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1. HINDUSTANMACHINETOOLSLIMITED
BytheendoftheSecondWorldWarthegovernmentofIndiawasconfrontedbyabig
problem ofdisposing the colossal warwaste. Ultimately acommittee was constituted to
inquireintothepossibilities.Thecommitteereportof1948proposedtheestablishmentofa
Govt.ownedmachinetoolindustry.Thiswasexpectedtofulfilltwoaspects.Thefirstwas
being utilization of Rs. 4000 Million worth of metallic waste. The second was the
incorporation of a state owned manufacturing facility. The result was the birth of the
HINDUSTANMACHINETOOLSLIMITED,whichdiversifiedinduecourseoftimetothe
presentstatureofthemultiproductindustrialgiantHMYLtd.TheHMTLtd.Wasstartedas
a single factory to produce Tool Room Lathes at Bangalore in collaboration with M/S
OerlikonofSwitzerlandin1953,withacapacitytomanufacturearound400machinesper
year.Sincethendifferentcollaboration,continuedinhouseR&Dandtremendousmarketing
effortsbroughtHMT,topresentstatus.
ThegrowthofHMTLtd.wascharacterizedbytheforwardandbackwardintegration
oftechnologyandproductdiversification.Thusthecompanythatstartedwithmanufacturing
andsellinglathesexpandeditsmachinetoolsproductrangetoevolveastheultimatesolution
inmetal cutting.Theproductdiversificationeffortstookthecompanytothebusinessof
watchesin1976,FoodprocessingMachineryin1980,CNCSystemin1986,BallScrewin
1986andreconditioningin1990.
ThemultiproductactivitiesmadeHMTLtd.ChangesitsidentityasHINDUSTAN
MACHINETOOLSLTD.
Today, HMT Ltd. Has 16 manufacturing units with 22 product divisions, spread
throughthelengthandbreadthofINDIA.ASUBSIDIARYVise,HMT(international)Ltd.
undertakestheexportsofthecompany.TheyarealsoexportagentsforseveralotherIndian
Companies.
HMT Ltd. Was restructured in 1992 to facilities better administration of the
multiproductbusinessgroupswasestablished.

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MachineToolsBusinessGroup,toconcentrateonthemetalcuttingmachines.
IndustrialMachineryBusinessGroup,todealwithprintingMachines,Diecastingand
plasticsinjectionmoldingmachines,Foodprocessingmachinesandmetalforming

machines.
AgriculturalBusinessGrouptoconcentrateonTractors Engineeringcomponents
BusinessGrouptodealwithcastingandBallScrewsConsumerproductsBusiness
Grouptodealwithwatchesandlamps.Inadditiontothisbusinessgroupthecompany
ownsthreesubsidiariesasfollows:

2. ORGANIZATIONCHART

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TOPEXECUTIVES

3.HMTMACHINETOOLSLIMITED:
TheHMTMACHINETOOLSLIMITEDisengagedinthemanufacture
and marketing of General Purpose Machine Tools, Special Purpose Machine Tools,
Computer Machines, Metal Forming Presses, Die Casting and Plastic injection Molding
Machines,FerrousCasting.

1.1.1HMTMACHINESTOOLSUNITS:

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1.HMTmachinetoolsltdBangalore
2.HMTmachinetoolsltdHyderabad
3.HMTmachinetoolsltdkalamassery
4.HMTmachinetoolsltdpinjore
5.HMTmachinetoolsltdAjmer

6.PragamachinetoolsltdHyderabad

KALAMASSERY:
CNCTurningCenters
TurnMillCentre
FlexibleturningCell
CentreLathe
OffsetPrintingMachines
PaperCuttingMachine.

