Internship Report

Internship Report

Submitted to: Respected Lt. Col. Shafqat Hussain

Supervised by: Respected Maj. Muhammad Shoaib Qazi
Submitted by: Muhammad Muhammad Faran
10-HITEC-ME-104
HITEC University, Taxila Cantt

Duration: 06 Weeks

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No Title Page No.

1 Abstract 3

2 Acknowledgement 3

3 Introduction to Heavy Industries Taxila 4

4 Modules of Internship 10

5 Pro Engineer Modeling 11

6 CNC Manufacturing Codes 13

7 Pro Engineer Modeled Images & Auto Cad Drawings 20

8 Finite Element Analysis 22

9 Observations 25

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Abstract:
The report describes my six weeks experience and technical activities performed at APC
Factory HIT.

The report comprises of Detailed study and modeling of the armored Cover Plate for the
fuel cell of Armored Personnel Carrier Vehicle SAAD manufactured at the APC
manufacturing facility Heavy Industries Taxila. The plate model was generated using Pro
Engineer Software, Creo Parametric 2.0 available in the CAD/CAM section of Factory.

Acknowledgement:
My internship at APC Factory gave me a golden opportunity for learning and self
development. I consider myself very lucky and honored to have so many wonderful people to
lead me in this whole session.

My grateful thanks to Honorable Lt. Col. Shafqat Hussain, who allowed me six weeks
internship here, I also want to say thanks to Respected Maj. Muhammad Shoaib Qazi, who
in spite of being extraordinarily busy with his duties, took time out to hear, guide and keep
me on the correct path. A humble Thank you sir!

Last but not the least I also want to say thanks to the my dear instructors

AWM Mr. Mian Abdul Hafeez, AFM Mr. Muhammad Sarfraz, AFM Mr. Dawood Khan &
HS-I Mr. Mahfooz-ul-Haq who equipped me with technical knowledge and shared valuable
information that helped me so much in the whole session and will help me in the future.

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Introduction to HIT:
Heavy Industries or (HIT) Taxila lies 35 km north-west of Rawalpindi/
Islamabad. Heavy Industries Taxila (HIT) is a manufacturing facility which has
built the Main Battle Tank Al-Khalid", Armoured Personel Careers, Al-Zarar
Tank. Heavy Industries Taxila formerly known as Heavy Rebuild Factory (HRF)
was established in Taxila in the late seventies to undertake rebuild and modernization of
Chinese tanks. Heavy Rebuild Factory (HRF) was renamed to Heavy Industries Taxila (HIT)
in September 1992. Now HIT consists of six major military factories. Activities of HIT now
include the cost effective manufacture of armoured fighting vehicles, armoured personnel
carriers and tank guns.

Facilities:
Heavy Industries Taxila comprises various defense factories and facilities:

Heavy Rebuild Factory T-Series

To rebuild and modernize tanks/armoured recovery vehicles of Chinese and Eastern
European origin.

Heavy Rebuild Factory M-Series

Heavy Rebuild Factory (M-Series) carries out rebuild of tracked vehicles of US origin. The
factory specializes in M113 Series vehicles.

APC Factory
The M113 Family of vehicles are manufactured in this factory using CNC machines
CAD/CAM system and manufacturing technology on MIG and TIG aluminum welding,
radiographic inspection, chemical cleaning, coating and painting according to military
specifications.

Gun Factory
The Gun factory has the capability of machining barrels ranging from 105 mm to 203 mm
caliber. It manufactures 105mm gun barrels for upgraded T-59 & T-69 tanks. Each barrel is
auto-frottage and subjected to high precision work on state of the art machines.

Tank Factory
Tank Factory is equipped with modern manufacturing facilities, including 7-axis CNC
machines, for flexible heavy-duty machining operations and a complete infrastructure for hull
and turret manufacture.

Development, Engineering Support And Components Manufacture (DESCOM)

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This production facility has been established to provide engineering support to all the
factories of HIT. Equipped with CNC machines, it undertakes manufacture of components,
assemblies, tools, dies, gauges and arranges development of spare parts through the vendor
industry. It also provides repair and maintenance support to machinery and equipment
installed in HIT.

Evaluation, Training And Research Organization (ETRO)

This is a supporting organization which undertakes Quality Assurance of finished products
with quality assurance laboratories which test physical and chemical properties of production
materials, calibration facilities are available to ensure accuracy of tools and gauges used in
rebuild and manufacturing processes.

