Study Report 3

Study ReportSUMMER TRAINING 2015

512 ARMY BASE WORKSHOP

ByMr Omkar V. PattanshettiMr Ashwin DixitMr Omkar Tunge-MIT College of Engineering, Pune

Word of GratitudeWE FEEL GREAT HONOUR TO GET TRAINING AT 512 ARMY BASE WORKSHOP

DURING THE COURSE OF WHICH WE GOT THE OPPORTUNITY TO DEVELOP OUR EXPERTISE AND DEFINE OUR TECHNICAL AND PROFESSIONAL INTERESTS.

Weekly Summery of Training Phase 1

Week 1 : Mfg Gp Week 2 : EOD & ETH Week 3 : ARD, VRD & LSD

Phase 2 Week 4 : Mini-project

Phase 1• Goal : Practical Exposure to various engineering processes• Learning Value : Hands on experience • Daily report to DGM • Everyday working on a m/c

Week 1• Sections covered :

Moulding SectionMetal Smith SectionRubber Component SectionHeat Treatment PlantMachine Shop

Technical exposure• Sand Casting, pit furnace, • Hot forging, impact forging, open die forging, dies,

powered hammer • Heat treatment furnaces with vivid operating temperatures• Rubber mixing mill, steam vulcanizer, injection moulding

m/c, hydraulic press• Capstan lathe m/c, watch maker lathe m/c

We gained…• Learnt about various casting defects• Practically saw the forging• Learnt about practical procedures of various heat

treatments• Extra knowledge about rubber moulding• Hands on experience on Capstan lathe m/c

Food for thought by DGM • Is sand reused for mould making?• What are modern Trends in casting? • What is the material of hammers & dies?• How are high temperatures measured?• How is hardness of rubber is measured?

Scope for Improvement• Safety measures for workers • Maintenance of quenching bath • Installation of advanced furnace• Installation of laser cutting m/c

Week 2• Sections covered :

Material Testing Lab.Engine Overhaul Dept. (UTD-20)Engine Test HouseElectroplating Section

Technical exposure• Chemical analysis of alloys, physical testing of material,

calibration of measuring instruments• Diesel Engine • Engine testing• Electroplating, neutralisation of waste water• Universal & vertical milling m/c

We gained…• Learnt about physical testing & chemical analysis of material• Learnt about calibration of measuring instruments• Info about flow of process of engine overhauling• Learnt about dismantling, assembling of diesel engine &

reclamation of its various components • Deep info about major engine mountings such as FIE, Head Assy,

Pipelines, Engine block, Crankshaft & Connecting Rod• Practical exposure to testing procedures of the same are carried out

& to testing of various parameters of assembled engine• Learnt about processes in electroplating & effluent water plant

Food for thought by DGM• How are engine, motor & generator distinguished?• What are functional requirements of an injection system?• What is the need of electroplating?

Scope for Improvement• Maintenance of electroplating plant is necessary• Noise reduction measures need to be enhanced at ETH• Preservation of manuals by foreign manufacturers is

needed

Week 3• Sections covered :

Gearbox Assembly SectionTurret Line Armament SectionLock Smith Dept.

Technical exposure• Gear box assembly & testing• Basics of tank• Main Gun testing• Pipe bending, fitting, sheet metal work, welding, profile

cutting, shot blasting, painting

We gained…• Practical knowledge regarding a synchromesh gear-box

assembly• Learnt about parameters affecting transmission• Extra knowledge about working of turret, its operation and

assembly• Extra knowledge about main gun of BMP-2• Practical exposure to processes like pipe bending,

shearing of sheet metals, profile cutting, TIG welding, shot blasting, fitting of small components & painting

Food for thought by DGM• Can plastic be welded?• How does a pipe-bending m/c work? What are different

methods of tube bending?• What is rifle?• What is recoilless gun? How does it operate?

Scope for Improvement• Modern trends in welding, if installed, can be of great

advantage• For profile cutting, LASER cutting is advantageous

Phase 2MINI PROJECT

Design of Close loop water circulation system• Statement : To design & implement a close loop system to

recirculate the water wasted from boiler• Details : • Temperature of Steam before use - 140˚ C• Flow rate of water- 36 litre/min• Steam pressure- 7 kg/cm2

• Requirement : Condensation of steam• Concept of solution : Use of a Heat Exchanger

Proposed design 1.1

Courtesy- Thermax Ltd.

Proposed design 1.2

Proposed design 1.3

Heat exchange to feed water tank

Proposed design 1.4.1

Heat exchanger is installed in the sump tank

Proposed design 1.4.2

Heat exchanger in sump tank

Copper plate

Steam

Finalised design

Sump tank with Heat Exchanger

Close Loop

• Material requirement :• ½” dia. pipe 1.8m long• 1” dia. pipe 2.5m long• Elbows• Ball valve• Pump of head capacity 2.5m• Copper plate 1mm thick • Sump tank• Rivets

Thank You