Government of India,Ministry of Defence

Indian Ordnance Factories

Ordnance Factory Khamaria

Jabalpur, Madhya Pradesh-482007

VOCATIONAL TRAINING REPORT 2018

SUBMITTED TO :- SUBMITTED BY :-

S.K. VISHWAKARMA NIKHIL KUMAR

HOS/A1/OFK, JBP 0217ME151015
 Government of India,Ministry of Defence
Indian Ordnance Factories

Ordnance Factory Khamaria

Jabalpur, Madhya Pradesh-482007

CERTIFICATE

This is to certify that NIKHIL KUMAR is the student of mechanical discipline of

Lakshmi Narain College of Technology has successfully completed 2 weeks of
vocational training from 01/06/2018 to 15/06/2018 at Ordnance Factory Khamaria,
Jabalpur under the supervision of Mr. S.K. Vishwakarma.

This report does not contain any classified information about the ordnance Factory.

During the tenure, I found him sincere and hardworking. I wish him all the best for his
future endeavours.

Place-Jabalpur

Date-
( Mr. H.K.PAIKRA )
Jt. General manager/OFK
 Government of India,Ministry of Defence
Indian Ordnance Factories

Ordnance Factory Khamaria

Jabalpur, Madhya Pradesh-482007

CERTIFICATE

This is to certify that NIKHIL KUMAR is the student of mechanical discipline of

Lakshmi Narain College of Technology has successfully completed 2 weeks of
vocational training from 01/06/2018 to 15/06/2018 at Ordnance Factory Khamaria,
Jabalpur under the supervision of Mr. S.K. Vishwkarma.

This report does not contain any classified information about the ordnance Factory.

During the tenure, I found him sincere and hardworking. I wish him all the best for his
future endeavours.

Place-Jabalpur

Date-
( Mr. S.K. BISWAL )
HOS/HRD/OFK/JBP
 Government of India,Ministry of Defence
Indian Ordnance Factories

Ordnance Factory Khamaria

Jabalpur, Madhya Pradesh-482007

CERTIFICATE

This is to certify that NIKHIL KUMAR is the student of mechanical discipline of

Lakshmi Narain College of Technology has successfully completed 2 weeks of
vocational training from 01/06/2018 to 15/06/2018 at Ordnance Factory Khamaria,
Jabalpur under my supervision.

This report does not contain any classified information about the ordnance Factory.

During the tenure, I found him sincere and hardworking. I wish him all the best for his
future endeavours.

Place-Jabalpur

Date- ( Mrs. SWEETI RAI )

HOS/A1/OFK/JBP
 ACKNOWLEDGEMENT

I sincerely express my indebtedness to esteemed and revered Mr. B.P. Mishra -

AGM/MDO/OFK, for permitting me to perform training in this reputed organization
Ordnance Factory Khamaria, Jabalpur.

I also express my grateful thanks to Mr. H.K. PAIKRA – Jt. GM/OFK and Mr. S.K. Biswal -
HOS/HRD/OFK and all the staff of HRD and other sections who were extremely friendly
and eager to share their knowledge with me.

No words can express my gratitude to my Coordinating Officer Mr. S.K. Vishwakarma

who was a constant source of information and inspiration to me and who ungrudgingly
patiently extended his fullest cooperation.

Lastly, I express my profound gratitude to section Chargeman, Tool Setters and all the
workers for their friendly attitude in pursuing my training.

Date: NIKHIL KUMAR

B.E. (Mechanical engineering)
Ordnance Factory Khamaria Government of
India, Ministry of Defence

ABOUT :-

Indian Ordnance Factories is a giant industrial setup which functions under

the Department of Defence Production of the Ministry of Defence. Indian
Ordnance Factories, headquartered at Kolkata, is a conglomerate of 41
Factories, 9 Training Institutes, 3 Regional Marketing Centres and 4 Regional
Controller of Safety.

