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CHAPTER 1
INTRODUCTION

1.1 EXECUTIVE SUMMARY

M/s. Sri Ram Tek is situated in Hebbal industrial estate Mysore, Karnataka, near
outer Ring road Mysore. M/s Sri Ram Tek commenced in commercial production in
the year 2010.
M/s Sri Ram Tek is engaged in the manufacturing of industrial gear components and
shafts namely cover intermediate, carrier seal, locking plate, pump mounting cover.

1. INTRODUCTION- Type of the company where internship carried out

2. PRODUCTS/SERVICE -Products manufactured and its distribution
3. PROCESSING – Activities carried out in the organization
4. FACILITY LAYOUT AND LOCATION- equipments available ,layout
diagram
5. CRITICAL OBSERVATION- made during internship program- Learning
happened
6. MAPPING- connecting observed activities to the subject studied in BE
7. IMPROVEMENT / SUGGESTION – made by students team
8. CONCLUSION

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CHAPTER 2
PRODUCTS
2.1 SHAFTS

A shaft is a rotating machine element, usually circular in cross section, which is used

to transmit power from one part to another, or from a machine which produces power
to a machine which absorbs power.

The material used for ordinary shafts is mild steel. When high strength is required,
an alloy steel such as nickel, nickel-chromium or chromium-vanadium steel is used.
Shafts are generally formed by hot rolling and finished to size by cold
drawing or turning and grinding.

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Fig:2.1 SHAFT

2.2 GEAR COMPONENTS

Gear, machine component consisting of a toothed wheel attached to a rotating shaft.

Gears operate in pairs to transmit and modify rotary motion and torque (turning
force) without slip, the teeth of one gear engaging the teeth on a mating gear.

Most gears are circular. To transmit motion smoothly and with a nonvarying
speed ratio at every instant, the contacting surfaces of gear teeth must be carefully
shaped to a specific profile. If the smaller of a gear pair (the pinion) is on the driving
shaft, the pair acts to reduce speed and to amplify torque; if the pinion is on the
driven shaft the pair acts as a speed increaser and a torque reducer. If the driven gear
has twice as many teeth as the pinion, for example, the torque of the driven gear is
twice the pinion torque, whereas the pinion speed is twice the speed of the driven
gear.

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FIG:2.21 FIG:2.22

2.3 PRESS TOOL

Press tools are commonly used in hydraulic, pneumatic, and mechanical presses to
produce the sheet metal components in large volumes. Generally press tools are
categorized by the types of operation performed using the tool, such as Blanking,
Piercing, Bending, Forming, Forging, Trimming.

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FIG:2.3 PRESS TOOL

2.4 PUMP MOUNTING COVERS

These are used to seal the inside of the pump to atmosphere to prevent the
leakage and retain the pressure, it is used to hold the pump tightly to the body to
increase the pressure.

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2.5 LOCKING PLATES

3.5mm PHMA locking plate (Proximal Humeral Multi Angle) Hole

3H,4H,5H,6H,7H,8H,9H,10H,11H,12H. (Stainless Steel & Titanium). These are
used as surgical tools used to stabilize fractures. They differ from standard plates in
that the screw heads lock into the plate, providing a composite unit, or ‘fixed-angle
device’. Standard plates are compressed against the underlying done by the pressure
applied using normal screws.

CHAPTER 3
MACHINES
3.1 CNC (Computer Numerical Control Machine)
CNC Turning is a manufacturing process in which bars of material are held in a chuck and rotated
while a tool is fed to the piece to remove material to create the desired shape. A turret (shown
centre), with tooling attached is programmed to move to the bar of raw material and remove

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material to create the programmed result. This is also called “subtraction machining” since it
involves material removal. If the centre has both tuning and milling capabilities, such as the one
above, the rotation can be stopped to allow for milling out of other shapes.

The starting material, though usual round, can be other shapes such as squares or hexagons.
Depending on the bar feeder, the bar length can vary. This affects how much handling is required
for volume jobs.
CNC lathes or turning centres have tooling mounted on a turret which is computer-controlled. The
more tools that that the turret can hold, the more options are available for complexities on the part.

 Company – ASKAR
 Chuck dia – up to 250mm
 Job dia – up to 300mm
 Job length – up to 500mm

FIG:3.1 CNC Machine

3.2 HORIZONTAL BANDSAW

A Horizontal bandsaw (also written band saw) is a power saw with a long,
sharp blade consisting of a continuous band of toothed metal stretched between two
or morewheels to cut material. They are used principally
in woodworking, metalworking, and lumbering, but may cut a variety of materials.
Advantages include uniform cutting action as a result of an evenly distributed tooth

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load, and the ability to cut irregular or curved shapes like a jigsaw The minimum
radius of a curve is determined by the width of the band and its kerf. Most bandsaws
have two wheels rotating in the same plane, one of which is powered, although some
may have three or four to distribute the load. The blade itself can come in a variety
of sizes and tooth pitches (teeth per inch, or TPI), which enables the machine to be
highly versatile and able to cut a wide variety of materials including wood, metal and
plastic.

 Company – MANFORD
 Fully automatic
 Job dia – 20mm-250mm
 Cutting blade
19mm/1mm*2600mm

FIG:3.2 Horizontal Band saw

3.3 DRILLING/MILLING MACHINE

Milling is the process of machining using rotary cutters to remove material by advancing a cutter

into a workpiece. This may be done varying direction on one or several axes, cutter head speed, and
pressure. Milling covers a wide variety of different operations and machines, on scales from small
individual parts to large, heavy-duty gang milling operations. It is one of the most commonly used
processes for machining custom parts to precise tolerances.
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Milling can be done with a wide range of machine tools. The original class of machine tools for
milling was the milling machine (often called a mill). After the advent of computer numerical
control (CNC) in the 1960s, milling machines evolved into machining centres: milling machines
augmented by automatic tool changers, tool magazines or carousels, CNC capability, coolant
systems, and enclosures. Milling centres are generally classified as vertical machining centres
(VMCs) or horizontal machining centres (HMCs).

The integration of milling into turning environments, and vice versa, began with live tooling for
lathes and the occasional use of mills for turning operations. This led to a new class of machine
tools, multitasking machines (MTMs), which are purpose-built to facilitate milling and turning
within the same work envelope.

 Company – MANFORD
 Bed Length –
1000mm/300mm

FIG:3.3 Drilling/milling Machine

CHAPTER 4
MANUFACTURING SEQUENCE
4.1 FLOW PROCESS

DESIGNING

RAW MATERIAL SELECTION

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BAR STOCK FORGING

 METAL CUTTING

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DRILLING

CNC TURN

GEAR CUTTING KEY WAY

HEAT TREATMENT

GEAR/BORE GRINDING

QUALITY ANALYSIS

PRODUCT

 DESIGNING
A design is a plan or specification for the construction of an object or system or
for the implementation of an activity or process, or the result of that plan or
specification in the form of a prototype, product or process. The verb to design
expresses the process of developing a design. In some cases, the direct
construction of an object without an explicit prior plan (such as in craftwork,
some engineering, coding, and graphic design) may also be considered to be a
design activity. The design usually has to satisfy certain goals and constraints,
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may take into account aesthetic, functional, economic, or socio-political

considerations, and is expected to interact with a certain environment. Major
examples of designs include architectural blueprints, engineering drawings,
business processes, circuit diagrams, and sewing patterns.
The person who produces a design is called a designer, which is a term generally
used for people who work professionally in one of the various design areas—
usually specifying which area is being dealt with (such as a fashion designer,
product designer, web designer or interior designer), but also others such as
architects and engineers. A designer's sequence of activities is called a design
process, possibly using design methods.
There are several types of software to carry out machine design
 AutoCAD

 Solid Works

 NX

 Fusion 360

 CATIA/ProE

 RAW MATERIAL SELECTION

The materials selection process already described is more closely associated with the
activities of technical (or engineering) design. As a consequence, the approaches
adopted for materials selection are by far the most developed for this design
discipline. There are many systematic methods, most numerically based, with some
implemented as computer software tools, for matching material properties with
technical design requirements. There is also relatively easy access to a lot of detailed

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and verifiable technical information (materials and design) available from many
different sources (organizations and publications). These facilities are particularly
useful for novice product designers involved in materials selection.
Raw materials, including ingredients, processing aids, and packaging, are the
foundation of finished food products. As such, they must meet not only your
specifications, but also regulatory requirements.
The material used in Production by this Company
 HCHS-Stainless Steel.

 HCHB-Phosphor Bronze.

 OHNS-oil hardening, non-deforming tool steel which can be

hardened at relatively low temperatures.

 16MnCr5- Structural steel for parts that are surface hardened. It is a

special alloy steel.

 20MnCr5- Case hardening steel with low carbon content.

 BAR STOCK
Bar stock, also (colloquially) known as blank, slug or billet is a common form of
raw purified metal, used by industry to manufacture metal parts and products. Bar
stock is available in a variety of extrusion shapes and lengths. The most common
shapes are round (circular cross-section), rectangular, square and hexagonal or hex.
A bar is characterised by an "enclosed invariant convex cross-section", meaning that
pipes, angle stock and objects with varying diameter are not considered bar stock.

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Bar stock is commonly processed by a sequence of sawing, turning, milling, drilling

and grinding to produce a final product, often vastly different from the original stock.
In some cases, the process is partially automated by specialized equipment which
feeds the stock into the appropriate processing machine.

FIG:4.12 BAR STOCK

 FORGING
Forging isa manufacturing process involving the shaping of metal using
localized compressive forces. The blows are delivered with a hammer (often a power
hammer) or a die. Forging is often classified according to the temperature at which it
is performed: cold forging (a type of cold working), warm forging, or hot forging (a
type of hot working). For the latter two, the metal is heated, usually in a forge.
Forged parts can range in weight from less than a kilogram to hundreds of metric
tons. Forging has been done by smiths for millennia, the traditional products

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were kitchenware, hardware, hand tools, edge weapons, cymbals, and jewellery.

Since the Industrial Revolution, forged parts are widely used
in mechanisms and machines wherever a component requires high strength;
such forgings usually require further processing (such as machining) to achieve a
finished part. Today, forging is a major worldwide industry.

FIG:4.13 FORGING

 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.Drilled holes are characterized by their
sharp edge on the entrance side and the presence of burrs on the exit side (unless
they have been removed). Also, the inside of the hole usually has helical feed marks.

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Drilling may affect the mechanical properties of the workpiece by creating low
residual stresses around the hole opening and a very thin layer of highly stressed and
disturbed material on the newly formed surface.

FIG:4.14 DRILLING

 CNC TURNING
CNC Turning is a manufacturing process in which bars of material are held in a
chuck and rotated while a tool is fed to the piece to remove material to create the
desired shape. A turret (shown centre), with tooling attached is programmed to move
to the bar of raw material and remove material to create the programmed result. This
is also called “subtraction machining” since it involves material removal. If the
centre has both tuning and milling capabilities, such as the one above, the rotation
can be stopped to allow for milling out of other shapes.

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There are many different kinds of CNC turning centres with various types of tooling
options, spindle options, outer diameter limitations as well as power and speed
capabilities that affect the types of parts that can be economically made on it.
Depending on the bar feeder, the bar length can vary. This affects how much
handling is required for volume jobs. CNC lathes or turning centres have tooling
mounted on a turret which is computer-controlled. The more tools that that the turret
can hold, the more options are available for complexities on the part.

FIG:4.15 CNC TURN

 GEAR CUTTING
Gear cutting is any machining process for creating a gear. The most common gear-
cutting processes include hobbling, broaching, milling, and grinding. Such cutting
operations may occur either after or instead of forming processes such
as forging, extruding, investment casting, or sand casting.
Gears are commonly made from metal, plastic, and wood. Although gear cutting is a
substantial industry, many metal and plastic gears are made without cutting, by
processes such as die casting or injection moulding. Some metal gears made

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with powder metallurgy require subsequent machining, whereas others are complete

after sintering. Likewise, metal or plastic gears made with additive
manufacturing may or may not require finishing by cutting, depending on
application.

FIG:4.16 GEAR CUTTING

 HEAT TREATMENT
Heat treatment is the process of heating metal without letting it reach its molten, or
melting, stage, and then cooling the metal in a controlled way to select desired
mechanical properties. Heat treatment is used to either make metal stronger or more
malleable, more resistant to abrasion or more ductile.
Heat treating (or heat treatment) is a group of industrial, thermal
and metalworking processes used to alter the physical, and sometimes chemical,

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properties of a material. The most common application is metallurgical. Heat

treatments are also used in the manufacture of many other materials, such as glass.
Heat treatment involves the use of heating or chilling, normally to extreme
temperatures, to achieve the desired result such as hardening or softening of a
material.

FIG:4.17 HEAT TREATMENT PROCESS

 GEAR/BORE GRINDING
Gear grinding process is the method of finish grinding gear teeth and is a significant
step when building high precision gearing. Gears with precision ground teeth work
more softly and consume more evenly than gears with cut teeth. Normally, gear
grinding process is done after gear has been cut and heat-treated to high
hardness. Grinding is essential for parts above 350 HB (38 HRC) where cutting

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becomes very hard. Teeth produced by grinding are normally those of definite pitch,
where the number of metals extracted is very small.
In gear manufacturing, gear grinding is a finishing method which utilizes abrasive
wheels to exclude small variations on gear teeth. It is generally known to be the most
perfect way to end a high precision gear, giving a more accurate tooth finish than
gear cutting.

FIG:4.18 GEAR GRINDING

 QUALITY ANALYSIS
Quality analysis is one of the major aspects in software development and
maintenance. Quality analysis and assurance gives high quality end products and
customersatisfaction. Experts in various testing, automation and quality assurance
methods are in high demand with a great career scope.
 PRODUCT
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The Final Product is done after these all process is done step by step with
a greater precession work undergoing all the process. Below given are
some of the products produced by the company.

1. SHAFT 2. GEAR COMPONENT

3.PRESS TOOL

CHAPTER 5
MEASURING INSTRUMENTS
5.1 VERNIER CALIPER

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A vernier scale is visual aid to take an accurate measurement reading between

two graduation markings on a linear scale by using mechanical interpolation;
thereby. increasing resolution and reducing measurement uncertainty by
using vernier acuity to reduce human estimation error.

The vernier is a subsidiary scale replacing a single measured-value pointer, and has
for instance ten divisions equal in distance to nine divisions on the main scale. The
interpolated reading is obtained by observing which of the vernier scale graduations
is co-incident with a graduation on the main scale, which is easier to perceive than
visual estimation between two points. Such an arrangement can go to a higher
resolution by using a higher scale ratio, known as the vernier constant. A vernier may
be used on circular or straight scales where a simple linear mechanism is adequate.
Examples are calipers and micrometers to measure to fine tolerances,
on sextants for navigation, on theodolites in surveying, and generally on scientific
instruments.

FIG:5.1 VERNIER CALIPER

5.2 MICROMETER

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A micrometer, sometimes known as a micrometer screw gauge, is a

device.incorporatinga calibrated screw widely used for accurate measurementof
components
In mechanical engineering and machining as well as most mechanical trades, along
with other metrological instruments suchas dial, vernier, and digital calipers.
Micrometers are usually, but not always, in the form of calipers (opposing ends
joined by a frame). The spindle is a very accurately machined screw and the object to
be measured is placed between the spindle and the anvil. The spindle is moved by
turning the ratchet knob or thimble until the object to be measured is lightly touched
by both the spindle and the anvi.

FIG5.2: MICROMETER

5.3 DIAL GAUGE

A dial test indicator, also known as a lever arm test indicator or finger indicator, has
a smaller measuring range than a standard dial indicator. A test indicator measures
the deflection of the arm, the probe does not retract but swings in an arc around its
hinge point. The lever may be interchanged for length or ball diameter, and permits
measurements to be taken in narrow grooves and small bores where the body of a
probe type may not reach. The model shown is bidirectional, some types may have to
be switched via a side lever to be able to measure in the opposite direction.

5.4 BORE GAUGE

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The gauges are locked by twisting the knurled end of the handles, this action is

performed to exert a small amount of friction on the telescopic portions of the gauge
(the smaller diameter rods found at the T head of the gauge). To use, the gauge is
inserted at a slight angle to the bore and gently locked to a size slightly larger than
the bore while at that angle. Then, rocking the handle side-to-side, slowly move the
handle across the bore to the other side. The rocking will first align the gauge with
the bore axis and the act of moving the handle to the other side of the bore will bring
it to the exact bore diameter. This action compresses the two anvils where they
remain locked at the bores dimension after being withdrawn.

5.5 ENGINEERING SQUARE

A machinist square or engineer's square is the metalworkers' equivalent of a try
square. It consists of a steel blade inserted and either welded or pinned into a heavier
body at an angle of 90°.Usually a small notch is present at the inside corner of the
square. This prevents small particles from accumulating at the juncture and affecting
the square's reading.

5.6 THREAD GAUGE

Thread pitch gauges are used as a reference tool in determining the pitch of a thread
that is on a screw or in a tapped hole. This tool is not used as a precision measuring
instrument, rather it allows the user to determine the profile of the given thread and
quickly categorize the thread by shape and pitch. This device also saves time, in that
it removes the need for the user to measure and calculate the pitch of the threaded
item.

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CONCLUSION

It was a new insight for us in the industrial environment, as we got to have a live
experience of all the processes and as well as the day to day functioning of
corporation. Apart from all the technical aspects we also got to know many more
things about non-technical aspects like corporate ethics and values, and how the
people in the working environment communicate with each other on daily basis. We
got the chance to explore the industry and had a detailed and informative tour of the
industry floor plan. We also got to know about the bill of materials and what are the
necessary transactions taking place or the communication between the customer and
seller before the actual process of manufacturing occurs. This was our first
experience in M/s. Sri Ram Tek various Gear components and shafts being
assembled from the first stage.
We are thankful to everyone who has helped us to make this learning experience so
amazing.
We also like to give a special thanks to our both internal and external guides for all
the support and guiding us throughout the internship.

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