Mechanical Complex
This complex manufactures sugar plants, cement plants, boilers, cranes, road construction
machinery, brick-making machinery and other equipment to cater for the needs of Railways
and other civilian organizations.

Research And Development (R&D)

HIT has undertaken R&D projects on required basis wherein it has carried out successful
R&D in the following areas:

Tank design
Tank modernization
Infantry fighting vehicles
Tank fire-control systems

Production:
Former:

Type 69-II - Main battle tank produced under license.

Type 85-IIAP - Main battle tank produced under license.
M113 - Armoured personnel carrier produced under license.
Current:
Main battle tanks (MBT)

Al-Khalid
Al-Zarrar
Artillery

MKEK Pinter towed howitzer.

Armoured personnel carriers (APC)

Talha :

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APC based on M113 chassis with 5 road wheels, accommodates 11 fully equipped
troops. 250 delivered to the Pakistan Army by 2006.

Saad :

APC based on the Talha design. Modified with extended hull and 6 road wheels,
14.5 mm machine gun, improved amour protection and a more powerful engine supplied
by Germany's MTU. Accommodates 13 fully equipped troops.

Sakb :

Armoured command vehicle based on Talha APC.

Al-Hamza:

Infantry fighting vehicle (IFV) based on the Saad APC, fitted with 25 mm automatic
cannon, an export product not in service with the Pakistan Army.

Armoured guided missile carriers:

Maaz: Based on the Talha APC, armed with the Baktar-Shikan anti-tank
guided missile (ATGM) launcher and operated by a crew of 4. There is
capacity for 8 extra rounds and the missile firing unit on the roof is retracted
into the cabin for reloading.
Mouz: Based on the Talha APC, armed with either the RBS 70 or Anza
I/II air-defense missile systems. The missile firing unit on the roof is retracted
into the cabin for reloading.

Auxiliary armoured vehicles:

Al-Hadeed : Armoured recovery vehicle (ARV) based on Saad APC.

Al-Qaswa : Armoured logistics vehicle (ALV) based on the Talha APC.
Armored cars:

Muhafiz :

Armoured security vehicle based on the Land Rover Defender.

Under development:

155 mm Self-propelled artillery gun - Project revealed at IDEAS 2002 defense

exhibition.
Al-Khalid II - Under development.

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Pictures:

(M113P) (Al-Zarrar)

(AL-Khalid) (Muhafiz Vehicle)

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Flow Process Steps APC M113P (Saad):

The step wise process is given below

1- Material Cutting
2- Finishing
3- Quality Control QC
4- Bottom Plate Fabrication
5- Final Drive left/Right Assembly
6- Box Beam Assembly
7- Storage
Lower Nose Plate
8- Auto Weld
9- Top Plate
10- Rear Plate
11- Slide Plate
Left /Right
12- Sponson
Plates
13- Driver
Hatch Assembly
14- Upper Hull
Welded
15- Lower &
Upper Hull Welded
16- Auto Weld
Hull
17- Position
Welding
18- Ramp Mating on Hull
19- Hull Inspection
20- Hull Machining
21- Deoxidization
22- Engineering Compartment
23- Bulk Head Assembly
24- Grill Mating
25- Storage Position Welding
26- Final Storage Read Line
Fuel Cell
Grill Assembly
Ramp & Door
Cargo Hatch
Driver Hatch Cover Plate Door
27- Quality Control

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28- Sub Assembly welded

29- ITB
30- STS
31- Track Fitted
32- Engine Installment
33- Final Paint
34- Ready

Flow Process Steps of Security Vehicle (Muhafiz):

The step wise process is given below

1- Material Cutting
2- Finishing
3- Quality Control QC
4- Bottom Plate
Fabrication
5- Side Plate Left/
Right Stowage
6- Rear Plate
Stowage
7- Job Plate
Stowage
8- Hull Mating
9- Final Stowage
Door Retainer
Rifle Rack
Fire Extension
Eng Safety Plate
Hull
10- Hull Finishing
11- Door Stowage
12- Door Fitting
13- Bonnet Fitting
14- Cargo Hatch
Extension Cover Fitting
15- Driver Compartment Safety Plate
16- Fuel & Governor Box
17- Bumper Assembly
18- Turret Assembly
19- Final Finishing

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20- Quality Control

21- STS Anodizing
22- Hull Painting
23- Hull Chases Mounting
24- Front/ Rear Bumper Fitting
25- Dash Board Fitting
26- Steering/ Gear Box Fitting
27- Electric Fitting
28- Minor assembly Fitting
29- Final Paint
30- Bullet Proof Glasses/ Tyre Fitting
31- AC work
32- Final Inspection
33- Quality Control QC
34- Ready

Modules of internship:
My internship was divided into three major modules. These modules are listed below and
there detail is on next pages.

