[2009]

AVINASH ARYAN & MY

CONTACT NO. IS
9559515717,,ME FINAL
YR.FROM F.G.I.E.T.
RAEBARELI

Indian
telephone
industry Ltd.
Feroze Gandhi institute of
engineerin g & technology Feroze
Special thanks to :
Gandhi institu te of engineerin g
My sincere thanks to all the personal manager
& technology Feroz e Gandhi
staff, general manager,astt.

institute of engineerin&workers
Manager,engineers,supervisors g & te of
“Indian telephone industry Ltd. raebareli”for
chnology Feroze Gandhi institute
helping me during my training schedule at every
of epossible
ngineerin
way g & technology
Feroze Gan dhi institute of
engineerin g & technol ogy
Feroze Gandhi institute of engine
ering & technology Feroze
Gandhi ins titute of engineerin g
& technology Fe roze Gandhi
institute of engineering &
technology Feroze Gandhi
institute of engineerin g &
technology Feroze Gandhi
institute of engineerin g & tec
hnology Feroze Gandhi institute
 Company Profile
India’s first Public Sector Unit (PSU) - ITI Ltd was established in 1948. Ever since, as a pioneering venture in
the field of telecommunications, it has contributed to 50% of the present national telecom network. With state-
of-the-art manufacturing facilities spread across six locations and a countrywide network of marketing/service
outlets, the company offers a complete range of telecom products and total solutions covering the whole
spectrum of Switching, Transmission, Access and Subscriber Premises equipment.
ITI joined the league of world class vendors of Global System for Mobile (GSM) technology with the
inauguration of mobile equipment manufacturing facilities at its Mankapur and Rae Bareli Plants in 2005-06.
This ushered in a new era of indigenous mobile equipment production in the country. These two facilities supply
more than nine million lines per annum to both domestic as well as export markets.
The company is consolidating its diversification into Information and Communication Technology (ICT) to hone
its competitive edge in the convergence market by deploying its rich telecom expertise and vast infrastructure.
Network Management Systems, Encryption and Networking Solutions for Internet Connectivity are some of the
major initiatives taken by the company.
Secure communications is the company's forte with a proven record of engineering strategic communication
networks for India's Defence forces. Extensive in-house R&D work is devoted towards specialized areas of
Encryption, NMS, IT and Access products to provide complete customized solutions to various customers.
More About ITI :
Multi-locational state-of-the-art electronic assembly & component manufacturing facilities accredited with ISO
9001:2000
Multi-locational ISO 14001 :2004 Environmental Management System certified plants First Indian company to
manufacture BTS & other infra products for GSM / WiMAX
Countrywide marketing and customer care centers
In-house R&D for absorption of technology, indigenous development of products for in-house manufacturing
RESOURCES : Dedicated Network Systems Unit (Bangalore, New Delhi, Kolkata, Bhopal, Ambala) . State-of-the-
art Manufa~turing Plants (Bangalore, Mankapur, Rae Bareli, Naini, Palakkad, Srinagar) . R&D Centre
SMPS : Fabrication of 100 A - 150A Power Plants with 25A base Module for GSM . Fabrication of 200A-3000A'
Power Plants with 100A base Modules for telecom installation
PRODUCTS : Cellular Mobile Infrastructule-GSM, WLL-CDMA
Switching-OCB-283, ISDN EPABX, IP-TAX, SSTP . Transmission- Satellite, Optical, Microwave, VHF /UHF .
Broadband Equipment-ADSL, WiMAX, G-PON, EDW AS . Customer Premises P-quipment-IFWT, ADSL Modem,
CLI Phones . GSM-FCT (Fixed Cellular Telephone),; WiMAX CPE
SERVICES : Systems Integration - Telecom, IT . Shared Hub V -SAT Services . Customer Care Service .
Installation & Commissioning of Telecom Eqpt like GSM, CDMA, MLLN, Microwave, Optical Fibre, etc. . Pre-
warranty & Post-warranty maintenance sefYices for all Products/Projects . Services for all products/projects : .
Enterprise businesses like Data Centers etc
Infrastructure
1-Inhouse Research & Development
2-Network System Unit capable of undertaking turnkey jobs
3-Self contained component evaluation centre
4-Fully automated assembly lines
5-In circuit tester (ICT)
6-Modern Chemical, Metallurgical Labs
7-Mechanical fabrication/Machine shops with modern CNC machines
8-Moulding & Die casting
9-Full fledged state of the art tool rooms
10-SMT (Surface mount technology)
11-Environmental testing
12-Component approval center approved by BSNL
Facilities
1-PCB manufacturing facilities
2-Mechanical Fabrication / Machine Shop with modern CNC machines and Finishing shop
3-Card assembly and Testing including Incircuit tester
4-SMT Line
5-Plastic Injection Technology
6-Through-Hole Component Assembly
7-Manufacturing facilities for Mechanical items
8-Fabrication of Towers and Shelters for GSM
 Diversified Products
SMPS -Switched Mode Power Supply
FEATURES

• Low cost & light weight

• Controls up to three LVD
• Hot plug-in rectifiers
• Fan cooling
• Temperature compensated battery charging
• Intelligent battery health monitoring
• Wide AC Input range
RS485 Compatible (Remote Monitoring)
DIGITAL INVERTER
Digital Inverter provides AC Output Voltage during mains AC failure for domestic purposes. This is backed up by
a Battery which is automatically being maintained on regular basis on availability of AC mains. This is fully
automatic PWM based technology which takes care of Over load cut off with auto reset timer switch and deep
discharge battery cut off. Unit has multi display unit which provides visual indication for AC mains, Inverter
‘ON’, Battery Low, Battery charging and Over load.
Output Power : 750 VA
Output Voltage : 230 V AC ± 10%
Output Frequency : 50 Hz ± 1 Hz Technology : PWM Technology
Certified by ERTL Delhi
Output Wave Shape : Quasi Sine Wave
Battery Charging : CCCV with normal and boost charging
AC Input Voltage : 150 V AC to 260 V AC
CURRENCY COUNTING MACHINE

FEATURES

ITI's Note Counting Machine can be used for counting a wide variety of freshly issued, soiled and old currency
notes whether bundled or loose.

