Six week training report on Machining

7/30/2019 Six week training report on Machining

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TRAINING REPORT

OF

SIX WEEK INDUSTRIAL TRAINING, UNDERTAKEN

AT

DAWN MOTORS PVT. LTD

CHD ROAD, VILLAGE JANDIALI, LUDHIANA

B.TECH ME 4th SEMESTER

RIMT-INSTITUTE OF ENGINEERING & TECHNOLOGY

Submitted to: Submitted By:Name: Er. Deepinder Singh Name: Naman Jain

Designation:Head Of Department College Roll No.: 10666(Mechanical Engg.) University Roll No.: 100641132032


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TABLE OF CONTENTS

Title Page no

1 Introduction of Project1.1 Time Table.1.2 Need for the Application1.3 Purpose of the Document

1-4

2 Hardware and Software requirements2.1 User requirements

2.2 System requirements

5-7

3 Methodology and flow charts3.1 Feasibility study3.2 System Development life cycle

3.3 Phases of system development life cycle3.4 Data flow diagram

8-18

4 Results and discussion 19

5 Bibliography 20

6 SQL Server tables and Screenshots5.1 Admin Login5.2 User Login

5.3 Database file

21-41


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ACKNOWLEDGEMENT

With profound respect and gratitude, I take the opportunity to

convey my thanks to complete the training. I express gratitude

to the Program Manager and other faculty members of

Mechanical Department of Regional Institute of

Technology(RIMT-IET) for providing this opportunity to

undergo industrial training at Dawn Motors, Ramgarh,

Ludhiana. I do extend my heartfelt thanks to Mr. Amit Sharma

for providing me this opportunity to be a part of this esteemed

organization. I am extremely grateful to Mr. Vijay Saini,

Quality Incharge at Dawn Motors for guidance during whole

training.

I am extremely grateful to all the technical staff of Dawn

Motors for their co-operation and guidance that helped me a lot

during the training period. I learnt a lot under them and I will

always be indebted of them for this value addition of me.


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ABOUT THE COMPANY

INTRODUCTION

The unit is located in the northern region of INDIA in the

well known city of LUDHIANA (PUNJAB), which is famous

for its engineering and manufacturing capabilities in the state

of Punjab. Company is known for it's commitments and

customer orientedness, as it depicts from slogan

"We believe in doing what we said, and

commiting for, WHAT WE CAN DO"

This Unit is the Head Office of Dawn Group. It is

approximately 8 Km. away from the Ludhiana Junction and

approx. 9 Km away from main Bus stand of Ludhiana city. The

approach from either point is very easy.

PROFILE HISTORY

The unit was established in 1976 by SH. B.D. Sharma as a job

worker for ancillary of B.H.E.L (Bharat Heavy Electricals Ltd.).

The enterprising and innovative leadership added a new chapter

in the history of DAWN Engineering Enterprises by adding

Punjab Tractor Limited, Mohali, in its Customers list in 1980.

After that there was never any lack of acceleration on the path

of progress of Company and started Gear Shifting Forks

supplies for Eicher Tractor, Parvanoo, Eicher Tractor,

Faridabad & Eicher Motor Limited, Indore in 1984, 1986 and

1990 respectively.


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PRODUCT RANGE

Categories :

Gear Box Component

Hydraulic Component

Hydraulic Lift Assy. Components:

P.T.O. Components

Sheet Metal Components

Propeller Shaft Components


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ACHIEVEMENTS

1.In year 1990, Best vendor of the year Award given by

Mr.Vikram Lal (Chairman Eicher Group).

2.Self Certification Supplier Quality Program by Eicher Motors

Ltd.

3.Eicher gave a name Fork Man to DAWN in year 2003 in

annual Vendor Meet.

4.Quality certification ISO 9001-2000 from DNV.

5.Quality Certification ISO 9001-2000 from BVQI in 2005.

