INTRODUCTION

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 specialise 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
Centreless 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.

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 HMT MACHINE TOOLS LTD., AJMER
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. Skodaexport 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 merge
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.

Technological Base:
The Unit is well equipped with modern machine shops having 200 nos. of different types of
precision machines, such as, CNC Machining Centres, CNC Lathes, High precision Jig Boring
Machines, High Precision Cylindrical Grinders and Slideway 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 fulfil requirement of Business operations to the satisfaction of customers.

Unit Business:

1. Manufacture of Machine Tools:

Wide range of CNC, Conventional General Purpose & Special purpose Grinding Machines

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(Cylindrical, Centreless, Internal, Duples, Horizontal & Vertical, and Tool & Cutter).

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.

(1.A) CNC Turning Centre’s.

(1.B) CNC Training Machines (Lathe & Machining Centre).

2. Reconditioning/Refurbishing of Machine Tools:

(2.A) All types of Grinding Machines.

(2.B) Other Machine Tools

(2.C) Conversion of old machines into CNC machines & retrofitting

of CNC control on conventional machines.

3. Job Orders/Customer Component Manufacture:

(3.A) Hydraulic Groups for Defence

Unit got National award for excellence in indigenisation of Defence 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.

(3.B) Hydraulic Lifts for Tractors.

(3.C) High Precision Components/operations on job work basis

Automobile Industry and BHEL.

(3.D) Jigs & Fixtures

(3.E) Wiping Cylinders for Bank Note Press Supply of castings

4. Other Services offered:

(4.A) Chemical, Mechanical & metrological tests, instruments

calibration.

(4.B) Training to outside customers.

Productivity & Quality:

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Great emphasis is given on Productivity and Quality in HMT. The Unit has achieved substantial
progress in implementation of productivity improvement activities. KAIZEN, ISO-9000, Total
Customer Satisfaction, TQM, Multi-trade training, Good House Keeping through 5-S, Waste
Elimination and Small Group Activities etc.

The Unit has the distinction of getting "National Productivity Award" (instituted by National
Productivity Council of India), in Machine Tool Category for the year 1986-87 from the Hon'ble
President of India.

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 LOCATION & HISTORY
The H.M.T. Ajmer is situated near Ajmer Dairy 6 Km. from Ajmer City of Ajmer-Beawar Road. Its

foundation stone was laid on December 16, 1966 and production was started in 1970. It produced

various types of Grinding Machine, Lathe Machines of various sizes. The product of H.M.T.

however could not orient the local market towards them due to tough competition but they have

nicely attached the foreign market. The H.M.T. was highly appreciated by Foreign Experts in many

industries trade fair organized in India and Abroad.

H.M.T. (H.M.T. Machine Tools):

Hindustan Machine Tools is a public sector undertaking it was setup as Banglore and registered in

Feb. 1953.

It is one of the ten largest manufactures of machine tools in the world.

MARKETING:

H.M.T. has a type marketing network throughout the country. While each business group has a

central marketing division, each factor has also a unit Sales Department.

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 HMT MACHINE TOOLS LTD.

MARKETING NETWORK

MARKETING DIVISION:

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Machine Tools - Banglore
Watches - Banglore
Tractors - Chandigarh

Sales and Service Centres at:

Agra, Ahmedabad, Banglore, Bhilai, Bhopal, Bhubaneshwar, Bombay, Calcutta, Chandigarh,
Coimbtore, Cochin, Guwahati, Hyderabad, Indore, Jabalpura, Jaipur, Kanpur, Karnel, Luckhnow,
Madras, Mohali, Nagpur, New Delhi, Patna, Puna, Ranchi, Srinagar, Tunkur.

H.M.T. (International) limited:

Head Office Banglore
Overseas Branches Australia, Kenya, USA
Overseas Offices Algeria, Indonesia, Nigeria. Malasiya

H.M.T. FACTORIES

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(A) AJMER PRODUCT
1. Cylindrical & Universal Grinder.
2. Internal Grinder.
3. Tool & Cutter Grinder.
4. Crank Shaft Grinder.
5. Roll Chamber Grinder.
6. Vertical Surface Grinder.
7. Duplex Surface Grinder.
8. CNC Trainer Lathe T-70 & VMC 200T
9. LENS Grinding & Polishing Machine.
10. Centreless Grinding Machine.
11. Knife edge Grinding Machine.
12. Hydraulic Cylindrical Grinder K-130

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 SALIENT FEATURES OF
HMT MACHINE TOOLS LTD, AJMER
HMT Ajmer is a member of Nation's prestigious Company. The HMT LIMITED, Bangalore offering
widest range of Machine Tools in the world with its factories spread all over India. Other products
with significant market presence are Industrial Machinery, Watches & Tractors. HMT Ajmer Unit
manufactures mainly range of Grinding Machines and Training Machines. It also has entered in the
areas, such as, Reconditioning & Retrofitting of old machines, job Orders/Customer Components
manufacture, Hydraulic Groups manufacture and supply of castings.