Today OFB along with its 41 factories spread over India provide

 a broad and versatile production base with multi-technology

capabilities
 state of the art manufacturing facilities
 large reservoir of skilled and professionally qualified manpower and
managerial personnel
 strict adherence to quality standard (all the units are ISO-9000
certified)
 original as well as adaptive research & development to make need
based refinement and modifications
 project engineering capability
 a strong base for industrial training facilities
 ready market access due to convenient location

Ordanace Factories Board (OFB) consisting of the Indian Ordnance Factories,

Bharatiya Ayush Nirmaniyan) is an industrial organization functioning under
the Department of Defence Production of Ministry of Defence, Government of
India. It is engaged in research, Development, production, testing,
marketing and logistics of a comprehensive product range in the areas of air,
land and sea systems. OFB comprise forty-one Ordnance Factories, nine
Training Institutes, three Regional Marketing Centers and four Regional
Controllerates of Safety, which are spread all across the country.

OFB is the world’s largest government-operated production organization,

and the oldest organization run by the Government of India. It has a total
workforce of about 164,000. It is often called the “Fourth Arm of Defence”,
and the “Force behing the Amend Force” of India. It is amongst the top 50
defence equipment manufactures in the world. Its total sales were at $3
billion (Rs 19982.71 Crores) in 2015-16. Every year, 18 March is celebrated
as the Ordnance Factories’ day in India.
 INDEX

1. STUDY ABOUT SECTION A1

2. ABOUT 30mm BMP II SHELL BODY (HE/I)

3. ABOUT CNC (COMPUTER NUMERICAL CONTROL)

4. COMMON G CODES & M CODES OF CNC

5. MANUFACTURING PROCESS OF 30mm BMP II SHELL

6. KAIZEN
 MY PROJECT

Study about Section A1 & process of formation of 30mm BMP-II shell.

SECTION A1
AIM: Shell formation

I. 40 mm L70
II. 40 mm L60
III. 84 mm HE/I (high explosive inert)
IV. 84 mm illuminating case
V. 30 mm BMP-II (HE/I)
VI. 20 mm AMR
a) Saphie
b) TPT
c) HEI

30 mm BMP – II AMMUNITION HE/I

GENERAL
30 MM Ammunition is fired from 30 mm automatic Gun 2A42 mounted on infantry
combat vehicle BMP II as the main armament. The gun had double belt feed
system, one belt with armour piercing tracer round and the other with both High
Explosive Incendiary and HE Tracer rounds generally in ratio of 4:1.

30 mm HE/I ammunition is a fixed type of ammunition and is intended for use

against main power and non armoured ground and aerial targets 30 mm Gun is
designed for single shot firing as well as automatic firing at rapid & slow rates.

PHYSICAL CHARACTERISTICS :
Total length of ammunition (High) 292.84 mm
Total Length of ammunition (Low) 289.45 mm
Mass of Complete Round 0.833 kg
Mass of projectile 0.389 kg ± 0.006 kg

Mass of propellant 0.122 kg

Mass of bursting charge 0.0485 kg ± 0.001 kg

PERFORMANCE CHARACTERISTICS :
Muzzle Velocity 960 m/s ± 10 m/s

Mean pressure of propellant 3600 Kg/cm 2

Self destruction time of fuze 9.0 to 14.0 Sec

Maximum Range :
a) At ground target 4000 m
b) At aerial target 2000 m

c) Slant range 2500 m

SPECIAL FEATURES :
HE/I projectiles are equipped with fuze A670M designed to explode on impact with
the target and it can cause self destruction of the shell if it misses the target.

QUALITY :
The raw material used for components are tested by independent Quality Assurance
Wing. Major components are test-fired and only passed proof components are taken
into final assembly of ammunition. The final round is dynamically proved for i) MV
ii.) Pressure iii) Safety & functioning at low rate of fire and high rate of fire.

SAFETY:
Adequate mechanical safety arrangements are provided for safety during handling
and transportation.

RELIABILITY:
Due to its sound design and careful manufacture, the ammunition is very reliable for
use in combat field environment.

SHELL LIFE :
The shell life of this ammunition is 7 years.

PACKING :
30 rounds are packed in one steel box H-60, a hermetically sealed metallic
container.