MODELS

ITI's Note Counting Machines are available in two models with functional features being the same in both the
models.
Floor Model : ANCM-01
Desktop Model : ANCM-02

The machine has the following features which enable quick and accurate counting:

• Advanced solid-state electronics and precision tool mechanical assembly, which provide highly accurate and
reliable performance.
• Silent and smooth operation at super high counting speed.
• Vacuum suction is provided by a build-in vacuum pump, which has a filter to keep out dust and fiber, thus
increasing the life of the machine.
• Maintains hygienic condition for the operator.
• The machine automatically adds the continuously counted notes on to the last counted in FREE COUNT, BATCH
AND CHECK MODE.
The accumulated count is stored in the memory and retained after power OFF and will display again on power
ON.
• The machine can count different denominations of Currency Notes and has a capacity to insert up to 200 notes.
• The pip alarm will automatically sound a warning if the counted number is not equal to the preset number in
CHECK and Batch modes.
Tropicalised Diagnostics with easy error codes for easy maintenance by quick fault detection.
Defense Products
OWS -ORDERWIRE SECRECY
Orderwire secrecy: (OWS) Orderwire Secrecy encrypts and Decrypts Voice calls between operators on Radio.
During alignment of Radio and setting up of the link the voice information is secured by this encryptor. It uses
state of the art Components with Proprietary alogorithm. It has additional feature of working in repeater and
Regenerator mode during long hop working. It can work in Broadcast mode as well as Voice call mode. It can be
customised to work with any type of radio. The system design also use of this in static as well as Mobile

MIL PCM SECRECY

Mil PCM Secrecy: MIL PCM Secrecy is a ruggedised encryptor to encryprt and decrypt 2 Mbps / E1 data of PCM
Format. It can accept various types of Signalling format like CAS, CCS, PRI, ADPCM, ATM etc., It can work from
Internal, External or Recovered clock. It uses Proprietary algorithm. It meets stingent Defence Envirommental
Specifications of JSS 55555 and EMI/EMC Specifications of MIL STD 461C. It works from 230V AC or -48v DC.
Normally works from AC and in case of failure automatically swithches over to DC working.

ANANDA MK II BEU
ANANDA MK II: (Name to be corrected in WEB Page) ANANDA MK II encryptor to encryprt and decrypt 2 Mbps
/ E1 data of PCM Format. It can accept various types of Signalling format like CAS, CCS, PRI, ADPCM, ATM etc.,
It can work from Internal, External or Recovered clock. It can also work with Framed / Unframed Data. It meets
QM 333 Envirommental Specifications. It works from -48v DC with duplicated power Supply. It is housed in a
standard 19" subrack and a main rack can house 4 Such subracks. Each subrack carries four independent 2
Mbps Channel effectively this can be used as 8 Mbps Encryptor.
STM1 ENCRYPTOR
STM 1 Encryptor encrypts/decrypts SDH formatted data at bit rates of 155Mbps. It accepts either electrical /
Optical Interface as clear data input and gives out encrypted data again as Electrical or Optical Interface. Works
with proprietary algorithm and Key management. The encryptor provides NMS interface for monitoring and
alarm indication. It is equipped in standard 19” sub rack. While working on long haul Optical lines it has in built
facility of Optical regenerators. Unit has low power consumption and works from -48v DC Power supply.

BEU IP
BEU IP is designed and developed by ITI to encrypt / decrypt Internet Protocol (IP) data at layer 2 / layer 3 of
OSI layer. It can work in either Tunnel mode or Transport mode. Uses Proprietary algorithm and key
Management. Designed to accept data from LAN / WAN and give a throughput of 10/100 Base T. On media side
it can work on Optical / Satellite media. The unit is available as table top model or as standard 19” sub rack
construction in 1’U’ height.

FAX ENCRYPTOR
FAX Encryptor is terminal end Secrecy device designed to encrypt / decrypt Voice / FAX / data. It accepts FAX
data from either G3 FAX Machine or Super G3 FAX Machine and encrypted data is sent on 2W PSTN line. When
switched to Voice encryption it encrypts / decrypts analog Voice data. It also can encrypt / decrypt digital data
at 9.6 Kbps rate through RS 232 interface. Uses Proprietary algorithm and key Management. The unit is
available as standard 19” sub rack construction in 1’U’ height. It works from either 230V AC supply or from
-24V DC supply.
Organization chart:

Unit Profile
 Raebareli Manufacturing unit was setup in 1973 and boasts a world-class infrastructure. Presently, this unit
manufactures GSM network equipments and CDMA handsets. ITI Raebareli has taken a leap to enter broadband
equipment G-PON and WiMAX. This unit is India's first telecom equipment manufacturer to conduct field trial of
G-PON technology in India, and is all set to rollout India's first lot of G-PON equipment.
Areas of Business
Telecom Equipment Manufacture
GSM network equipments and CDMA handsets
Broadband equipment G-PON and WiMAX
Products
GSM - Infra(BTS) ,Shelter,Tower,RTT,SMPS,Control Panels ,Franchise
Wimax & Wimax CPEs and GPON
Facilities
SMT Line

PCB Assembly

In-Circuit Testing

Cabinet and Rack Manufacturing

Pressed and Formed Sheet Metal Components

Plastic Moulded Components

Electroplating and Powder Coating Facilities

GSM / CDMA Products
BTSBase Trans-
Receiver Station (BTS) “BTS A-9100”, is radio frequency mobile communication product based on GSM
technology. It is a set of equipments that facilitates wireless communication between user equipment (UE) and
a network. A BTS in general consists of Trans-receiver module, Antenna Network Combiner, Controller (SUMA) &
Alarm Extension System (XIBM). It is a self contained unit for transmitting / receiving signal for mobile
communication.
Types of BTS:

1. Indoor BTS
2. Outdoor BTS
3. Dual Band BTS
4. Twin TRX BTS
BTS SHELTER
• Shelter is a portable Sealed cabin made up of sandwiched insulated panels with polyurethane as filler material
between galvanized pre-coated steel sheet.
• Floor is made up of 19mm thick marine plywood and is covered with PVC antistatic flooring.
• MS tube is reinforced inside floor panel for higher floor load capacity.
• Secondary slanting roof is provided to protect primary roof from direct sunlight and rainwater.
• Door is fixed with heavy-duty hinges. It is equipped with hydraulic closer & three way locking arrangement.
• Shelter is installed on suitable base frame of galvanized I-beam supported on concrete pedestal.
 ITI LIMITED Rae Bareli is manufacturing Prefabricated Shelter for housing of BTS & its accessories used in
Telecom Mobile Service.

ROOF TOP TOWER

PRODUCT RANGE

Square Lattice Type of RTT(as per GR) : - 10M, 15M, 20M Height.
Triangular Type RTT(SERC) : - 9M, 12M, 15M & 18M Height.

TECHNICAL SPECIFICATION

• Square Lattice type of RTT are manufactured as per GR No. GR/TWR-09 FEB. 2004
• Design of triangular type RTT is duly approved from Structural Engineering Research Center (SERC), Chennai.
• All members of RTT are made up of structural steel as per IS2062 Grade A & hot dip Zinc galvanized as per IS
4759.
• It can carry 6 Nos. GSM/WLL Antenna & 3 Nos. 0.6M dia Microwave Antenna.
Basic design of RTT is for wind speed 200 Km/h. It can survive wind velocity up to of 210 km/h for short
duration.