MTA AT A GLANCE
1. Date of Registration 11-01-1967
2. Commencement of Production 1970-91
3. Merger with HMT 01-04-1975
4. Capital Employed Rs. 3071 L
5. Land Area — Total 178 Acres
Plant & Foundry 60 Acres
Township 118 Acers
6. Covered Area (Plant) 31848 sq. m.
7. No. of Quarters 136
8. No. of Employees (as on 1.5.05) 541
9. No. of Machines 168

RANGE OF GRINDING MACHINES & TRAINING MACHINES

1. Internal Grinders
2. Tool & Cutter Grinders
3. Double Disc Grinders
4. Centre less Grinders
5. Vertical Surface Grinders
6. Cylindrical Grinders
7. Key Stone Grinder
8. Crankshaft Grinders
9. Roll Camber Grinders
10. Knife Edge Grinding Machine
11. CNC Train Master Machining Centre
12. CNC Train Master Lathe
13. Gap Grinding Machine
14. Cot Grinding Machine
15. Coil Winding Machine

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Above Grinders are manufactured in different variants. Machine are manufactured in versions,
.such as, General Purpose Machines without CNC controls, machine with CNC system/PLC
controls and Special Purpose Machine to suit customers requirements.

OTHER SERVICES OFFERED

1. Manufacture of Jigs, Fixtures, Toolings,
2. Manufacture of Hydraulic Group for Defence.
3. Hydraulic Assembly for Tractors.
4. Manufacture of High Precision & critical items, assemblies.
5. Reconditioning & Retrofitting of old machines.
6. Supply of castings.
7. Maining to outsiders/customers.
8. Chemical, Mechanical & Metrological Tests, Checking & Calibration

AWARDS & RECOGNITIONS

1. National Productivity Award, in Machine Tools Category for the year1986-87.
2. National Award for R&D efforts in Mechanical Engineering Sector in 1990.
3. ISO-9001 Certification on 24th February, 1994. HMT Ajmer was the first Unit to
receive this Certification in Rajasthan and second in HMT Units.
4. National award for excellence in indigenisation 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 T-72 Tank
5. MTA product, computer controlled Double Disc Grinder CNC GDS-22 displayed in
IMTEX'98 at New Delhi, was conferred upon CMTl-Trust award for the best
innovative design of the year.

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 MANUFACTURING 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 have a manufacturing dept. This is divided in the following sections.

1. Mfg. H.P. (Heavy Parts)

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

6. M.M.S. (Medium Machine Shop)

7. Special accessories & spindle Assembly

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 ROUND SECTION

Here small rounded components are manufacture. Following m/c are used to manufacture the round
parts.

Name of M/C No. Off Type

1. Capstan Lathe 1
2. Drum Turret Lathe 1 RTV50
3. Turret Lathe 2
4. Centre Lathe 6
5. Drilling m/c 1
6. Radial Drilling m/c 1
7. In growing m/c 2
8. Centre less Grinding m/c 1 GCL60
9. Cylindrical Grinding m/c 1 KI30 U
10. BUA31 Grinding m/c 1
11. Circular Dividing m/c 1
12. Linear Dividing m/c 1
13. K-130 Grinding m/c 1
14. Horizontal Milling m/c 1
15. Vertical Milling m/c 1
16. Slotler m/c 1 CH-25

Centre Lathe LB17

Manufactured by Chamundi Machine Tools Limited

Versatile lathe equally adaptable to precision tools room work and high speed production turning.

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 1. Direct multiple V belt drive to spindle ensures smooth torsional vibration.

2. Free high turning speeds

3. Five inter

4. Changeable tool holders with quic.

5. Change tool post, interlocked feed levers, full overload

6. Protection foot brake and many other feature facilitiate fatigue

7. Free, easy operation of the machine

MAIN DATA

Centre height mm 170

Distance between centres mm 700 or 1000

Spindle nos/bore mm Americal type L 1/42

Main motor KW 7.5

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 Pre-selector turret lathe L 22

HMT's own design

Salient features:

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. Dropworm mechanism avoids overloading-hardened guideways.

MAIN DATA

Centre height 237mm

Distance between spindle nose and 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

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 NON-ROUND SECTION

In this department non rounded component of any M/C is manufacture.

Following facilities are available in this dpt.

(Name of m/c) (Type) (No. of)

1. Horizontal Milling M/C FN-2H 1

2. Vertical Milling M/C FN-2X 1

3. Vertical Milling M/C FM-3 1

4. Vertical Milling M/C M2-Y 2

5. Vertical Milling M/C FN-3 1

6. Radial Drilling RM-62 2

7. Centre Lathe LB-20 2

8. Drilling M/C VS-20 1

9. Shaping M/C CMS-63 1

10. Surface Grinding M/C SFW-2 2

11. Surface Grinding M/C BPH20 (NA) 1

12. Straightening M/C 1

13. Hydraulic press 1

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 MEDIUM MACHINE SHOP
(M.M.S.)

