COVER

AT

HMT MACHINE TOOLS LTD,

BANGALORE COMPLEX
[Reporting period: 11/07/2018 - 11/08/2018]

Submitted by:
NAME UNIVERSITY SERIAL NO.
Akshay D Shetty 1PL15ME006
M S Somanna 1PL15ME019
Ranjith K S 1PL16ME409
Yandapalli Ganesh 1PL15ME046

From the DEPT. OF MECHANICAL ENGINEERING

SHRI PILLAPPA COLLEGE OF ENGINEERING

[Approved by AICTE New Delhi, Affiliated to Visvesaraya Technological University, Govt. of Karnataka]
#79, Kondasethi halli Road, Hesaraghata Hobli, Bengaluru North, Karnataka, India, 560 089.

Under the guidance of

Mr. Gopal Krishna
Dept. of training, HMT Machine Tools Ltd, Bangalore Complex
Preface
As per the rules and regulations of Visvesvaraya Technological University, Belagavi,
Karnataka, every student of Bachelor of engineering/technology has an essential
requirement to do four weeks of internship in any well reputed organisation. The purpose
of this program is to acquaint the students with industrial exposure and technical
knowledge through practical applications of theoretical concepts thought to them during
the conduction of their course.
This report is a literary reflection of what we learnt and the work we did in the organisation
during the period of our internship. Though utmost care was taken to avoid any errors in
this internship report, some errors might have crept in, to which we would like to
apologise.

Thank you.

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 ACKNOWLEDGEMENT

We would like to thank the entire HMT organisation, who has provided us this four weeks
internship. We are thankful to the manager of training- Mr. Venugopal M, who had
organized our internship and are especially thankful to Mr. Gopal Krishna for guiding us
through the internship. We are also thankful to the managers of various shop departments
who have provided us adequate knowledge about their respective shops and had guided
us during the shop visit.
We would also like to thank the workers of their respective shops/departments, who were
always ready to clarify our doubts and helped us in enhancing our knowledge on various
machining operations by illustrating the same for us.
We wish to express our deep gratitude to all the concerned persons, whose co-operation
and co-ordination have enabled us to perform and complete the internship programme in
their organization.

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 INTRODUCTION

About the organisation

Hindustan Machine Tools (HMT) is a multi-unit, multi-product manufacturing company

established as a public sector enterprise by the Govt. of India in the year 1953 and is
currently under the Ministry of Heavy Industries, Govt. of India.
Built on a strong foundation of technical knowledge acquired from world-renowned
machine tool manufacturers such as Oerlikon, Gildemeister, Manurhin, Liebher and
RinoBeradi and further strengthened by continues in-house R&D, HMT’s machine tools
expertise has been developed to such an extent that it has enabled HMT to design and
manufacture world-class products.
Though being established as a machine tool manufacturer, HMT diversified into other
product lines which include watches, tractors, printing machinery, metal forming presses,
die-casting, plastic processing machinery and CNC systems and bearings.
HMT is headquartered in Bengaluru.
From simple lathes to multi-station transfer lines, from stand-alone CNC machines to
flexible manufacturing systems, leading to factory automation, HMT manufactures it all.
HMT’s broad range of machine tools cover General Purpose Machines, Special Purpose
Machines, CNC Machines, meeting the needs of every engineering service.
HMT is well known for pioneering the concept of CNC technology in India and for being
the first company to successfully manufacture its own CNC systems, while associating
with Siemens Inc.
HMT’s commitment to the development of machine tools technology is clearly reflected
in the fact that HMT has many as seven exclusive machine tools unit spread across the

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country. Each superbly equipped to meet the most challenging demand for machine tools.
These units are in Bengaluru, Pinjore, Kalamassery, Hyderabad and Ajmer and are all
ISO 9000 certified.
Today HMTs manufacturing plants employ a highly skilled workforce strongly supported
by R&D. Today over 78000 machine tools manufactured by HMT are in use in India and
elsewhere.

The HMT Bangalore complex

The Bengaluru unit of HMT officially called as “HMT Machine Tools Ltd., Bangalore
complex” is the mother unit of HMT. This unit was established in 1961 and is located at
Jalahalli, Bengaluru. This unit is a house to production of a variety of machinery, from
small machine components to large machine tools.

The major products manufactured in this unit include turning machines, lathes – L45, L70,
CNC lathe, CNC grinding machine, surface grinding machines, gear hobbing machines,
high speed gear shaping machines, radial drilling machines, die-casting machines, special
purpose machines, precision machines, precision ball screws and CNC control systems.

The major manufacturing facilities in this unit include pattern making, foundry,
fabrication, machining shops consisting of conventional & CNC machines - lathes, milling
machines, grinding machines, drilling machines, planing machines, plano milling
machines, slideway grinding machines, vertical machining centres, horizontal machining
centres and heat treatment facilities.