1. General overview of different Machines and their operations in Factory

2. Pro Engineer Modeling of armored fuel Tank cover plate
3. Analysis using Finite Element Methods software
Introduction of machines in Workshop
The APC factory has a number of different Machines working the operations
regarding manufacturing and bullet proofing of armored personnel carrier vehicles. Most of
the machines are CNC operated. Their codes are feed in them by using floppy disks. These
codes are generated by using the Pro Engineer software. Workers in the CAD/CAM section
model the required jobs in the software and the software generates codes for the working of
machines. These codes are then feed in the machines and machines perform operations
accordingly.
There is an engine assembly section in which engines imported from foreign countries are
fitted in the chasses of the Land Rover vehicle and then the vehicle is armoured with
aluminium and steel metals

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Pro Engineer Modeling:

The project assigned was to model the armoured plate of fuel cell cover. This was modeled in
pro engineer and the codes for CNC machines were generated. The plate is manufactured
using operations of Profile milling, drilling and cutting. Three codes were generated to avoid
the problem of availability of drilling tools. Cutters (Profile millingh)were used in substitute
to that issue.
G & M codes:
Generally G codes are written in and performed by the CNC processor and operate the
motion control part of the control, the M codes are MACHINE codes, these operate most of
the basic electrical control functions such as Coolant, Tool changers, safety circuits etc, the
M, S & T codes are written in a separate PLC processor, both processors usually
communicate with each other over a common bus.
The tool changer and spindle are both configured to suit particular machine specifics.
Al.

G CODES CHART M CODES CHART

G00 Positioning (rapid traverse) M00 Program stop

G01 Linear interpolation (feed) M01 Optional stop
G02 Circular interpolation CW End of program
M02
G03 Circular interpolation CCW (no rewind)
G04 Dwell M03 Spindle CW
G07 Imaginary axis designation M04 Spindle CCW
G09 Exact stop check M05 Spindle stop
G10 Offset value setting M06 Tool change
G17 XY plane selection M08 Flood coolant ON
G18 ZX plane selection Flood coolant
M09
OFF
G19 YZ plane selection
Spindle
G20 Input in inch M19
orientation ON
G21 Input in mm M21 Tool
G22 Stored stroke limit ON M22 Tool
G23 Stored stroke limit OFF M23 Tool
G27 Reference point return check M24 Tool
G28 Return to reference point M25 Tool clamp
G29 Return from reference point M26 Tool unclamp
Return to 2nd, 3rd & 4th ref. M27 Clutch neutral ON
G30
point
Clutch neutral
G31 Skip cutting M28
OFF
G33 Thread cutting End program
M30
G40 Cutter compensation cancel (rewind stop)

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G41 Cutter compensation left M98 Call sub-program

G42 Cutter compensation right M99 End sub-program
Tool length compensation +
G43
direction
Tool length compensation -
G44
direction
G45 Tool offset increase
G46 Tool offset decrease
G47 Tool offset double increase
G48 Tool offset double decrease
Tool length compensation
G49
cancel
G50 Scaling OFF
G51 Scaling ON
Local coordinate system
G52
setting
Work coordinate system 1
G54
select
Work coordinate system 2
G55
select
Work coordinate system 3
G56
select
Work coordinate system 4
G57
select
Work coordinate system 5
G58
select
Work coordinate system 6
G59
select
G60 Single direction positioning
G61 Exact stop check mode
G64 Cutting mode
G65 Custom macro simple call
G66 Custom macro modal call
Custom macro modal call
G67
cancel
Coordinate system rotation
G68
ON
Coordinate system rotation
G69
OFF
G73 Peck drilling cycle
G74 Counter tapping cycle

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G76 Fine boring

G80 Canned cycle cancel
G81 Drilling cycle, spot boring
G82 Drilling cycle, counter boring
G83 Peck drilling cycle
G84 Tapping cycle
G86 Boring cycle
G87 Back boring cycle
G89 Boring cycle
G90 Absolute programming
G91 Incremental programming
Programming of absolute
G92
zero point
G94 Per minute feed
G95 Per revolution feed
Constant surface speed
G96
control
Constant surface speed
G97
control cancel
Return to initial point in
G98
canned cycle
Return to R point in canned
G99
cycle
CNC Manufacturing codes:
Plate 1 code:
%