TRANSCEIVER
• Alcatel's new Twin TRX radio transceiver doubles the capacity of existing equipment, while occupying the same
space in the rack.
• The new Twin TRX is particularly adapted for densely populated urban areas, with a maximum capacity of 24
TRX per Base Station cabinet.
Twin TRX transceivers can be installed in the full range of Alcatel's indoor and outdoor BTS.
 CDMA (Code Division Multiple Access)
CDMA (Code Division Multiple Access) is a digital wireless technology to provide mobile communication.
CDMA works by converting speech into digital information, which is then transmitted as a radio signal over a
wireless network. CDMA uses a unique code to distinguish each different call. The receiving device is
instructed to decipher only the data corresponding to a particular code to reconstruct the signal. This
enables many subscribers to share the same frequency band and, at the same time, without any cross talk or
interference.CDMA WLL technology provides option of limited as well as full mobility to the customers. This
helps to provide faster last mile connectivity, where laying of cables is difficult.

Division of mechanical production dept.(MPD) :

1-mfg
2-toolroom
3-mfg(BTS)
Mfg(roof top tower shop)(LAY OUT)

Hydruaulic press:

Pre Hydraulic press area

processing Powerhacksaw Multy 60 (kingsland)
shop cabin
gallery
Cnc Milling machines Power press
punching
Punching
machines
Drilling machines

Arc Mig Spot

welding welding welding

Plastic injection moulding shop

Powder coating plant

USES & APPLICATIONS
Auto service station, Repairing workshop, Pressing of ball bearings, Removal of old bushes and mounting new
bushes, Industries engaged with the work of straightening, Pressing, Drawing, Embossing, Broaching, Bending,
Breaking and Joining of steel, iron, plastic, rubber & plywood, Electric Motor, Gold /Silver Coin / Monogram
Embossing, Submersible Pump, Mosaic Tiles.
FRAME:
The crown column and bottom are mild steelfabricated construction. The table is vertically operated by worm
winch and it rests on load pin placed in holes in column at required height. Rollers are provided with the table
for easy handlig of heavy jobs.
CYLINDER :
The hydraulic cylinder & Ram are made from mildsteel. Meoprene rubber pressure seal is mounted at bottom of
ram. Socket is provided to fecilitate attachment of dies with ram.
HAND PUMP :
Double plunger pump gives quick ram travel by low pressure plunger and slow speed develops with high
pressure plunger.
POWER PACK :
The suitable hydraulic powerpack provided with the unit includes either Gear pump, Vane pump or plunger
pump driven by an electric motor of reputed brand, control valves, connecting hoses & pipes etc.
Power Press
FRAME: The frame is made of steel construction and their heavy cross section and rigid design
assure minimum deflection and accurate alignment cast iron legs will be supplied up to 30 ton presses.
CRANK SHAFT : Crank shaft materials are made of special alloy steel to withstand the effective load fitted in
busher with high accuracy.
GEAR : The gears are made of cast steel or fabricated and it teeth are generated by hobbing.
CLUTCH : The cluth is provided of pin / rolling key type also it is rigid and well supported for the mass
production clutch can gives continuous stroke.
FLYWHEEL : The flywheel is made of high grade cast iron and is balanced for storng and releasing
adequate energy for the pressing operations.
LUBRICATION : An accurate lubriction system has been proved for lubrications the sliding surfaces and
moving parts.
TABLE & RAM : Table and Ram are made of high grade heavy duty cast iron & properly seasoned. they are
perfactly aligned to each other to obtain high accuracy & precision press operation.

Milling Machine
A milling machine is a machine tool used for the shaping of metal and other solid materials. Milling machines
exist in two basic forms: horizontal and vertical, which terms refer to the orientation of the cutting tool spindle.
Unlike a drill press, in which the work piece is held stationary and the drill is moved vertically to penetrate the
material, milling also involves movement of the work piece against the rotating cutter, the latter which is able to
cut on its flanks as well as its tip. Work piece and cutter movement are precisely controlled to less than 0.001
inches (.025 millimeters), usually by means of precision ground slides and lead screws or analogous technology.
Milling machines may be manually operated, mechanically automated, or digitally automated via computer
numerical control (CNC).
Milling machines can perform a vast number of operations, some very complex, such as slot and keyway
cutting, planing, drilling, die sinking, rebating, routing, etc. Cutting fluid is often pumped to the cutting site to
cool and lubricate the cut, and to sluice away the resulting swarf.
Types

There are many ways to classify milling machines, depending on which criteria are the focus:

Example classification

Criterion Comments
scheme
Manual; In the CNC era, a very basic distinction is manual versus
Mechanically automated via CNC.
Control
cams; Among manual machines, a worthwhile distinction is
Digitally automated via NC/CNC non-DRO-equipped versus DRO-equipped
Number of axes (e.g., 3-axis, 4-
axis, or more);
Within this scheme, also:

Control (specifically • Pallet-changing versus

among CNC machines) non-pallet-changing

• Full-auto tool-changing
versus semi-auto or
manual tool-changing
Spindle axis Vertical versus horizontal; Among vertical mills, "Bridgeport-style" is a whole class
orientation Turret versus non-turret of mills inspired by the Bridgeport original
General-purpose versus special-
Purpose
purpose or single-purpose
Toolroom machine versus
Purpose Overlaps with above
production machine
A distinction whose meaning evolved over decades as
technology progressed, and overlaps with other purpose
Purpose "Plain" versus "universal"
classifications above; more historical interest than
current
Micro, mini, benchtop, standing
Size on floor, large, very large,
gigantic
Line-shaft-drive versus Most line-shaft-drive machines, ubiquitous circa 1880-
individual electric motor drive 1930, have been scrapped by now
Power source
Hand-crank-power versus Hand-cranked not used in industry but suitable for
electric hobbyist micromills

Arc welding

Arc welding is one of several fusion processes for joining metals. By applying intense heat, metal at the joint
between two parts is melted and caused to intermix - directly, or more commonly, with an intermediate molten
filler metal. Upon cooling and solidification, a metallurgical bond is created. Since the joining is an intermixture
of metals, the final weldment potentially has the same strength
properties as the metal of the parts. This is in sharp contrast to non-
fusion processes of joining (i.e. soldering, brazing etc.) in which the
mechanical and physical properties of the base materials cannot be
duplicated at the joint.

In arc welding, the intense heat needed to melt metal is produced by an

electric arc. The arc is formed between the actual work and an electrode
(stick or wire) that is manually or mechanically guided along the joint.
The electrode can either be a rod with the purpose of simply carrying the

Fig. 1 The basic arc-welding circuit

current between the tip and the work. Or, it may be a specially prepared rod or wire that not only conducts the
current but also melts and supplies filler metal to the joint. Most welding in the manufacture of steel products
uses the second type of electrode.

Basic Welding Circuit

The basic arc-welding circuit is illustrated in Fig. 1. An AC or DC power source, fitted with whatever controls
may be needed, is connected by a work cable to the workpiece and by a "hot" cable to an electrode holder of
some type, which makes an electrical contact with the welding electrode. An arc is created across the gap when
the energized circuit and the electrode tip touches the workpiece and is withdrawn, yet still with in close
contact. The arc produces a temperature of about 6500ºF at the tip. This heat melts both the base metal and
the electrode, producing a pool of molten metal sometimes called a "crater." The crater solidifies behind the
electrode as it is moved along the joint. The result is a fusion bond.