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CONTENTS
Page No.
1. Pattern Shop……………………………………………………………….. 07
2. Foundry & Fettling………………………………………………………… 10
3. Planing……………………..……………………………………………….12
4. HTC………………………………………………………………………... 14
5. Gears………………………………………………………………………..16
6. Spindles……………………………………………………………………. 19
7. Non-rounds………………………………………………………………… 21
8. Rounds……………………………………………………………………... 23
9. L-45 Assembly……………………………………………………………...25
10.RD Assembly……………………………………………………………….27
11.PSB Assembly……………………………………………………………... 29
12.Gear Hobber Assembly……………………………………………………. 31
13.RD Production……………………………………………………………... 33
14.Ball Screw Division……………………………………………………….. 34
15.Material Testing…………………………………………………………… 36
16.Inspection………………………………………………………………….. 42
17.Calibration…………………………………………………………………. 47
Conclusion…………………………………………………………………. 51

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 1. PATTERN SHOP

In casting, a pattern is a replica of the object to be cast, used to prepare the cavity into
which molten material will be poured during the casting process.
Patterns used in sand casting may be made of wood, metal, plastics, thermocol or other
materials.
A pattern shop is where patterns of various shapes and sizes are built using the available
material.

Materials used in pattern shop: Wood and Thermocol

Teak wood was the type of wood used in pattern shop. Wood was being used to make
pattern in the 1970s and 80s but now wood is not being used and only thermocol is being
used.
The thermocol being used is considerably strong and the thickness varies from 50 mm to
100 mm.

 Properties of thermocol:
 Low thermal conductivity
 Cheap procurement costs
 Economic production rates
 Can be used to make any type of pattern
 Light in weight
 Low machining time

 Allowance:
 Shrinkage allowance
 Machining allowance
 Draft allowance
 Distortion allowance

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  Shake allowance

 Machining operations:
 Cutting
 Drilling
 Planing
 Shaping
 Grinding
 Wire cutting

 Machinery used:
 Disk sander
 Wood jointer machine
 Wood turning lathe
 Surface grinding machine
 Drilling machine
 Wood planning machine
 Circular saw
 Wood milling machine

 Hand tools used:

 Divider
 Outside callipers
 Inside callipers
 Steel rule
 Hand saw
 Chisel
 Hammer
 Scriber

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  File

 Steps involved in building a pattern:

1. With the help of the blueprint provided draw the designs on the thermocol
2. Make four crates for one design
3. Jointly perform machining operations to cut, drill, plan, and grind the thermocol
material.
4. Once the machining operations have been performed, join all the four pieces
together using glue and screws
5. Cure pattern for two days
6. Inspect the pattern before using it in the foundry.

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 2. FOUNDRY
Foundry is a factory where metal castings are made as per the design provided. Metals are
cast into shape by melting the metal, pouring the molten metal into a mould and removing
the solidified metal from the mould.

 The foundry consists of the following sections:

1. Sand plant system: Where sand is filtered and mixed.
2. Core making and setting section: Where the core is prepared
3. Melting and pouring section: Where metal is melted in a furnace and poured into
the mould.
4. Fettling section: Where the solidified metal undergoes cleaning, grinding and
sanding.

 Moulding sand:
The moulding sand is a mixture of silica sand, resin and Omega 3 catalyst.

 Furnace used in the foundry: JUNKER FURNACE

 Heat supply: Electrical coil
 Capacity: 3.5 tonnes
 Furnace temperature: 1450°C
 Time required for melting: 4-5 hrs
 Container: Refractory lining
 Inoculants added: ferrosilicon and calcium silicate

 Metals used in the furnace:

 Carbon: 15%
 Silicon: 15%
 Steel: 15%

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  Home scrap plus pig iron: 55%

 Foundry process:
1. Sand undergoes filtering and is collected in the bunker.
2. The sand is sent to the mixing chamber where sand mixes with oil and binders.
3. The mould is brought near the mixing chamber and the mixture is sprayed inside
the walls of the mould.
4. The cores and allowances are imprinted in the mould.
5. The metal is melted in the furnace.
6. The molten metal is poured in a ladle.
7. The ladle is lifted by chains using the overhead crane and brought close to the mould
and is then tilted causing the molten metal is drop into the mould.
8. After pouring, the metal is allowed to solidify and cool for at least 24 hrs.
9. Once the metal is solidified, it is separated from its mould and left for seasoning.
10.Once the metal is completely cooled and seasoned, fettling operations are
performed on the metal to clean its surface and remove excess material on the
surface by grinding and sanding.

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 3. PLANING
Planing is defined as a machining operation done on a planning machine.
The planning department along with planing machine also houses shaping machine,
grinding machine, milling machine and drilling machine.

Details of machines used in the planing department are as follows:

1. Planing machine:

A planning machine is a type of machine tool in which the job moves linearly relative to
the tool in order to cut the job. In planing machine the job moves and the tool remains
stationary.