4. PRODUCTIONPLANNING

4.1INTRODUCTION
Theproductionplanningdepartmentisthemostvitallinkbetweenproductdesignand
productiondepartment.Theproductionplanningdepartmentprovidesthenecessaryfacilities
andtechnicalnowhowforthemanufactureoftheproduct.Productionrequirestheorganized

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utilizationofnaturalresourcesmenmoneymaterialandmachine.Theroleofproduction
planningdepartmentMTKisasshownbelow.Productionplanningdepartmentcomparesthe
followingsections.
ProductionpreplanningandplanningestimationPPPandPPE
ProductionplanningorderingandPPSPPOandFPC
4.2OBJECTIVEOFPRODUCTIONPLANNING
Inanybusinessorganizationproductionactivitiesmustberelatedtomarketdemands
as indicated by continuous stream of customer orders. Objective of production planning
departmentensurethatannualproductionplanningisachievedisaneconomicmanner.
4.3FUNCTIONSANDRESPONSIBILITYOFPLANNINGPERSONNEL
1.Processingofdesigndocumentreceivedforcorrespondingproducts
2.Implementationofdesignalternation
3.Coordinatingactivityrelatedtoalterationrequestsreceivedfromotherdepartments
4.CoordinatingallactivitiesrelatedtocomputerizationPPPfunction
5.Coordinationwithfoundryforthemanufactureoralterationofpatterns

4.4FUNCTIONSANDRESPONSIBILITYOFPPCPERSONNEL
1.Estimationofstandardtimeforallmanufacturingorassemblyoperation
2.Identifiedinoperationlayoutsassemblylistofoperations
3.Attendingshopcomplaintsregardingstandardtime

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4.Authorizationforspecialtimeinjobcards.

5.QUALITYCONTROL
INTRODUCTION
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Qualitycontrolinit'ssimplesttermrefertocontrolofqualityduringmanufacturing
bothquality.Controlandinspectorareenvisagedtoassurethequalityisentireareaofany
productionprocessinspectionisdeterminefunction.Whenthecontrolbecauseeffectivethe
needofinspectiondecreases.Hencequalitycontroldeterminesthecausesofvariationinthe
characteristicsofproductionandgivessolutionbywhichtherevariationscanbecontrolled.It
iseconomicalinit'spurposeobjectiveinit'sproceduredynamicinit'soperationandhelpful
needtreatment

OBJECTIVE
Thetotalqualitymanagementdepartmentseriesmeasurablequalityobjectiveforevery
year.Theseobjectivesensurethattherequirementofproductsnotonlyidentifiedandmetbut
alsoconsulterwideandimproved.Themeasurableobjectivesaretakingit'stoconsidering
the followings *To reduce internal losses due to scrap rejection and reworks To reduce
externallossesduetosciencecostTomaximizethecustomersatisfaction3.3PURPOSE

To ensure in coming items or raw material being used directly indirectly are not
supplied for manufacturing and product without inspection or verification for it's
conformancetospecifiedstandard

Toensurethecastingproductsinthefoundryneedspecifiedstandards

Toensurethecomponentsandassembledunitsduringvariousstagesofit'sprogress
areinspectedortestedandthedetailsdocumented

To ensure major components at various manufacturing process are inspected and

designrecordedinthereagentdocuments.

INTERACTIVEGRAPHICSYSTEMINCOMPUTERAIDEDPART
PROGRAMMING
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6.HIGHTECHNOLOGYCENTRE
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INTRODUCTION
ThemostimportantsectioninthemanufacturingdepartmentistheHighTechnology
Centre(HTC).ThisistheprestigiousmanufacturingsectionofHMT.inthissection,thereare
fiveCNCmachines
1.VMC(VerticalMachiningCentre)
2.HMC(HorizontalMachiningCentre)
3.HM.4(HorizontalMachiningCentrewith4axis)
4.VTC.1(VerticalMachiningCentrewithautomatictoolchanger)
5.VTC.2(VerticalMachiningCentrewithautomatictoolcentre)
AllthesemachinesareworkingwiththehelpofCNCcontrol.Controllingamachine
toolbymeansofapreparedprogramwhichconsistsofblocksorseriesofnumbersisknown
numericalcontrolorNC.AnNCmachinetoolsystemcontainsamachinetoolitself.

DEFINITION
Computer Numerical Control(CNC) is one which the functions and motions of a
machinetoolarecontrolledbymeansofapreparedprogramcontainingcodedalphanumeric
data.

APPLICATIONS
TheapplicationsofCNCincludebothformachinetoolaswellasnonmachinetool
areas.InthemachinetoolcategoryCNCiswidelyusedforthe,drillpress,millingmachine,
grindingunit,laser,sheetmetalpressworkingmachine,tubebendingmachineetc.Highly
automated machine tools such as turning centre and machining centre which change the
cuttingtoolsautomaticallyunderCNCcontrolhavebeendeveloped.