Arc Shielding

However, joining metals requires more than moving an electrode along a joint. Metals at high temperatures
tend to react chemically with elements in the air - oxygen and nitrogen.
When metal in the molten pool comes into contact with air, oxides and
nitrides form which destroy the strength and toughness of the weld joint.
Therefore, many arc-welding processes provide some means of covering
the arc and the molten pool with a protective shield of gas, vapor, or
slag. This is called arc shielding. This shielding prevents or minimizes
contact of the molten metal with air. Shielding also may improve the
weld. An example is a granular flux, which actually adds deoxidizers to
the weld.

Figure 2 illustrates the shielding of the welding arc and molten pool with
a Stick electrode. The extruded covering on the filler metal rod, provides
Fig. 2 This shows how the coating on a
a shielding gas at the point of contact while the slag protects the fresh
weld from the air. coated (stick) electrode provides a
gaseous shield around the arc and a slag
The arc itself is a very complex phenomenon. In-depth understanding of covering on the hot weld deposit.
the physics of the arc is of little value to the welder, but some knowledge
of its general characteristics can be useful.

Nature of the Arc

An arc is an electric current flowing between two electrodes through an ionized column of gas. A negatively
charged cathode and a positively charged anode create the intense heat of the welding arc. Negative and
positive ions are bounced off of each other in the plasma column at an accelerated rate.

In welding, the arc not only provides the heat needed to melt the electrode and the base metal, but under
certain conditions must also supply the means to transport the molten metal from the tip of the electrode to the
work. Several mechanisms for metal transfer exist. Two (of many) examples include:

1. Surface Tension Transfer® - a drop of molten metal touches the molten metal pool and is drawn into it
by surface tension.
2. Spray Arc - the drop is ejected from the molten metal at the electrode tip by an electric pinch propelling
it to the molten pool. (great for overhead welding!)

If an electrode is consumable, the tip melts under the heat of the arc and molten droplets are detached and
transported to the work through the arc column. Any arc welding system in which the electrode is melted off to
become part of the weld is described as metal-arc. In carbon or tungsten (TIG) welding there are no molten
droplets to be forced across the gap and onto the work. Filler metal is melted into the joint from a separate rod
or wire.
More of the heat developed by the arc is transferred to the weld pool with consumable electrodes. This
produces higher thermal efficiencies and narrower heat-affected zones.

Since there must be an ionized path to conduct electricity across a gap, the mere switching on of the welding
current with an electrically cold electrode posed over it will not start the arc. The arc must be ignited. This is
caused by either supplying an initial voltage high enough to cause a discharge or by touching the electrode to
the work and then withdrawing it as the contact area becomes heated.

Arc welding may be done with direct current (DC) with the electrode either positive or negative or alternating
current (AC). The choice of current and polarity depends on the process, the type of electrode, the arc
atmosphere, and the metal being welded.

Mig welding
Gas Metal Arc Welding (GMAW) is frequently referred to as MIG welding. MIG welding is a commonly used high
deposition rate welding process. Wire is continuously fed from a spool. MIG welding is therefore referred to as
a semiautomatic welding process.

MIG Welding Benefits

• All position capability

• Higher deposition rates than SMAW
• Less operator skill required
• Long welds can be made without starts and stops
• Minimal post weld cleaning is required

MIG Welding Shielding Gas

The shielding gas, forms the arc plasma, stabilizes the arc on the metal being welded, shields the arc and
molten weld pool, and allows smooth transfer of metal from the weld wire to the molten weld pool. There are
three primary metal transfer modes:
Spray transfer (MP3 Audio)
Globular transfer (MP3 Audio)
Short circuiting transfer (MP3 Audio)
The primary shielding gasses used are:
Argon
Argon - 1 to 5% Oxygen
Argon - 3 to 25% CO2
Argon/Helium
CO2 is also used in its pure form in some MIG welding processes. However, in some applications the presence
of CO2 in the shielding gas may adversely affect the mechanical properties of the weld.

Common MIG Welding Concerns

We can help optimize your MIG welding process variables. Evaluate your current welding parameters and
techniques. Help eliminate common welding problems and discontinuities such as those listed below:

Weld Discontinuities

• Undercutting
• Excessive melt-through
• Incomplete fusion
• Incomplete joint penetration
• Porosity
• Weld metal cracks
• Heat affected zone cracks

MIG Welding Problems

• Heavily oxidized weld deposit

 • Irregular wire feed
• Burnback
• Porosity
• Unstable arc
• Difficult arc starting

Spot welding

Spot welding is a process in which contacting metal surfaces are joined by the heat obtained from resistance to
electric current flow. Work-pieces are held together under pressure exerted by electrodes. Typically the sheets
are in the 0.5-3.0 mm thickness range. The process uses two shaped copper alloy electrodes to concentrate
welding current into a small "spot" and to simultaneously clamp the sheets together. Forcing a large current
through the spot will melt the metal and form the weld. The attractive feature of spot welding is a lot of energy
can be delivered to the spot in a very short time (ten to one hundred milliseconds[citation needed]). That permits the
welding to occur without excessive heating to the rest of the sheet.

The amount of heat (energy) delivered to the spot is determined by the resistance between the electrodes and
the amplitude and duration of the current. The amount of energy is chosen to match the sheet's material
properties, its thickness, and type of electrodes. Applying too little energy won't melt the metal or will make a
poor weld. Applying too much energy will melt too much metal and make a hole rather than a weld. Another
attractive feature of spot welding is the energy delivered to the spot can be controlled to produce reliable welds.

Projection welding is a modification of spot welding. In this process the weld is localized by means of raised
sections, or projections, on one or both of the workpieces to be joined. heat is concentrated at the projections,
which permits the welding of heavier sections or the closer spacing of welds. The projections can also serve as a
means of positioning the workpieces. Projection welding is often used to weld studs, nuts, and other screw
machine parts to metal plate. It's also frequently used to join crossed wires and bars. This is another high-
production process, and multiple projection welds can be arranged by suitable designing and jigging

Processing and Equipment

Spot welding involves three stages; the first of which involves the electrodes being brought to the surface of the
metal and applying a slight amount of pressure. The current from the electrodes is then applied briefly after
which the current is removed but the electrodes remain in place in order for the material to cool. Weld times
range from 0.01 sec to 0.63 sec depending on the thickness of the metal, the electrode force and the diameter
of the electrodes themselves.The equipment used in the spot welding process consists of tool holders and
electrodes. The tool holders function as a mechanism to hold the electrodes firmly in place and also support
optional water hoses which cool the electrodes during welding. Tool holding methods include a paddle-type,
light duty, universal, and regular offset. The electrodes generally are made of a low resistance alloy, usually
copper, and are designed in many different shapes and sizes depending on the application needed.
The two materials being welded together are known as the workpieces and must conduct electricity. The width
of the workpieces is limited by the throat length of the welding apparatus and ranges typically from 5 to 50
inches. Workpiece thickness can range from 0.008in. to 1.25in.[2]
After the current is removed from the workpiece, it is cooled via the coolant holes in the center of the
electrodes. Both water and a brine solution may be used as coolants in spot welding mechanisms.

Plastic injection moulding

Injection molding (British English: moulding) is a manufacturing process for producing parts from both
thermoplastic and thermosetting plastic materials. Material is fed into a heated barrel, mixed, and forced into a
mold cavity where it cools and hardens to the configuration of the mold cavity. [1] After a product is designed,
usually by an industrial designer or an engineer, molds are made by a moldmaker (or toolmaker) from metal,
usually either steel or aluminium, and precision-machined to form the features of the desired part. Injection
molding is widely used for manufacturing a variety of parts, from the smallest component to entire body panels
of cars.

Process Characteristics

• Utilizes a ram or screw-type plunger to force molten plastic material into a mold cavity
• Produces a solid or open-ended shape which has conformed to the contour of the mold
 • Uses thermoplastic or thermoset materials
• Produces a parting line, sprue, and gate marks
• Ejector pin marks are usually present

Applications
Injection molding is used to create many things such as milk cartons, containers, bottle caps, automotive
dashboards, pocket combs, and most other plastic products available today. Injection molding is the most
common method of part manufacturing. It is ideal for producing high volumes of the same object.[5] Some
advantages of injection molding are high production rates, high tolerances are repeatable, wide range of
materials can be used, low labour cost, minimal scrap losses, and little need to finish parts after molding. Some
disadvantages of this process are expensive equipment investment, running costs may be high, and parts must
be designed with molding consideration

Tool room department:

TR&ME DEPT.(MPD)

Tool room(layout)
Precision High speed
lathe lathe Surface grinding
machine
Bench
Cylindrical Cylindrical repairing
grinding grinding
Turning machine
Optical Zig grinding
profile machine
Gallery
grinding
Milling machine
Visual Zig boring
grinding machine

Profile Universal
projector milling Bench
&boring assembly
EDM Zig boring
machine

Cnc milling Cnc zig

boring
&milling

Cnc wire
cut

CNC wire cut

CNC wire cut also known as cnc wire cut edm which is working base on electro sparking principle. If there is a
load, the wire edm will moving slowly towards the electrical conductive workpiece. The wire will be energize and
create electrical spark between the wire cut cnc machine and workpiece. The electrical spark created between
the wire and workpiece will erode some small amount of workpiece and flush away by the deionized water to
form the spark gap between the wire and the workpiece. The electrical sparking process will stop if reach the
required depth. The spark gap size can be controlled as small as 0.0127mm.
If there is no load the machine will run only one cycle until the required depth and stop.

