Practical Training Report

On
ASSEMBLY OF CNC TURNING MACHINE

RICO AUTO INDUSTRIES,GURGAON

Submitted in partial fulfillment for the award of the degree of

BACHELOR OF TECHNOLOGY

In

Mechanical Engineering

2018-2019

Submitted to: - Submitted by:-

Mr. SANDEEP JHAMB DEVENDRA SINGH
Head of Department SHEKHAWAT
Mechanical Department 15EAIME721
B.Tech IV Yr. VII Sem.
RAJASTHAN TECHNICAL UNIVERSITY, KOTA

DEPARTMENT OF MECHANICAL ENGINEERING

ARYA INSTITUTE OF ENGINEERING & TECHNOLOGY
SP-40, RIICO INDUSTRIAL AREA, KUKAS, JAIPUR, RAJASTHAN

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 CERTIFICATE

This is to certify that the Practical Training report for Casting and Assembly of CNC Turning

Mschine taken at RICO AUTO INDUSTRIES LTD. GURUGRAM from 7th MAY

2018 to 7th JULY 2018 is submitted by Devendra singh shekhawat in partial

fulfillment for the award of degree of Bachelor of Technology in Mechanical Engineering has

been found satisfactory and is approved for submission

(PTS GUIDE) (PTS INCHARGE)

Mr. Pankaj Kumar Mr. Gurmeet Singh

Assistant Professor Assistant Professor
Department Of Mechanical Engg. Department Of Mechanical Engg.

Mr. Sandeep Jhamb

(Head Of Department)
Department Of Mechanical Engineering

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 ACKNOWLEDGEMENT

I would like to express my sincere gratitude to Dr. Arvind Agarwal, chairman Arya group of
colleges and Dr. Puja Agarwal, group director Arya group of colleges for providing me such a
great infrastructure and environment for my overall development.
I am grateful to Mr. Yogesh Bhomiyaa, Principal and Mr. Sandeep Jhamb, Head Of
Department of mechanical Engineering, for their necessary guidance in the fulfillment of this
PTS report
I would like to express my heartfelt gratitude to our PTS coordinators Mr. Gurmeet Singh
and Mr. Pnakaj Kumar for their valuable.

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LIST OF TABLES

TABLE NO. TABLE NAME PAGE NO.

1.1 PRODUCTS OF RICO

3.1 PROPERTIES OF CAST IRON

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CONTENT

CERTIFICATES FROM DEPARTMENTS

CERTIFICATE FROM COMPANY

ACKNOWLEDGEMENT

ABSTRACT

LIST OF FIGURES

LIST OF TABLES

1. CHAPTER 1

1.1 Introduction

1.2 Rico Auto Industries-

1.3 Plant Specification-

2. CHAPTER 2

2.1 Casting

2.2 Aluminum Casting

2.3 Ferrous Casting

2.4 Fettling

3. CHAPTER 3

3.1 Definition of Assembly

3.2 Assembly Of CNC Turning Machine-

3.3 Assembling Part of CNC Turning machine

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 CHAPTER 1

1.1 INTRODUCTION

The training report is about the manufacturing the product of RICO Auto Industries Ltd.

RICO AUTO is a dynamic world class engineering company supplying a wide range of

high precision fully machined ferrous and aluminum components and assembles them

and transport it to various countries.

COMPANY PROFILE

Rico is known for supplying a wide range of automotive components throughout the
globe. It is a world-class engineering company as we say supply a wide range of high
machined aluminum and ferrous components .
Rico’s has a annual total turnover is over Rs 1500 Crore. Rico provide services like
design, development, tooling, casting, machining and assembly of ferrous and aluminum
products.

HISTORY

It is established in 1983 by Arvind Kapur and Arun kapur.

1986
Rico Auto Industries is started in 1983 but commercial production is Started in1986 and
aluminum HPDC Plant is set up in Dharuhera which is 40 Km distance from Delhi, India

1992

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The Ferrous Casting & Machining Plant is set up in Gurgaon which is 20 Km from
Delhi, India and entered International market as OEM Supplier to MEC Japan.