 Angular surface planer: used to cut jobs at an angle.

Make: Boehringer
Parts: side tool head, cross head, column, bed and table.

2. Shaping machine:

A shaping machine is similar to a planing machine, but smaller than planing machine and
with tool moving and job remaining stationary.

Both planing and shaping machines utilises a single-point cutting tool.

3. Milling machine:

Milling machine performs cutting operation by advancing a rotating multi-pint cutting

tool into the job at a certain direction.

4. Grinding machine:

Grinding machine is a machine tool consisting of rotating abrasive wheel, used for
grinding surfaces of the jobs by bring the job in contact with the rotating wheel.

 Slide-way grinding machine: A type of grinding machine used to grind only flat
surfaces.

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5. Drilling machine:

Drilling machine is a machine tool consisting of a drill bit as the tool, used to drill holes
into the job.

 HMT RM-62: It is a type of radial drilling machine designed and made by HMT.
It consists of a radial arm that can be revolved about the axis of the column.
Power: 4.5 kW.
Spindle speed: 40-1800 rpm.

6. Boring machine:

Boring machine is used to enlarge an already drilled hole on the job by the means of a
single-point cutting tool.

Power: 4.5 kW
Max. boring diameter: 300 mm

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 4. HIGH TECHNOLOGY CENTRE (HTC)
HTC is a department in HMT where all machining operations are performed CNC
machines. Since CNC is based on high-technology, the name “high technology centre” is
given to the department.

 Operations performed:
 Milling
 Chamfering
 Drilling
 boring

 Machine tools used:

 CNC horizontal milling machine

 Features:
1. 45 tools can be fixed
2. Manufactured by HMT
 Operations performed: Drilling, up-milling, down-milling, end milling, slot
milling, chamfering, boring etc.
 Tool: Multi-point cutting tool

 CNC vertical milling machine

 Features:
1. 25 tools can be fixed
2. Manufactured by HMT
 Operations performed: Drilling, up-milling, down-milling, end milling, slot
milling, chamfering, boring etc.
 Tool: Multi-point cutting tool

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Other major machines used in HTC include Waldrich Coburg (having dimensions 0.5
m X 2 m X 9 m) and UTX – 160 which is a floor type milling machine manufactured by
HMT Hyderabad.

NOTE: In machines manufactured by HMT, the tool moves and the job remains
stationary, while in the German made machines, the job moves and the tool remains
stationary.

 Main axes used in CNC machines:

+Y

+X

-Z +Z

-X

-Y

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 5. GEARS
A gear is a toothed wheel that meshes with another toothed mechanism in order to change
the speed (torque) or direction of the transmitted motion.

The gears section manufactures various types of gears using various gear cutting
machines.

 Gear materials:

The materials used in the gears section for manufacturing gears include:

 C1 steel
 C2 steel
 Cast Iron
 Brass

 Types of gears produced:

 Spur gear
 Helical gear
 Worm gear
 Bevel gear
 Rack & pinion
 Internal gears

 Machines used:

 Gear hobber
 Milling machine
 Shaper
 Gear tooth rounder

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 Operations performed:
 Gear shaping
 Rack shaping
 Internal gear cutting
 Vertical broaching
 Horizontal broaching
 Milling

 Tools:
Tools used can be single-point or multi-point cutting tool.

 Coolant:
Coolant used is blue coolant.

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 Operations performed for producing a gear:

Raw material

Marking

Initial operations

Toughening

Gear cutting

Heat treatment
(Carburizing)

Finished gear

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 6. SPINDLE
Spindle is a cylindrical component of a machine that serves as an axis for other rotating
parts of the machine.

In the spindle section various types of spindle and shafts are produced.

 Components produced:
Spindles of various machine tools such as lathe, miller, grinder, driller etc.

 Operations performed:
 Internal cylindrical grinding
 External cylindrical grinding
 Tapering

 Machines used:
 L 45
 G 17
 K 130
 Y 16976

 Tools Used:
 Popples indicator
 Millimess indicator

 Coolants used while machining:

 White coolant
Avoids rust and good for finishing. Contains G3 oil and water. Used in
grinding operations and used for 3-4 mm of material removal.

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 Green coolant
Used for faster cooling on jobs rotating faster than 3800 rpm and for material
removal of 1-2 mm.

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 7. NON-ROUNDS
In the non-rounds section, operations are done on non-rounds jobs such as cubical,
rhombus shaped jobs.

 Machines used:
 Horizontal boring machine
 Vertical boring machine
 Universal milling machine
 Planing machine
 Grinding machine
 Horizontal milling machine
 Vertical milling machine

 Operations performed:
 Horizontal boring:
 Creates slots outside
 Power capacity (25HP)
 Tools (carbide inserts)

 Planing machine:
 Used for cutting the surfaces

 Universal milling machine:

 Consists of knee, saddle, table etc.
 Speed (515rpm)
 Feed (105rpm)
 Indexing
 Keyways
 Broaching

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  Vertical milling machine:
 Used for milling jobs
 Used for finishing

Each operation is done by a specific machine, but the universal milling machine can
perform a variety of operations.

