Internship Report

Heavy Industries Taxila

DESCOM
 SUBMITTED BY:
 HAMID ALI
 MUHAMMAD OSAMA
 M HUZAIFA TARIQ
 HASEEB KHALID
 M ALI

UNIVERSITY OF THE PUNJAB

METALLURGY & MATERIALS ENGINEERING

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 Acknowledgement
We have taken efforts in this Internship Project. However, it would not have been possible without the
kind support and help of many individuals and organizations. We would like to extend my sincere thanks
to all of them. We are highly indebted to Heavy Industries Taxila for their guidance and constant
supervision as well as for providing necessary information regarding the project & also for their support
in completing the Internship. We would like to express our gratitude towards member of DESCOM for
their kind co-operation and encouragement which help us in completion of this project.

Our Special Thanks and appreciation go to our Mentor Engr. M Nadeem Azam for giving his precious
time, Experience and every possible facility so that we can learn as much as possible.

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 Introduction to HIT
Heavy Industries Taxila commonly abbreviated as HIT is a substantial resistance gear generation
industry of Pakistan. It is presumed for the most part since it is a primary one and only tank fabricating
industry of Pakistan.

Objectives
1- Manufacture, Rebuild, Upgrade & Develop Tanks, Tank Guns & APCs.
2- Utilize surplus capacity of factories to meet requirements of civil sector and friendly countries
Administration
The whole production is carried out by co-ordination of number of sub factories along with
budget, Administration and technical directorate.
Sub-Factories
1- DESCOM
2- HRF-T
3- HRF-M
4- AARDIC
5- APC
6- Tank Factory
7- Gun Factory
*Our Internship was in DESCOM.
DESCOM
DESCOM is an abbreviation of Development Engineering Support & Component Manufacturing.
This production facility has been established to provide engineering support to all factories of HIT.
Equipped with CNC machines it undertake manufacture of components, assemblies, tools, dies, gauges
and arranges development of spare parts through the vendor industry. It also provides repair/maintenance
support to machinery/equipment installed in HIT.
Machining covers a few procedures. DESCOM undertakes manufacture of components, assemblies,
tools, dies, gauges and arranges development of spare parts there are no. of shops which are additionally
outfitted with CNC s and talented labour. This industrial facility is furnished with EM branch and in
addition Quality Control branch. Primary items it gives our nation are tanks, APC, ARV and Guns.

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 Contents

Topic Page Number

Foundry & Pattern Making Shop--------------------------------------------------- 6

Heat-Treatment Shop-------------------------------------------------------------------12

Surface-Treatment Shop---------------------------------------------------------------19

Forging Shop -----------------------------------------------------------------------------28

Machine Shop (K) ----------------------------------------------------------------------33

Machine Shop----------------------------------------------------------------------------38

Quality-Control (D) --------------------------------------------------------------------43

Project ------------------------------------------------------------------------------------44

References--------------------------------------------------------------------------------49

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 Foundry Shop
Operational In Charge
AWM Engr M Nadeem Azam
Mission:
 To cast components for Tank, APC’S, ASV, 125mm Gun Barrel.
 To Produce Casting required for tooling items.
 To Cast Machinery Spares for all Projects of HIT.
Foundry Shop is dedicated for the casting of equipment parts that are joined together. Foundry is
a backbone of HIT and is solely located in DESCOM. It is equipped with modernized equipment’s to
maximize the production with minimization of time and labor.
Capability of Shop
Sr.No Process Max Capability Materials
1 Investment Casting 1.5 Kg Steel
03 Kg Aluminum
1.5 Kg Cu-Alloy
2 Sand Casting 0.15-1.5 Ton Ferrous
Non-Ferrous
3 Pressure Die Casting 3 Kg Aluminum Alloys
4 Centrifugal Casting Dia = 400 mm Cu Based Alloys
Length = 500 mm Al Based Alloys
5 Vacuum Casting Dia = 60 * 300 mm Cu Based Alloys

Machinery Held within the Shop

Machinery Qty Held
Molding Equipment’s 02
Sand Muller (small, Large) 02
Molding M/C
Melting Furnaces 02
Induction Type 02
Electric Resistance
Vacuum Casting M/C 01
Centrifugal Casting 01
Investment Casting Equipment (China) 01 sets
Investment Casting Equipment (Germany) 01 sets
Pressure Die Casting M/C 01

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Casting
In casting processes, a solid material is first melted, heated to proper temperature, and sometimes
treated to modify its chemical composition. The molten material, generally metal, is then poured into
a cavity or mold that contains it in the desired shape during solidification. Thus, in a single step, simple
or complex shapes can be made from any material that can be melted. The resulting product can have
virtually any configuration the designer desires. Because of these features, casting is one of the most
important of the manufacturing processes.
Molding
Pattern i.e. replica of thing to be casted is used to make mold. Pattern is either made up of wood
known as master pattern or maybe made up of metal.
Pattern is made in two parts lower part that is known as drag and upper part or cope.
Baking
Baking is carried out in pit furnace by heating at 400 degree Celsius for sufficient time.
Sand
Granular particle of sand are used to make mold which is either dry or green sand. Sand is mixed
with molasses to enhance binding ability.
Sand Muller
Sand Muller is used to mix and restore ready to use texture of molding sand
Casting Techniques
Sand Casting
The sand grains are blended with little measures of different materials, for example, clay and
water, to enhance pliability and firm quality, and are then stuffed around a sample that has the shape of
the coveted casting. Since the grains will pack into thin segments and can be utilized financially in large
amounts, items crossing an extensive variety of sizes and detail can be made by this technique.