1996

It started supplying globally to United states & UK.

2000
In 2000 the second aluminum HPDC & machining plant is set up in Gurgaon, Haryana

2002

In 2002 Rico Auto Industries setup the full service Engineering and setup Design &
Development function in Gurgaon and added Ford, Jaguar, Land Rover as customer.

2004

In 2004 it expand the Ferrous & Aluminum Capacity and added Caterpillarl, Detroit
Diesel, Volvo as customer.

2004-06

In ths period R&D Center started in Gurgaon, Haryana and added Nissan, Tata, as
customer

2007

In 2007 JV with continental Automotive Systems JV with JINFEI CHINA (Aluminum

Alloy Wheels -2 Wheelers) Acquired 25 acres of land in Chennai India.

FUTURE PLANS OF THE FIRM :

 To reduce the dependency on other industries.

 Searching for new customers which will expand the market of the Rico products .
 Expansion of the firm.

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 Investment in the other profitable industrial sectors for increasing the growth.

Table no 1.1 products of Rico:

PRODUCTS CUSTOMER
Clutch assembly Hero –Honda
Wheel hub assembly Hero- Honda
Brake panel assembly Hero- Honda

CUSTOMER:
Hero & Honda is one of the leading company in vehicle manufacturing. The other major
customers of Rico are:
 Maruti Suzuki
 Jatco
 Ford motor company
 Jaguar
 Volvo
 Toyota

WASTAGES DURING PRODUCTION:

 over production of goods.

 Rejection of products.
 idle time
 unnecessary transportation and unnecessary transportation cost.

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OBJECTIVE OF RICO:
-
Primary Objective:

 The primary objective of Rico is to study the production department of RICO

Secondary Objectives

 To procure the inventory level

 To store the inventory
 To issue the inventory of the company

1.2 PLANT SPECIFICATION

Rico is known for the production of various automotive components and assembly is
done throughout the globe.

R&D Department (Research and development)

Research and development is the first stage of development of a product or the

production process.
In R&D department various activities are taken by the company’s employees to enhance
new services of the company or to increase the production of the company.
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Research and development may differ from in every industry with two primarily
functions of an Research and Development either staffed by engineers and tasked directly
developing new products or staffed with industrial scientists and tasked with applied
research in scientific or technological fields to improve the technology of the company.
Rico Auto Industries has highly skilled engineers which focuses on the development of
new products with desires specification.

FUNCTION OF R&D DEPARTMENT

Research of new product

Before making of new product the research and development department conducts a
complete study for the betterment of the project. The research study includes determining
specifications of the , cost of the production and time of production whose production is
going to be done . The research also help in determining the need for the product before
the design begins they ensure that it is a functional product that customers want to use.

Development of new product

The research guides the way for the development of product. This is the time when the
new product is actually developed. It is based on requirements and ideas created during
research process. The developed product should meet the product guide product
specifications.

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Check the Existing Product Updates of the company

The department has the responsibility to check the existing products of the company also
fall under research and development. The department regularly check the products
offered by the company to ensure they are still functional so that the production will stop.

Check the quality of products

In Rico Auto Industries the research and development team also handles the quality
checks of the products manufactured by the company. The department has a proper
knowledge of the requirements and specification of a particular project. This makes the
team members to ensure that product should meet the standards so the company can make
good quality products.

Innovation

The department is able to research and analyze the products other businesses are creating
as well as the new trends in the market. This research aids the department in developing
and updating the products created by the company. The team helps to direct the future of
the company.

ENGINEERING CAD &CAM

CAD (Computer Aided Design)

Rico uses CAD software for the design of various automotive components .Computer-
aided design (CAD) is the use of computer systems to aid in the creation, modification,
analysis of a design and to design the products with specification. CAD software is used
to increase the productivity of the industry and to improve the quality of designed
products, improve, and to create a database for manufacturing process. CAD output is

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often used in the form of electronic files for print, machining process, or other
manufacturing operations in the organization.