STOWAGE DIMENSION :
Packing box size 355 mm x 241 mm x 315 mm
Estimated weight of box 35.43 kgs/box
Net weight 24.99 kgs/box
Volume 0.027 cu m

HAZARD CLASSIFICATION :
This ammunition is classified in
Compatibility group F

Hazard Division 1.2

Fire fighting Group 2
PROCESS LAYOUT:
1) ROD PARTITION
2) DRILLING
3) REAMING
4) TURNING
5) TAPER TURNING
6) GRINDING
7) REAMING
8) FACING
9) GROOVING(PROFILE MAKING)
10) TURNING & NOSE MAKING
11) FINAL NOSING
12) GRINDING
13) THREADING
14) KNURLING
15) FINAL FACING
16) DEBURRING
17) TABLE INSPECTION
18) CDB FITTING (PRESSING)
19) CDB TURNING
20) EXTRA COPPER REMOVAL
21) FINAL GAUGING(INSPECTION)
22) STUMPING
23) PHOSPHATING
24) PAINTING
25) AUDITING

1. ROD PARTITION
This is a process of cutting end parts of the reel rod using Automatic Hexa machine.This process is done so
that the end parts of rod do harm the cutting tools used.This process is important for efficient working.

2. PROCESSES IN MULTI SPINDLE AUTOMATIC MACHINE

MULTI SPINDLE AUTOMATIC MACHINE

Multi Spindle Automatic Lathe can provide the various types of machining such as boring, turning,
chamfering, threading, grooving, and drilling by moving the workpieces between 6 or 8 stations(machining
position). This machine tool enables to realize overwhelmingly fast cycle time by dividing into 6 or 8
processes. Generally Multi Spindle Automatic Lathe can provide approx. 4－5 times of machining speed
comparing to the Single Spindle NC Lathe

MACHINE USED :- MULTI SPINDLE AUTOMATIC MACHINE (6 SPINDLES)

GILMIDSTER - AS 67
Processes involved:-

1) Drilling
2) Reaming
3) Turning
4) Taper Turning
5) Parting

Considerations/Dimensions :-

Sl. PARAMETERS DIMENSION (mm) GUAGES USED

no & [TOLERANCES]
1. MOUTH TAPER 27.5 [ -0.2] KHWG100288
2. SMALL BORE 18.1 [+0.43] KHWG110970
3. BIG BORE 23.03 [+0.43] KHWG110971
4. BODY DIA. 31.8 [ -0.2] KHWG121261
5. TOTAL LENGTH 113.5 [-1.0] KHWG291750
6. BORE DEPTH 104.5 [+0.25] KHWG290950
 SECTIONAL VIEW

a)Drilling
Drilling is a cutting process that uses a drill bit to cut a hole of circular cross-section in solid materials. The
drill bit is usually a rotary cutting tool, often multi-point. The bit is pressed against the work-piece and
rotated at rates from hundreds to thousands of revolutions per minute. This forces the cutting edge
against the work-piece, cutting off chips from the hole as it is drilled.

DRILLS USED:

1) 22.25mm dia
2) 22.50mm dia
3) 17mm dia

b) Reaming
Reaming is a mechanical process that creates precision holes, typically after drilling, by rotating a precision
cutting tool into a hole sized slightly under the diameter of the reaming tool.
The main advantage of reaming is the high tolerance of the resulting hole and smooth internal surfaces.
The process is applied to cylindrical holes. Example applications include press fit holes, slip fits, holes
where minimal play is required, etc.

c) Turning
Turning is a form of machining, a material removal process, which is used to create rotational parts by
cutting away unwanted material. The turning process requires a turning machine or
lathe, workpiece, fixture, and cutting tool. The workpiece is a piece of pre-shaped material that is secured
to the fixture, which itself is attached to the turning machine, and allowed to rotate at high speeds. The
cutter is typically a single-point cutting tool that is also secured in the machine, although some operations
make use of multi-point tools. The cutting tool feeds into the rotating workpiece and cuts away material in
the form of small chips to create the desired shape.

d) Taper Turning
Taper turning means, to produce a conical surface by gradual reduction or increase in diameter from a
cylindrical work piece. This tapering operation has wide range of use in construction of machines. Almost
all machine spindles have taper holes which receive taper shank of various tools and work holding devices.

This process is done to create a little nose for further processing.

e) Grinding
Centerless grinding is a machining process that uses abrasive cutting to remove material from a workpiece.
The workpiece is secured between two rotary grinding wheels, and the speed of their rotation relative to
each other determines the rate at which material is removed from the workpiece.