Centrifugal Casting
Centrifugal casting is used as a means of casting small, detailed parts or jewelry. An
articulated arm is free to spin around a vertical axle, which is driven by an electric motor or a spring. The
entire mechanism is enclosed in a tub or drum to contain hot metal should the mold break or an excess of
metal be used. Single use molds are prepared using the lost wax method. A small amount of metal in a
crucible (a sort of ceramic pan) next to the mold is heated. When the metal is molten the arm is released,
forcing (by centrifugal force) the metal into the mold. The high forces imposed on the metal overcome the
viscosity, resulting in a finely detailed work piece.

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 Figure 1 Centrifugal Casting Apparatus

Investment Casting
Investment casting is carried out by using paraffin wax and urea cores to make internal shape of
casting. Urea is used to make cores because when casting is placed in water urea dissolve in water leaving
behind a core print.
It is carried out when dimensional accuracy and higher surface finish is required.

Figure 2 Investment Casting Flow chart

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Figure 3 Silicon Molds used for Investment Casting

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Furnaces
Following Furnaces are available in Foundry
1- Cupola
2- Induction
3- Pit Furnace
Cupola
It is used on Foundry for melting of cast iron and is a vertical cylindrical furnace.
Induction
DESCOM foundry is equipped with two induction furnaces of 15 ton melting capacity. They are
used to melt iron, steel, Aluminum or precious metal by heat applied on basis of induction heating of
metal i.e. by resistance of electron movement within a metal.

Pit Furnace
Descom Foundry is equipped with 1 Pit furnace.
Copper Coil
It is an equipment which is used to melt metal the metal by induction of current in a copper coil
that generate heat and melt metal.
Wax Injector
It is used to inject wax into the die according to requirement. It is a semi-automatic apparatus
used to make wax pattern.

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Cyclone System
It is used for coating purpose. It comprises of two tanks
1- Primary
2- Secondary
This apparatus coat 11 Layers i.e. 3 Layers are coated by upper tank and 8 are coated by lower tank.

OTHER MACHINES IN FOUNDRY SHOP

1- Infrared drying oven
2- Silicon mold making
3- Funnel and consumable cup
4- Shake out
5- Tilting machine

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 Heat-Treatment
Operational In Charge
AWM Engr M Nadeem Azam
Mission
 Heat Treatment of newly made parts required for Re Build of Tanks, ARV, APC, T-
80UD, Gun Barrel 125 mm.
 Heat Treatment of tools and Dies
 Heat Treatment of Components required for repairing of Machinery
 Manufacturing and Inspection of springs.
Organizational Setup
 Hardening Section
 Salt bath Hardening Section
 Inspection Section
 Spring Manufacturing Section
 Scale Removing & Straightening Section
 P & C Maintenance Section

Shop 8 is dedicated for heat treatment of different metallic parts in order to enhance their working
capability and making them friendly for certain task.
Objective
The main objective of heat treatment is to alter physical and sometime chemical properties of metal
by heating or chilling of metal usually at extremely high temperature. There are two mechanisms that may
change an alloy's properties during heat treatment: the formation of martensitic causes the crystals
to deform intrinsically, and the diffusion mechanism causes changes in the homogeneity of alloy.

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 Figure 4 Fe-C Diagram

Effect of heat treatment on steel

1. Increase the hardness
2. Improve the toughness
3. Increase the ductility
4. Improve the machinability
5. Refine the grain structure
6. Remove the residual stresses
7. Improve the wear resistance

General terms used are

1- Hardening
2- Tempering
3- Softening a Hardened Structure
4- Re-crystallization
5- Stress relief
6- Hot-working operations
6- Diffusion of Alloying Elements
Hardening
Steels can be heat treated to high values of hardness and strength levels.

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Structural components subjected to high operating stress need the high strength of a hardened structure.
E.g. tools such as dies, knives, cutting devices, and forming devices need a hardened structure to resist
wear and deformation
Tempering
 As-quenched hardened steels are so brittle that even slight impacts may cause fracture.
 Tempering is a heat treatment that reduces the brittleness (increase the ductility of a steel without
significantly lowering its hardness and strength).
 All hardened steels must be tempered before use.
Recrystallization
 If a metal is cold worked, grains or crystals deform (become elongated) and in doing so harden and
strengthen a metal.
 There is a limiting amount of cold work that a particular metal can be subjected to.
 In rolling of steel into thin sheets, you can reduce the cross-sectional area to some extent before it
gets too hard to roll.
 At this point it would be desirable to return the grains to their original shape.
 Heat treatment can achieve this. The transformation of cold-worked grains to an undistorted shape
is called re-crystallization.
Stress Relief
 One of the most frequent reasons for heat treatment is to remove internal stresses from a metal that
has been subjected to cold working or welding
Annealing
Annealing is a technique used to recover cold work and relax stresses within a metal. Annealing
typically results in a soft, ductile metal. When an annealed part is allowed to cool in the furnace, it is called
a "full anneal" heat treatment. When an annealed part is removed from the furnace and allowed to cool in
air, it is called a "normalizing" heat treatment. During annealing, small grains recrystallize to form larger
grains. In precipitation hardening alloys, precipitates dissolve into the matrix, "solutionizing" the alloy.