 Special operations performed:

 Indexing
 Keyways

 Tool used:
 Carbide tip tool
 Grinding wheel (aluminium oxide and silicon carbide)

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 8. ROUNDS
In the ‘rounds’ section, operations are performed on round shaped jobs such as cylindrical
shafts, spindles etc.

 Operations performed:
 Internal diameter boring
 Outer diameter boring
 Drilling
 Turning
 Taper turning
 Knurling
 Step-turning

 Machines used:
1) Turning machine
 Maximum diameter - 250mm
 Speed - 2400rpm
 Power - 5HP
 H-22 (first manufactured machine in round section )

2) Oerlikon lathe
 Tool - Single point cutting tool, made of HSS.
 Chuck - Three jow chuck

3) Slotting machine
 Used to make slots on outer diameter
 Tool (HSS)

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4) Radial drilling
 Used for drilling holes into heavy work pieces.
 Speed - 1800rpm

5) Internal grinding operations

 Consists of a bore-comparator used to measure diameter
 Speed - Low speed

6) Turret lathe
 Consists of Desk set tool and collets, used for holding the job
 Speed - 1200rpm
 Cutting processes done on this machine are interchangeable.
 Idling system is used to lock and unlock the clamps.

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 9. L-45 ASSEMBLY
L-45 lathe is a heavy-duty CNC lathe, indigenously developed by HMT for performing
extensive machining operations with ease.

The term 45 refers to 450 mm which is the distance between the centre of the spindle and
the guideway of the lathe.

 Special feature of L-45:

 Has a separated saddle guideway
 Tailstock is situated away from the sadle
 No interruptions, as a full job can be operated in one go.
 Induction motor is used
 DC current is used

 Specifications of l-45:

Height of centres 450 mm

Swing over bed 900 mm
Swing over cross slide 470 mm
Distance between centres 2000 mm
Spindle power 22 kW
Speed range 4.5 – 200 rpm
Capacity 15 tonnes
No. of motors used 4
CNC system Siemens 840D/Funac

 Main parts:
Headstock, tailstock, apron, saddle, gearbox, chain gears, nylon grip belt, main
spindle, hold chuck, screw rod, auto liver, tool post, Teflon, nylon belts and cross slide.

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 The belts used are C1-R, C2-R, C3-R.

There are four motors in the lathe, the main motor placed in the head stock, the speed
motor placed in the saddle, the lubrication motor and the tailstock motor placed in the
tail stock.

 Operations performed:
 Turning
 Taper-turning
 Step-turning
 Knurling
 Drilling, etc.

 Difference between L-45 and regular lathe:

Regular lathe L-45 Lathe

1 Arrangement: Arrangement:
Two guideways
Head Tail Head Tail
Stock Stock Stock Stock
Saddle

Four guideways Saddle

Two guideways

All four guideways are together Has two sets of two separate guideways
2 Saddle might disturb steady operation Saddle does not interrupt steady
operation
3 Operates only on light to medium weight Can operate on heavy jobs
jobs
4 Consists of screw rod and lead screw for Consists of ball screw and rack & pinion
translation of motion for translation of motion
5 Dimension checking is done manually. Dimensions are checked by CNC system
6 Consists manual gear selector Consists hydraulic gear selector
7 Costs less when compared to L-45 High cost

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 10. R.D. ASSEMBLY
R.D. assembly, an acronym for Radial Drilling Machine assembly, is a shop where radial
drilling machines are assembled.

Radial drilling machine is a type of drilling machine whose vertical column supports a
radial arm that can be swung around at any position over the work bed of the machine.
This enables a radial movement of the arm. Also, the drill head can be moved horizontally
along the arm and vertically along the column. These three movements can be combined
together to permit the drill bit to be located at any desired position on the work peace
where the hole needs to be drilled. This special feature is what makes the radial drilling
machine unique to other drilling machines.

Elivation motor Spindle motor

Radial Arm Drill head

Feed hand wheel

Spindle
Elevating
Column screw Drill

Job
Table

Base

Schematic of a RD machine

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 Main parts:
Spindle, drill head, sleeve, bed, motors etc.

 Motors used:
 Elevation motor – for vertical movement of drill head.
 Drill head motor – for rotating the spindle.

 RD Machine variations:

RM 52, RM 61, RM 62, RM 63, RM 65

All variations of the RD machine are equipped with high technology fluid power
supply.

