/42
Main motor KW 7.5
3.4.2 PRE-SELECTOR TURRET LATHE L 22
1. Pre selection of speeds and feeds
2. Precision indexing of turret head with solid 'V clamp locking.
3. Single lever for unclamping turret and withdrawing indexing pin extra
sturdy to take overload stresses
4. Drop worm mechanism avoids overloading-hardened guide ways.
MAIN DATA
Centre height MM 237
Distance between
Spindle nose and

25. 16
Turret case
Min MM 390
Max MM 1120
Spindle nose/bore MM A2-6/65 mm
Bore in turret MM 54
Main motor MM 9.3
3.4.3 SHAFT & SPINDLE SECTION
This is a dept where machines shaft and spindle are manufacture. The accuracy of
any shafts or spindle keeps in microns.
In this dept a special m/c called SPILOTE m/c. I have seen this machine used for
copying to the job. For example if we want to manufacture lot of shafts in same
directions, then we can copy from manufacture shaft.
3.4.4 Silent FEATURES:-
Available in universal, production and plunge grinding models, universal and
production models have infinitely variable table transverse, with a dwell and
automatic in feed at table reversals. The universal models are equipped with
swiveling wheel head and built in provision for internal grinding.
A single lever during production runs, control transverse, work rotation coolant
flow and rapid approach of wheel head. Large capacity coolant tank and hydraulic
aggregate are separate from the machine, minimizing the thermal effects on the
structure.
Other Facilities are available in this section:-
Machine No.
Cylindrical grinding m/c 2
Lathe m/c 5
SPILOTHE m/c 1
Keyway milling m/c 1
3.5MEDIUM MACHINE SHOP (M.M.S.)
3.5.1 KNEE TYPE MILLING MACHINE
1. Production milling machine
2. Wide range of speeds and feeds
3. Longitudinal automatic programmed cycle

26. 17
4. Rapid traverse to minimize idle time
5. Separate motors for spindle and feed drives
6. Centralized push button controls for ease of operation
7. Main spindle runs on precision taper roller bearings
Main Data:-
Horizontal Universal Vertical
Table size (length & width) mm 1070x230 1070x230 1070x230
Powered operated mm 560 560 560
longitudinal
traverse
Cross traverse mm 275 275 275
(manual)
Vertical traverse mm 375 300 375
(manual)
Main motor kw 2.2 2.2 2.2
Fig. 3.2 Knee Type Milling Machine FN2/FN3
Salient Features:
 Streamlined construction, rugged and vibration free.
 7.5/5l5 kW Motor for heavy stock removal.
 Power operated feeds and rapid traverses in all directions.

27. 18
 Independent main drive and feed drive motors.
 Wide range of spindle speeds and feeds.
 Instantaneous braking of spindle and table drives through electromagnetic clutches.
 High rate of rapid traverses.
 Light fingertip push button controls.
 Inching push button for speed and feed drive
3.5.2 CNC Trainmaster Machining Center VMC 200T PC
Fig. 3.3 CNC Trainmaster Machine
Salient Features:
 An economical and user friendly PC based system to meet Training requirements of
all Training Centers, Technical and Educational Institutions in CNC machine tools
operation & programming.
 Provides a comprehensive range of CNC functions for both Vertical and Horizontal
modes of operation, with a CRT monitor and many more advanced features.
 PC based CNC system
 Compact table top model, most ideal for training institutes.
 Stepless DC drive with RPM and load indication for spindle.
 Hardened and ground spindle runs in Precision antifriction bearings.
 Economical CNC system best suited to educational institutions.
 Recirculating Ball screw and Nut arrangement for all axis
 Machine lamp