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PATTERNSHOP
A pattern is defined as anything used for an important is called mould in the sand
mould when filled with molten material on solidifying forms a reproduction of pattern and is
known as mould. Its slightly longer in size then casting. as the first stage in preparing the
casting the pattern of casting prepared at pattern shop with either of the material as its given
below.
WOOD;-Wood is most commonly used pattern material as its cheap, easily available can also
easy to joint and fabricate
METALS;-Metals have advantage of that they do not wrap, very accurate and have high
strength. But shaping is slightly difficult and it's also subjected to rusting and the cost is high
PLASTICS;-The most common example is gypsum cement prepare cannot easily done and it
does not need skilled labors
THERMOCOAL;-Single use pattern are made using thermo coal in the process of casting a
pattern of casting of pattern is repair of the object to be cast used to prepare the cavity into
which molten material will poured during the casting process. the pattern made to incorporate
suitable shrinkage allowance depending or material followed heat transfer considerate.
Pattern making is skilled technique that was highly indulgent.
In sand casting pattern is usually of wood where as it may be metal or other material in
pressure of centrifugal casting. The pattern making also decide where the space respect to the
pattern parts object which have holes or depression. Material will not flow sometime pattern
may also accommodate chills, solid piece of final material to make rapid cooling resisting in
mastinsticness during in high neighborhood of chill
SAND MAKING PROCEDURE
The procedure of making a typical sand molding start by placing a button board, first
either the molding plate form on the floor making the surface when the drag molding flask is
kept upside down on the bottom board acting with the drag part of pattern at the centre of the
board. These should be enough clearance between the pattern and the walls of the flask. Rest
of the drug flask is completely filled with backup sand and uniformly rammed to compact the
sand and after the ramming out the excess sand in flask is completely suspend using a flat bar
to lead of flask edge. The finished drag flask is near rolled out to the bottom board expose the
pattern using stick. The edge of sand around is replaced and cope with the help of pattern is
replaced. Out the drag pattern changing with the help of the pins dry parting sand sprinkled
all over on the drag on the pattern.

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The space pin for making the replaced passage is located at the small distance to form
the pattern also a riser pin of required is kept at an appropriate place and freshly prepared
molding sand similar to that of the drag along with backing sand is sprinkled. The sand
thoroughly removed excess sand shaped and holes are made all over in the copy as in the
drag. Now the cope and the drag pattern holes are withdrawn by using the draw spikes and
rapping the pattern all around to slightly enlarge the mould cavity that the mould wall are not
spilled by withdrawing pattern.

MOULDINGPROCEDURE

Thepigiron,msscrap,carbon,andotherconstitutematerialsaremeltedinelectricarc
furnace.Themoltenmetalisdrawnintoaladderandtransportedcasingalloverhead.The
moltenmetalispouredintothemouldcavitywhichdesigned

FORGING
It's the operation of where the metal is heated and then the force is applied to
manipulate themetal insuchawaythattherequired final shapeis obtained. Forgingis
generallyahotworkingoperationthoughcoldforgingisusedsometimes

FETLING
Thecompleteprocessofcleaningofcastingcalledfetling.itinvolvestheremovalof
cores gate,riscus cleaning of the casting surface and chipping of any of unnecessary

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projectionsonthesurfacethedrysandcoverscanberemovedsimplybyremakingofwith
ironbarBymeansofcorevibratororbymeansofhydroblasting.Themethoddependupon
the size completely and core material used in gates and raisers can be removed by
hammering,chipping,obsessivecutofforbigflamesorcuttingremovalofgatesandresults
can be simplified by providing a reduced by metal sultan at the casting joint for brittle
materialsuchasgraycastironinthegates.Labeasilybebrokenbyhittingwithhammerfor
steelandothersimilarmaterialssavingwithanymetalcuttingsawlikehacksaworbandbe
more