KNEE TYPE MILLING MACHINE (HMT’s own design)

Salient Features:-
1. Production milling machine
2. Wide range of speeds and feeds
3. Longitudinal automatic programmed cycle
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

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 Milling Machine FNR

HMT’s own design

Salient Features:
1. Streamlined construction, rugged and vibration free
2. 5.5 kw motor for heavy stock removal
3. Power operated feeds and rapid traverses in all direction
4. Independent feed drive motor
5. Wide range of spindal speeds and feeds
6. Speeds upte 1800 rpm and feeds upto 800 mm/min.
7. All operations controlled with effortless ease by push buttons
8. ‘Inching’ push button for speed and feed drives
Main Data:
Horizontal Vertical
Table size clamping area mm 1350x310 1350x310
(length & width)
Powered operated mm 800 800
(table traverses)
longitudinal traverse
Cross mm 265 265
Vertical mm 400 400
Main motor kW 5.5 5.5
This section consists of basically CNC operated machine. There are three machines in this section

capable of doing several operations in one complete cycle. Two of the machines are HMC

(Horizontal machine centre) and one is VMC (Vertical machining centre)

The centre is so called as machine centre as the spindle centre remains same for various operations

irrespective of their function.

Each tool with its collect chuck gets attached to spindle before operation.
VMC Vertical M/C centre at Pinjore unit.
HMC Horizontal M/C centre.
1. in KTM, London
2. In HMT, copied of KTM in Hydrabad unit
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 VMC 200 T PC
VERTICAL MACHINING CENTRE

SPECIFICATIONS:
TABLE: Table size Mm 420x125
Max job weight KG 20

AXES TRAVELRANES
Longitudinal (table) Mm 200
Cross(Saddle) Mm 125
Distance from spindle nose to table top Mm 25-225
Throat, spindle centreline to Mm 155
(horizontal) to table top Mm 114-314

SPINDLE :
Spindle nose 150 30
Spindle motor KW 0.44 DC
Speed range(infinitely variable) RPM 200-2000

FEED RATES:
Rapid transverse rate mm/min. 700
Feed rate mm/min. 2-550

TOOLS:
Tool change Manual with CNC programming
No. of tools 8

CNC SYSTEM:
Type PC Based
No of axes 3
Axes drives Stepper Motor
Resolution 0.01 mm
Rapid transverse rate 750 mm/min.
Manual rate (incremental)

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MAIN DATA
Horizontal Universal
FN RH FN RU
Table size-clamping area
(length x width) mm 1350*310 1350*310
Power-operated table transverses:
Longitudinal mm 800 800
Cross mm 265 265
Vertical mm 400 400
Universal head swivel ( on either
side along the table as well as
towards and away from the
column face) 450 450
Main motor KW 5.5 5.5
Universal head motor KW 0.75 0.75

SHAFT AND SPINDLE SECTION

This is a department where machines shafts and spindle are manufacture. The accuracy of any shafts
or spindle keeps in microns (according to the requirement of part).

In this department a special m/c called SPILOTE m/c, I Rave seen. This machine is used for copying
to the any job. For example if we want to manufacture lot of a shafts in same dimensions, then we

19
can copy from are manufactured shaft.

SALIENT FEATURES:
Available in universal, production and pluge grinding models - universal and production models
have infinitely variable table transverse, with a dwell and automatic infeed at table reversals. The
universal models are equipped with swivelling 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.

SPECIAL ACCESSORIES:
3 - Jaw chuck
Face Table
Spring rest 10 to 40 MM.
Closed steady rest 5 to 80 MM. end at the table
Set of collets, set of drivers.
Micrometric showlder grinding device.
Sheel balancing stand.

Automatic work sizing device for plungs grinding fine hand feed attachment for table.

STANDARD EQUIPMENT:
1. Electrical equipment complete with wiring. Suitable for standard Ac supply.
2. Set of Standard wheel flanges for external block and grinding wheel for external grinding.
3. Balancing Manderal
4. 2 Caride sipped centre
5. Driving pin
6. Hinged driving doy
7. Wheel dresser on table.
8. Adaptor for centres and adaptor with flanges for face place/ chucks. Protection cap for wheel
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 spindle
9. Splash guards for internal grinding belt and chucks.
Another special, m/c in this department is "Whorm & Thread Grinding
m/c" (Type GUS-B) is rarely seen in industries. This machine upto the
2mm. pitch threads directly grinds of prepared and after that grinds.