 Specifications:

 Drilling capacity: In steel – 50 mm

In cast iron – 60 mm

 Max. drilling depth: 325 mm

 Spindle speed: 12 – 1800 rpm

 Max. drilling radius: 1500 mm for RM 62

1790 mm for RM 63
2350 mm for RM 65

 Main motor power: 3.6/4.5 kW

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 11. PSB ASSEMBLY
PSB is an acronym for Precision Systems Bangalore. The PSB department produces
special purpose machines that operate with high degrees of precision.

The need for precision, repeatability and mass production has led to the development of
advanced machinery. These machinery are being manufactured and assembled in the PSB
department of HMT.

 Machines assembled in the PSB Department:

1. Three Phase Manipulator (TPM)
2. Servo Manipulator

1. Three phase manipulator

TPMs are used for mixing of harmful radioactive chemicals such as cobalt, thorium
and uranium. These machines are usually used by nuclear research and
development centres. The Baba Atomic Research Centre (BARC) and Indira
Ghandi Research Centre (IGRC) are two of the research centres that purchase and
use the TPMs manufactured by HMT.

 Main components:
 Three motors, one for each axis
 Pulleys and connecting rods
 Steel ropes
 Tape

 Operation:
There are two main components fitted into the manipulator in order to
multiply torque and translate and transfer motion. One component is
called as a Master controller and the other is called as a Slave. The
master is controlled by human hand and performs certain actions that

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 are copied by the slave. Hence the name Master and Slave. The master
and slave by a wall having thickness of 1-2 m. The master is placed in
the control chamber and the slave is placed in the radiation chamber.

2. Servo Manipulator
The Servo Manipulator is a chemical mixer, similar to TPM, but is more advanced
than TPM. Like TPM, servo to has a master and a slave. Where the master is a robot
and the slave is robotic arm of a jointed arm configuration.
The slave is operated by opening and closing of valves and can carry loads up to 24
kg. The arm can extend up to a distance of 30 m. The machine is controlled by a
CNC controller and works with the help of program controlled servo motors.

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 12. GEAR HOBBER ASSEMBLY
Hobbing is the machining process for gear cutting, splines cutting, and sprockets on a
hobbing machine, which is a special type of milling machine.

The Gear Hobber assembly department collects various components of the gear hobbing
machine and assembles them.

 Components assembled:
 Headstock
 Chuck
 Tailstock
 Spindle
 Motor
 Hob
 Shaft
 Lubrication and coolant system.

1. Headstock:

Different gears and belts are fitted inside the headstock to produce the required motion.
Also electrical connections and lubrication systems are fitted into the headstock.

2. Spindle:

The hobber consists of two spindle, one is mounted on the head stock and the other with
a hob.

3. Hob:

The cutting tool used in the gear hobbing machine is called as a hob. It is a helical cutting
tool.

4. Types of Hobs:

 Worm wheel hob

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  Spline hob
 Chamfer hob
 Spur gear hob
 Helical gear hob
 Involute spline hob

5. Shafts:

There are two shafts that are fitted in the hobber. One shaft is fitted in the head stock
which transmits power from the gear to the spindle and the other is fitted to the hob.

 Some calculations:

Machine constant
1. Spur gear ratio =
No. of teeth

18.75 X Sin θ
2. Helical gear ratio =
πXgXm

Where,
m = module
θ = Helical angle

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 13. RD PRODUCTION
The RD production department is where the various components of the Radial Drilling
Machine are produced.

 Components produced:
 Vertical column
 Horizontal arm
 Drill head
 Spindle
 Shaft
 Base plate
 Lubrication and coolant system

 Machines used:
 Grinding machine (Sleeve grinding machine)
 Lathe
 Drilling machine
 Boring machine

1. The grinding machine is used to grind the surfaces of various components such as
the drill head, spindle etc.

2. The lathe is mainly used perform turning operations on the spindles and shafts of
the drilling machine.

3. The drilling machine is used make holes in on the drill head through which shafts
pass and the boring machine is used to enlarge the holes to required sizes.

Once the grinding operations are done, honing is done on the job for finishing
purposes.

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 14. BALL SCREW DIVISION
During the year 1987, employees from HMT went to Germany and visited Ball screw
manufacturing firms and learnt techniques to manufacture ball screws. The Germans there
provided machine and knowledge to HMT. By 1992 HMT was ready to manufacture their
own ball screws.

A ball screw is a linear actuator that translates rotational motion to linear motion with very
little friction.

The ball screw division of HMT designs and manufactures various types of ball screws
and related components.

Manufacturing ball screws is a slow and steady process. Hence it around 4-6 weeks for
full assembly.

Ball screws are usually made of CF 53, which is a type of ferrous carbon material.

Since ball screws experience high loading and unloading of weights, it must be relieved
of stresses. Since CF 53 has a spring nature, it chosen as the material to manufacture ball
screws.

Steps involved in manufacturing Ball Screws:

Step 1 - Turning

 Turning is done either manually or with CNC.