CAM (Computer Aided Machining)

Computer aided manufacturing (CAM) is an application technology that uses computer

software and machinery for the automatic manufacturing processes. CAM is the vital part
of computer-aided engineering (CAE) which is used with computer-aided design (CAD)
these two are the vital part of computer aided engineering. CAD is mainly used for
designing of 3D models or 2D drawings of components like design of machines, but it is
also used for the engineering process from conceptual design and layout of new products
and also used for the dynamic analysis of assemblies of products.

CASTING

Casting is a manufacturing process in which a liquid material is poured into a mold or

hollow cavity to make a product, which contains a hollow cavity of the desired shape
whose product is to be made and then allowed to solidify. The solidified part is also
known as a casting. There are two types of casting is done in Rico Auto Industries
aluminum and ferrous casting.

MACHINING & ASSEMBLY

Machining

Machining refers to the variety of actions on the raw material that take a raw material
and turn into product .The process of changing a raw material with the help of machines
with the help of actions performed on machines. It is also defined as a controlled process
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that takes raw material and transforms it into a product of desired specification andfinal
shape and size. This can include material-removal with such actions lke cutting, drilling
or boring, or material addition.

Assembly

Rico Auto Industries Limited is engaged in the manufacturing of clutch and crank case. It
manufactures and supplies high precision and machined components and assemblies,
both aluminum and ferrous products.
Assembly is the process of putting parts together to make a machine or any other
product.

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 CHAPTER 2

2.1 CASTING
Casting is a manufacturing process in which a liquid material is usually poured into a
mold or cavity of desired shape which is going to be made and then allowed to solidify.
The solidified part is also known as a casting. which is drawn out or broken out of the
mold to complete the process of casting. Casting materials are usually metals or various
cold setting materials or alloys that made after mixing two or more metals together;
examples are epoxy, plaster and clay.

fig no.2.1 Aluminum casting

Casting is most often used for making complex shapes that would be otherwise difficult
or uneconomical to make by other methods. Which is difficult to make products by
machining so casting is done
We are done two types of casting in Rico Auto Industries.
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1) Aluminum casting
2) Ferrous casting

2.2 ALUMINUM CASTING

We have melted the aluminum in the foundry shop.

Heat for about 10 minutes before placing aluminum inside the foundary. The
temperature in the foundry will need to be above 1220 O Fahrenheit (660O Celsius) it is
the melting temperature of aluminum. When the foundry is glowing orange, the foundry
is hot enough to melt aluminum.
Aluminium is a chemical element with symbol Al and have a atomic number 13. It is a
,soft, nonmagnetic and ductile metal.
Symbol of aluminum (Al)
Boiling point of aluminium is about2470oC.
Density of aluminium is about 2.70g/cm3.
Atomic number of aluminium is 13.

Rico has over 100 High Pressure Die Casting (High Pressure Die Casting Machines)
from 135 Ton to 2500 Ton locking force equipped with Real time Shot monitoring & and
controlled by industrial robots . Robots are used in such places because it is a dangerous
place and may harm the human being.

Rico is one of the largest High Pressure Die Casting facility in India.

Rico is currently producing over 50,000 MT of High Pressure Die Cast components per
annum.

Die Casting component weight range from 100gms to 15kgs

Current High Pressure Die Casting machines are from Buhler, Toshiba, ITAL Press
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THINGS TO KEPT IN MIND

Things which is kept in mind before casting are:

Proper pieces of aluminum.

The best sources for aluminum for the casting of aluminum is the scrap aluminum are old
machine parts. Car cylinder heads, water pump housings and pistons are good examples
and can be used for melting of aluminum. More common sources of aluminum like beer
and pop cans, furniture frames, home siding, window frames, and pie pans. However,
these sources tend to be weaker alloys and also have lots of impurities, which means that
they create more slag and oxidize quickly.

An easy and best way to melt aluminum cans and prevent oxidizing is to add them to a
already molten aluminum.

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 fig no 2.2.1 Casting safety

Wear proper safety equipment

When you are working around extremely high temperature that is the temperature around
the foundry is very high it is important to wear proper safety equipment so that it will not
affect you. When handling molten metal, you should wear a thick and long sleeved shirt,
pants or an apron, a face shield or glasses, and leather gloves so that it will not harm you.
These things will prevent molten metal from burning your skin. Because molten
aluminum can give off noxious gasses, you should also wear a respirator.