Other facilities are available in this section are:-

1. Cylindrical grinding m/c BUA63/3000 1
2. Lathe m/c LB20 2
3. Lathe m/c H26 3
4. SPILOTHE m/c 1
5. Key way milling m/c LF4 1
6. Cylindrical grinding m/c - BUA31/1000 1

TOOL ROOM
Various small parts having a great accuracy are manufactured in tool - room dept. Also tool room
used to manufacture various tooling for different machine tools. And due to this reason this section is
called as tool room. The dept. is equipped with different critical machines imported when the
industry was set-up. The dept. also manufactures jigs fixtures for the machine tool projects. Three
critical machines are given below with their details:-

Coordinate Jig- Boring Machine WKV- 100

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The machine is called as coordinate jig - boring machine because the machine operates on three
coordinate axis named as x- axis, y-axis and Z -axis. The machine is in HMT, Ajmer since October
1968 and is giving miraculous accuracy. The machine is of Czech made. The x- axis is the vertical
head’s across movement. The y-axis movement is longitudinal movement of the table holding the
job.The z-axis movement is the up and down movement of the horizontal head. The machine is
provided with microscopic indicator for ease of reading the measurements. The machine was initially
used to make jigs. The salient features of the machine are as follows:-

General Specifications:
1. Hydraulic table movement
2. Maximum and main product-Jigs & fixtures
3. At present rectified jigs and highly accurate components.
4. Three coordinate axis motion control.
5. Two spindle heads namely horizontal and vertical.

6. Control temperature 20o C2oC

Technical specifications:
1. Machine accuracy = 0.001 mm
2. Vertical head:
(2.a) Min. RPM =12.5
(2.b) Max. RPM= 2000
(2.c) Spindle movement = Right and Left
(2.d) Spindle working length = 300 mm (with work piece)
(2.e) Spindle chuck diameter = 135 mm
3. Horizontal Head:
(3.a) Min. RPM =20
(3.b) Max. RPM= 1000
(3.c) Spindle movement = up and down
(3.d) Spindle working length = 300 mm (with work piece)
(3.e) Spindle chuck diameter = 135 mm
(3.f) Spindle sleeve taper =100: 15 (ISO Taper)
4. Size of machine table:
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 (4.a) Working length = 1400 mm
(4. b) Table Width = 1000 mm
5. Two Accessories:
(5.a) Universal indexing head
(5.b) Rotary table

23
 STUDER S-30 RHV 650/125 C
{Precision Cylindrical Grinding Machine}
Make - Switzerland
Machine Specifications:
1. Maximum swing diameter 250 mm
2. Distance between centers 700 mm
3. Achievable accuracy
(3.a) Circularity on live spindle 0.5 micron (0.0005 mm)
(3.b) Cylindricity 2 micron (0.002 mm)

General specification:
1. The studer s-3 machine (made in Switzerland) was imported to make precision
components with a greater accuracy at the time of HMT machines tools unit, Ajmer set-up.
2. The machine is equipped with a magnetic chuck with a great holding capacity, dressing head,
internal grinding head and external grinding head.
3. The machine is capable of both internal Grinding and external grinding. Generally external
grinding is done by using this machine. There is one attachment is provided for the internal
grinding and the external grinding head is set to be idle.
4. The machine was initially used to ground Various Gauges specially. Various Gauges comprise
plain gauges and taper gauges.
5. Presently it is being used to ground precision components requiring microns level accuracy.
6. The components being ground comprise Gear Blanks, Hollow Shafts, Sleeves and Spindles etc.

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 HEAT TREATMENT
Heat treatment may be defined as an operation of heating and holling of metals in the solid state to
induce certain desired properties into them. It is generally employed.

1. To improve machinability
2. To refine grain size
3. To relive the stress of the metal induced during cold or hot working
4. To improve electric & magnetic properties.
5. To increase resistance to wear, heat & corrosion.
6. To produce a hard surface on a ductile interior.

HARDENING/TOUGHENING OPERATION
PROCEDURE:
1. Study the drawing and process sheet and take work instruction whenever equired from
supervision.

2. Set the temp of furnace as per requirement of the component vide L6051 to L6057.

3. Ensure the components are dry.

4. Ensure the components are properly wired as per work instruction.

5. Ensure that the components are preheated as per L6051 to L6057.

6. Component should be put slowly/gradually in salt bath furnace and ensure that the component are
not touching electrode of the furnace.

7. Ensure proper quenching media and temperature as per L6051 to L6057.

8. Do not put the component in water from tempering/quenching bath directly.

9. Check first piece for hardness, distortion and soft portion before carrying out bath

25
 STABLISING OPERATION

PROCEDURE:

1. Wire the components 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 each other/furnace.

4. Ensure that the components are fully dipped in oil.

5. Set the temperature between 130° -170° C and put 'ON' the furnace.

6. Hold on temp for 4-6 hour depending on the section of component.

7. Put 'off' the furnace after completion of soaking time.

8. Cool furnace/still air to room temperature.

9. Cut wire/remove from bucket or fixture and clean.

STRESS RELIEVING OPERATION

PROCEDURE:

1. Ensure that the temperature of furnace is <200° C

2. Load the component taking care that they do not strike each other as well as furnace refractory
and heating elements.

3. Set the temp of furnace as given below:

Steel - 550-5600C
Grey Iron (G, & G,) - 540-5640 C
Gey Iron (G4) - 565-6000 C
SG Iron - 600-6200 C
All Copper Base Casting - 250-3300 C
Put 'ON' the furnace

4. Soak for one hour plus one hour for every additional 25mm. cross section at temperature.

5. Put 'OFF' heating and cool in furnace.

6. Remove Component.

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 NITRIDING

PROCEDURE:

1. Preparation for Nitriding:

De grease the component by cleaning the surface with thinner.