Centerless grinding is typically used in preference to other grinding processes for operations where many
parts must be processed in a short time.

It is done in two steps:-

i) Rough grinding
ii) Smooth or final grinding

f) GROOVING & FACING (CNC MACHINE)

This is a process of creating grooves using CNC machine.Using this process the C.F dia is created and
maintained.A little bit of turning is all done here to smoothen the surface and to make the diameter of
workpiece of desdired shape.

INTRODUCTION TO CNC MACHINE

CNC machining is a manufacturing process in which pre-programmed computer software dictates the
movement of factory tools and machinery. The process can be used to control a range of complex
machinery, from grinders and lathes to mills and routers. With CNC machining, three-dimensional cutting
tasks can be accomplished in a single set of prompts.
 CDB PROFILE MAKING IS
DONE THROUGH CNC
MACHINE

CNC G & M CODES

CNC G codes:-
G00 - Positioning at rapid speed; Mill and Lathe
G01 - Linear interpolation (machining a straight line); Mill and Lathe
G02 - Circular interpolation clockwise (machining arcs); Mill and Lathe
G03 - Circular interpolation, counter clockwise; Mill and Lathe
G04 - Mill and Lathe, Dwell
G09 - Mill and Lathe, Exact stop
G10 - Setting offsets in the program; Mill and Lathe
G12 - Circular pocket milling, clockwise; Mill
G13 - Circular pocket milling, counterclockwise; Mill
G17 - X-Y plane for arc machining; Mill and Lathe with live tooling
G18 - Z-X plane for arc machining; Mill and Lathe with live tooling
G19 - Z-Y plane for arc machining; Mill and Lathe with live tooling
G50 - Set coordinate system and maximum RPM; Lathe
G52 - Local coordinate system setting; Mill and Lathe
G53 - Machine coordinate system setting; Mill and Lathe
G54~G59 - Workpiece coordinate system settings #1 t0 #6; Mill and Lathe
G61 - Exact stop check; Mill and Lathe
G65 - Custom macro call; Mill and Lathe
G70 - Finish cycle; Lathe
G71 - Rough turning cycle; Lathe
G72 - Rough facing cycle; Lathe
G73 - Irregular rough turning cycle; Lathe
G73 - Chip break drilling cycle; Mill
G74 - Left hand tapping; Mill
G74 - Face grooving or chip break drilling; Lathe
G75 - OD groove pecking; Lathe
G76 - Fine boring cycle; Mill
G76 - Threading cycle; Lathe
G80 - Cancel cycles; Mill and Lathe
G81 - Drill cycle; Mill and Lathe
G82 - Drill cycle with dwell; Mill
G83 - Peck drilling cycle; Mill
G84 - Tapping cycle; Mill and Lathe
G85 - Bore in, bore out; Mill and Lathe
G86 - Bore in, rapid out; Mill and Lathe
G87 - Back boring cycle; Mill
G90 - Absolute programming
G91 - Incremental programming
G92 - Reposition origin point; Mill
G92 - Thread cutting cycle; Lathe
G94 - Per minute feed; Mill
G95 - Per revolution feed; Mill
G96 - Constant surface speed control; Lathe
G97 - Constant surface speed cancel
G98 - Per minute feed; Lathe
G99 - Per revolution feed; Lathe

CNC M Codes :-

M00 - Program stop; Mill and Lathe

M01 - Optional program stop; Lathe and Mill
M02 - Program end; Lathe and Mill
M03 - Spindle on clockwise; Lathe and Mill
M04 - Spindle on counterclockwise; Lathe and Mill
M05 - Spindle off; Lathe and Mill
M06 - Toolchange; Mill
M08 - Coolant on; Lathe and Mill
M09 - Coolant off; Lathe and Mill
M10 - Chuck or rotary table clamp; Lathe and Mill
M11 - Chuck or rotary table clamp off; Lathe and Mill
M19 - Orient spindle; Lathe and Mill
M30 - Program end, return to start; Lathe and Mill
M97 - Local sub-routine call; Lathe and Mill
M98 - Sub-program call; Lathe and Mill
M99 - End of sub program; Lathe and Mill

G) Nosing & Turning (COPYING LATHE) :-

Again here the workpiece is fed into copying lathe for turning and nosing.