6.Regular participation in Auto Expo from 2004 (Indias Bigget

Automobile Exhibition).

7.Udyog Rattan Award from Institute of Economic Studies in

year 2005 for Excellence in Productivity, Quality, Innovation &

Management by Dr.Bhishma Narain Singh (Honble Former

Governor of Tamil Nadu & Assam).


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MACHINES USED AT DAWN

TOOL AND CUTTER GRINDERS: These machines

areprimarily intended for tool room work for grinding cyclinderical

andtapered multitooth cutting tools, like milling cutters, hobs,

drills,rreamers, taps, broaches, gear shaper cutters, etc.

They are also capable of doing light cylinderical, surface and internal

grinding operations. They are made in various different designs. The

most versatile and widely used form is a Universal tool and cuttergrinder.

It carries a workhead and a tailstock on a uppertable, which is

mounted on a lower tableon which the former can be sxivelled to

grind the tapered tools. The lower table travels longitudinally on the

ways provided on a saddle under it. The saddle travels in cross

direction. The saddle and table travels are usually controlled by hand.

The wheel head is usually mounted on a elevating coloumn and

consists of housing carrying a wheel spindle, which runs in two

bearings. Both ends of the spindle are tapered to receive the clamping

sleeves, carrying the grinding wheels. The wheel head can be

swivelled about a vertical axis together with the coloumnand its

driving motor.


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SURFACE GRINDER: surface grinders do do almost the same

operation as the planers, shapers or millingmachines, but with more

precision. Primarily they are intended to machine flat surfaces,

although irregular, curved or tapered surfaces can also be ground on

them.

Horizontal spindle reciprocating table grinder:

Figure . illustrates this machine with various motions required for

grinding action. A disc type grinding wheel performs the grinding


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action with its peripheral surface. Both traverse and plunge grinding

can be carried out in this machine .

PILLAR DRILLING MACHINE: These drilling machines,

usually called pillar drills, are quite similar to the table top drilling

machines but of little larger size and higher capacity (0.55 ~ 1.1 kW)

and are grouted on the floor (foundation). Here also, the drill-feed and

the work table movement are done manually. Fig. typically shows a

pillar drill. These low cost drilling machines have tall tubular columns

and are generally used for small jobs and light drilling.

COLUMN DRILLING MACHINE:These box shaped column

type drilling machines as shown in Fig. are much more strong, rigid

and powerful than the pillar drills. In column drills the feed gear box

enables automatic and power feed of the rotating drill at different feed

rates as desired. Blanks of various size and shape are rigidly clamped


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on the bed or table or in the vice fitted on that. Such drilling machines

are most widely used and over wide range ( light to heavy) work.

RADIAL DRILLING MACHINE:This usually large drilling

machine possesses a radial arm which along with the drilling head can

swing and move vertically up and down as can be seen in Fig.. The

radial, vertical and swing movement of the drilling head enables

locating the drill spindle at any point within a very large space

required by large and odd shaped jobs. There are some more versatile

radial drilling machines where the drill spindle can be additionally

swivelled and or tilted.


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GANG DRILLING MACHINE:In this almost single purpose

and more productive machine a number (2 to 6) of spindles with drills

(of same or different size) in a row are made to produce number of

holes progressively or simultaneously through the jig.

.


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VERTICAL BROACHING MACHINE: In pull-up type

machine the ram is provided at the top which carries the pulling heads

at its bottom. The elevators are provided inside the bed to hold the

broach in vertical position. The work piece is clamped to the

underside of the table and elevators raised to pass the pass the front

pilots of the broaches through the work piece and the table, where

they are gripped by the pulling head.


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HORIZONTAL MILLING MACHINE: Its principal parts

are shown in fig. The vertical column serves as a housing for

electrical, main drive, spindle bearings, etc. The knee acts as a

support for the saddle, worktable and other accessories. The arbor

carrying the cutter rotates about a horizontal axis.