 Machine used: Hinumerik 3100
 Tools: Multiple tools used. Two for cutting and one for chamfering.
 The belts are locked exactly perpendicular to the job.

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Step 2 – Straightening

 Done to straighten the job

 Machine used: NC & CNC machines
 Gap: 50 μ
 Pressure applied: 220 pounds

Step 3 – Induction hardening

 Combination of heat treatment is done to the job in order to increase the rigidity of
the material.
 Heat treatment processes such as case hardening, annealing, tempering, quenching
etc.
 Induction coil is used during heat treatment.
 Gap maintained: 2 mm
 Hardness: 60 HRC

If the hardness obtained is satisfactory the job is sent out for other operations, if the
hardness obtained is not satisfactory it is again heat treated until the required
hardness is obtained.

Step 4 – Ball track grinding

 In this step grinding operations are done on the ball screw

 Machine used: Reishauer DL-2000
 Both internal and external grinding are performed
 Tool must be set at 20°
 Tool: Diamond wheel
 Oil used: Servo cut 945

Step 5 – Laser calibration

 Calibration done for pitch accuracy and low run-out

 Instrument used: Carl Zeiss jena

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Step 6 – Assembly

Different techniques such as soldering, floating etc., can be used in assembly. In

India, soldering technique is commonly used.

Parts used: Wiper, 2-Z nuts, housing etc.

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 15. MATERIAL TESTING
Materials testing is a technique of measuring the characteristics and behavior of
substances such as metals, ceramics, or plastics under various conditions. The data thus
obtained can be used in specifying the suitability of materials for various applications -
e.g., building or aircraft construction, machinery, etc. A full- or small-scale model of a
proposed machine or structure may be tested. There are various testing capabilities such
as tensile strength test, compression test etc. and various techniques and instruments are
available for performing these tests.

The material testing department of HMT is equipped to perform various tests on a wide
variety of materials and components produced by HMT.

 Testing capabilities
 Tensile strength
 Compression strength
 Shear strength
 Flexure strength
 Impact testing
 Torsion testing
 Balance testing
 Bond strength
 Creep and stress relaxation
 Elongation
 Toughness

 Testing machines and instruments

 Universal Testing Machine (UTM)
 Charpy Impact Testing machine
 Elasticometer

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 Brinell Hardness tester
 Rockwell Hardness tester
 Magnetic crack detector
 Copy turning tester

1. Universal Testing Machine (UTM):

A universal testing machine is used to test the tensile strength and compressive
strength of materials. An earlier name for a tensile testing machine is a tensometer.
The "universal" part of the name reflects that it can perform many standard tensile
and compression tests on materials, components.

Working:
The specimen is placed in the machine between the grips and an extensometer if
required can automatically record the change in gauge length during the test. If an
extensometer is not fitted, the machine itself can record the displacement between
its cross heads on which the specimen is held. However, this method not only
records the change in length of the specimen but also all other extending / elastic
components of the testing machine and its drive systems including any slipping of
the specimen in the grips. Once the machine is started it begins to apply an
increasing load on specimen. Throughout the tests the control system and its
associated software record the load and extension or compression of the specimen.

2. Charpy Impact tester

This machine is used to conduct the Charpy impact test which is a standardized high
strain-rate test which determines the amount of energy absorbed by a material
during fracture. This absorbed energy is a measure of a given material's notch
toughness and acts as a tool to study temperature-dependent ductile-brittle
transition.

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 Working
The Charpy test involves striking a suitable test piece with a striker, mounted at the
end of a pendulum. The test piece is fixed in place at both ends and the striker
impacts the test piece immediately behind a machined notch.
At the point of impact, the striker has a known amount of kinetic energy. The impact
energy is calculated based on the height to which the striker would have risen, if no
test specimen was in place, and this compared to the height to which the striker
actually rises.
Tough materials absorb a lot of energy, whilst brittle materials tend to absorb very
little energy prior to fracture.

3. Rockwell Hardness Test

Rockwell hardness test involves a Rockwell scale which is a hardness scale based
on indentation hardness of a material. The Rockwell test determines the hardness
by measuring the depth of penetration of an indenter under a large load compared
to the penetration made by a preload. There are different scales, denoted by a single
letter, that use different loads or indenters. The result is a dimensionless number
noted as HRA, HRB, HRC, etc., where the last letter is the respective Rockwell
scale. The testing is done on a machine called as Rockwell Hardness Tester.

Indenter used: Conical diamond indenter

Load applied: Two loads, Minor 10 kgf and Major 60 -100-150 kgf

Working:
1) Place the specimen on the base
2) Load an initial force
3) Load main load
4) Hold for a certain time the main load
5) Release the load, Rockwell value will display on dial or screen automatically.