N15 ( / MFG0001)
(use cutter one inch)
N20 M6
N25 S7000 M3
N30 G0 X13.28 Y.375
N35 Z1. M7
N40 Z.5
N45 G1 Z-.5 F100
N50 X6.53
N55 G2 X.375 Y6.53 I6.53 J6.53
N60 G2 X6.53 Y12.685 I6.53 J6.53
N65 G1 X13.28
N70 G2 X19.435 Y6.53 I13.28 J6.53
N75 G2 X13.28 Y.375 I13.28 J6.53

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N80 G1 Z1.
N85 G0 Y.875
N90 Z.5
N95 G1 Z-.5 F100
N100 X6.53
N105 G2 X.875 Y6.53 I6.53 J6.53
N110 G2 X6.53 Y12.185 I6.53 J6.53
N115 G1 X13.28
N120 G2 X18.935 Y6.53 I13.28 J6.53
N125 G2 X13.28 Y.875 I13.28 J6.53
N130 G1 Z1.
N135 G0 Y1.375
N140 Z.5
N145 G1 Z-.5 F100
N150 X6.53
N155 G2 X1.375 Y6.53 I6.53 J6.53
N160 G2 X6.53 Y11.685 I6.53 J6.53
N165 G1 X13.28
N170 G2 X18.435 Y6.53 I13.28 J6.53
N175 G2 X13.28 Y1.375 I13.28 J6.53
N180 G1 Z1.
N185 G0 X6.53 Y13.56
N190 Z.5
N195 G1 Z-1.5 F100
N200 X13.28
N205 G2 X20.31 Y6.53 I13.28 J6.53
N210 G2 X13.28 Y-.5 I13.28 J6.53
N215 G1 X6.53
N220 G2 X-.5 Y6.53 I6.53 J6.53
N225 G2 X6.53 Y13.56 I6.53 J6.53
N230 G1 Z1.
N235 M30
%

Plate 2 code:
:S1500 M3 T1

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:G0 X9.905 Y.905

N70 Z1. M7

N75 G81 X9.905 Y.905 Z-1.9002 R1. F50

N80 X15.8999 Y1.5524

N85 X18.905 Y6.53

N90 X15.8999 Y11.5076

N95 X9.905 Y12.155

N100 X3.8999 Y11.5023

N105 X.905 Y6.53

N110 X3.8999 Y1.5577

N115 G80

N120 M6

(Use Drill 1.125")

:S1500 M3 T2

:G0 X9.905 Y.905

N135 Z1. M7

N140 G81 X9.905 Y.905 Z-.888 R1. F50

N145 X15.8999 Y1.5524

N150 X18.905 Y6.53

N155 X15.8999 Y11.5076

N160 X9.905 Y12.155

N165 X3.8999 Y11.5023

N170 X.905 Y6.53

N175 X3.8999 Y1.5577

N180 G80

N185 M6

(Use degree 45')

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:S7000 M3

:G0 X6.53 Y13.31

N200 Z1. M7

N205 G1 Z-.25 F100

N210 X13.28

N215 G2 X20.06 Y6.53 I13.28 J6.53

N220 G2 X13.28 Y-.25 I13.28 J6.53

N225 G1 X6.53

N230 G2 X-.25 Y6.53 I6.53 J6.53

N235 G2 X6.53 Y13.31 I6.53 J6.53

N240 G1 Z1.

N245 M6

(Use cutter 1")

:S7000 M3

:G0 X6.53 Y13.56

N260 Z1. M7

N265 Z.75

N270 G1 Z-1. F100

N275 X13.28

N280 G2 X20.31 Y6.53 I13.28 J6.53

N285 G2 X13.28 Y-.5 I13.28 J6.53

N290 G1 X6.53

N295 G2 X-.5 Y6.53 I6.53 J6.53

N300 G2 X6.53 Y13.56 I6.53 J6.53

N305 G1 Z1.