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MACHINING PROCESSES

Boring : Boring is an operation of enlarging and finishing the

complete hole with a single point cutting tool. This operation is

normally done on boring machines but can also be

accomplished on lathe group of machine tools. Boring corrects

the positon of the hole and makes it cocentric with the axis of

rotation of spindle.

Boring tools: A boring tool consists of a single point cutting

tool held in a tool holder known as boring bar, where the boringbit is held in a cross-hole at the end of a boring bar. The boring

bit is adjusted and held on postion with the help of set screws.

The material of the boring bit can be: Solid H.S.S, Solid

carbide, Brazed carbide, Dispisable carbide tips or Diamond

tips. Boring tools are of two types:

1. Fixed type 2. Rotating type

Fixed type of boring tools are used on work rotating machines,

such as lathes, whereas rotating type boring tools are used ont

tool roating machinessuch as drill presses, milling machines and

Boring machines. Lathes, drill presses and milling machines can

be used only for smalljobs. However, for large jobs, boring

machines are used. The boring bar or the boring head in the case

of rotating type tools, is held in the main spindle of the

machine.


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MILLING PROCESS

MILLING: Milling may be defined as a machining process

for removal of excess material from a work piece with a rotating

cutting tool. The rotating cutting tool call the Milling Cutter

is a multiple cutting tool having the shape of a solid of

revolution with cutting arranged either on the periphery or on

end face or on both. Milling process involves simaltaneously

rotary cutter and usually linear motion of the work, with the

work fed against the cutter. Milling process is used for

producing flat, contoured, helical surfaces, for cutting threads

and toothed geared and for making helical grooves.

Types of milling cutters : There are many different kinds

of milling cutters, according to the design may be of the solid or

inserted blade type that are mechanically retained and are

usually adjustable.

Some of the common kind of cutters are discussed

below:

1. PLAIN MILLING CUTTER : these cutters are cylinderical inshape and have cutting teeth on the periphery only. They are

used for milling plain or flat surfaces. A plain cutter may have

either straight or helical teeth. In the operation of a cutter with

straight teeth each tooth enters the cut simaltaneously along its

full length. The leads to intermmitent loads acting on the

machine and impairs the quality of the surface machined.

Cutters with helical teeth operate more smoothly since the cutter

enter the cut gradually and the load on the machine is uniform.


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If a set of two cutters operate side by side to mill wide surface,

one has right hand helix and the other has left-hand helical

flutes so that the axial forces are counterbalanced.

2. FACE MILLING CUTTERS: Face milling cutter, with teeth onthe end face are used for maching large, flat surfaces. The cutter

may be mounted on the arbor or rigidly clampedon the nose of

the machine spindle. Face milling cutters are similar to end

mills but they are consideraly larger in diameter. They are

designed to machine flat surfaces which are perpendicular to the

rotational axis of the spindle. The cutters are used on vertical

milling, planer type milling and bed type milling machines.

3. END MILLS: End mills have cutting on the teeth on the end aswellas on the periphery. End mills may be made as solid cutters

in which the cutter body is part of the shank. End mills are used

in tracer-controlled profile milling operations. They are

employed for making deep grooves in the base parts, profile

recesses, steps, perpendicular planes etc.

4. SIDE MILLING CUTTERS: These cutters have teeth on theperiphery and also on one or both sides. These cutters are made

in width from about 5mm to 25mm and in diameters from 50 to

200mm. Half-side milling cutters have teeth on only one side

and around the circumference.

5. ANGULAR MIILING CUTTERS: These are made as single ordouble-angle cutters are used to machine angles other than 90

0.

Some of the common cutters are the 450

and 600

single angle

cutter nad the 450,60

0,90

0double-angle cutters.

6. According to the purpose or use, we have t-slot milling cutters,woodruff keyslot milling cutters and dove tail cutters for

milling dovetail guides.