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 Rockwell scales:
Scale Abbreviation Load Indenter Use
A HRA 60 kgf 120° diamond spheroconical Tungsten carbide
1
⁄16 -inch-diameter steel Aluminium, brass, and
B HRB 100 kgf
sphere soft steels
C HRC 150 kgf 120° diamond spheroconical Harder steels >B100

4. Brinell Hardness Test

Brinell hardness test is based on The Brinell scale which like Rockwell hardness
scale is based on the indentation hardness of materials. It also work on a principle
similar to that of Rockwell Hardness Test. It determines the hardness by making an
indentation on the surface of the specimen by applying a load on the indenter and
then mathematically relating the indentation area with the load applied. This is done
by using a formula.

Formula:

Where:

BHN = Brinell Hardness Number (kgf/mm2)

P = applied load in kilogram-force (kgf)

D = diameter of indenter (mm)
d = diameter of indentation (mm)

Indenter used: Ball Indenter with 1mm, 2.5mm, 5 mm and 10 mm ball diameter.
Load applied: Single load from 1kgf to 3000 kgf

Working:
1) Place the specimen on the base
2) Create an indentation on the specimen by applying the load

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 3) Remove the load
4) Observe the indentation and measure its diameter
5) Using the diameter, calculate the indentation area.
6) Substitute the value of indentation area and load applied in the formula and
obtain the hardness value.

5. Copy turning

Copy turning is the process of producing a replica of an object. It is carried out on

special lathes that control the cutting tool in a particular manner to produce identical
replicas.
The copy lathe uses a template to guide the cutter. They are capable of creating
good quality components. The lathes may use rotary tooling, profile tools, or CNC
driven cutters to produce the shape.

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 16. INSPECTION
Inspection is an important tool to achieve product quality. Inspection is necessary to assure
confidence to the manufacturer and provide satisfaction to the customer. Inspection is an
indispensable tool of modern manufacturing process. It helps to control quality, reduces
manufacturing costs, eliminate scrap losses and assignable causes of defective work.

The inspection section of every department in HMT is responsible for appraising the
quality of incoming raw materials and components as well as the quality of the
manufactured product or service. It checks the components at various stages with
reference to certain predetermined factors and detecting and sorting out the faulty or
defective items. It also specifies the types of inspection devices to use and the procedures
to follow to measure the quality characteristics.

Inspection is the most common method of attaining standardization, uniformity and

quality of workmanship. If the said item does not fall within the zone of acceptability it
will be rejected and corrective measure will be applied to see that the items in future
conform to specified standards.

 Objectives of inspection:

1. To detect and remove the faulty raw materials before it undergoes production.
2. To detect the faulty products in production whenever it is detected.
3. To bring facts to the notice of managers before they become serious issues to enable
them discover weaknesses and solve the issue.
4. To prevent products of substandard quality reaching the customer and reducing
complaints.
5. To promote reputation of the company/brand for quality and reliability of product.

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 Instruments used in inspection:

1. Calipers - There are several different types of calipers designed to measure length,
depth, internal and external dimensions. Calipers can also be used to transfer
dimensions from one object to another. Commonly used caliper is a Vernier
Caliper.
2. Bore gages - Take an internal diameter measurement or compare to a pre-
determined standard.
3. Fixed gages - Used only to compare an object to a standard. Fixed gages can
measure attributes such as angle, length, radius, bore size, thickness, and other
parameters.
4. Micrometers - These dimensional inspection hand tools can use mechanical,
digital, laser, dial, or scale technology to precisely measure length, depth, thickness,
diameter, height, roundness, or bore.
5. Protractors - Measure angles with a variable protractor or compare the angle of an
object to a standard with an angle gage.
6. Ring gages - Typically used as a pass/fail test, ring gages can be threaded, smooth,
or tapered to test the size of pins, threaded studs, and shafts.
7. Length gages - These devices are used to measure or compare the length of an
object.
8. Thread gages - The spacing, shape, size, and geometry of a thread can be verified
or measured with a thread gage.

Although dimensional inspection hand tools are frequently a simple and elegant solution,
they still must be treated with care. Some devices must be calibrated or regularly cleaned
to ensure that they provide consistent, accurate results. It is also important that the operator
is appropriately trained to prevent human error.

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 Inspection is usually done on:
 Length
 Diameter
 depth
 Tolerance
 Grind
 Surface finish, etc.

Vernier Caliper
The Vernier caliper is an extremely precise measuring instrument. It is used to measure
internal and external distances with very high precision, the error may be very low. The
VERNIER scale is a small movable graduated scale for obtaining fractional parts of
subdivisions on a fixed main scale of the Vernier caliper. With a normal scale we may be
able to measure down to 0.50 mm or so, while with a Vernier scale the least count may be
0.02 cm.

Least Count:
Least count is the smallest value that can be measured by the measuring instrument is
called least count.