Electrical discharge machining or EDM

Electrical discharge machining or EDM is a thermal erosion process in which the work piece material is removed
through a series of rapidly reoccurring electrical discharge between electrode (cutting tool) and an electrical
conductive work piece in a presence of a dielectric fluid.
There is a voltage gap between the electrode and the work piece that form the spark vaporize minute particles
of the work piece material, which is then washed out from the gap by the continuously flushing dielectric fluid.
The two main types of the EDM are Ram and Wire cutting. EDM is a diverse process that produces products
ranging from tiny electric connectors, medical parts, and automatic stamping dies and aircraft body panels.
EDM has replaced much of the machining, grinding steps needed in die making which represents the largest
single use of EDM. Die component cut with EDM can often be made in a single piece no matter how complex
the internal form. The single piece die are always stronger than those made of segments.
Die cut are from hardened steel, heat-treated steel, carbide. Other materials that can be EDMed are
polycrystalline diamond, titanium, hot rolled and cold rolled steel, copper, brass and high temperature alloys.
The process of EDM has many benefits since the work piece and electrode never touch, no cutting forces
are generated this makes EDM will suited to produce fragile parts that can not take the stress of conventional
machining, burr free edges, intricate details, superior surfaces. EDM process eliminates the risk of damaging
expensive work pieces, allows heat treatment before final machining. Final EDM tools with build in process
knowledge helps reduce the training workers need to produce complex parts.
The EDM process also has its limitations. The metal removal rates are low compared to conventional
metal cutting processes. Complex materials require lead-time for fabrication and are consumable while cutting
and the work piece materials must be conductive.
The basic components of the electrical discharge machinery are relatively simple. The electrode is attached to
the RAM, which is connected to one pole of the electric power supply. The work piece is connected to the other
power supply. The work piece is then positioned so that there is a small piece between work piece and
electrode. This gap is flooded with dielectric fluid which acts as insulator until the power is turned out. Once on,
the machine delivers thousands of electric pulses per second to the gap and erosion begins. The sparks are
generated at on time but it ranges from 100s up to 1000s of time per second. Each spark has a temperature of
1400 up to 21000 degrees Fahrenheit. As erosion continues the machine control advances the electrode
through the material and is containing a constant gap distance. To understand how EDM removes the material
lets examine a single spark in the erosion process.
As a pulse of DC Electricity reaches the electrode and part an intense electric field develops in the gap,
microscopic contaminates suspended in the dielectric fluid are attracted by the field and concentrated in the
field’s strongest point. These contaminates builds a high conductivity along the gap as the field’s voltage
increases. These materials in the conductive bridge heat up. Some pieces ionize to form a spark between the
electrode and the work piece. At this point the both the temperature and pressure in the channel increase
generating a spark. A small amount of the materaial melts and vaporizes from the material and the work piece
at the point of spark contact. A bubble composed of gaseous by products vaporize rapidly expands rapidly
outward from the spark generated. Once the pulse ends the spark and the heating action stop collapsing the
spark channel. Dielectric fluid then rushes into the gap forcing melted material out from the surfaces. This EDM
residue consists of solidified parts of material and gas bubbles.
The resulting EDM cut can have several observable surface layers. The top surface is created when
expelled molten material and small amount of electrode material melt forms spheres on part of the surfaces,
this layer is easily removed. The next layer is a recast or white layer as EDMing has altered the piece
metallurgical structure. This layer can be reduced by using the right settings or by polishing the part. The third
layer is the heat affected zone or annealed layer. It has been only heated not melted. The part surface is a
function of EDM cycles that has on time and off time expressed in microseconds. All work occurs during the on
time so pulse duration and the number of cycles per second. The sum of on time and off time are important.
Metal removal is proportion to the amount of energy during on time that energy is controlled by the time
variables. The peak Amperage or intensity of the spark and the length of the on time. The larger the on time
the more the metal erodes. May also produce a larger recast layer and a deeper heat affected zone. Off time
also affects speed and stability of the EDM cut. Too shorten off time, the ejected material will not flood easily
with the dielectric fluid. The next spark may then be not stable. The duty cycle is the percentage of on time
relative to the total cycle time. The higher the duty cycle means increased cutting efficiency. Gap distance
between work piece material and the electrode also impact the material removal rate. Generally the smaller the
gap the better the accuracy and the surface finish are and the metal removal rate is. The EDMing cavity is
always larger than the electrode with the difference called the Kerf. The average off time and on time increases
also the over cut. It is important to know the expected over cut during EDMing because the electrode can
probably be under sized.
RAM EDMing
In Ram EDMing machines the work piece must be inside a tank and is covered with Dielectric fluid. The
electrode is lowered to a distance of few thousands of an inch from the work piece. To begin EDMing. Ram types
EDMing have the ability to produce complex cavities out of a solid piece of metal. Ram EDMing machines are
also referred to as die sinkers or vertical EDMs and range in sizes and automation from manual operating table
top systems to large CNC ones. A ram EDM a number of main subsystems:
-Power supply
-Dielectric fluid
-Electrode
-Servo system.
The power supply provides series of DC current Electric discharges between the electrode and the work piece. It
also controls:
-Pulse voltage
-Current
-Pulse frequency
-Electrode polarity
There is a direct relationship between the voltage and the gap. The servo system must sense the voltage
between the electrode and the work piece. This signal controls the servo system and maintains a constant gap
distance between the electrode and the work piece through out the EDM cycles. Most power supplies provide a
cut off or fault protection system to stop power flow to the system if a short circuit between the electrode and
the work piece occurs.
To successful EDMing flushing is very essential, where the EDM dielectric system introduces clean
dielectric to the EDM cutting zone flushing away the EDM debris and cools the work piece and electrode. Popular
dielectric fluids for EDM systems are hydrocarbon and silicon based oil.
 The dielectric fluid is pumped through nozzles through the electrode or through the work piece or some
combination of them to continuously flush the work area. Flushing requires careful consideration because of the
high forces involved forcing the fluid through small passageways. Many low-pressure holes are preferred to
many high-pressure holes.
The shape of the work shape of the electrode or cutting tool is a negative or reverse of the cavity
generated on the work piece. The ram EDM electrical polarity is usually has a positive charge and the work
piece polarity is negative. Although the metal removal is smaller than if the polarity is reversed. A positive
electrode polarity protects the electrode from excessive wear and preserves its dimensional accuracy. So
EDMing requires multiple electrodes that perform roughing then finishing operations. Copper and graphite are
the most common electrode materials. Whatever the electrode material is used it should combine high strength
and high melting point. To help the electrode resist the erosion of the corners where electric field is
concentrated. Making the electrode is an important step in ram EDM. The electrodes are shaped on all types of
machines. Since the graphite material turns to dust, the machine must be equipped with a system of dust
control and evacuation.
The servo system controls the in feed of the electrode to precisely determine the rate of material
removal. If the gap voltage system determine that there is a residue reducing the gap between the electrode
and the work piece. The servo system will reverse the feed until contamination is flushed away. The greatest
benefit of the CNC ram EDM machine comes from the capability to change tool automatically boosting
unattended time. The tool changer holds multiple electrodes and the part program automatically change them.
This allows multiple cavities of a variety of work piece to be EDMed. Orbiting is a pattern movement between
electrode and the work piece increasing the EDM capabilities not achieved by straight ram sinking. Orbiting the
electrode distributes wear eventually so that corners do not wear as fast. Less cutting is done by the bottom
and the bottom corners of the electrode and more with the sides. Orbiting is commonly accomplished on a non-
CNC machine by using an orbiting device on the machine. Implying a motion on a standard or electrical
electrode can be used without a shape or machined electrode to be of the shape of the work piece.
Wire EDMing.
CNC wire cut EDM machines use a traveling wire electrode to cut a complex outline of fine details of stamping
and blanking dies of too harden steel. The wire die system continuously delivers fresh wire under constant
tension to the work area guided by a set of guides or diamond wire guide. New wire is always exposed to the
part so electrode wear is not a problem like in ram EdMing. Wire EDM machines are also easier to learn than
ram EDM. They can run un attended for long periods including overnight and weekends. There are four basic
wire EDM subsystems, all of which are CNC controlled. These subsystems include:
- Power supply
- Dielectric system
- Wire feeding system
- Positioning system.
The wire EDM power supply principles are similar to ram EDM. It provides the series of DC electric discharges
between the wire electrode and the work piece. As with ram EDM flushing is critical. The wire EDM dielectric
system uses deionized water, which can remove heat more efficiently than conventional than conventional
dielectric systems and produce extremely thin recast layer. Flushing is done along the wire with flushing
nozzles. In some cases the work piece and wire are completely submerged under water. The downsize of
submerged EDMing is that the deionized water can cause corrosion to the work piece additionally machines with
tanks are more expensive and cycle time are increased by fill and drain time.
The positioning system use a CNC two axis table and provide a variety of multi axis wire positioning
capabilities depending on the cuts that must be made. A two-axis wire EDM can make only right angle cuts the
worktable. An independent 4-axis machine can create tapered angles even with a top profile with a different
shape than the bottom profile. This is necessary for producing extrusion dies and flow valves. As in ram EDM
the electrode never touches the work while cutting. The servo system maintains at least thousands of an inch
gap between wire and work piece. During spark erosion each wire produces a kerf or over cut in the work
surface that is slightly larger than the wire diameter. As a 0.012 diameter wire for example can create 0.015-
diameter kerf. The wire cuts along a programmed path. The wire starts to cut from the side of the work piece or
through drilled holes made by EDM drilling machines made for that purpose. Wire EDM machines can also
process parts that are stacked, cuts perhaps so thin parts in one path. Under these conditions flushing can be
problematic.
The third type of EDM involves drilling small deep holes and slots of round and regular shapes. These
machines use long rounded electrodes. These electrodes rotate with a moderate speed about 100 revolutions
per minute. During drilling this rotation aids in flushing the cut and tends to create uniform electrode wear.
These machines can drill very minute holes. This process can obtain length to diameter rotation of 30:1 or
better
 Fire is the worst with ram EDMing. If the dielectric falls bellow the level of which sparking occurs. When
this happens the dielectric can be heated above its flushing point and sparks can ignite it. Machines should turn
of automatically when the dielectric drops below a safe level. Smoke from the process can be irritant. Smoke
should be properly ventilated or smoke-consuming units can be attached to the machines. Finally EDM can
produce hand skin irritation which is remedy with hand creams.
profile projector

What is a profile projector? Also known as an optical comparator, or even called a shadowgraph, a profile
projector is an optical instrument that can be used for measuring. It is a useful item in a small parts machine
shop or production line for the quality control inspection team. The projector magnifies the profile of the
specimen, and displays this on the built-in projection screen. On this screen there is typically a grid that can be
rotated 360 degrees so the X-Y axis of the screen can be aligned with a straight edge of the machined part to
examine or measure. This projection screen displays the profile of the specimen and is magnified for better
ease of calculating linear measurements. An edge of the specimen to examine may be lined up with the grid on
the screen. From there, simple measurements may be taken for distances to other points. This is being done on
a magnified profile of the specimen. It can be simpler as well as reduce errors by measuring on the magnified
projection screen of a profile projector.
The typical method for lighting is by diascopic illumination, which is lighting from behind. This type of lighting is
also called transmitted illumination when the specimen is translucent and light can pass through it. If the
specimen is opaque, then the light will not go through it, but will form a profile of the specimen. Measuring of
the sample can be done on the projection screen. A profile projector may also have episcopic illumination which
is light shining from above. This useful in displaying bores or internal areas that may need to be measured.
If you have a need for a profile projector or optical comparator, please contact us today. We have several lines
available, including versions with manual micrometers or newer versions with digital readouts and digital
micrometers for accurate and fast microscope measuring.
Lathe

A lathe (pronounced /ˈleɪð/) is a machine tool which spins a block of material to perform various operations
such as cutting, sanding, knurling, drilling, or deformation with tools that are applied to the workpiece to create
an object which has symmetry about an axis of rotation.
Lathes are used in woodturning, metalworking, metal spinning, and glassworking. Lathes can be used to shape
pottery, the best-known design being the potter's wheel. Most suitably equipped metalworking lathes can also
be used to produce most solids of revolution, plane surfaces and screw threads or helices. Ornamental lathes
can produce three-dimensional solids of incredible complexity. The material is held in place by either one or two
centers, at least one of which can be moved horizontally to accommodate varying material lengths.
Examples of objects that can be produced on a lathe include candlestick holders, cue sticks, table legs, bowls,
baseball bats, musical instruments (especially woodwind instruments), crankshafts and camshafts.
History
The lathe is an ancient tool, dating at least to the Egyptians and known and used in Assyria, Greece, the Roman
and Byzantine Empires.A turned wood bowl with natural edgesThe origin of turning dates to around 1300BC
when the Egyptians first developed a two-person lathe. One person would turn the wood work piece with a rope
while the other used a sharp tool to cut shapes in the wood. The Romans improved the Egyptian design with the
addition of a turning bow. Early bow lathes were also developed and used in Germany, France and Britain. In
the Middle Ages a pedal replaced hand-operated turning, freeing both the craftsman's hands to hold the
woodturning tools. The pedal was usually connected to a pole, often a straight-grained sapling. The system
today is called the "spring pole" lathe (see Polelathe). Spring pole lathes were in common use into the early
20th Century. A two-person lathe, called a "great lathe", allowed a piece to turn continuously (like today's
power lathes). A master would cut the wood while an apprentice turned the crank.[1]
During the industrial revolution, mechanized power was applied to the lathe via steam engines and line
shafting, allowing faster and easier work. The design of lathes diverged between woodworking and
metalworking to a greater extent than in previous centuries. Metalworking lathes evolved into heavier machines
with thicker, more rigid parts. The application of leadscrews, slide rests, and gearing produced commercially
practical screw-cutting lathes. Between the late 19th and mid 20th centuries, individual electric motors at each
lathe replaced line shafting as the power source. Beginning in the 1950s, servomechanisms were applied to the
control of lathes and other machine tools via numerical control (NC), which often was coupled with computers
to yield computerized numerical control (CNC). Today manually controlled and CNC lathes coexist in the
manufacturing industries.

Parts

Parts of a wood latheA lathe may or may not have a stand (or legs), which sits on the floor and elevates the
lathe bed to a working height. Some lathes are small and sit on a workbench or table, and do not have a stand.
Almost all lathes have a bed, which is (almost always) a horizontal beam (although some CNC lathes have a
vertical beam for a bed to ensure that swarf, or chips, falls free of the bed). A notable exception is the Hegner
VB36 Master Bowlturner, a woodturning lathe designed for turning large bowls, which in its basic configuration
is little more than a very large floor-standing headstock.
At one end of the bed (almost always the left, as the operator faces the lathe) is a headstock. The headstock
contains high-precision spinning bearings. Rotating within the bearings is a horizontal axle, with an axis parallel
to the bed, called the spindle. Spindles are often hollow, and have exterior threads and/or an interior Morse
taper on the "inboard" (i.e., facing to the right / towards the bed) by which accessories which hold the
workpiece may be mounted to the spindle. Spindles may also have exterior threads and/or an interior taper at
their "outboard" (i.e., facing away from the bed) end, and/or may have a handwheel or other accessory
mechanism on their outboard end. Spindles are powered, and impart motion to the workpiece.
The spindle is driven, either by foot power from a treadle and flywheel or by a belt drive to a power source. In
some modern lathes this power source is an integral electric motor, often either in the headstock, to the left of
the headstock, or beneath the headstock, concealed in the stand.
In addition to the spindle and its bearings, the headstock often contains parts to convert the motor speed into
various spindle speeds. Various types of speed-changing mechanism achieve this, from a cone pulley or step
pulley, to a cone pulley with back gear (which is essentially a low range, similar in net effect to the two-speed
rear of a truck), to an entire gear train similar to that of a manual-shift auto transmission. Some motors have
electronic rheostat-type speed controls, which obviates cone pulleys or gears.
The counterpoint to the headstock is the tailstock, sometimes referred to as the loose head, as it can be
positioned at any convenient point on the bed, by undoing a locking nut, sliding it to the required area, and
then relocking it. The tailstock contains a barrel which does not rotate, but can slide in and out parallel to the
axis of the bed, and directly in line with the headstock spindle. The barrel is hollow, and usually contains a taper
to facilitate the gripping of various type of tooling. Its most common uses are to hold a hardened steel centre,
which is used to support long thin shafts while turning, or to hold drill bits for drilling axial holes in the work
piece. Many other uses are possible
Metalworking lathes have a carriage (comprising a saddle and apron) topped with a cross-slide, which is a flat
piece that sits crosswise on the bed, and can be cranked at right angles to the bed. Sitting atop the cross slide
is a tool post, which holds a cutting tool which removes material from the work piece. There may or may not be
a lead screw, which moves the cross-slide along the bed.
Woodturning and metal spinning lathes do not have cross-slides, but rather have banjos, which are flat pieces
that sit crosswise on the bed. The position of a banjo can be adjusted by hand; no gearing is involved.
Ascending vertically from the banjo is a tool post, at the top of which is a horizontal tool rest. In woodturning,
hand tools are braced against the tool rest and levered into the work piece. In metal spinning, the further pin
ascends vertically from the tool rest, and serves as a fulcrum against which tools may be levered into the work
piece.
Surface grinding

Surface grinding is a widely used process of machining in which a spinning wheel covered in rough particles cuts
chips of metallic or non metallic substance making them flat or smooth.
Process
Spark out is a term used when precision values are sought and literally means "until the sparks are out (no
more)". It involves passing the workpiece under the wheel, without resetting the depth of cut, more than once
and generally multiple times. This ensures that any inconsistencies in the machine or workpiece are eliminated.
As with any grinding operation, the condition of the wheel is extremely important. Diamond dressers are used
to maintain the condition of the wheel, these may be table mounted or as the first image shows, mounted in
the wheel head where they can be readily applied.
Lubrication
Lubricants are sometimes used to cool the workpiece and wheel, lubricate the interface, and remove swarf. It
must be applied directly to the cutting area to ensure that the fluid is not carried away by the grinding wheel.
Common lubricants include water-soluble chemical fluids, water soluble oils, synthetic oils, and petroleum-
based oils. The type of lubrication used depends on the workpiece material and is outlined in the table below