FOUNDRYPATTERN

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7. M T K SMALL PARTS

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INTRODUCTION
MTKSmallpartsisaseparatedivisionofHMTKalamasserywhichmanufactureand
producessmallpartsrelatedwithlatheandCNC'sMTKSmallpartscanbedecidedinto
followingalldepartmentsonthebasisofeffectivecostcalculationmanufacturingprocessetc.
1.NonRoundSection5.Leadscrew2.CNCTurning6.Accessories3.RoundSection7.
Spindles4.Gears8.Turrets10.2NONROUNDSECTION
Thissectionmainlyconsistsofmillingoperationofthenonroundpartsoflathe.Inthe
millingmachinekeylegclampingisusedtoholdthewhichistheworkpiecc.Thereare2
typesofmillingmachines.Verticalmillingmachine2.Horizontalmillingmachine

GEARS

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Gearsareusuallyusedtotransmittingpowerfromoneshafttoanotlier.Gearsnecessary
belathetoproperadding,turning,facingandholdingshapingarevariousspacesusually
involvedingearmanufacture.Shapingismoreaccurateandusuallyusedforproduction
ofgearsitsmoveeconomic.Afterholdingprocessthegearshouldundergogrindingfor
squarefinishgearsareproducedbygearshapingmach

ACCESSORIES
1. Accessoriesasthetoolandequipmentusedinlathetheoperation.Theyhavethetools
whicharegeneraloperation.Theyhavethetoolswhichareprovidedwithlitheand
intrudetoolsforlatheandCNC'Sandalsochecks4gearsand3gears.Checkisa
devicewhichisusedtoholdsworkpiece.
2. TURRETS:Itproducedbyusingdies.Turretreferstoasetofarrangement.Itsusedto
severalbuoyancywhichcanbeinspectandlowspeedinnecessaryforthreadingthe
turret. The proper preparation of turret is necessary. The coolant usually used in
satisfied.
3. Features : Rotary and reciprocating motion Shearing actions used Honing
operationislimitedtoveryfewnumberofindustries

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BORINGMACHINE
Theyareusedtomilldrillboreandcutthreadscuringrotatingtool,usuallyacutter,
drillerormillinghead.Boringmachineisusedfordrillclosedandopenopeningissolid
materials boring, reaming, threading. Boring machine include vertical boring mill and
horizontalboringmachinemill.Boringoperationistoenlargeandfinishhole.

FEATURES
WorkpieceonecommonlyH04molesindiameter
Controlsystemcanliecomputercased
Bottomcoolingoftheboresaredonethroughahollowpassagewayt
Horizontalandverticalmovement
Handoperationknurledsocketattachedtohandstockdrivemotor
Highsurfacefinish
GRINDINGMACHINE

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Grinding machine is used to fresh work piece that must shows. Accuracy of shape and
dimension.Itconsistsof
abedwithafracturetoguideandholdtheworkpiece
Powerdivinegrindingwheelspinningatrequiredspeed
Surface grinding work piece moved back and forth under the grinding wheel 1E4
DRILLINGMACHINEThismachineisusedtodrill,mainlyrotationandmovementofthe
rail.Drillbitisdampedmanuallyorautomaticallyandspeedofmovementandrotationare
varied. Features : o Electromagnetic damping provide for drill head and arm sleeve o
Machinedrillingcapacityis80mm/100mmoMassiveandrigidconstructionoPreciousdepth
releaseoElectricmotorAC/400V

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8.HEAVYPARTS
HeavypartssectioninHMTincludesmillingplanning,drilling,boringetc.operations.
Pantsoflathesliketide,headstock,tailstocketc.aremachinedhere.
PLANE MILLING Plane milling is the process of production of plane, flat, horizontal
surfaceparalleltothecrisisoftherotationofaplanecutterFeatures:DCmotorRack&
pinionarrangementsusedLengthupto13metersused.

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PLANOMILLINGMACHINEPlanomillingmachineiswidelyusedinpreciseshapingof
methods of various processes such as slot cutting, routing, welding & turning in many
industry.

Features:
Precisedimension
Easytoinstall
Highoperationefficiency
Hydraulicpressisused
Variouslengthsof1.5m,lm&3mareused.

9.CNCASSEMBLY

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Ever increasing demands the need for accuracy, scrub reduction have pushed for
developmentinthefieldofmachiningandmanufacture.Allthishaveledtotheinventionand
improvementofCNCmachineswhichcanundoubtedlybelearnedasoneofthemilestones
ofthecentury.ApartfromrocketingtheproductionsskyhighCNCmachineshavemadeit
possibletomachineuptoanaccuracyofmicrontoamodestoneofthegrowingpopularityof
CNCmachinescanalsobeattaintedtorepeatabilityofCNCpartprogramsandreachedskill
demandsoflabors.
HMTmachinetoolsKalamasseryisfamousforitsworldclassCNCturningcentre.It
wasinthelate80'sthatHMTmachinetoolsLtd.Kalamasserystaredtheproductionofthe
CNC turning centers. The earlier models of machines and liniment and numeric control
systemandMCU(machinecontrolunit)whereasthenewgenerationCNCmachineofthe
unitwas(fame/sins)controlsystem.
TheassemblyofCNCturningcenterscanbedividedinto:
1.Groupassembly
2.Prefinalassembly
3.Finalassembly
ELEMENTSOFACNC
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ACNCsystemconsistofthreebasiccomponents
1.Partprogram
2.Machinecontrolunit(MCU)
3.Machinetool(lathe,drillpress,millingmachineetc...)
Part program:Part program is a detailed set of commands to be followed by the
machine tool. Each command specifies a position in the car tension coordinate
system(x, y, z) or motion (work place travel or cutting tool travel),machining
parametersandon/offfunction.
Machinecontrolunit (MCU):Itis amicro computerthat storestheprogramand
executesthecommandsintoactionsbythemachinetool.TheMCUconsistoftwo
mainunitsthedataprocessingunit(DPU)andcontrolloopsunit(CLU).
Machine tool:It could be one of the following: Lathe, milling machine,
laser,plasma,coordinatemeasuringmachineetc.
POINTTOPOINTSYSTEM
PointToPointSystemisthosethatmovethetoolortheworkplacefromonepointto
anotherandthenthetoolperformstherequiredtask