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fig no.2.1.2 Casting safety

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Find an open or well-ventilated space.

When you are working with molten aluminum or any other molten metal, some alloys
will give off noxious gases. To prevent from this you have to work in a well-ventilated
space or outdoors. This will also help keep you cool while working around extreme high
temperature and also avoid dehydration.

fig 2.1.3 Casting safety equipment

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Use proper tools or handling tools.

Before the beginning melting of aluminum or any other metal make sure that you have
the necessary or proper tools for handling the molten metal.

fig no.2.1.4 Casting safety

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Be safe during casting

Wear proper clothes and gloves and handle the molten metal with proper tool so that it
would not affect you or harm you .

If you are new to working with molten metals so be sure that to work under the guidance
of experienced person before attempting to melt aluminum.

ALUMINUM PRODUCTS

fig no 2.2.1 Wheel hub fig no 2.2.2 Crank case cover

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2.3 FERROUS CASTING

The die casting process forces molten metal under high pressure into mold cavities or
hollow cavities. Most die castings are made from nonferrous metals, such as zinc, copper,
and aluminum based alloys, but ferrous metal die castings are also done. Ferrous alloys
are iron alloys that has a use wide range of use in various industries because of its
unique properties like strength, toughness of iron, it is used for industrial applications.
These properties depends on the heating treatment which make the final structure or
product. Examples of ferrous alloys include carbon steels, alloy steels, stainless steels,
tool steels, cast iron, cast steel, and iron-based alloys.

Types of Ferrous Alloys

Various types of ferrous metals and alloys are available in the market:

Carbon steels are ferrous alloys that contain carbon and small levels of manganese or
aluminum.

Alloy steels contain low to high levels of elements such as chromium,, vanadium and
nickel.

Stainless steels are highly corrosion resistant metal and ferrous alloys that contain
chromium and nickel additions.

Cast iron is also a ferrous alloy contains high amounts of carbon like gray iron and white
cast iron grades are types of cast iron.

Cast steel alloys are made by pouring molten iron into a mold cavity.Cast Iron Alloy and
Iron Alloy are two major ferrous alloys which is used in industries for manufacturing
products .

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In Rico Auto Industries the ferrous casting is done by shell mold casting and sand
casting.

SHELL MOULD CASTING

Shell mold casting process in which the casting process that uses a resin covered sand to
form the mold.

In shell mold casting process the mold is made like a shell that is a thin or hollow mold is
used so that weight of mold is less and handling of mold or the metal is easier.

For manufacturing the thin mold a small amount of addition of silica sand are used as the
mold material.

For making shell-mold casting requires the use of a metal pattern, oven, sand-resin
mixture, dump box and molten metal.

Shell-mold casting allows the use of both ferrous and non-ferrous metals, most
commonly used metals in casting are cast iron, carbon steel, alloy steel, stainless steel,
aluminum alloys and copper alloys.

The shell-mold casting process consists of the following steps:

Creation of pattern for mold

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 A two-piece metal pattern is created in the shape of the desired pattern required.

Creation of mold

In beginning, each pattern is heated to 180o-380°C and coated with a proper lubricant for
the easy separation from the pattern formed. Next step is that the heated pattern is
clamped into the dump box. The dump box is inverted, which helps in sand-resin
mixture to coat the pattern. The heated pattern partially cures the mixture, which now
form a shell around the pattern. Each pattern half and surrounding shell is cured to
completion in an oven and then the shell is drawn out from the pattern and after that
finishing or fettling process is done to remove unwanted projections.

Mold assembly

After the creation of mold the mold assembly is done the two shell halves o rparts are
joined together and clamped securely to form the complete shell mold. If any cores are
required, they are inserted prior to closing the mold. The shell mold is then placed into a
flask and supported by a backing material.

Pouring

The mold is securely clamped together while the molten metal is poured from a ladle
into the gating system and fills the mold cavity.