Least count = 1MSD – 1VSD

No. of main scale divisions coinsiding with vernier scale

1VSD =
No. of Vernier scale divisions

49
= = 0.98
50

1VSD = 0.98 mm
1MSD = 1 mm

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 ∴ Least count = 1 – 0.98 = 0.02

Least count = 0.02 mm

Tolerance
Tolerance is the allowable variation for any given size by which a given dimension may
vary in order to achieve proper function of the device.

 Types of tolerance:-

1. Unilateral tolerance
In this type, the dimension of a part is allowed to vary only on one side of the basic
size.

2. Bilateral Tolerance
In bilateral tolerance, dimension of the part is allowed to vary on both the sides of
the basic size.

 Tolerance code:
Tolerance codes are codes containing an alphabet followed by a number, used to
describe the value of tolerance and the type of component (eg. hole or shaft).
Lower case alphabets are used to indicate shafts and upper case alphabets are used to
indicate a hole.

Example: Few tolerance code for holes – E6, E7, H9, H10
Few tolerance code for shafts – d6, e6, h7, h8

Given a tolerance code for a hole or a shaft, their tolerance values can be found by
referring to an ISO tolerance chart.

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Fit
Fit usually refers to the clearances that are permissible between mating parts in
a mechanical device that must assemble easily and that must often move relative to each
other during normal operation of the device.

 Types of fit:-

1. Clearance fit: A clearance fit results in limits of size that assure clearance between
assembled mating parts. For Clearance fit, the size of the shaft will always be
smaller than the hole. A clearance fit has positive allowance.

2. Interference fit: Interference fit has limits of size that always result in interference
between mating parts. For Interference fit, the size of the shaft will always be larger
than the hole. Interference fit has a negative allowance.

3. Transition fit: Transition fit can be a clearance or interference fit. In this case shaft
may be either larger or smaller than the hole in a mating part. Transition fits are a
compromise between clearance and interference fits. Transition Fit are used where
accurate location is important but either a small amount of clearance or interference
is permissible.

 System of fit:

1. Basic hole system: In basic hole system, size of the hole is kept constant and shaft
size is varied to obtain various types of fits.

2. Basic shaft system: In basic shaft system diameter of the shaft is kept constant and
hole size is varied to obtain various types of fits.

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 17. CALIBRATION
Calibration is the comparison of measurement values obtained from a device under test
with those of a calibration standard of known accuracy. Such a standard could be another
measurement device of known accuracy.

The calibration department carries out calibration of various measuring instruments used
in all other departments of HMT. It is also used to teach calibration to the newly appointed
trainees.

 Purpose of calibration
 To maintain accuracy
 To perform quality inspection
 To reduce costs from manufacturing errors caused due to inaccurate measurements.
 To obtain accreditation and certificate and maintain the same

 Instruments used
 Vernier caliper
 Micrometre
 Strain gauge
 Plug gauge
 Snap gauge
 Sine bar
 Sine centre
 Thread checker
 Surface roughness tester

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1. Vernier caliper
It is used to measure internal and external distances with very high precision.
The least count of vernier scale is given by:

Least count = 1MSD - 1VSD

= 1 – 0.98

= 0.02 mm

2. Micrometer
Micrometer is a gauge which measures small distances or thicknesses between its
spindle and anvil, the spindle can be moved away from or towards the anvil by
turning a screw with a fine thread.
It is similar to the Vernier, but a particular type of micrometer can measure only
either the external dimensions or internal dimensions of an object, unlike Vernier
which can measure both internal and external dimensions.

Pitch
Least count =
Number of divisions

0.5
=
50

= 0.01 mm

3. Strain Gauge
A strain gauge is a device used to measure strain on an object. It is a sensor whose
resistance varies with applied force; It converts force, pressure, tension, weight,
etc., into a change in electrical resistance which can then be measured.

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4. Plug Gauge
It is a type of go/no-go gauge used to check the accuracy of a hole. It is a cylindrical
bar with highly finished ends of different diameters. If the hole size is correct within
tolerable limits, the small end (marked “go”) will enter the hole, while the large end
(“not go”) will not. If that does not happen, then the hole size is declared to be
wrong.

5. Snap Gauge
A snap gauge is formed like the letter C, with outer “go” and inner “not go” jaws,
and is used to check diameters, lengths, and thicknesses of objects.

6. Sine bar
Sine bar is an angle measuring device used to accurately the angles as well as
locating a work-piece in required angle. Angles are measured using a sine bar with
the help of slip gauges and a dial gauge. The obtained values are used in a
trigonometric function to obtain the angle.

Formula used:
Perpendicular
Sin (angle) =
Hypotenuse

Applications of sine bar:

 Checking flatness of a surface
 Locating a work in required angle
 Checking angle of taper key
 Checking bevel gears

7. Sine Centre
Sine centre is basically a sine bar with block holding centres which can be adjusted
and rigidly clamped in any position. These are used for inspection of conical objects
(having male and female centres.) between centres. These are used up to an

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inclination of 45 or 60°. