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Internship Report on Online Training at

Sandvik Asia pvt.ltd.

▪ University Name – Government Polytechnic Pune.

▪ Name of Company – Sandvik Asia pvt.ltd.
▪ Student Name – Shravani Anil Gogawale
[email protected]
th
▪ Semester – 4 semester (Even2021)
▪ Internship period – 16th Aug to 17th Sep 2021
▪ Mentor Name – Anagha Patil
[email protected]

Declaration

Shravani Gogawale hereby declare that this report has been carried out under the guidance
Of Mis. Anagha Patil. This report neither in full nor in part will ever be submitted for certificate
of any other university.

Acknowledge
Industrial training has been always an essential part of the whole engineering curriculum. It
gives the idea of industry and also we get to the applications of various concepts. I am really
glad that I have completed my 5 weeks internship at Sandvik Asia pvt.ltd. And submitting
the report for the same.

I would like to give my sincere thanks to my mentor Mis. Anagha Patil for guiding me and
helping me whenever I needed. Thank you for making this internship easier and interactive.

I would also like to thank my partner Purva Chalindrawar from Government Polytechnic Pune
for the support and all help.
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Company Overview

Sandvik is an engineering group in mining and rock excavation, metal-cutting

And material technology.
This is a global engineering group with about 37,000 employees.
Stefan Widing is the president and CEO of the company.
The company has enabled to achieve world-leading positions in following areas:
▪ Tools and tooling systems for industrial metal cutting
▪ Equipment and tols, service and technical solutions for the mining and construction
industries.
▪ Advanced stainless steels and special alloys as well as products for industrial heating.
The Vision is to enhance customer productivity, profitability and sustainability.

Summary

I did an internship of 5 weeks at Sandvik Asia pvt.ltd. The whole internship

Included completion of Metal Cutting course offered by company itself. Then
A brief introduction to the various processes use for the Manufacturing of
An Insert. At the end the there was the completion of mini-project. It was
done in the Autocad.

Table of contents

Metal cutting course contains 9 chapters -

▪ Machinability
▪ Turning
▪ Parting and grooving
▪ Threading
▪ Milling
▪ Drilling
▪ Boring
▪ Tool holding
▪ Machining economy and maintenance
Insert manufacturing processes
Insert drawings (mini-project)
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Metal cutting course

Week 1

▪ Machinability: Metal cutting is one of the most important aspect in industry. Getting
metal cutting processe right means workpiece material, insert geometry and insert
grade must be correct.
There are 6 ISO standard material group -
P-steel
M-stainless steel
K-cast iron
N-non ferrous
S-heat resistant
H-harden material
Factors that must be identified in order to determine a material's machinability – classification
of workpiece, the cutting-edge micro and macro geometry,the cutting tool material (grade).
Workpiece material, hardness, component, applications, condition, cutting environment these
are the parameters which influences cutting parameters.
Design and insert geometry of cutting edge is of vital importane for the chip formation,tool life
and feed rate data in metal cutting.
We can calculate the tangential force using following formula -
Fc = Kc * ap * Fn
The design of modern insert usually have layers of TiN, Al2O3, Ti(C,N). ER treatment gives the
cutting edge the final micro geometry.
Some of the following are cutting tool material:
- Ucoated cemented carbide (HW)
- Coated cemented carbide (HC)
- Cermet (HT,HC)
- Ceramic (CA,CN,CC)
- Cubic boron nitride (BN)
- Polycrystalline diamond.
The two main coating methods are PVD (physical vapour deposition) and CVD (chemical vapour
deposition). Generally PVD is tougher than CVD coating. Total thickness of the PVD is 3 to 6
microns. Main difference between these two is PVD has sharper edge but CVD hasmore wear
resistant edges.
the basic wears that happen on inserts are:
- Flank wear: happens during cutting tool material is lost on the flank face due to friction
against the surface of the work piece material.
Remedy – reduce cutting speed and increase feed.
- Flanking: an adhesive load can develop, where the cutting edge is subjected to tensile
stresses. Remedy - increase cutting speed and selecting insert with a thinner coating.
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- Notch wear: chemical wear, growth of adhesive or thermal waer, work hardening burr
formation. Remedy – select smaller entering angle and vary depth of cut.
- Crater wear: result of chip contact with the rake face of the insert. Remedy - reduce
cutting speed and choosing an insert with right geometry.
- Cracks (thermal): comb cracks form as a result of rapid fluctuations in temp. Remedy –
tougher insert grade can be used. Coolant should be applied in large amount or not at
all.
- Fracture: allowing the wear to progress too far leading to increased cutting forces.
Remedy - selecting due wrong cutting data or stability issues in the setup.
- Plastic Deformation: subjected high cutting forces and temp. Resulting stress state,
exceeding the tool materials yield strength and temp. Remedy – using grade with higher
hot hardness, coating.
- Chipping: with chipping insert can still be used.
- Build-up edge: cause due to increase cutting forces, leading to failure or releasing.
Remedy – incrase cutting speed.

▪ Turning: Three common operations- longitudal turning

- Facing
- Profiling
What is spindle speed and cutting speed.
Formula for the calculation of cutting speed
Terms related to turning- n= spindle speed (rpm) Vc= cutting speed (m/min) Fn= cutting speed
(mm/rev) ap= depth of cut (mm) KAPR= entering angle PSIR= lead angle
Inclination angle (lamda) and rake angle (gamma)
Fn= the feed rate(Fn) is the distance the edge moves long the cut per revolution along the cut
per revolution.
Various shapes of the inserts.
Formula for power consumption
How to choose the right insert and types of chipbreaking.
Various aspects of insert like positive or negative inserts, clearance angle, KAPR, PSIR, nose
radius, rule of thumb.
Tool holder types
Effects of larger and smaller entering angles on the cutting and chip formation
Code keys for for inserts, tool holder, boring bars.
Troubleshooting (causes/solutions) I learned
the solutions for following problems-
Long unbroken snarls winding around tool or workpieces.
Very short chips, often sticking together, caused by too hard chip breaking.
The surface looks and feels "hairy” and does not meet the tolerance requirements.
Burr formation at the end of the cut when the cutting edge is leaving the workpiece.
Vibrations.
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▪ Parting and grooving: Terms related to Parting -

n = spindle speed (rpm)
Vc = cutting speed (m/min)
Fnx = radial cutting speed (mm/r)
OH = overhang recommended (inch/r)
Terms related to Grooving.
n = spindle speed (rpm)
Vc = cutting speed (m/min)
Fnz = axial cutting speed (mm/r)
Fnx = radial cutting speed (mm/r)
ar = depth of groove (mm)
ap = depth of cut in turning
Terms relate to Fce Grooving
n = spindle speed (rpm)
Vc = cutting speed (m/min)
Fnz = axial cutting speed (mm/r)
Fnx = radial cutting speed (mm/r)
ar = depth of groove (mm)
DAXIN= minimum 1st groove dia.
DAXX = maximum 1st groove dia.
Selection procrdure for tools, inserts, machines.
Tools – 1. multiple grooving 2. plunge turning 3. ramping
Deep/ medium/ shallow parting.
General recommendation of tool selection
Troubleshoot – cause and solution for bad surface, bad solution on aluminium,
Bad chip breaking, vibration, poor tool life.

▪ Threading: Different ways of making threads - molding, metal cutting, rolling.

Metal cutting threading method – thread turning, thread milling, tapping, thread,whirling, grinding
Terms – Vc = cutting speed (ft/min) n = spindle speed ap = total depth of threads nap =
number of passes.
Pitch, different major and minor diameter, helix angle.
Marking of the threading insertd and shims.
Tools – 1.Multi point inserts 2.Full profile inserts 3.V-profile inserts
External and internal threads.
Different thread forms
Insert geometry
Variety of tool holder
Infeed methods – 1.modified flank indeed 2.radial infeed 3.incremental infeed
Insert choice preferences
Troubleshooting – cause and solutions of following
Plastic deformation
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Built-up edge
Insert breakage
Rapid flank wear
Abnormal flank wear
Vibration
Poor surface finish
Poor chip control
Shallow profile
Incorrect thread profile
Excessive edge pressure
Tapping – long / medium / short chamfer
Different standards – 1. ISO and ANSI
2. DIN and ANSI
Tapping processes
Types and advantages of use of coolant supply.

▪ Milling: Basic terms for milling -

n= spindle speed
Ve = effective cutting speed (m/min)
DC = cutter dia, mm
DCX = maximum cutting dia, mm
Fz = feed per tooth, mm/tooth
Vf = table feed, mm/min
Zn = number of cutter teeth
Zc = effective no of teeth
Fn = feed per revolution, mm/rev
Ae = radial depth of cut, mm
Ap = axial depth of cut, mm
Formula fpr calculation of Net power (metric/inch)
Climb mlling and conventional milling
Basic requirements of procedure
Selection procedure – 1. cutter with round inserts
2. 45 degree face mill
3. 90 degree square shoulder face mill
Face milling/ profile milling/ slots and grooves cutters
Insert design (rake angle, primary land)
Difference between coarse pitch, close pitch, extra close pitch.
Advantages of wiper.
Feed compensation for different entering angles.
Application hints.
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Week 2
▪ Drilling: Methods of drilling- simple drilling, trepanning, chamfer drilling, step drilling.
Most common types of holes.
Basic terms- cutting speed
one effective cutting edge/rev.
Solid carbide tool cutting edge
Point angles for solid carbide drills and HSS drill.
Advantages of SCD over HSS drills
Basic terms related to measurement.
Effects of too high and low cutting speed.
Formulae for feed rate/power consumption/torque.
Short hole drills/ large hole drills.
Precautions related to alignment.
Types of radial offset
Procedures for entering non-flat surfaces.
Using proper chuck for best performance.
Tips for chip formation and coolant supply.
Tolerance charts.
Methods for drilling
Nomenclature of solid carbide and HSS drills.