CUTTER MATERIALS: General purpose solid milling

cutters are made of H.S.S. some cutters are tungsten-carbide


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teeth which may be brazed on the tips of the teeth or

individually inserted and held in the body of the cutter by some

machanical means. Carbide tip cutters are especially adapted to

heavy cuts and increased cutting speeds.

CUTTING SPEEDS, FEEDS AND DEPTH OF CUT:

Since the milling cutter is a multi-point cutter, the feed may be

given as :

Feed per rev., mm/rev, f,=Feed per tooth,mm*number of cutter

teeth

Feed per min.(table feed),F= Feed per rev*cutter speed(r.p.m)

or F(mm/rev.)= ft*n*N

Where ft = feed rate per tooth,mm

n=number of cutter teeth

The r.p.m of the cutter is obtained as,

N=1000*V/3.14D

D is cutter diameter in mm. V is the cuting speed in m/min.

STRADDLE MILLING : It is a milling operation in which

a pair of side milling cutters is used for machining two parallel

vertical surfaces of a work piece simultaneously.


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Parallel facing by two side (single) cutter


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ANGULAR MILLING: It is a milling process which is used

for machining flat surfaces at an angle, other than right angle to

the axis of the revolving cutter. The cutter used may be a single

or double angle cutter depending upon whether a single surface

is to be machined or two mutually inclined surfaces

simultaneously.

GANG MILLING: It is the name given to the milling

operation which involves the use of a combination of more than

two cutters, mounted on a common arbor, for milling a number

of flat horizontal and vertical surfaces of a work piece

simultaneously. This combination may consist of only side

milling.


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DRILLING PROCESS

DRILLING PROCESS: The drilling process is extensively

used machining operation by which through or blinf holes are

cut or originated in a workpiece. The drilling tool is called a

drill is a multi-point cutting tool. The hole is produced by

axially feeding the rotating drill into the workpiece which is

held on the table of the drilling machine.

DRILLING TOOLS: The most widely employed drillingtool is a twist drill with two cutting edges or lips. A twist drill

consists of the following main parts: the point, the body, the

neck and the shank. The point comprises the cutting elements

while the body guides the drill in operation. The body of the

twist drill has two grooves called flutes cut into its surface.

The flutes form cutting surface and also assists in removing the

chips out of the drilled hole and making the coolant to get tio

the edges. The drill is held and rotated by its shank. The cutting

edges are straight and are separated by web thickness of the

drill. To help provide adequate strength and rigidity to the drill,

the web becomes progressively thicker towards the shank.

DRILLING MACHINES: Drilling machines are classified

into: general purpose, single-purpose and specialized drilling

machines.

General Purpose machines: Any hole making operation can

be performed in the general purpose machines. This class

includes:

1. Bench type drill press.


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2. Single and multiple spindle upright drill press.

3. Radial drilling machines and others.

Single purpose machines: This class includes:

1. Centre-drilling and deep holing machines2. Semi-automatic and automatic drilling machines.


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BROACHING PROCESS

BROACHING: Broaching is a process of machining a

surface with a special multipoint tool called a broach whose

teeth remove the whole machining allowance in a single stroke.

The process differs from other machining processes in that the

only motion is the primary cutting motion of the tool. The feed

is obtained by placing the teeth progressively deeper with in the

tool, thus, each tool edge takes off a successive layer of the

material. The primary cutting motion is translational along the

broach axis.

Broaching is used for machining through holes of any cross

sectional shape, straight and helical slots, external surfaces of

various shapes, external and internal toothed gears, splines,

keyways and rifling. Broaching of inside surfaces is called

internal or hole broaching and that of the outside surfaces as

Surface broaching. Typical internal broaching operations are :

the sizing of holes, cutting of serrations, straight or helical

splines, keyways and gun rifling.

Although the cutting speeds used in broach are relatively low(2

to 5 m per min.) , the production rate is very high since the total

length of the cutting edges that are simaltaneously in operation

is very great.

Material: High speed steel (H.S.S) is by far the most widely

used material for the broaches. Carbide tools are also used to an

advantage on steel casting to offset the damaging effect of local

hard spots.


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Types of broaching machines:

1. Internal broaching machines:a) Vertical pull down broaching machines: In these machines, the

broach, instead of being pushed, is pulled through the job. The

pulling mechanism is in the base of the machine. The broach is

suspended above the work-table by an upper carriage. To start

the broaching operation, the broach is lowered through the

workpiece held in a fixture on the worktable. The broach is

automatically engaged by the pullingmechanism and is pulled

down through the job. After the completion of operation, the

broach returns to its starting position.

b) Vertical pull up broaching machines: Here, the pushingmechanism is above the worktable and the broach is I the base

of the machine. The broach enters the job held against the

underside of the table and is pull upward. At the end of the

operation, the work is free and falls down into a container.

REAMING

REAMING: It is an operation to finishing the hole to bring it

to accurate size and have a fine surface finish. The operation is

performed by a multitooth tool called reamer. The operation

serves to produce a straight, smooth and accurate hole. The

accuracy is expected is within plus-minus 0.005mm


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TAPPING

TAPPING:It is the operation done for forming internal threads

by means of the tool called tap. To perform this operation the

machine should be equipped with a reversible motor or some

other reversing mechanism.

TAP DRILL SIZE: For tapping, the size of the hole to be

made through drilling has to be smaller than the size of the tap.

It is because the tap size is equal to the outside diameter of the

threads whereas the size of the drill o be used before tapping

should be equal to the core diameter of the threads.

For common usage approximate tap-drill size given by a rule:

Drill size= 0.8*tap size

ng cutters or of side and plain milling cutters.

INDUCTION HARDENING

INDUCTION HARDENING: It is a form of heat treatment in

which a metalpart is heated by induction heating and then

quenched. The quenched metal undergoes a martensitic

transformation, increasing the hardness and brittleness of the part.

Induction hardening is used to selectively harden areas of a part or

assembly without affecting the properties of the part as a whole .

Induction heating is a non contact heating process which utilises

the principle of electromagnetic induction to produce heat inside

the surface layer of a work-piece. By placing a conductive material

into a strong alternating magnetic field electrical current can be

made to flow in the steel thereby creating heat due to the I2R

losses in the material. In magnetic materials, further heat is


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generated below the curie point due to hysteresis losses. The

current generated flows predominantly in the surface layer, the

depth of this layer being dictated by the frequency of the

alternating field, the surface power density, the permeability of the

material, the heat time and the diameter of the bar or material

thickness. By quenching this heated layer in water, oil or a

polymer based quench the surface layer is altered to form a

martensitic structure which is harder than the base metal.

BURNISHING

BURNISHING: Burnishing operation is the process of getting a

smooth and shiny surface by contact and rubbing of the surface

against the walls of a hard tool. It is a finish and strengthening

process.


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TOOL ROOM

JIGS AND FIXTURES: Jigs and fixtures are the devices

which help in increasing the rate of production of identical

parts and simaltaneously reducing the human efforts requiredfor producing these parts. Suitable devices has to be used for

holding and locating purposes so that the repition of work can

be done economically. These devices are called jigs and

fixtures.

ADVANTAGES OF JIGS AND FIXTURE

1. They enable easy means for manufacturing of interchangeableparts and thus facilitate easy and qiuck work.

2. Pre-machining operations, like marking, measuring, lay-out, etc.required in case of individual parts, are totally eliminated with

the use of jigs and fixtures.

3. Once a properly designed jig or fixture is set up in position, anynumber of identical parts can be produced without any

additional setup.

4.

Production capacity is increased with their use because of singleset up.

5. Reduce the work handling time6. They offer a high clamping rigidity. Therefore, higher speed,

feed and depth of cut can be used for machining.