2. Etching:
Prepare 10% HCL solution in water dip the component In solution for 15 to 20 min clean the
component throughly with running water wipe off water by clean cloth. Hang to the fixture.

3. Loading:
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.

4. Nitriding:
Allow ammonia (NH) gas to flow in line after 156 min. Switch on the furnace and set the temp
to 510° C + 5° C maintain the (%) percentage of ammonia dissociation to 25-30%

Switch off the furnace after 72 hour. Remain charge then temp.
Comes to 100-120° C

ANNEALING OPERATION

PROCEDURE:
1. Ensure that the furnace is <200°C
2. Load the component taking care that they do not strike with each other as well as
furnace refractory and heating elements.
3. Set the furnace temp as given below - for steel having carbon % upto 0.8 - 750° C
4. Put 'ON' the furnace and give soaking time 1 hour plus additional and hour for
each 25 mm cross section.
5. Put 'OFF' the furnace and cool the component in furnace below 200° C
6. Remove component from the furnace.

BLACKENING
PROCEDURE:
27
1. Degrease the component.
2. Ensure that the components are rust/paint free.
3. Prepare blacking batch
Water = 50% by weight (314 of blackening pot)
Black - 15salt-48% by weight (3bags of 20kg.each)
Black D - 2% by weight (1/2 bag of 5 kg.)
PRECAUTION: Always add salt to water and not water to salt while pouring bath.
4. Heat liquid to boiling.
(4.a) Hang component free from all of the pot and each other.
(4.b) Check for blackening result it components are getting iron and water.
5. Remove the components.
6. Oil the components.

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 HEAVY PARTS SECTION
Heavy Parts section Deals with the parts having greater dimensions. All the bed of different castings
are 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 this
gives two advantages. First - The Consumption of paint will be less while painting. And second -
The marking will become visible.

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 =2m
3. Table Width =2m
4. Table Length = 10 m
5. No. of Side Heads =2
6. No. of Cross-Heads =2
7. Height of Machine Housing =3m
8. Maximum Permissible Table Load = 40,000 kg.

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 WD - 130 HORIZONTAL BORING MACHINE

Make – Czech Republic

Specifications:
1. Capable of doing boring, Drilling and Milling operations.
2. Whole Machine travels on a Spring - Bed.
3. Rotary table.
4. Table Size
(4.a) Length = 2000mm
(4.b) Width = 2000 mm

5. Clamping Surface Area of table = 2000x2000mm2

6. Length of Bed = 3000mm
7. Width of ways on Bed = 1430mm
8. Height of table = 890 mm
9. Table travel on Bed = 1200 mm
10. Feed Motor = 4 KW
11. Motor RPM = 1720
12. Max Permissible Table Load = 20,000 kg
13. Rates of Rotary feed are applied to the 450 mm diameter of circular scale.
14. Hydraulic systems for the movement of the Machine & Table on Anti
friction guide ways.

30
 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:-
1. Co-ordinate measuring machine:
Make 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.
2. Universal measuring machine (for length) MUL 1000:
Make Societe Genevoise (Swiss).
Range of measurement 100 mm
Least count 0.5 micron.
System Optical.
Applications Measuring data of internal and
External head’s length of
precision components etc.
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

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 thecylindrical test piece.

31
 Least count : 0.5 micron.
System : pneumatic and CNC.
Applications : to check the roundness of cylindrical
Parts after grinding etc.
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:-
1. Dial gauges ( make: Mitutyo, Japan )
2. Slip gauges (set M 112)
3. Height gauge (make : Mitutoyo, Japan)
4. Surface plates (cast iron and graphite)

32
 FOUNDRY & PATTERN SHOP

1. Moulding material:
(1.a) Green sand
(1.b) Dry sand
(1.c) Semi Bake sand
(1.d) Bake sand
(1.e) No bake sand

2. Binding material:
Part – A Binding
Part – B Chemical
Part – C Setting

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 moulding sand.

Preparation of a mould:
Following element are used for preparing a mould.
1. Pattern
2. Moulding box
3. Moulding sand
4. Face plate
5. Split plate
6. Matching pins etc.
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

33
Closing of boxes:
After heating process cope and drag are clamped and some packing material also used for good
packing of boxes.

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.

Accessories:
1. Chills – Chills are provided in the moulding at the places where more hardness is required
in the casting. These are iron plates.
2. Chaplet – Chaplet are provided in the gaps to maintain the gaps.

Furnace:
1. 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.
2. Ferro Manganese
3. Ferro Silicon
4. Ferro chromium
5. Carbon (as required)
6. 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.

Chemical Name – Calcium Salsite.