Cooling

After the mold has been filled, the molten metal is made to cool and goes for cooling and
solidify the metal into the desired shape with desired specification.

Casting removal

After the cooling of the metal, the process is go for the removal of metal for the removal
the mold is broken and the casting is removed. The cleaning processes are done to

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remove any excess metal from the surface of metal and to separate the small sand
particles from the mold.

fig no 2.3.1 Shell mold casting

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SAND CASTING

Sand casting is also known as sand molded casting. It is a casting process by using sand
as the mold material. The term "sand casting" can also refer to a product is made with the
help of sand casting process. Sand castings is done in factories called foundries. About
75% of all metal castings is done by sand casting process.

In sand casting the mold is made of sand. The molds are relatively cheap because sand is
easily available and is in abundant quantity, and sufficient for refractory even for steel
foundry use. In addition to the sand, a suitable bonding agent such as clay is mixed or
occurs with the sand for increasing the strength. The mixture is moisturized with the help
of water but sometimes with other substances, to increase the strength of the clay and to
make the mold suitable for molding. The sand is put in a system of frames or mold boxes
which is also known as flask. The mold cavities and gate system are created around
models with the help of patterns, by inserted directly into the sand.

Automatic Molding Lines in Rico Auto Industries

Rico has the 2 automatic molding lines diametric size 750 x 545 and 2 Horizontal size
710 * 410

Alloys

It uses alloys like Gray Iron , Ductile Iron ,, SiMo Cr

Core making

Rico has inbuilt house core making facility and continuous online shot blasting facility,
Laser Controlled Pouring & Auto Inoculation and has a Component weight range from
100gms to 13 kg

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2.4FETTLING

Fettling is defined as the process of removing unwanted projection from the surface of
casting products. Fettling is the process by means of which a casting product is turned
into a effective quality product such that the product will meets all the standards which
the customer demanded. In casting process fettling means the removal of unwanted metal
for example, risers etc. It include the processes like chipping, grinding etc.

Fettling process

It is the removal unwanted projections like cores, gates runners, risers and chipping of
any of unnecessary projections on the surface of the casting metal.
.
Fettling operations can be divided into different stages which are knocking the dry sand
cores and removal of gates & riser and the removal of fins unwanted projections .

Dry sand cores may be removed by knocking with iron bar which is the sudden knocking
on the casting surface with the iron bar. Knocking can be done by pneumatic or
hydraulic devices this method is used for the small or medium work. For large castings,
the fettling process is the hydro blast process is employed for the effective removal of
metal.
Removal of gate and riser with chipping hammer By using cutting saw and flame cutting
With abrasive cut off machine for the cutting of abrasive material.

Fettling is done by:

By using chipping hammer

it is particularly suited in case of grey iron castings and brittle materials. The gates and
risers can easily be broken by hitting the hammer.

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With the help of cutting saw

These saws may be hand driven saw and power driven saw are used for cutting the
ferrous metals like steel and malleable iron and for nonferrous metals but doesnot usecd
for the aluminum casting products..
The hand saws are used for small and medium products but power saws are used for large
products and large work.

With the help of flame cutting

This method uses the flame for removing the unwanted metals from the surface of casting
or we can say for the fettling process. This type of method used for ferrous metals of
large size casting products where the risers and gates are very heavy and big.
In this process the gas cutting flames and arc cutting methods are used for the cutting
process.

With the help of abrasive cutting of machine

These machines are designed for hard metals which cannot be saw or sheared & also
where flame cutting and chipping is not feasible or the metals which is not removed by
other methods.

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 CHAPTER 3

3.1 ASSEMBLY

The connection and attachment of parts, subassemblies, and modules are joined in
sequence to produce a machine. More than one part is joined together to make a machine
is termed as assembly.
A module is a detachable or no detachable grouping of parts.
The feature of a module is that it can be assembled part from the other elements of the
final product.
A combination of two or more parts in a module with the help of nuts and bolts is called a
assembly..
The highest order assembly may be separated only into parts.
Assembly is the process of putting parts together or to join to make a machine or any
other product.