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CONTINOUSPATHSYSTEM(Straightcut&contouringsystem)
These systems provide continuous path such that tool can perform while they are
moving, enabling the system to generate angular surfaces, two dimensional cut or three
dimensionalcontours.Exampleisamillingmachine.
GROUPASSEMBLY
This is the place where Assembly of the headstock, tailstock, turret, indexingunit,
powerstockturretfixing,etc.isdone.Thepartsrequiredfortheassemblyareproducedby
variousunitsandkeptinstore.Asperrequirementbytheassemblyunit,thestoresissuesthe
requiredcomponentsfortheassemblyoftheproducts.Afterassemblyofeachparttheyare
settoanextensivetestandarepassedontoprefinalassemblyonlyaftertheinspection
departmentcertifyonit.Themostcommonlyusedmethodistheuseofcurviercoupling.It
hastwogearslikeparts.Oneofthemhasaconvexsurfaceandotheraconcavesurfacefor
firmcontact.Anothermethodistousehydraulicpressureabout4Mpaforclamping.When
thepressureisreleasedtheturretisunclampedandreadyforindexing.
PREFINALASSEMBLYTheprefinalassemblyisthesectionwheretheassemblies
ofvariouscomponentsoftheCNClikeheadstocktakesplacetothelathebed.The
head is moved from the heavy parts store to the preassembly directly upon the
request.
FINALASSEMBLY Thelathe isbroughtfromtheprefinal assembly thevarious
electricalcomponentsrequiredforthefunctioningareinstalled.Theelectricaldrives,
systems andspecial accessories like tools,studyrests,etc. are imported Themain
suppliers are Siemens and Franc. The stabilizer unit and coverer belt are also
assembledduringthisstage.Thevariousfunctionalgroupsareexplainedbrieflyas
follows:
BED MostofCNCturningcenters ofHMTisofslantbedtype.Therearemany
reasonsbehindsuchadesign.Afewcanbelistedas:reducedthermalgrowth:The
thermalgrowthduringmachiningcanbeconsiderablyreducedbyusingslantbeds.
Chip removal becomes easier when it comes to slant beds. Loading/Unloading
becomemuchlesstediousinslantbedmachines.
HEADSTOCK:Unliketheheadstockofconventionallathes,theCNCdonothave
speedshiftgearsincorporated.Twotypesofpulleysareusedtotransferpowerfrom
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themainmotortospindle.Taperedpulleysandkeyedpulleys.Moreovertwotypesof
beltsareused:Vbeltsandparallelbelts.Themainspindlehasalsoanencoderwhich
actsastothefeebackservomotorsothattherequiredspeedisattained.Allspindles
arestabilized(Startingfromlowspeedthespeedofthespindleisgraduallyincreased
toitsmaximumratedspeed)andthenputonthetestrunbeforemountingonthe
machine.Manufacturingthespindlesfreeofvibrationsiscriticaltomaintainaccuracy
inmachiningandforlifeoftheentireunit.
DRIVES:The machinecontainsthreeservomotors.Oneformainspindles,onefor
saddleTraversoverthebedandthethirdoneforcrossslide/turretmovementacross
thesaddle.Thedrivingunitandaredirectlycontrolledbythecomputerwhileonrun.
SADDLE:Saddleisthatportionwhichcarriestheturretandslidesoverthebed.The
saddleactuallyisfixedtotheballnut.Theballscrewmountedonbearingispowered
byaservomotor.Asthescrewrotates,thenutmovescausingtheturretandhencethe
cuttingtooltomoveintheaxialdirection(Z).
TURRET:TurretisthatpartofaCNCmachinethatholdsvarioustoolsandpositions
therequiredformtoperformthecutting.Thesequenceofoperationsthattakesplace
duringindexingisgivenbelow:
i.Unclamping:Theturretmalepartunclampsfromthecurvy coupling.Thisactuatedbya
pistoncylinderarrangementenclosedwithintheturrethousing.ii.Rotation:Thehydraulic
motorisactuatedbymeansofadirectioncontrolvalvesolenoidvalves(DCV).Thisrotation
isfedbacktothecontrollerbyanotherencoder.Thisrotationistakesplaceinthedirectionof
shortestpossibleangle.iii.Creep:Astheturretreachesthedesiredangleanoppositeflowis
giventomotorsoastoreducethespeedofrotation.iv.Clamping:oncethedesiredposition
isattainedtheturretclampsbacktothecouplingandreadyformachining.
TAILSTOCKThe tailstockofaCNCmachineishighlyadvanced.Insteadofrotatinga
rotatingcentreisusedtoreduceheatgeneration.Thetailstockbodyisusedtoreduceheat
generation. The tail stock Body is moved by means of a special hooklike mechanism
providedattheendofthesaddle.Thetailstockisclampedtotheguidewaybytheplungerin
andplungeroutoperationsandmovementareonlypossibleiftheplungerisexecuted.
HYDRAULLIC SYSTEMS Many of the critical operations of the CNC machines,
includingfoolproofsetuparehydraulicsystemsowingtheirflexibilityandcontrollability.
Themajorhydraulicsystemsaredescribedbelow:i.Headstock:Asexplainedabovethe
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workpieceisclampedbymeansofapistoncylinderarrangement.ii.Tailstock:thetailstock
cylinderisalsocontrolledvalves.TheplungertooishydraulicallyControlled.iii.Turret:As
abovementionedtheturretclamping/unclamping,indexing,creepingandallarecontrolled
hydraulically. iv. Gearbox: The gear shifts in CNC machines are actuated by hydraulic
systems.Theleversareshiftedwhenthepistoninsidethecylinderpushesthem.
LUBRICATIONSYSTEM
Ensuringsufficientlubricationfortherotatingaswellasslidingpartsareessentialto
maintainsmoothrunningforthemachineaswellastoreducevibrationsheatgenerationsand
errors.Thelubricationpipesaremadeofcopperpipesandflowiscontrolledbymetering
cartridges.
LUBRICATIONSYSTEM
Ensuringsufficientlubricationfortherotatingaswellasslidingpartsareessentialto
maintainsmoothrunningforthemachineaswellastoreducevibrationsheatgenerationsand
errors.Thelubricationpipesaremadeofcopperpipesandflowiscontrolledbymetering
cartridges.
OTHERSYSTEMS
Chipconveyorforremovalchipsinsidethemachine.
Cabinetcoolingsetuptokeeptheelectroniccircuitsandoptimumtemperature
Oilrefrigerationunitforcoolingandcontroltemperatureofoilinsidethepowerpack.
Powersupplysystemtoprovideconstantvoltagetothepumpandservomotors.
TheMCVCsuppliedbythecontrolsystemmanufacture.

AXISALIGNMENT
AxisalignmentisdoneoneverymachineproducedatHMT.ButforCNCmachineit
is of slightly higher importance, because the accuracy of machine is determined by this
process.This is different fromthosedoneonconventional lathes producedinthatslight
errorsbeyondallowablevaluesarecompensatedforthecontrolsystem.