N310 M30

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Plate 3 Code:

%
N5 G90 G94

N10 G40 G49

N15 ( / PLATEPART2)

N20 M6

N25 S1500 M3 T1

N30 G0 X1.41 Y7.905

N35 Z1. M7

N40 G81 X1.41 Y7.905 Z-.8112 R1. F50

N45 Y9.155

N50 G80

N55 M6

N60 S1500 M3 T1

N65 G0 X9.905 Y.905

N70 Z1. M7

N75 G81 X9.905 Y.905 Z-1.9002 R1. F50

N80 X15.8999 Y1.5524

N85 X18.905 Y6.53

N90 X15.8999 Y11.5076

N95 X9.905 Y12.155

N100 X3.8999 Y11.5023

N105 X.905 Y6.53

N110 X3.8999 Y1.5577

N115 G80

N120 M6

N125 S1500 M3 T2
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N130 G0 X9.905 Y.905

N135 Z1. M7

N140 G81 X9.905 Y.905 Z-.888 R1. F50

N145 X15.8999 Y1.5524

N150 X18.905 Y6.53

N155 X15.8999 Y11.5076

N160 X9.905 Y12.155

N165 X3.8999 Y11.5023

N170 X.905 Y6.53

N175 X3.8999 Y1.5577

N180 G80

N185 M6

N190 S7000 M3 T2

N195 G0 X6.53 Y13.31

N200 Z1. M7

N205 G1 Z-.25 F100

N210 X13.28

N215 G2 X20.06 Y6.53 I13.28 J6.53

N220 G2 X13.28 Y-.25 I13.28 J6.53

N225 G1 X6.53

N230 G2 X-.25 Y6.53 I6.53 J6.53

N235 G2 X6.53 Y13.31 I6.53 J6.53

N240 G1 Z1.

N245 M6

N250 S7000 M3

N255 G0 X6.53 Y13.56

N260 Z1. M7

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N265 Z.75

N270 G1 Z-1. F100

N275 X13.28

N280 G2 X20.31 Y6.53 I13.28 J6.53

N285 G2 X13.28 Y-.5 I13.28 J6.53

N290 G1 X6.53

N295 G2 X-.5 Y6.53 I6.53 J6.53

N300 G2 X6.53 Y13.56 I6.53 J6.53

N305 G1 Z1.

N310 G0 X3.8999 Y11.4398

N315 G1 Z-.55 F100

N320 G3 X3.9624 Y11.5023 I3.8999 J11.5023

N325 G3 X3.8999 Y11.5648 I3.8999 J11.5023

N330 G3 X3.8374 Y11.5023 I3.8999 J11.5023

N335 G3 X3.8999 Y11.4398 I3.8999 J11.5023

N340 G1 Z1.

N345 G0 X.905 Y6.4675

N350 G1 Z-.55 F100

N355 G3 X.9675 Y6.53 I.905 J6.53

N360 G3 X.905 Y6.5925 I.905 J6.53

N365 G3 X.8425 Y6.53 I.905 J6.53

N370 G3 X.905 Y6.4675 I.905 J6.53

N375 G1 Z1.

N380 G0 X3.8999 Y1.4952

N385 G1 Z-.55 F100

N390 G3 X3.9624 Y1.5577 I3.8999 J1.5577

N395 G3 X3.8999 Y1.6202 I3.8999 J1.5577

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N400 G3 X3.8374 Y1.5577 I3.8999 J1.5577

PRO ENGINEER MODEL IMAGES:

By using Creo Parametric 2.0 fuel cells cover plate was modeled. This helped us to
understand drawing reading concepts from paper. We translated the dimension readings from
paper and then drew the model according to the dimensions given in the drawing sheet. A
separate drawing sheet was also generated using Auto Cad 2007. The model from Pro
Engineer was imported into Auto Cad.

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Finite Element Analysis:

The designed part was tested using Finite Element Methods (FEA). This testing helped us to
understand the strength and durability of the part. The method uses Mechanics of Materials
theory. For analysis the cover plate was fixed for all degree of freedom constraints at the
coordinates where bolts are tightened.

A projected force momentum was applied at 10mm above in Y-axis from the center of plate.
The results for deformation produces in the plate and stress were observed. The values of
deformation stress were in range of safe design as proved by Von Mises theory. Following
are the graphics attached from FEA Analysis. Ansys 14.0 software package was used for the
analysis purposes.

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Observations:
The model of plate was generated on pro engineer and then analyzed using Ansys 14.0
software. The results were very satisfactory and the plate showed a very little deformation on
the impact of bullet striking. This confirms that the plate manufactured have a high factor of
safety and is reliable.

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