3.2 ASSEMBLY OF CNC TURNING MACHINE

In Rico Auto Industries we have done the assembly of CNC Turning Machine .
It is a CNC machine which is used to manufacture bike and car rims.

What is CNC Machine?

Numerical control is the automated control of machining tools by means of a computer.

An NC machine alters a blank piece of material to meet desired specifications with the
help of programmed instructions which can be either letters and without a manual
operator.

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CNC is refers to the Computer Numerical control. We have seen that the NC machine
works according to the program and instructions given into the controller unit of the
machine. The CNC machine has the mini computer or the microcomputer that is the
controller unit of the machine. While in the NC machine the program is fed in the form of
punch tapes, in CNC machines the program or instructions is given directly to the
computer with the help of CNC controller keyboard a small board similar to the
traditional keyboard.

In CNC machine the program and instructions according to which the CNC will work are
stored in the memory of the computer. The programmer can easily write the codes
manually in the computer, and also can edit the programs as per the requirements of the
machining product. These programs can be used for different parts, and they don’t have
to be repeated again and again.

As compared to the NC machine, the CNC machine oprovide the great accuracy and
desired specification and computational capability. New systems can be incorporated into
the CNC controller simply by reprogramming the unit.

HOW CNC MACHINE WORKS?

The CNC machine has the computer in which the program is fed for machining of the
metal of the job according to desired specification and requirements of the costumer. All
the cutting processes are done and all the final dimensions are fed into the computer with
the help of program or we can say as a program. Thus the computer knows what exactly
is to be done and carries out all the machining processes. CNC machine works like the
Robot which has to be fed with the program and it has follow all our instructions.

Some of the common machine processes that can be done on the CNC are:

Milling machines, Drilling Machine etc.

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The main important purpose of these machines is to remove some of the metal or the
cutting of metals so as to give a proper shape such as circular, helical, rectangular, etc. In
the general these machines are operated by the operators or experts in the operation of
these machines which can operate these machines easily. Most of the jobs need to be
machined accurately so the operator should be expert to make the precision jobs so that
the product is of good quality and doesn’t contain any error. In the CNC machines the
role of the operators is minimized. The operator has to instruct the computer with the help
of program or instructions and rest of the work is done by the computer automatically
that is the computer made the machine to work. The computer directs the machine tool to
perform various machining operations as per the program of instructions fed by the
operator.

We don’t have to worry about the accuracy of the job all the CNC machines are designed
to meet accuracies and desired specification and standard quality of product. In fact these
days for most of the precision jobs CNC machine is compulsory. When your job is
finished you don’t even have to remove it the machine does that for you and it picks up
the next job on its own. This way your machine can keep on doing the fabrication works
all the 24 hours of the day without the need of much monitoring, of course you will have
to feed it with the program initially and supply the required raw material.

Most of the manufacturing companies are now equipped with the CNC machines as the
markets have got very competitive; however, getting the expert labors for operating these
machines is becoming quite difficult. Even the machine operators of these days prefer to
operate the machine by programming instead of operating it manually. In most of the
machine tools training institutes the new operators are taught manual machining as well
as CNC machining and programming.

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WHAT IS CNC TURNING MACHINE?

It is a computer numerical control machine which is used to manufacture bikes and car
rims.

fig 3.2.1 CNC Turning Machine

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 fig no 3.2.2 Car rim

3.1 VARIOUS ASSEMBLING PARTS

Bed
Runner slide
LM guide ways (linear motion guide ways)
Ball screw & ball screw nut
Bearing block & Bearings
Cap
Seals
Chuck nut
Spacer
Cross slide
CNC control panel
Monitor

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BED

Bed is the base of the machine and it is made up of cast iron. It is the main building block
of machine.
The bed of the machine provides the foundation for the whole machine and holds the
headstock, tailstock and carriage in alignment and all the parts of machine. The surfaces
of the bed that are finely machined and upon which the carriage and tailstock slide are
known as ways.
All the parts of the machine such as the monitor, LM guide ways, CNC control panel are
placed on it. It is the stationary part of the machine.
The whole machine is withstand on it.

Why bed of a machine made up of cast iron?

Not all kinds of cast irons are used as machine base beds. But Grey Cast iron is used because of
having exceptional Damping Capacity because of its ability to absorb vibration. The bed is made
of cast iron because it has great strength and toughness which can bear any load of force..

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Table no.3.1 properties of cast iron

Nominal Yield
Elongation
composition Form and strength Tensile
Name [% (in Hardness Uses
[% by condition (0.2% strength
2 inches)]
weight] offset)]
Engine
cylinder
Grey cast blocks,
iron C 3.4, Si 1.8, flywheels,
Cast — 50 0.5 260
(ASTM Mn 0.5 gearbox
A48) cases,
machine tool
bases
White cast C 3.4, Si 0.7, Cast (as Bearing
— 25 0 450
iron Mn 0.6 cast) surfaces
Axle
Malleable
bearings,
iron C 2.5, Si 1.0, Cast
33 52 12 130 track wheels,
(ASTM Mn 0.55 (annealed)
automotive
A47)
crankshafts
C 3.4, P 0.1,
Ductile or Gears,
Mn 0.4,
nodular Cast 53 70 18 170 camshafts,
Ni 1.0,
iron crankshafts
Mg 0.06
Ductile or
nodular cast
iron — (quench 108 135 5 310 —
(ASTM tempered)
A339)
Ni-hard C 2.7, Si 0.6, Sand-cast — 55 — 550 High strength
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 type 2 Mn 0.5, applications
Ni 4.5, Cr 2.0
C 3.0, Si 2.0,
Resistance to
Ni-resist Mn 1.0,
Cast — 27 2 140 heat and
type 2 Ni 20.0,
corrosion
Cr 2.5

Grey cast iron has these property due to the presence of carbon in the form of graphite flakes.
The availability of graphite as a flake in grey cast iron enables to absorb the compressive and
vibrational loads and the dynamic and static forces without a crack.

In general, vibration can cause an unsatisfactory operation or error during manufacturing or

even failure.

For this reason, it is ideally suited for machine bases and supports made of cast iron.

Cast iron
A few common mechanical properties for cast iron include:

Hardness – material's resistance to abrasion.

Toughness – material's ability to absorb energy or bear any load.

Ductility – material's ability to be drawn into wires.

Elasticity – material's ability to return to its original length or dimension after it has been
deformed.

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RUNNER SLIDE

It is the moveable part of the machine and it is mounted on the linear motion guide ways.

fig .3.2.3 Runner slide

There are two runner slide ways are attached on the bed and on each runner slide ways there are
two LM guide ways are mounted.

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LM GUIDE WAYS

It stands for linear motion guide ways. A linear guide ways allows a type of linear motion that
utilizes rolling elements such as balls or rollers. By using recirculating elements between rail and
block, a linear guide way can achieve high precision linear motion as compared to traditional
slide.

The Guide way is one of the important elements of machine tool. . The main function of the
guide is to make sure that the cutting tool or machine tool is operative element moves along
predetermined path. The Linear Motion Guide ways provide a smooth and linear motion in
machine tools, due to which higher accuracy and precision can be obtained. Linear Motion Guide
ways (LM Guide ways) also known as Linear Motion bearings have a mechanism to bear the
load and to guide their linear motion simultaneously.

A linear guide way to a type of linear motion that uses rolling elements such as balls or rollers.
By using recirculating elements between rail and block, a linear guide way can achieve high
precision linear motion. Compared to traditional slide, the coefficient of friction is 1/50.

Structure of LM guide ways

Fig.3.2.4 LM guide ways

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The linear guides consist of a mechanism in which steel balls are circulated infinitely to enable
an infinite stroke of ball slides theoretically. Balls roll along the ball groove formed on a rail and
a ball slide and there, they are scooped at the point A by the tip of an end cap. There, they are
forced to change their circulating direction by a return guild of the end cap and guided to a
circulating direction to pass through the hole to the other end of the ball slide and further. go
through the circulation circuit to the tip of the end cap of the other side and then. return to the
ball grooves of rail and balls the balls repeat their endless circulation motion slide.