28. 19
3.6HEAVY PARTS SECTION
Heavy Parts section Deals with the parts having greater dimensions. All the bed of
different castings is dealt here along with other heavy castings. The process plan here
starts with the marking three basic equipments are used viz. Tri-square, Height gauge
& Surface plate. The marking is done to pave the way of casting for other operations.
After marking planning is done on a huge machine called as Double Housing Plano-
Milling Machine. The machine is capable of having four cuts in a single pass. After
planning drilling, boring etc. are done. Before marking the priming is done which
gives two advantages? First - The Consumption of paint will be less while painting.
And second - The marking will become visible.
3.6.1 Double housing Plano-Milling Machine
The double housing Plano Milling Machine, as its name implies, Does planning
and milling. There are two vertical heads, which travel on horizontal rails. Each
head comprises of two head one Side head and the other Cross head. So in a
single pass four cuts are possible. The brief specifications of the machine are as
given below:
1. Length of Bed 20 m
2. Width of Bed 2 m
3. Table Width 2 m
4. Table Length 10 m
5. No. of Side Heads 2
6. No. of Cross-Heads 2
7. Height of Machine Housing 3 m
8. Maximum Permissible Table Load 40,000 kg.
3.6.2 METROLOGY SECTION
One of the most important parts of production process is measuring and
inspection. All the components produced on machines are inspected after each
step using sophisticated techniques of measurement. The accuracy is maintained
at the level of microns. To keep up such level of quality control, metrology
section becomes quite important part of the unit.
It consists of very sophisticated and accurate machines that can measure at the
level of one micrometer and even less. The temperature of measuring and
standards room is set constant at 20 deg. to insure uniformly.
Some of the important machines used in this section are:-

29. 20
3.6.2.1 Co-ordinate measuring machine:
Carl Ziess Jena Company, Germany.
Range of measurement 100 mm * 200 mm
Least count 1 micron.
System Optical.
Applications Measuring thread’s profile, radii,
tapers indexing etc.
3.6.2.2 Universal measuring machine (for length) MUL 1000:
Make : SocieteGenevoise (Swiss).
Range of measurement : 100 mm
Least count : 0.5 micron.
System : Optical.
Applications : Measuring data of internal and external
thread’s length of precision components etc.
3.6.2.3 Tool maker’s microscope:
The working of this machine is like that of universal measuring machine
except that:-
Least count : 10 micron.
System : Mechanical
3.6.2.4 Roundness testing machine FORMTESTER MMR 4:
The machine consists of a very accurate round table and a sensor. A printer
attached that gives a quantitative idea about the roundness plots a profile of
the cylindrical test piece.
Least count : 0.5 micron. Sys: pneumatic and CNC.
Applications :to check the roundness of cylindrical Parts after
grinding etc.
3.6.2.5 Surface-roughness testing machine PERTHOMETER:
Make Perthen, Germany.
Least count 0.5 micron.
System Pneumatic and CNC.
An important feature of above two machines is that the macro errors on the
surface can be filtered automatically.
Along with these highly technical and accurate machines some other simple
but equally important machines and apparatus are also used in the metrology
lab for example: - Dial gauges, Slip gauges (set M 112), and Height gauge

30. 21
CHAPTER 4
HEAT TREATMENT
Heat treatment may be defined as an operation of heating and holing of metals in the solid
state to induce certain desired properties into them. It is generally employed.
 To improve machinability
 To refine grain size
 To relieve the stress of the metal induced during cold or hot working
 To improve electric & magnetic properties
 To increase resistance to wear, heat & corrosion
 To produce a hard surface on a ductile interior
4.1HARDENING OPERATION
4.1.1 PROCEDURE:-
1. Study the drawing and process sheet and take work instruction whenever
required from supervision.
2. Set the temp of furnace as per requirement of the component vise.
3. Ensure the component is dry.
4. Ensure the components are properly wired as per work instruction.
5. Ensure that the component is preheated as per component vise.
6. Component should be put slowly in salt bath furnace and ensure that the
component are not touching electrode of the furnace.
7. Ensure proper quenching media and temp as per component.
8. Do not put component in water from quenching bath directly.
9. Check first piece for hardness, distortion and soft portion before carrying
out bath.
4.2STABILIZING OPERATIONS
4.2.1 PROCEDURE:-
1. Wire the component as per instruction.
2. Use bucket/fixture as per requirement of component.
3. Load the component in the furnace taking care that they do not strike with
furnace.

31. 22
4. Ensure that the component is fully dipped in oil.
5. Set the temp between 130 to 170 deg C and put ‘on’ the furnace.
6. Hold on temp for 4-6 hours depending on the section of component.
7. Put ‘off’ the furnace after completion of soaking time.
8. Cool furnace air to room temp.
9. Cut wire/remove from bucket or fixture and clean.
4.3STRESS RELIEVING OPERATIONS
4.3.1 PROCEDURE:-
1. Ensure that the temp of furnace <200°C
2. Load the component taking care that they do not strike each other as well
as furnace refectory and heating elements.
3. Set the tempo of furnace as given below
Steel 550-560°C
Grey Iron 540-564°C
SG Iron 565-600°C
All Copper Bases Casting 250-330°C
Put ‘ON’ the furnace
4. Soak for one hour plus one hour for every additional 25mm.cross section
at temp
5. Put ‘OFF’ heating and cool in furnace.
6. Remove Component.
4.4NITRIDING :
4.4.1 PROCEDURE:-
 Preparation for Nitriding:-
De grease the component by cleaning the surface with thinner.
 Etching:-
Prepare 10% HCL solution in water dip the component in solution for 15 to 20
min clean the component thoroughly with running water wipe off water by clean
cloth. Hang to the fixture.
 Loading:-

32. 23
Loading the fixture along with tool piece in nitriding furnace tighten the lid of
furnace to make leak proof checking the leakage with PH paper.
 Nitriding:-
Allow ammonia gas to flow in line after 156 min. Switch on the furnace and set
the temp to 510+5°C maintain the % of ammonia dissociation to 25-30%.
Switch off the furnace after 72 hours. Remain charge then temp comes to 100-
120°C.
4.5 ANNEALING OPERATIONS
4.5.1 PROCEDURE:-
1. Ensure that the furnace temp < 200°C.
2. Load the component taking care that they do not strike with each other as
well as furnace refectory and heating elements.
3. Set the furnace temp as given- for steel having carbon % up to 0.8.
4. Put ‘ON’ the furnace
5. Soak for one hour plus one hour for every additional 25mm.cross section
at temp
6. Put ‘OFF’ heating and cool in furnace.
7. Remove Component.
4.6 BLACKENING
4.6.1 PROCEDURE:-
1. Degrease the component.
2. Ensure that the components are rust/paint free.
3. Prepare blacking batch
Water =50% by weight
Black = 15 salt 48% by weight
Black D= 2% by weight
PRECAUTION; Always add salt to water and not water to salt while
pouring bath.
4. Heat liquid to boiling
5. Hang component free from all of the pot and each other.
6. Check for blackening result it components are getting iron and water.
7. Remove the components.
8. Oil the components.

33. 24
CHAPTER 5
PRODUCTS OF HMT
5.1 HYDRAULLIC CYLINDRICAL GRINDER G17/22
Fig.5.1_G17/22
5.1.1 SALIENT FEATURES:
 Designed for high rates of stock removal for batch production requiring fine
tolerance limits with finest surface finish.
 Available in universal and production models, having infinitely variable table
traverse, with a dwell and automatic infeed at table reversals.
 The universal models are equipped with swiveling wheel head and built-in
provision for internal grinding.
 A single lever controls table traverse, work rotation, coolant flow and rapid
approach of wheel head during production runs.

34. 25
5.1.2 SPECIFICATIONS:
G17/800 G17/2000 G22/2000
Center height Mm 175
(225 with G22 set-
up)
175
(225 with G22 set-
up)
225
Maximum grinding dia. mm 250 250 250
Swing over bed Mm 350
(450 with G22 set-
up
350
(450 with G22 set-
up
450
Distance between centers Mm 800 1200 2000
Speed (infinitely variable) m/min 0.05-5 0.05-5 0.10-4
Grinding wheel dia. (Max. /
Min.)
U model
P model
Mm
Mm
450/320
500 / 360
450/320
500 / 360
450/320
500 / 360
Speed
U model
P model
Rpm
Rpm
1060/1320
960 / 1150
1060/1320
960 / 1150
1060/1320
960 / 1150
Grinding wheel motor kW 5.5 5.5 5.5
Table 5.1 specification of hydraulic cylinder grinder
5.2 CNC DOUBLE DISC GRINDER CNC CDS – 22
5.2.1 SALIENT FEATURES:
1. Grinding wheel spindle is mounted on precision preloaded NNK bearings and
Double row angular thrust bearing
2. Provision of coolant supply through spindle bore
3. Preloaded antifriction recalculating roller bearings for wheel head slide motion
with narrow guide ways system