34
35
 1. CNC DOUBLE DISC GRINDER CNC
CDS 22

Fig 1. CNC DOUBLE DISC GRINDER CNC CDS 22

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 recirculating roller bearings for wheel head slide motion with narrow
guideways system

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

7. Automatic size correction due to wheel wear

8. Automatic lubrication

9. Dust proof electrical cabinet consisting of CNC system and other switch gear items is free
standing type

10. Built in interlocks for safe operations of machine.

36
11. Panel air conditioner

Tooling:
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

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.

Standard Accessories:
1. Balancing mandrel
2. Oil gun
3. Test mandrels
4. Straight edges
5. Ampere meter
6. Diamond dressers
37
7. Automatic dressing/Grinding cycles
8. Coolant supply pipings
9. Electrical equipment for 3 phase, 4 wire, 415 ±6% Volts, 50 ±3% Hz AC supply

10. Tools for normal operation.

38
 2. IDEAL GRINDER FOR TOOL ROOM AND
PRODUCTION APPLICATIONS.
SGC1 CNC SURFACE GRINDING MACHINE

SGC1 CNC SURFACE GRIENDER MECHINE

Salient Features:
CNC Surface Grinder SFC1 with table clamping area of 800 mm x 400 mm is suitable for precision
surface grinding. The wheel spindle is supported on large diameter angular contact ball headings.
Wheel head slide movement (Y axis) and transverse movement of compound table (Z axis) are on
preloaded, antifriction, linear recirculation roller bearings. The table with antifriction liner moves on
longitudinal guideways of the compound table. X and Z axes driven by digital AC servomotors
directly coupled to ball screw and nut. The Y axis ballscrew is coupled to the digital AC servomotor
through gear box. Interfaced with Sinumerik 840D CNC System. Interfacing with Fanuc system
optional. Dressing is by means of table mounted dresser or retraction type of dresser mounted on
table. Centralised lubrication for adequate lubrication of machine members.

Special Accessories:
1. Electromagnetic chuck with power supply and control unit size 800 mm x 400 mm.
2. Variable power for EMC.
3. Paper band coolant filtration system with magnetic separator.
4. AC Unit for electrical panel.
5. Voltage stabiliser.

6. Wheel balancing stand.

7. Retraction type table mounted dresser.

8. Isolation transformer.

39
 9. Additional set of wheel flanges with balancing blocks.

10. Diamond roll dressing unit.

Standard Equipment:
1. Electrical equipment suitable for 3 phase, 415V, Siemens/Fanuc 3 axes CNC system.
2. One set of wheel flanges with balancing blocks
3. Oil cooling unit for lubrication system.
4. One no. grinding wheel of size 400mm x 127mm x 50mm.
5. One set of grinding wheel clamping and extraction unit.
6. Centralised lubrication system.
7. Machine lamp for 220V or 415V.
8. One set of services tools and manuals.

40
 3. CNC CYLINDRICAL GRINDING
MACHINE G12 CNC

Fig 2. CNC CYLINDRICAL GRINDING MACHINE G12 CNC

Salient Features:
1. CNC cylindrical Grinding Machine with angular wheel head/straight wheel head facility
2. High rapid traverse for slides
3. Rigid structure
4. Well ribbed cast iron bed
5. Wheel spindle supported on multilobbed hydordynamic bearings
6. Turcite pasted table guideways
7. Preloaded antifriction guideways for X-axis (wheel head slide) to have high positioning
accuracy
8. Work head spindle mounted on preloaded ball bushings for axial movement of the spindle
through electromechanical drive
9. Tailstock quill mounted in preloaded ball bushings with manual taper correction
10. CNC dresser (2 axes) driven by DC servomotors
11. Moving weight type insitu balancing equipment
12. Air blast oil cooler/ refrigerating type'to maintain temperature of lubrication oil.
13. Automatic wheel slide retraction facility during power failure
14. 3 axes CNC system Sinumerik 810G/Hinumerik 3G.

41
Optional Features:
1. Refrigeration type oil cooler to control the temperature of lubrication oil, with
reference to ambient
2. Automatic centre depth compensation facility
3. Inprocess gauging unit for controlling component diameter. AC servo motors in place of DC
servo motors
4. DC motor for work head/wheel head
5. Paper band cum magnetic separator for fine filtration of coolant
6. Match grinding equipment
7. Cam grinding.

42
 4. RADIAL DRILLING MACHINE RD 63

Fig 3. Radial Drilling Machine RD 63

Salient Features:
1. 3.6/4.5 kW radial drills with 50mm capacity in steel.
2. Column diameters of 350 & 400mm.
3. Drilling radii from 1500 to 2350mm.
4. Compact, 12-speed drill head.
5. Six feeds from 0.125 to 1.25mm/rev.
6. Electro-hydraulic clamping.
7. 225° arm girdle split.

Standard Accessories:
Electricals suitable for 3 phase, 415 Volts, 50 cps, AC supply or as per any other international
standard. Set of service tools, Electro-hydraulic clamping.

Special accessories:
1. Box table for normal work settings has two 90° faces and clamping areas of
500 x 600 mm and 1000 x 750 mm each.
2. Universal table for angular work settings has two 90° faces and accurately graduated scale
for precise positioning.
3. Coolant system has 45.5 liter sump (10 gallons) and 0.1 kW pump for
applications requiring a continuous supply of coolant.
4. Machine lamp.
5. Set of spares.
6. Additional base plate in various configurations.
43
44
 5. KNEE TYPE MILLING MACHINE FN1 VERTICAL

Fig 4. KNE TYPE MILLING MACHINE FN1 VERTICAL

Special Accessories:
1. Coolant equipment.
2. Precision machine vice without swivel base.
3. Precision machine vice with swivel base.
4. Self-centering vice.
5. Collet chuck and collets.
6. Universal diving head.
7. 3-Jaw self-centering.
8. Hand-operated, horizontal indexing head.
9. Hand-operated circular table.
10. Machine lamp for 220 volts or 24 volts.
11. Reduction milling sockets.
12. Angle plate and sine table.
13. Milling kits.

For Horizontal and Universal Models Only:

1. Vertical milling head.
2. Universal milling head.
3. Slotting attachment.
4. Milling arbors

Standard Equipment:
1. Electrical equipment suitable for 3 phase, 415 volts, 50 cycles,
AC supply, - chip tray on base plate.
2. One draw bolt with nut.
3. One set of service tools.
45
 4. Operation manual.

Additional for Horizontal and Universal Models:

1. One milling arbor ISO-40 022 x 500 mm.

2. Two arbor support bearing brackets one over arm brace.

Additional for Vertical Model:

1. One stub arbor ISO-40 ∅22 x 19/25 mm.

46
 6. CNC STC 25

Fig 5. CNC STC 25

Special Accessories:
1. Hydraulic self-centering 3 Jaw chucks.
2. Additional tool holders.
3. Automatic chip conveyor with built-in coolant tank and chip bin.
4. Universal face plate 355.
5. Hydraulic self-centering steady ests.
6. Face driving centres.
7. Selection of pre-set dual chucking pressure/tape control of Dual chucking pressure.
8. Hydraulic bar feed unit.

Standard Equipment:
1. Electrical complete with wiring suitable for standard 3 phase 415Volts, 50Hz, AC
supply.
2. Coolant system.
3. Sliding machine cover with splash guard.
4. Dead centre with reduction sleeve.
5. One set of external and internal tool holders.
6. Hydraulic tank with motor and hydraulic elements.
7. Service tool kit.
8. Machine lighting equipment.
9. Voltage stabilizer.
10. 2 sets of instruction manuals.
11. AC unit for system/drive cabinet.

47
 7. KTM – 760

Fig 6. KTM-760

GENERAL:
The KTM-760 Machining centre is a CMC-controller Horizontal Spindle Machining Centre which
consist basically of the following Units.
Machine Control Unit and Hydraulic Power Supply
The Machine offers three perpendicular axes motion together with a Rotary X axes pallet shuttle
automatic tool selection for 40 tool magazine and an automatic tool changer the X axis motion is
provided by the motion of the table along the hardened and ground ways of the front bed. The Y axis
motion is provided by the vertical motion spindle. Head perpendicular to the spindle axis on the
hardened and ground way of the column.
The Z axis is provided by the Horizontal motion of the column parallel to the spindle axis, along the
hardened and ground ways of the rear bed.
The machine control Unit is either a specially designed Kongsberg CNC 2000 or 7320 CNC
equipped with resolver/encoder. Feed back capable of controlling the X axis motion of the machine.

PARTS OF MACHINE:
1 X - bed
2 Up right (Column)
3 Spindle
4 Spindle head Stock and Spindle speed
5 Tool Magazine
6 Tool change arm

48
7 Rotary 4th axis
8 Pailet Shuttle.
9 Automatic work piece changing by removable pailet system that can
be applied to either of Index table.

49
 8. CNC TURNING CENTRE PUSHKAR 200

Fig 7 CNC TURNING CENTER PUSHKAR 200

Built-in quality, excellent, performance, flexible machine with high poer, speed and accuracy
for increased productivity.
Ideal for Auto, Auto ancillaries, Defence and General Engineering Industries.

DESIGN CHARATERISTICS:
1. 45 degree slant bed for efficient chip & coolant management.
2. LM guideways for both the Axes for precise positioning and rigidity.

3. Directly Driven Ball screws with high response AC digital servo drive.

4. High acceleration rate minimises idle time during machining.

5. Spindle supported on Precision Angular contact Ball Bearigns of consistent accuracies.

6. 8- station Bi-directional electromechanical turret.

7. Power chuck Dia 200 (250) mm. Hydraulic actuation of quill.
8. Integrated hydraulics an Electricals for PLUG & START facility.

50
Seminar

51
 Principal of Accident prevention

MANAGEMENT
CONTROL

Eliminating Unsafe Discovering Causes Elimination of Unsafe

Condition Action
( by mean of) ( by mean of) ( by mean of)
• Safe guarding of • Job safety • Personal
machine. analysis. adjustment.

• Preventing • Investigation of • Safety education

defective cond. accident. & training.