Advantage of LM guide ways

Following are the advantages of LM Guide ways due to which their demand for CNC
Machine under high precision work is increasing velocity measurements.
1. High Positional Accuracy when a load is driven by a LM guide way, the frictional
contact between load and bed desk is rolling contact. The coefficient of friction is only
1/50 of traditional contact linear measurement.
2. Long Life with high motion Accuracy With a traditional slide, errors in accuracy are
caused by the counter flow of oil film. Insufficient lubrication causes wear between the
contact surfaces. In contrast rolling contact has little wear, therefore machines can
achieve a long life with motion accuracy CNC feed drives.

BALL SCREW & BALL SCREW NUT

The ball screw assembly consists of a screw and a nut, the nut have helical grooves
which matches with the nut, and balls which roll between these grooves providing the
only contact between the nut and the screw. As the screw or nut rotates, the balls are
deflected by the deflector in the ball return system and it travel through the return system
to the opposite end of the ball nut in a continuous path.

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The circulating balls travel on the threads which are on the nut. The thread form of the screw and
nut, and balls are re-circulated through various types of return mechanisms. If the ball nut did not
have a return mechanism the balls would fall out of the end of the ball nut when they reached the
end of the nut. For this reason several different recirculation methods have been developed.

An external ball nut employs a stamped tube which picks up balls from the raceway by use of a
small pickup finger. Balls travel inside of the tube and are then replaced back in the thread
raceway.

A ball screw is a mechanical linear actuator that translates rotational motion to linear
motion with little friction. A threaded shaft provides a helical raceway for ball bearings
which act as a precision screw.

fig.3.2.4 Ball screw and nut

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As well as being able to apply or withstand high thrust loads, they can do so with minimum
internal friction. They are made to close tolerances and are therefore suitable for use in
situations.

BEARING BLOCK AND BEARINGS

A block bearing consists of a mounting bracket that houses a bearing and is used in low-torque,
light load applications. They differ in that plumber block bearings do contain an inner bearing
and they are also designed for higher loads and more corrosive environments.

fig 3.2.5 Bearing block

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Two ball bearings are used which has inner diameter of 30mm and outer diameter of 60mm.

fig.3.2.6 Bearing

A bearing is a machine element that constrains relative motion to only the desired motion, and
reduces friction between moving parts.

CAP

A bearing cap is a rigid, semi-circular part that fits around one half of a bearing and secures it.
Oil the new lower bearing and install it in the bearing cap.

It is mounted on bearing block and it is made up of mild steel.

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SEALS

Seals are used on rotating, reciprocating, and oscillating shafts to contain oil and grease and
exclude contaminants. Known as oil or radial lip seals, shaft seals can also contain pressure or
separate fluids. The purpose of a seal is to block the clearance gap so that nothing passes through
it.

fig.3.2.7 Spacer

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CHUCK NUT

It holds the rotating tool whereas in lathes it holds the rotating workpiece. The jaws are tightened
up to hold the tool or workpiece. Often the jaws will be tightened or loosened with the help of a
chuck key, which is a wrench-like tool made for the purpose.

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 fig.3.2.8 Chuck nut

SPACER

Bearing spacers sit within the wheel on the axle between the two bearings.

This makes sure the inner races of the bearing are properly lined up. When these are aligned
correctly, the balls and outer races also align.

With the wheel rotating, this alignment is critical to avoid unwanted friction.

When you have the spacer and two bearings aligned on the axle, the tightening force from
screwing on your axle nuts is transferred through the bearings and spacer.

With properly sized spacers, this will align the bearings perfectly on the axle, creating the fastest
spin with minimal friction.

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 fig.3.2.9 Spacer

CROSS SLIDE

It is generally mounted on the inner ways. Cross Slide is mounted on the carriage. Its function is
provide cross feed of the tool and its movement is perpendicular to the center of the lathe
machine. Its function is to hold the tool or the tool holder.

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CNC CONTROL PANEL
The machine panel for all CNC machining centers will also include several buttons and switches
related to manual control of the machine tool's functions .Common manual functions include
spindle control, coolant control, manual tool change control, and control of axis movements.

fig3.2.10 CNC control panel

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