35. 26
4. Wheel head slides are driven by servomotors directly coupled with preloaded ball
screw and nut with rotary encoder feed back with resolution accuracy of one
micron.
5. Hydraulic swing arm dresser mounted at rear side
6. Machine is suitable to execute automatic plunge/through grinding cycle by CNC
system with operator friendly software design
5.2.2 Automatic size correction due to wheel wear
1. Automatic lubrication
2. Dust proof electrical cabinet consisting of CNC system and other switch gear items
is free standing type
3. Built in interlocks for safe operations of machine
4. Panel air conditioner
5.3 TOOLINGS
1. Rotary feeder
2. Through feeder
3. Belt feeder
4. Roller feeder
5. Swing Arm feeder
6. Pusher feeder
7. Magnetic plate feeder
8. Matching grinding wheel guard
9. Component carrier plate and component guiding system
10. Loading and unloading system for components
5.4 DESCRIPTION
5.4.1 SPECIAL ACCESSORIES:
1. Balancing stand
2. Grinding wheel
3. Diamond dressers
4. Set of back plates for mounting grinding wheels
5. coolant tank with magnetic separator and paper band filter
6. Two years spares.
5.4.2 STANDARD ACCESSORIES:
1. Balancing mandrel
2. Oil gun

36. 27
3. Test mandrels
4. Straight edges
5. Ampere meter
6. Diamond dressers
7. Automatic dressing/Grinding cycles
8. Coolant supply pipingsElectrical equipment for 3 phase, 4 wire, 415 ±6% Volts,
50 ±3% Hz AC supply
9. Instruction manuals
10. Tools for normal operation.
5.5 CNC DOUBLE DISC GRINDING MACHINE CNC GDS 15 / 22
Fig. 5.2 GDS15/22
5.5.1 SALIENT FEATURES:
1. Ideal grinder for mass production of components having two flat and opposite
parallel surfaces with higher geometrical accuracies.
2. Machines up to 4-axes CNC control.
3. User-friendly grinding cycles by customized screen (picto programming).
4. Preloaded antifriction guide ways for precise positioning and rigidity.
5. Super precision antifriction bearings for grinding spindles. Direct driven ball
screws with AC digital servomotors for linear axes.

37. 28
6. Hydraulic swing arm dresser.
7. Automatic centralized lubrication system. Free-standing electrical panel and
hydraulic power pack.
8. Pendant type operator panel.
9. Built-in safety interlocks.
5.5.2 SPECIAL EXECUTIONS:
1. Variable speed drives for grinding wheels suitable for different areas on opposite
surfaces.
2. Machine can be equipped with rotary feeder, through feeder, rotary magnetic
plate through feeder, reciprocating feeder, swivel arm feeder, oscillating feeder as
per requirement.
3. Diamond wheels.
4. Post-process gauge.
5. Wheel positioned for grinding wheel.
5.5.3 SPECIFICATIONS:
CNC GDS 15 CNC GDS 22
Grinding wheel size (ODxW ) Mm 400/450/500x65 585/660/762x70/80
Peripheral/cutting speed m/sec 30 30
Dressing distance Mm 80 200
Grinding wheel motor kW 11/15 18.5/22/37
Spindle speed of both wheels rpm 1000 900
Dressing distance between wheels mm 80 200
Rotary feeder capacity - Job dia. Mm 10-50 20-80
Rotary feeder capacity - Thickness Mm 3-30 3-40
Through feeder - Job outer dia. Mm 20-70 35-220
Through feeder - Job thickness Mm 3-25 3-40
Control system Siemens/Fanuc Siemens/Fanuc
Table 5.2 : specification of CNC

38. 29
CHAPTER 6
CONCLUSON
 It was a wonderful experience for all of us having our first industrial exposure
at HMT-Machine tools Ltd.
 Realized the experience of team work.
 Get the knowledge of a production company
 Get the knowledge of working of machinery in the company.
 Get the little knowledge of CNC machine working.
 Good experience of the production of machine tools.

39. 30
REFERENCES
1. Website
1.1 www.hmtajmer.co.in.
1.2 www.google.co.in
1.3 www.hmti.com
2 Book
2.1 Production technology Dr. R.K.Jain.
2.2 Workshop technology Hajra And Choudhary