• Safe arrangement • Inspection of • Supervision .

process method of plant &
work. equipment.
• Adequate & • Recording & • Motivation
suitable tabulation of
illumination data.
• Suitable & safe • Analysis of data.
design and
construction
• Safe dress and
personal predictive
equipment.

52
 Function of CNC Machine
A system which controlls a Machine tool by means of part programming
(coded function) perform by a computer.
• CNC system used to improve production.

• Insight of CNC system.

• Slide movement control by motors.

MAIN OBJECTIVE :- To reach at particular point accurately at a
required speed.
Difference between Conventional Machines Tool and CNC Machine
tools.
 Manual hand wheel replaced by Axis Drive Motors.

 Simple Motors replaced by Servo Motors.

 Sliding friction replaced by rolling friction.

 Encoders are used.

Features of CNC Machine Tools:-
1. Editing of part programming
2. Proof of part programming
3. Allow compensation for changes of tool.
ADVANTAGES
• Reduced Lead Time

• Elimination of Operator Errors

• Operator activity

• Lower Labors cost

• Smaller batches

• Flexibility in changes of component design

53
DISADVANTAGES
• Higher investment & maintenance cost.

• Costlier CNC personnel.

• Planned support facility.

COFIGURATION OF CNC MACHINE :-

54
 Programming of CNC Machine
A program is a set of instruction and encoded information and detail
indicated how a tool to be move in relation to work piece in order to
achieved a desired machine form.
Programming codes:-
• N – Line numbers
• X,Y,Z– Movement of axis
• F - Feed rate maintain
• S –Spindle speed
• G00 – Rapid traverse
• G01 – Linear traverse
• G02, G03 – Circular traverse CW & CCW
• G92 – Position present
NC words in CNC Machine:-
* Prepares the control unit to execute the instruction that are to follow.
Code Function
G00 Rapid Traverse
G01 Linear interpolation
G02 circular interpolation (CW)
G03 circular interpolation (CCW)
G17 XY plane designation.
G18 ZX Plane designation.

55
 G19 YZ Plane Designation
G33 Thread Cutting
G40 Cutter compensation cancel
G41 cutter compensation left
G42 cutter compensation right
G70 Dimensioning in inch units
G71 Dimensioning in metric units
G95 Feed rate mm / rev

M-Codes:-
* used to specify certain auxiliary function.
Code Function
M02 Programme stop
M03 Spindle start (CW)
M04 Spindle Start (CCW)]
M05 Spindle stop
M06 Tool change
M08 Coolant on
M09 Coolant off
M30 Programme stop

COMPUTERIZED NUMERICAL CONTROL

56
57
 Limit, Fit, Tolerances
Limit of size:-
There are two extreme permissible sizes for a dimension of the part as
shown in figure. The largest permissible size for a dimension of the part is
called upper or maximum limit, whereas the smallest size of the part is
known as lower or minimum limit.
Allowance:-
It is the difference between the basic dimensions of the mating part.
The allowance may be positive or negative. When the shaft size less than
hole size, then the allowance is called positive allowance and when the
shaft size is less than hole size, is called negative allowance.
Tolerance:-
It is the difference between the upper limit and the lower limit of the
dimension. In the other word, it is the maximum permissible variation in
the dimension.
Fit:-
The degree of tightness or looseness between the two mating part is
known as a fit of the part. The nature of fit is characterized by the presence
and size of clearance and interference.
The clearance is amount by which the actual size of the shaft is less
than the actual size of mating hole in an assembly. In other word, the
clearance is the difference between the size of hole and the shaft before
assembly. The difference must be positive.

The interference is amount by which the actual size of the shaft is

larger than the actual finished size of mating hole in an assembly. In other
word, the interference is the difference between the size of hole and the
shaft before assembly. The difference must be negative.

58
 CONCLUSION
It was a wonderful experience for all of us having our first industrial exposure at HMT-MTA. As
HMTs all manufacturing units are ISO 9001 accredited so it maintain the company to standardize in
high quality product. The sophisticated quality assurance facility ensures products that are highly
reliable and dependable. Here we not only have gained the technical knowledge but also the
professional qualities which one must have while working in a big company like HMT. Also its
world class machinery and 'State of the Art' equipments, updated manufacturing process &
professionally trained human resources are the major factors which has resulted in quality products
as well as has given all of us quantitative and qualitative exposure to high technology. The HMT
machine tools Ltd., amounts to 43% share in the Rs 570/- crores machine tools market. Also machine
tools division recently bagged Rs 150/- crores export order. In the next five years the turn over of the
company is likely to exceed Rs 600/- crores.

59
 REFERENCES
The main source of reference for me, during my training period have been the people here working
for the company since the company started its production. They were the only source of information
based on which I have formulated the departments section and came to know about the lacunas
existing in the company. Though the presence of the company's website cannot be ignored which
acts as a good platform to compare their product range with the other are of the same category. The
following are the sources of information:
1) www.hmtindia.com
2) www.hmti.com

60