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7. Machining accuracy is increased because of the automaticlocation of the work.

8. The parts produced with their use are very accurate. As such,the expenditure due to inspection and control of finished

components is considerably reduced.

9. There is large reduction in fatique to the operator. Enablesmachining of complex and heavy components.

10.Needs less skilled labour, and effecting in reducing labour cost.


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INSPECTION & QUALITYCONTROL

It is an essential component of production control through

which the necessary control over the quality of a product is

maintained right from the raw material stage to the final

finished stage. It is , thus, a tool for controlling the quality of a

product and assess its acceptability.

OBJECTIVES OF INSPECTION

THE MAIN OBJECTIVES OF INSPECTION ARE:

1. To separate the defective products from the acceptable onesand, thus, ensure proper quality standards of the products.

2. By doing so, to prevent the defective or sub-quality productsfrom reaching the assembly stage and hence, the customer.

3. Thus, to prevent the chances of lowering of image andreputation of an industry and at the same time protecting the

interests of the customers.

4. To find out defects in raw material and errors in workmanshipto prevent use of defective materials and further processing of

defective parts.

5. To find out errors in processing, feedback this information tothe concerned people to enable them to take corrective steps to

prevent manufacture of poor quality products.


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6. To collect and compile information about the performance ofthe product, which is used by several departments like

engineering, design, production, purchase, quality control, etc

MAIN FUNCTIONS OF INSPECTION

DEPARTMENT ARE:1. To inspect the incoming raw material.2. To carry out metallurgical operations.3. To carry out tests for determining mechanical and physical

properties.

4. To inspect the parts made from outside on sub-contract basis.5. To inspect standard components purchased from outside.6. To carry out in-process inspection.7. To inspect cuttingand other tools purchase from outside.8. To inspect reground tools, jigs and fixtures before they are

issued for use.

9. To periodically check the gauging equipment and measuringinstruments for their accuracy.

10.To inspect finished products.11.To detect errors in production methods and design of products

and report them to appropriate authorities for remedial

measures.

12.To segregate products which can be salvaged throughreworking, those which can be used and those which are to be

totally rejected.


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MEASURING INSTRUMENTS

MICROMETER: The micrometer is a precision measuring

instrument, used by engineers. Each revolution of the rachet

moves the spindle face 0.5mm towards the anvil face. The

object to be measured is placed between the anvil face and the

spindle face. The rachet is turned clockwise until the object is

trapped between these two surfaces and the rachet makes a

clicking noise. This means that the rachet cannot be tightened

any more and the measurement can be read.

Least count=0.01

Vernier caliper: The Vernier Caliper is a precision instrument

that can be used to measure internal and external distances

extremely accurately. The example shown below is a manual

caliper. Measurements are interpreted from the scale by the

user. This is more difficult than using a digital vernier caliper

which has an LCD digital display on which the reading appears.

The manual version has both an imperial and metric scale.

Manually operated vernier calipers can still be bought and

remain popular because they are much cheaper than the digital

version. Also, the digital version requires a small battery

whereas the manual version does not need any power source.

Least count= 0.02


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FORK SECTION

COMPONENTS

1-2, water cool 3-4 water cool 5-6 jaw 4-5 GT-51 Shifter fork Implus draft river Differential lock

PROCESSES/OPERATION

Fork 2nd gear shifter

Raw material inspection Drilling Reference facing Total length Chamfer Broaching Reference face grinding Pad milling Gap milling Angle milling Slot milling Spot milling Drilling


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Chamfer Tapping Burring Pad height Pad finish De burring Induction hardening Final inspection


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CNC SECTION COMPONENTS

Crank Sensor Spindle Brake Drum Guide Bush 3-Star Hydraulic Arm Lifter

PROCESS/OPERATION

CNC facing CNC turning CNC grooving Drilling Boring Reaming


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Chamfering Broaching

Hydraulic arm lifter

Crank

Documents

Six week training report on Machining