Case hardening

Case hardening is specified by hardness and case depth. The case depth can be specified in two ways

 Total case depth

 Effective case depth

Manufacturing of springs:

 Varieties = 375
 Inner diameter = 1.2~100mm
 Outer diameter = 1.8~120mm
 Length = 2~1000mm

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Machinery equipment statement:

 Box type electric resistance furnace = 8

 Well type gas carburizing resistance furnace = 3

 Well type tempering resistance furnace = 3

 Salt bath furnaces = 7

 High frequency induction heating equipment = 2

 Bevel gear quenching press = 1

 Quenching tanks = 8

 Sub-zero treatment equipment = 3

 Hydraulic press = 1

 Shot blasting machine = 2

 Sand blasting = 1

 Hermatic drying box = 1

 Floor type grinding = 3

 Engine lathe = 1

 Spring coiling machine = 1

 Gas nitriding furnace = 2

 Spring compression and tension tester = 3

 Spring fatigue tester = 1

 Bench drill = 1

 Double column inclinable press = 1

 Deep well type resistance furnace = 1

 Hardness tester = 9

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  Fire pin impact tester = 1

Available Capabilities:

1) Annealing/Normalizing:

 Full annealing/normalizing

 Stress relief annealing

 Isothermal annealing

 Process annealing

2) Hardening:

 Free hardening

 Press hardening

 Deep well hardening

3) Tempering:

 Low tempering

 High tempering

4) Salt bath treatment:

 Low temperature salt bath treatment

 Medium temperature salt bath treatment

 High temperature salt bath treatment

 Nitrate temperature salt bath treatment

5) Case hardening

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  Bright carburizing

 Gas carburizing

 Gas carbon nitriding

 Induction hardening

6) Flame hardening

7) Sub-zero treatment

 Up to 120 centigrade

8) Spring manufacturing:

 up to 10mm wire diameter

9) De-scaling:

 Shot blasting

 Sand blasting

Manufacturing of springs:

Following are the processes by which springs are manufactured;

1) Wounding of wire on mandrel of an engine lathe.

2) Diameter is then tempered up to 300~350 centigrade.

3) Cutting of wire

4) Grinding

5) Rectification

 Straightness

 Pitch variation

 Length

6) Again tempering

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 7) Inspection

 Surface treatment bath furnace = 1

 Magnetic flow detector = 1

 Vertical polishing machine = 1

 Metallurgical microscope = 1

 High temperature atmospheric control resistance furnace=1

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 Surface Treatment Shop
Operational In Charge
AWM Engr M Nadeem Azam
Mission
 Reclamation of worn out components by Electroplating.
 Surface Treatment of newly manufactured components for tanks, ARV, APC, and gun
125 mm.
 Surface treatment of newly manufactured tools and dies.
 Surface treatment of worn out parts machinery held in HIT.

Purpose
The surface treatment shop is an electroplating shop. Electroplating is the process of depositing
coating by means of electrolysis.

Purpose of Electroplating:

i. To improve appearance of job.

ii. Prevention from corrosion.

iii. Reflection and decoration.

iv. Reclamation of under-sized components.

v. Prevention from carburizing and nitriding.

vi. To increase solderability.

vii. To increase electrical conductivity.

Processes Carried Out At Surface Treatment Shop:

i. Zinc plating

ii. Cadmium plating.

iii. Copper plating.

iv. Tin plating.

v. Aluminum anodizing.

vi. Silver plating.

vii. Copper oxidation.

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 viii. Chromium plating.

ix. Phosphating.

x. Ferrous oxidation.

xi. Tin + lead plating.

General Principle of Electroplating

In compound solution, ions charged with electric current whether negative or positive and moves
to opposite poles and continue discharged and make deposit thickness on the component surface.
Hydrogen and oxygen comes out at the surface of the solution which shows the current flowing. Time for
this process is given according to deposit thickness.

Machinery Equipment and Process of Surface Treatment

East Hall

Features

a) Number of baths.

b) Main chemicals.

c) Main process.

d) Function.

e) Main components to be plated.

f) Time of deposition and time of bath.

1) Zinc plating

a) Number of plating tanks = 4

b) Zinc oxide, sodium cyanide, sodium hydroxide.

c) Degrease, pickle, plating, passivation.

d) Corrosion resistance.

e) Clamp, spring, torsion bar, pipe etc.

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 f) Time = 20~30 min at room temperature.

2) Cadmium plating:

a) Number of plating tanks = 1

b) Cadmium sulphate, sodium cyanide, sodium hydroxide.

c) Degrease, pickle, plating, passivation.

d) Preventing from rust and seepage.

e) Nut and washers

f) Time = 20~30 min at room temperature.

3) Copper plating:

a) Number of plating tanks = 2

c) Copper cyanide, sodium cyanide.

d) Degrease, pickle, plating.

e) Preventing from carburizing and rust.

f) Gears, shafts, nuts.

g) Time = 1.5~2 hours.

4) Tin Plating:

a) Number of plating tanks = 1

b) Sodium stagnate, sodium hydroxide, sodium acetate.

c) Degrease, pickle, plating.

d) Solder ability, preventing from nitriding.

e) Cylinder liners, thimbles, connectors.

f) Time = 40~50 minutes.