▪ Boring: Methods for boring- boring with a stationary tool

boring with a rotating tool
milling, helical interpolation
Definitions and formulae for specific speed, penetration rate, feed rate, torque, net power.
Hole making methods –productive boring
step boring
single edge boring
reaming
Rough boring tools – large dia tool with 2 inserts
tool with 1 insert and tool with 2 inserts
tool with 3 inserts
dampened adapter with 2 inserts
Fine boring tools
Roughing/Finishing operation
Effects of smaller and larger entering angle.
Factors affecting tolerance
Factors that have an influence on chip breaking.
How to apply reaming tool
Vibration tendencies for entering/lead angle, corner radius, micro and macro geometry, edge
design, depth of cut (DOC).
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▪ Tool holding: Vital important factors for successful machining

Stability
Handling
Time for tool changing
Accuracy
Storing
Flexibility
Modularity
Quick change system can increase the cutting time by 25% in turning centers.
History of machine tapers.
Coromant Capto holding system.
Only 36% of the machine time is used for metal cutting.
SL* Universal modular system of adaptors wit exchangeble cutting heads.
6 different coupling sizes
Turning centers
Machining centers
Multi – task m/c
Types of chucks.

▪ Machining economy and maintenance:

What factors affect the tool life most and least.
Formula for the calculation of productivity in turning and milling.
Machine economy – variable cost (cost incurred only during production)
fixed cost (costs which exist even when not in production)
▫ Machine tool utilization -
1. Decreased cost: A 30% decrease in price only reduces total cost per component by 1%.
2. Increased tool life: A 50% increase in tool life only reduce total cost per component by
1%.
3. Increased cutting data: A 20% increase in cutting data decrese total cost per component
by more than 15%.
▫ ISO 13399 international standard simplifying exchange of data for cutting tool
▫ Nomenclature of a tool.

After the completion and preparaton of whole syllabus I gave the final certification test. All
questions was based on the syllabus covered earlier. I achieved total 45 marks out of 50.
The drive link of the certificate is -
https://drive.google.com/file/d/1mWkhrrgn0Ar-UM8O71wR5G26v_d3zrCz/view?usp=sharing
The whole course built the strong basic foundation of various machining processes.
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Week 3

Manufacturing process of inserts – An typical insert is made up of 80% tungsten carbide and
20% metal matrix. From raw material to final product an insert goes through following
processes -
1. Pressing – this process needs press tools. The is pressed in dies with punches to produce
a basic shape of an insert. Nearly 12 tones of pressure is applied.
2. Shaping – any excessive powder is removed here.
3. Sintering – the pressed inserts are so fragile ad delicate so they needs to be sintered.
The inserts are heated upto 1500 degrees. This reduces the insert volume to half of its
original volume.
4. Blank inspection – this is the visual/computerized inspection process.
5. Periphery grinding – in this grinding process the the main focus is on periphery and
cutting edges.
6. CNC profile grinding – this is a special programming-based grinding.
7. ER treatment (edge rounding) – this is the process to give roundness to sharp edges.
8. Coating process – there are two types of coating: CVD and PVD. Coating is done to give a
long life.
9. Post coating – some special inserts need extra coating.
10. Subcontracting – this is an optional process.
11. Inspection – this is the final inspection which is done manually and with automatic
inspection m/c.
12. Final operation – this includes marking and labeling.
13. Delivery.

Week 4 and 5

We did our mini-project of inserts drawing in these 2 weeks.

we've drawn the diagrams in AutoCAD. Following are the links to see the orthographic and
isometric drawing of inserts.
Insert 1:
https://drive.google.com/file/d/1rQEbTD_jDy_ThLHXJCfS0Dl_lxp1AgPe/view?usp=sharing
https://drive.google.com/file/d/1LW3JDg0cMA14irRc1L3uewcm0RznNenP/view?usp=sharing
Insert 2:
https://drive.google.com/file/d/1E46FhAX_IzxEpECQnoXmkVlZLXcLDn2k/view?usp=sharing
https://drive.google.com/file/d/17rNR9fSsG36SIT3a1aDls-s3xqYdmrNP/view?usp=sharing
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Conclusion
It was a great event for me to work with Sandvik company. The whole program built well
foundation and gave very detailed information about the Inserts.
At the end I would like to thank the Sandvik Asia for allowing me to do this internship. This
definitely will help in the future.