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10. NH/NL ASSEMBLY

Assemblyistheprocessofcollaborationofallcomponentpartofalathetoforma
lathe. It involves three step of assembly: 1)pre assembly 2)group assembly 3)final
assembly
SCRAPING
Removalofhighpointstogetqualitycontactorbearingforgettingasmoothsurface
forgoodbattling.Itisamanualprocess.Thefollowingpartsarescrapedbyscrapes.
1.Saddle2.keepers3.crossslide5.apronsplitnut
4.Legs
6.Tailstockbase
7.Componentslide8.accessories
SADDLEASSEMBLY
a)Oilgrooving:forlubricationpurposes,somegroovesareprovidedonthesaddle
b)DistributionassemblyOilpiping:forreducingfrictiontheoildistributionProperly
c)Crossfeedassembly.
FEEDBOXASSEMBLY&INSPECTION
Itconsistofsizeshaftpreassembledwithgears.Itconsistoffeedrode,controlshaft,lead
screw.It'sstepsarefrictionconeassembly
APRONEASSEMBLY

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a)preassembly
b)groupassembly
Csplitnutleadscrewengagement
d)reciprocatingpumpandlubrication
e)feeddrivetransmissiontocrossslideandlongitudinalmovementonbed

HYDRAULICS
Lapping:Itistheprocessdonebyscribingthemetalpartwithmixtureofsiliconcarbide
and kerosene Pump assembly and inspection Pipe bending Valve body assembly
DistributeassemblyPipingontomachine
TAILSTOCKASSEMBLY
SleeveclampingRollerassembly=Topandclampingassembly
SWIVELASSEMBLY
HEADSTOCKASSMBLY
Headstock pre assembly Saddle balancing and pulley balancing Break assembly
Clutch assembly Lubrication distributes Dial assembly Head stock control
assemblyHeadstockgroupassembly
HEADSTOCKINSPECTION
CheckingnoiselevelCheckingmainspindleHeadstocklubrication
FINALASSEMBLY
Frontworkontobed
SpindleapronassemblyFeedboxassemblyLeadscrew,frictioncone,controlrod
andbearingassemblySupportassemblyRackassembly
TOPWORKONHEAD:
HeadstockpermeatingTailstockassemblyCrossslideassemblyswivelassembly
andit'sreading
QUADRENTBOXASSEMBLY
PickofgearswithdifferentgearratioscanbefittedatquadrantForfeedsasperthe
requirementandatkeyisusedtoshearithighloadoccur
MAJORMOUTING
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Pulleymotored.
MACHINES
SurfacegrindingTapergrindingTurninglatheMillingmachine
VARIENTSOFNH/NLASSEMBLY
Bed length wise1,1.5,2,3....etc Gap bed straight bed Hardness Centre height(nh
22,nh26,nh32)Headstock(A26,A28)Motorspeed(high/low)
PROTECTINGASSEMBLY
FrontcoverNameplateChiptrayWiperSplashguardsHydraulictankassembly

11.CONCLUSION
The machine tool industry is experiencing both evolutionary and revolutionary
change.Keycomponentssuchasspindlesandmotorsareimprovingincrementallywhile
researchesproposeradicalnewdesignsforbearingandmachinetoolconfiguration.HMTis
theleadingmachinetoolmanufacturingcompanyinIndia.Thecompanyhastofacetough
competitionfromvariouscompanies.Eveninthemidstoftoughcompetitionfromgiantsit
stillhasauniquereputationofbeingtheproducerofaqualityproduct.Eventhoughthe
producthasgoodwillandgooddemand,therecordshowsthatthecompanyisrunningon
loss.Therearemanyfactors,whichcontributestothelossofthecompany.
1itwasawonderfulexperienceforallofushavingourfirstindustrialHMTMachinetools
Ltd.
2.Realizedtheexperienceofteamwork.
3.Gettheknowledgeofaproductioncompany.
4.Gettheknowledgeofworkingofmachineryinthecompany.
5.GetthelittleknowledgeofCNCmachineworking.6Goodexperienceoftheproductionof
machinetools.

Dept.of Mechanical Engg

27

AWH PTC