5) Aluminum Anodizing:

a) Number of plating tanks = 1

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 b) Sulphuric acid.

c) Etching, bright, oxidation, coloring.

d) Surface hard and coloring of aluminum components.

e) Telescope body.

f) Time = 20~30 minutes.

6) Silver Plating:

a) Number of plating tanks = 1

b) Silver chloride, potassium cyanide.

c) Degrease, mercury dip, plating, and passivation.

d) Increase the conductivity.

e) Rotary ring, connector.

f) Time = 20~30 minutes.

7) Copper Oxidation:

a) Number of plating tanks = 1

b) Potassium per sulphate, sodium hydroxide.

c) Degrease, pickle, plating, oxidizing.

d) Preventing from reflection.

e) Screw, washer, nuts.

f) Time = 5~10 minutes.

West hall:

1) Chrome plating:

a) Number of plating tanks = 6

b) Chronic acid, sulphuric acid.

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 c) Degrease, pickle, plating.

d) Reclamation of under-sized components.

e) Gudgeon pin, shafts, bearings, seats etc.

f) Time = 0.15~1.0 hours.

g) Temperature = 55~60 centigrade.

2) Nickel plating:

a) Number of plating tanks = 1

b) Nickel sulphate, magnesium sulphate.

c) Polish, degrease, plating.

d) Reflection and decoration.

e) Reflectors, models.

f) Time = 30~45 minutes at room temperature.

3) Phosphating:

a) Number of plating tanks = 1

b) Grenadine No-111

c) Degrease, pickle, phosphate, seal.

d) Under coating for painting.

e) Covers, housing support, wheel idler etc.

f) Time = 40~60 minutes.

g) Temperature = 96~99 centigrade.

4) Fe-Oxidation:

a) Number of plating tanks = 2

b) Sodium hydroxide, sodium nitrate.

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 c) Degrease, pickle, oxidation seal.

d) Corrosion resistance without size disturbs.

e) Guns, bridge block, gauge.

f) Time = 40`501 minutes.

g) Temperature = 137~150 centigrade.

East Hall

1) Zinc plating:

Purpose
For protection from corrosion and for decoration.

Composition of bath
Zinc oxide, sodium cyanide, sodium hydroxide.

Bath Dimensions
2000x800x1000mm

Process Flow
Degreasing, pickling, zinc plating, passivation.

Loading capacity
Loading capacity is 50 DM2
Usage
Clamps, springs, torsion bars, pipes etc.

2) Copper Plating;

Purpose
For corrosion resistance, electrical conduction, prevention from carburizing and
jam.

Composition of Bath
Copper cyanide, sodium cyanide.

Bath Size
1500x900x1000mm

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 Process flow
Degreasing, pickling, copper plating.

Loading capacity
30DM2

Usage
Gears, shafts, nuts.

3) Silver plating:

Purpose
To increase electrical conductivity and soldering ability.

Composition of Bath
Silver chloride, potassium cyanide.

Bath size
400x300x300mm

Process flow
Degreasing, dip in mercury, silver plating, passivation.

Loading capacity
0.02 DM2

Usage
Rotary rings, connectors, thimbles etc.

4) Copper oxidation:

Purpose
Protection from light and decoration.

Composition of bath
Potassium persulphate, sodium hydroxide.

Process flow
Degreasing, pickling, copper plating, oxidation.

Usage
Screw washers, nuts etc.

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 West Hall
1) Aluminum anodizing

Purpose
For corrosion resistance, decoration, prevention from reflection and surface
hardness.

Composition of bath
Sulphuric acid.

Bath size
600x600x800mm
Process flow
Etching, brightening, anodizing, coloring.

Loading capacity
0.5DM2
Usage
Housing, telescope body etc.

2) Tin + lead plating

Purpose
To protect from whether effects, acidic effect of engine oil and to cushion the shell
from hard rotating shaft.

Composition of bath
Fluoric acid, lead fluoborate, tin fluoboarate.

Bath size
600x600x800mm

Process flow
Stripping, degreasing, pickling, tin +lead plating.

Loading capacity
0.5 DM2

Usage
Inserts, bearing shells etc.

3) Nickel plating:

Purpose
For decoration, corrosion resistance and reflection.
Composition of bath

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 Nickel sulphate, magnesium sulphate
Bath size
1200x800x800mm

Process flow
Polishing, degreasing, nickel plating, polishing.

Loading capacity
50DM2
Usage
Reflectors etc.

4) Ferrous oxidation

Purpose
For corrosion resistance.

Composition of bath
Sodium nitrite, sodium hydroxide.
Bath size
1500x800x1000mm
Process flow
Degreasing, pickling, oxidizing, sealing.

Loading capacity
60kg

Usage
Gun parts, breech block, cam shafts.