For this purpose a copying lathe is used which copies the dimensions of a master piece fed into it and
creates new pieces of same and accurate size.
H) Final Nosing (Press machine)
This machine is used to create the final desired nose by using hydraulic press machine.
COUNTER BALANCE AIR PRESSURE :-

PRESSURE (KG/Cm2) UPPER DIE PRESSURE (KG/Cm2) UPPER DIE

3.0 150 5.0 2045
3.5 625 5.5
4.0 1100 6.0
4.5 1570 6.5

MACHINE DATA :-

MODEL NO. :- CLS-100-112-HSF

SEIAL NO. :- H1747

CAPACITY (TONNES) :-100

STROKE :- 400

STROKE/MIN :- 12

SHUT HEIGHT :- 450

SLIDE ADJUSTMENT :- 125

SLIDE SIZE :- LR(710) FB (580)

BODSTER SIZE :- LR (1120) FB (910)

I ) INTERNAL THREADING
In this process internal threads are created from the nose side if the workpiece using CNC Machine.For
finishing purpose facing and reaming is also done using CNC machine.
J ) KNURLING
Here knurling is done using using lathe machine on the profile or the groove created in previous process on
CNC machine for COPPER RING setting purpose.

KNURLING GROOVE DIA. = 27.6mm -0.8mm

K ) DEBURRING
This process is done to remove the sharp edges or uinwanted pices of metal formed by machining.

It is usually an unwanted piece of material and is removed with a deburring tool in a process called
'deburring'. Burrs are most commonly created by machining operations, such
as grinding, drilling, milling, engraving or turning. It may be present in the form of a fine wire on the edge
of a freshly sharpened tool or as a raised portion of a surface.

This is done by holding the workpiece into chuck of lathe machine and using a rough surface hand tool to
remove burrs.
L ) TABLE INSPECTION
Here all the created workpieces are tested and checked using different gauges.For this purpose a team is
created which cheks all the workpieces for its desired dimensions.

M ) CDB PRESSING (COPPER DRIVING BIND)

In this process the copper driving ring is pressed aginst the workpiece’s CDB profile part to fit the copper
ring into the workpiece.

N ) CDB TURNING :-
This process is done again in CNC machine to get the copper ring in desired shape.

COPPER DIA :- 31.1 mm -0.17

COPPER WIDTH :- 10mm -0.3

CONSENSITY OF COPPER :- 0.15 mm

After this process the extra copper is removed manually.

O) FINAL GAUGING :-
It is also a table testing using different gauges.For this purpose a different team is formed.after this the
product is finalized.

P ) ROLLER STUMPING:-
It is a process of embossing serial numbers on products. For this purpose a stumping machine is used.
Q) PHOSPHATING:-
Phosphate coatings are a crystalline conversion coating for steel and other metals that is formed on a
ferrous metal substrate. The process of Phosphate coating is employed for the purpose of pretreatment
prior to coating or painting, increasing corrosion protection and improving friction properties of sliding
components.

TANK 1 TANK 2 TANK 3 TANK 4 TANK 5 TANK 6

PROCESS DEGREASING RUNNING RUSTODINE PHOSDINE PHOSDINE HOT WATER

COLD CLASS - II CLASS - I TREATMENT
WATER
TREATMENT
CHEMICAL DEGRESOLE COLD DERUSH 125 ZINC MAGNESE HOT WATER
USED (SEMI- WATER PHOSPAHTE PHOSPHATE
GLOSSY)
TEMPERATURE 70 -95 *C 10-12 *C 80 – 100 *C 90 – 100 *C 70 – 90 *C

TIME 1 – 2 MIN 1 – 2 MIN 1 – 2 MIN 10 – 30 MIN 15 – 30 MIN 1 – 2 MIN

R ) PAINTING :-
Painting is done to increase the life of workppiece.It protects from rusting of metals and prevents from
natural hazards.

In this products are divided into two different groups:-

1) Class 1 (No painting is done)

2) Class 2 (Painting is done)

After painting the products are heated in the oven at a temperature of 130 – 14 *C.

S ) AUDITING :-
In this process investigators arrives from auditing department to check for various parameters.They select
randomly a product from a lot and checks it briefly.Then they certifies it that it is perfect for filling.

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