Types of lubricants used for grinding based on workpiece material

Workpiece
Lubricant
material

Aluminium Light duty oil

Brass Light duty oil

Cast iron Heavy duty emulsifiable oil, light duty chemical and synthetic oil

Mild steel Heavy duty water-soluble oil

Stainless steel Heavy duty emulsifiable oil, heavy duty chemical and synthetic oil

Water-soluble oil, dry, heavy duty emulsifiable oil, light duty

Plastics
chemical and synthetic oil

Equipment
Surface Grinder with electromagnetic chuck, inset shows a Manual magnetic chuckA surface grinder is a
machine tool used to provide precision ground surfaces, either to a critical size or for the surface finish.
The typical precision of a surface grinder depends on the type and usage, however +/- 0.002 mm (+/- 0.0001")
should be achievable on most surface grinders.
The machine consists of a table that traverses both longitudinally and across the face of the wheel. The
longitudinal feed is usually powered by hydraulics, as may the cross feed, however any mixture of hand,
electrical or hydraulic may be used depending on the ultimate usage of the machine (ie: production, workshop,
cost). The grinding wheel rotates in the spindle head and is also adjustable for height, by any of the methods
described previously. Modern surface grinders are semi-automated, depth of cut and spark-out may be preset
as to the number of passes and once setup the machining process requires very little operator intervention.
Depending on the workpiece material, the work is generally held by the use of a magnetic chuck. This may be
either an electromagnetic chuck, or a manually operated, permanent magnet type chuck; both types are shown
in the first image.
Aluminum oxide, silicon carbide, diamond, and cubic boron nitride (CBN) are four commonly used abrasive
materials for the surface of the grinding wheels. Of these materials, aluminum oxide is the most common.
Because of cost, diamond and CBN grinding wheels are generally made with a core of less expensive material
surrounded by a layer of diamond or CBN. Diamond and CBN wheels are very hard and are capable of
economically grinding materials, such as ceramics and carbides, that cannot be ground by aluminum oxide or
silicon carbide wheels.
The machine has provision for the application of coolant as well as the extraction of metal dust (metal and
grinding particles).
Effects on work material properties
The high temperatures encountered at the ground surface create residual stresses and a thin martensitic layer
may form on the part surface; this decreases the fatigue strength. In ferromagnetic materials, if the
temperature of the surface is raised beyond the Curie temperature then it may lose some magnetic properties.
Finally, the surface may be more susceptible to corrosion.

Bts Manufacturing(MPD)
BTS MFG(MPD)
Bts Manufacturing(MPD)(LAY OUT)

Powder coating plant

Cnc bending Bts rack assembly

Cnc punching

Degreasing area

FLOW OF WORKING PROCESS(LAY OUT)

 The Powder Coating Plant Process
Powder coating has today established itself as the most effective means of metal surface finishing. It has
replaced liquid painting and various methods of electroplating due to the many advantages this process offers …
_ Substantial improvement to chemical corrosion
_ Substantially improved resistance to mechanical abuse – better scratch resistance, abrasion resistance and
mechanical wear and tear
_ Cleaner process for improved environment
_ Faster process for better productivity through the paint-shop
_ Requires less skills for high quality coatings
_ Guarantees uniform and consistent results
_ Substantially improved aesthetics for higher sales value of the finished product
_ Requires lower energy per Meter2 of surface coated
_ Requires lesser care in storing and packing due to the toughness of the coat
_ Is cost-effective
Powder coating is a simple process requiring minimal skills and training. The articles to be coated are first
cleaned of all foreign matter from the surface. Mild steel components need to go through a phosphate
conversion coating. Aluminum components go through a chromate conversion coating. This, known as
pretreatment, is employed for improved bonding of the powder coat to the material being coated to provide a
longer life to the coat. The method employed usually is a dip in chemicals and water in various tanks.
Occasionally, the process may be automated through a spray pretreatment process.
The Powder Coating System
Complete powder coating systems come in two versions – a batch system and a conveyorized system. The
primary difference is the mode of material movement from operation to operation. Powder coating itself may be
by manually held spray guns or by automated guns fixed-mounted or reciprocator-mounted.
A complete powder coating system requires the following components:
PRETREATMENT SYSTEM – consisting of tanks or tubs containing chemicals or water in which the
articles are dipped to clean and prepare the surface for powder coating. The size of the tanks depends on the
size and quantity of articles to be coated. The specific process depends on the metal make-up of the article.
AIR COMPRESSOR – fitted with appropriate filters provides clean and dry compressed air to the powder coating
system. A 3HP or a 5HP air compressor is normally adequate for a batch coating system using 1 coating
Machine. Conveyorized systems with multi-gun application may require a larger capacity air compressor.
POWDER SPRAY SYSTEM (also known as the powder coating machine) – is considered
the heart of the powder paint shop. Normally an electrostatic powder spray system is used. This sprays
electrostatically charged powder into the spray booth where the articles to be coated are hung. Electrostatic
forces provide a uniform and consistent coating quality. Major strides have been made in the design of these
machines offering major benefits to the user.
POWDER COATING BOOTH WITH RECOVERY SYSTEM – in which the actual powder coating is
carried out. The efficiency of recovery of oversprayed powder for reuse decides the economics of powder
coating. The efficiency of overall retention of oversprayed powder decides the pollution-free worthiness of the
system. There are two types of powder recovery booths – Filter Cartridge type and the Hyper Cyclone type.
CURING OVEN – in which the powder coated articles are placed for 10 to 15 minutes at the recommended
temperature for the powder to melt, polymerize, fuse and cure into the final finish of high aesthetic appeal with
strong mechanical and chemical properties.
. The Powder Spray System
electrostatic powder spray systems use only the in-built 100 kV technology – benchmark technology in powder
coating today – worldwide. The 100 kV integrated spray gun improves transfer efficiencies, productivity and powder
consumption substantially
The Powder Recovery Booth
The equipment that decides the economical viability of your powder coating paint-shop is the powder recovery
booth. The economies of your paint-shop depend on the genuine recovery of oversprayed powder for reuse.

The Powder Curing Oven

Powder curing ovens whether fuel-fired or electrical – are extremely energy efficient, lowering the power bills as well
as saving scarce fossil fuels. Ovens are guaranteed for stated performance characteristics. Uniform temperatures
throughout the entire internal working area of the oven ensure uniform powder curing. This becomes a very critical
factor in powder coating. Lower than required temperatures may mean an incomplete powder curing process, leading
to the powder coat peeling off (and the product suffers unnecessarily). Higher than stated temperatures could lead to
the powders’ important resistance to chemical corrosion and mechanical abuse components burning off. This would
translate into a lower life to the product being coated.