5) Chromium plating

6) Phosphating

7) Cadmium plating

8) Tin plating

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 FORGING SHOP
Operational In Charge
AWM Engr M Nadeem Azam
Mission
 Forging of the components of Al Zarrar, Al Khalid, T-59, T-69, and T-80 UD.
 Forging of tooling items including Die fixtures for manufacturing of tank parts.
Forging is the term for shaping metal by using localized compressive forces. Hot forging is done at a high
temperature, which makes metal easier to shape and less likely to fracture.
Capability
In shop-12 there are following m/cs under working
1. Pneumatic hammer 250 Kg
2. Chamber type gas heating furnace
3. Pneumatic hammer 750 kg
4. Chamber type gas heating furnace
5. Chamber type gas heating furnace
6. Double disc friction press 300 ton
7. Open type double column press
8. Porous type end heating furnace
9. Box type resistance furnace
10. Brinell hardness tester
11. Floor type grinder m/c
12. Tack pin heading m/c
13. Black smith furnace
14. Surface plate
15. Shot blasting tumbling m/c
16. Electric single beam cream
17. Hacksaw m/c
18. Hydraulic press m/c
19. Rockwell hardness tester
20. Hydraulic shear
21. Hacksaw m/c

Process:

Forging changes the size and shape, but not the volume, of a part. The change is made by force applied
to the material so that it stretches beyond the yield point. The force must be strong enough to make the material
deform. It must not be so strong, however, that it destroys the material. The yield point is reached when the
material will reform into a new shape. The point at which the material would be destroyed is called the fracture
point.

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 Most metals are hot forged; for example, steel is forged at temperatures between 2,100 oF and 2,300oF
(1,150oC to 1,260oC).

Open-die drop-hammer forging

Open-die forging is also known as smith forging. In open-die forging a hammer comes down and
deforms the work piece, which is placed on a stationary anvil. Open-die forging gets its name from the fact
that the dies (the working surfaces of the forge that contact the work piece) do not enclose the work piece,
allowing it to flow except where contacted by the dies. Therefore the operator needs to orient and position the
work piece to get the desired shape.

Impression-Die Drop-Hammer Forging

Impression-die forging is also called closed-die forging. In impression-die work metal is placed in a
die resembling a mold, which is attached to the anvil. Usually the hammer die is shaped as well. The hammer
is then dropped on the work piece, causing the metal to flow and fill the die cavities. The hammer is generally
in contact with the work piece on the scale of milliseconds. Depending on the size and complexity of the part
the hammer may be dropped multiple times in quick succession. Excess metal is squeezed out of the die
cavities; this is called flash. The flash cools more rapidly than the rest of the material; this cool metal is stronger
than the metal in the die so it helps prevent more flash from forming. This also forces the metal to completely
fill the die cavity. After forging the flash is trimmed off.

Press forging

Press forging is variation of drop-hammer forging. Unlike drop-hammer forging, press forges work
slowly by applying continuous pressure or force

The main advantage of press forging, as compared to drop-hammer forging, is its ability to deform the complete
work piece.

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Upset forging

Upset forging increases the diameter of the work piece by compressing its length. Based on number of
pieces produced this is the most widely used forging process. A few examples of common parts produced using
the upset forging process are engine valves, couplings, bolts, screws, and other fasteners.

Materials:

Common materials are used for forging of components are as under; 38 Crsi.A3, Steel-10, steel-40,
steel-35, steel-41, steel-15, 20Cr2Ni4A, 18Cr2Ni4A.

Optical pyrometer:

An instrument used for measuring of high degree heat.

Tools:

1. Tongs

2. Hand hammer

3. Horn

4. Anvil

5. Punch

6. Chisel

7. Swages

8. Forging dies

9. Saddle support

10. Mandrel

Anvil:

Used for hand forging, heated metal is shaped on anvil.

Swages:

Used to smooth round rods or round surfaces.

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Fullers:

These are forming tools which come in different shapes and sizes and can be manipulated to make
grooves and hollows.

Tongs:

It is used to hold the hot metal pieces which are manufactured in many shapes and sizes. There are 3
types of tongs;

1. Straight up tong

2. Curved up tong

3. Pick up tong

Hand hammer:

It is used in hand forging. There are 3 types;

1. Cross pin hammer

2. Sledge hammer

3. Ball pin hammer

Chisel:

It is used to cut metal. 2 types are used;

1. Hot chisel

2. Cold chisel

Types of forging:

i. Free forging

ii. Open type forging

iii. Die forging

Measuring instruments:

i. Steel rules

ii. Inside calipers

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 iii. Outside calipers

iv. Vernier calipers

Machines used in forging shop:

a) Pneumatic hammer:

It is used for medium and heavy forging.

1. Maximum weight forged on 250kg hammer=9kg

2. Maximum weight forged on 750kg hammer=40~45kg

3. Maximum diameter forged on 750kg hammer=1000mm

4. Maximum diameter forged on 250kg hammer=345mm

5. Maximum weight forged on 250kg hammer=1kg

6. Maximum weight forged on 750kg hammer=8kg

b) Press:

1. Double disc friction screw press used for forging of small and large components.

2. Open type inclined able press is used for trimming of forged components.
Heating:
Heating of steel is very important and main operation in forging practice. If a piece of steel is heated, it
becomes softer and its tensile strength is reduced and at the same time its plasticity and malleability is
increased. The structural transformations which occur in metals on heating their mechanical and physical
properties also change.
Safety measurements:

i. Keep shop clean

ii. Metal scraps should be placed in scrap box

iii. Never use compress air to clean the machine of chips

iv. Keep hand tools in good condition

Pre-heated temperature of forging dies:

v. 250~300 centigrade

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 Machine Shop (K)
Operational In Charge

Mission
Shop-K of DESCOM was estable as indigenous project for the purpose of in-house manufacture of the
critical components of tank T-59 parts. Shop-K is responsible for the manufacture of Breech Block, Breech
Ring, HUB, Gear Box, Cam Shaft, Plunger, Nozzle Body, Other tanks Al-Zarar, T-85, Al-Khalid, APC
Components.
MANUFACTURING AND MACHINING PROCESS
Main machines in this shop are
1. Lathe m/c =38
2. Grinder m/c =26
3. Drilling m/c =16
4. Milling m/c =30
5. Boring and reaming m/cs = 08
6. Cranes =04
7. Total m/cs = 172

Milling machine
Milling machine is a machine tool used for the
shaping of metal and other solid materials.
Milling machines exist in two basic forms:
horizontal and vertical, which terms refer to the
orientation of the cutting tool spindle. Milling
also involves movement of the work piece
against the rotating cutter, the latter which is able
to cut on its flanks as well as its tip. Milling
machines can perform a vast number of
operations, some very complex, such as slot and
keyway cutting, planning, drilling, die sinking,
rebating, routing, etc. Cutting fluid is often
pumped to the cutting site to cool and lubricate
the cut, and to sluice away the resulting swarf.

Grinding Machine
Value of Grinding as Finishing Process. When greater accuracy than that obtainable on the milling
machine or the lathe is required, recourse is had to grinding. This operation depends upon the abrasive or cutting
qualities of emery, corundum, and carborundum. With work properly held to a solid grinding wheel, it is not

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difficult to attain great accuracy. By means of the grinding machine, parts may be economically finished, even
in hardened steel that could not possibly be machined on such shop tools as the lathe, planer, or shaper.

Features of Grinding
The headstock and tailstock are mounted upon a traveling table, which moves back and forth in the same
manner as the platen of a planer. It is made to stop automatically at each end of the stroke. A coarse wheel
grinds faster than a fine one, but leaves deep scratches in the work. A soft wheel may be made of a much finer
grade than a hard one. A soft wheel grinds faster than a hard one, but it is apt to glaze over, or fill up with
particles, if used on a soft material.

Broaching
Broaching is a machining operation which uses a toothed tool, called a broach, to remove material. The
broach is used in a broaching machine, which is also sometimes shortened to broach. It is used when precision
machining is required, especially for odd shapes. Broaching finishes a surface in a single pass, which makes it
very efficient. Commonly machined surfaces include circular and non-circular holes, splines, and flat surfaces.

Process
Internal broaching is more involved. The process begins by either clamping the work piece into work
holder of the broaching machine or the work piece is placed on a spherical work holder designed to
automatically align the work piece to the broach. The elevator of the broaching machine then lowers the pilot
of the broach through work piece where the puller engages broach pilot. The elevator then releases the top of
the pilot and the puller pulls the broach through the work piece completely. The work piece is then removed
from the machine and the broach is raised back up to reengage with the elevator.

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Horizontal Boring Machine
A horizontal boring machine or horizontal boring mill is a machine tool which bores holes in a
horizontal direction. There are three main types — table, planer and floor. The table type is the most common
and, as it is the most versatile, it is also known as the universal type. A horizontal boring machine has its work
spindle parallel to the ground and work table. Horizontal boring machines are often heavy-duty industrial
machines used for roughing out large components but there are high-precision models too.

SPECIFICATIONS OF CNC MILLING

Automatic machines are generally used to minimize the need for manual effort. The benefits are
reduced operating costs, reduced operator errors, increased reliability, and minimum work reduction due to
human fatigue, illness and labor disputes.
Computers
Built in machine = 80486-100MHZ
Separate PC = 80486-66MHZ with machine through cable
Software
ELEXA =For CNC processing
DAM= for design and manufacturing of complex parts
Table size
1250 x560 mm
Spindle

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 Speed (max) =5000 RPM
Rated power of motor = 10KW
Travels
X-axis longitudinal = 1050mm
Y-axis transverse = 520
z –axis vertical = 420
C-axis tilting of milling head = +,-90°
A –axis CNC dividing head = 360°
Accuracy = .001
Tool magazine capacity =19
Sp-2 =.01
For 3-D digitizing = tracing
MP7
For determining of w/p origin
For measurement of jobs
Coolant

“27” no of oil use as a Coolant

Capability:

1. Simple milling.
2. Grooving.

3. Drilling.

4. Boring.
5. Reaming.

6. Tapping Operation.

7. Machine is capable of producing Complex jobs having internal & external contour.
8. Pockets and Conical profile with high accuracy.

Controls

1- Computerized
2- Manual

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 Cutters

1. Key way & anvil Cutter

2. Single flute cutter
3. End mill cutter
4. Straight drill

5. Taper shirk drill

Accuracy:

CNC milling machine is so accurate because its head is fix and does not have play. It has motor
systems instead of gear trains and also has hydraulic system and pressure system that increases its efficiency.

Operation:

Oil is pressurized which suck the tool and is fixed in collet and it cannot be released unless
the same pressure of oil is achieved.

Parts Made On CNC Milling Machine:

1) 2nd and 3rd speed synchronizer body.

2) Lever

3) Gear shaft

4) Stop

5) Hook

6) Pusher

7) Lower extractor

8) Upper extractor

9) Cocking lever shaft

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 Machine Shop
Operational In Charge
WM Engr Manzoor.
Mission
 To manufacture components for Tank T-59, T-69, T-85, AK-1, AK-2, 125 mm Gun, APC and
ARV etc.
 To Manufacture Components for ADDL Modification of Tanks like T-59, T-69, T-85, AK-1,
AK-2, etc.
 To Manufacture Components for 520HP, 580HP, 730HP, and 6TD-I Engines with in AVAL
Capacity.
MANUFACTURING AND MACHINING PROCESS
Machining is the broad term used to describe removal of material from a work piece; it covers several
processes, which we usually divide into the following categories:

 Cutting, generally involving single-point or multipoint cutting tools, each with a clearly defined
geometry.
 Abrasive processes, such as grinding.
 Nontraditional machining processes, utilizing electrical, chemical, and optimal sources of energy.

Main machines which are being used in shop-2 are as follows

Lathe
A lathe is a machine tool which spins a block of material to perform various operations such as
cutting, sanding, knurling, drilling, or deformation with tools that are applied to the work piece to create an
object which has symmetry about an axis of rotation. Metal is removed from the work piece using a hardened
cutting tool, which is usually fixed to a solid moveable mounting, either a tool post or a turret. The work
piece may be supported between a pair of points called centers, or it may be bolted to a faceplate or held in
a chuck. A chuck has movable jaws that can grip the work piece securely.

All lathes have a bed, which is (almost always) a horizontal beam. At one end of the bed (almost always the
left, as the operator faces the lathe) is a headstock. The headstock contains high-precision spinning bearings.
Rotating within the bearings is a horizontal axle, with an axis parallel to the bed, called the spindle. The
counterpoint to the headstock is the tailstock, sometimes referred to as the loose head, as it can be positioned
at any convenient point on the bed, by undoing a locking nut, sliding it to the required area, and then relocking
it. Metalworking lathes have a carriage (comprising a saddle and apron) topped with a cross-slide, which is
a flat piece that sits crosswise on the bed, and can be cranked at right angles to the bed. Sitting atop the cross
slide is a tool post, which holds a cutting tool which removes material from the work piece.

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Feed, Speed, and Depth of Cut
Cutting speed is defined as the speed at which the work moves with respect to the tool (usually
measured in feet per minute). Feed rate is defined as the distance the tool travels during one revolution of the
part. Cutting speed and feed determines the surface finish, power requirements, and material removal rate.
The primary factor in choosing feed and speed is the material to be cut. However, one should also consider
material of the tool, rigidity of the work piece, size and condition of the lathe, and depth of cut. To calculate
the proper spindle speed, divide the desired cutting speed by the circumference of the work. Experiment with
feed rates to achieve the desired finish. In considering depth of cut, it's important to remember that for each
thousandth depth of cut, the work diameter is reduced by two thousandths.
There are 3 Vertical lathes in this shop, which are commonly used for machining of sprocket.

Drilling machine
Drill can be defined as a rotary end cutting tool having one or more cutting lips, and having one or
more helical or straight flutes for the passage of chips and the admission of a cutting fluid

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Gear manufacturing
Gear Basics
Gears are used to reverse rotational direction, increase or decrease speed of rotation, transfer rotation
to a different axis, or to synchronize rotation across two or more axis in a machine or engine. The basic gear
train is comprised of two gears, one large and one small. They rotate in opposite directions from one another,
with their teeth interlocking and driving the rotation. A gear in a train is referred to as a driver (the gear that
effects the rotation), a driven gear (the gear last in the train), or an idler (any gear between the first and last
gear). The power output or torque produced by a gear train is determined by the gear ratios and the by output
direction (which gear drives which).

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Gear Types

 Spur Gear: characterized by their straight cogs, these gears are mounted on parallel shafts. You'll
find examples of spur gear trains in watches and clocks.

 Bevel Gear: characterized by cogs cut in a cone shape. The gear shafts are generally mounted at 90º
angles to each other.

 Worm Gear and Wheel: a gear comprised of a wheel gear with inclined cogs that is rotated by a
screw thread (a single-cogged gear called a worm).

 Helical Gear: characterized by cogs that are cut at an angle to the face of the gear. Can be mounted
perpendicularly or parallel. Automobile transmissions make use of these gears.

Manufacturing

Hobbing

Hobbing is a machining process for making gears, splines, and sprockets on a hobbing machine,
which is a special type of milling machine. The teeth or splines are progressively cut into the work piece by
a series of cuts made by a cutting tool called a hob. Compared to other gear forming processes it is relatively
inexpensive but still quite accurate, thus it is used for a broad range of parts and quantities such as cylinder
of tank engine

Honing machine
Honing is a manufacturing process that produces a precision surface on a work piece by scrubbing
an abrasive stone against it along a controlled path. Honing is primarily used to improve the geometric form
of a surface, but may also improve surface texture. Honing is a relatively expensive manufacturing process.
The improved shape after honing may result in a quieter running or higher precision component.

Thread rolling machine

This type of cold-forming process is used because cylindrical parts (such as the remaining round part
of the bolt) can easily have thread applied by rolling the work billet through two dies. The thread rolling
process is usually chosen over machining because thread rolling provides higher production rates, more
effective material usage, stronger thread due to work hardening, and finally better fatigue resistance because
the work billet undergoes compressive stresses during the rolling process.

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CNC LATHE MACHINE SHOP
The machine is controlled electronically via a computer menu style interface, the program may be
modified and displayed at the machine, along with a simulated view of the process.

Specifications of E45 CNC lathe

Working range
Swing over bed = φ 430
Max. Turning die = φ 220
Max turning length = φ 310
Travels
X = 160
Z = 310
Main spindle = clamping system
Max size of chuck = φ 160
Tool system
Revolve type tool turret with direct logic option with driven tool
Tooling fixture act to DIN 69880

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 Quality Control (D)
(QC)
ABOUT

QC’s function is to manufacture parts according to the requirements. In house products are the
products that are manufactured in shops. Its material is purchased before the operation e.g. springs.

Wender industries means products manufactured from the firms of Pakistan.

Strategies

QC follows 3 strategies;

a) Dimension inspection; visual as well as radiographic (gamma rays).

b) 2 tests;

 Destructive test in which the material is destroyed. 


 Non-destructive test involving gamma rays. 

c) To check the fitness in its application.

Lab tests

 Physical test in which hardness and tensile testing is done. 

 Chemical test in which elements are checked in any job. 

 Provide routine and consistent checks to ensure data integrity, correctness, and Completeness;
 Identify and address errors and omissions;
 Document and archive inventory material and record all QC activities.
QA
Quality Assurance (QA) activities include a planned system of review procedures conducted by
personnel not directly involved in the inventory compilation/development process. Reviews, preferably by
independent third parties, should be performed upon a finalized inventory following the implementation of
QC procedures. Reviews verify that data quality objectives were met, ensure that the inventory represents
the best possible estimates of emissions and sinks given the current state of scientific knowledge and data
available, and support the effectiveness of the QC programmed.

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 Project
To Study the effect of heat treatment on the resistance of Al and Fe based
alloys against localized plastic deformation.
Abstract
Aluminum and Fe based alloys hardness can be increased by proper heat treatment process keeping
in view the structural changes that occur during heat treatment process.
Introduction
Aluminum and iron based alloys of known composition was tested to measure hardness with the
help of Brinell hardness testing machine before undergoing heat treatment which results in an increase in
the hardness of alloys.
Experiment
Aluminum alloy and Iron alloy ZR 11 of following composition was casted in the mold using dry
sand. Following Steps were followed during making of Mold
1- Pattern was placed in the Mold.
2- Gating system was in co-operated in the mold.
3- Pattern was taken off.
4- Molten metal was added through sprue to fill mold cavity.
5- Metal was allowed to cool.
6- Sand mold was broken away to obtain desired casting.
Composition
Elements Si Fe Cu Mn Mg Cr Ni Zn Al
% in 6.89 2.32 1.04 0.210 0.322 0.0194 0.023 0.157 87.4
Sample 1
% in 7.43 3.50 1.20 0.384 0.500 0.0560 0.0343 0.190 84.9
Sample 2

 Some elements like Ag, Ti, Pb, P, etc. are also present in minor amount.
Testing
Metals was tested to measure hardness before undergoing heat treatment process and the obtain
results are
Sample # Major element % of Major element Hardness
1 Al 87.4 52 HB
2 Al 84.9 52 HB
3 ZL 11 0.11 C 57 HB

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Figure 5 Sample 2 before Age Hardening

Figure 6 Sample 3 Before age Hardening

Figure 7 Sample 1 before age Hardening

45
Afterward the samples undergo heating till red hot followed by water quenching and then undergo content
heating at 120 degree Celsius for 8 hours also known as aging process.
The result of change in hardness after heat treatment is following
Sample # Major Element Hardness
1 Al 57 HB
2 0.11 C 84 HB

Figure 8 Samples After Heat Treatment

Result
There is a sufficient increase in the Hardness of all samples after heat treatment process.

Discussion
The presence of second phase particles often causes lattice distortions. These lattice distortions result
when the precipitate particles differ in size and crystallographic structure from the host atoms. Smaller
precipitate particles in a host lattice leads to a tensile stress, whereas larger precipitate particles leads to a
compressive stress. Dislocation defects also create a stress field. Above the dislocation there is a compressive
stress and below there is a tensile stress. Consequently, there is a negative interaction energy between a
dislocation and a precipitate that each respectively cause a compressive and a tensile stress or vice versa. In
other words, the dislocation will be attracted to the precipitate. In addition, there is a positive interaction
energy between a dislocation and a precipitate that have the same type of stress field. This means that the
dislocation will be repulsed by the precipitate.
Factors which may be responsible for not achieving hardness up to potential may be following
1- Casting Defect i.e. Pin holes
2- Intermetallic precipitate’s formed during solidification do not dissolve easily during
solutionizing
3- Heterogeneous nucleation of precipitates
4- Ageing response maybe different at surface and in the core in thick sections
46
5- Low melting non-equilibrium phases formed during solidification tend to melt if solution
temperature is high.

47
 Suggestions
1- Although the staff is very co-operative but it will be more helpful if
internee taught software related to their field.
2- The apparatus not in use must be removed in order to make space for new
apparatus resulting in an increase in production rate.
3- There must be the production of Eglin Steel as it is a high strength,
Low alloy Steel with low Cost which is a prime factor to enhance its
importance.

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 References
1- Page # 90, Introduction to Physical Metallurgy by Avner.
2- Material Science and Engineering by Callister.
3- Page # 174-175, Principles of Metal Casting by Rosenthal.
4- Heavy Industries Taxila Official Website
5- Website:- Wikipedia Encyclopedia
6- ASM Handbook Volume 1, Heat treatment.

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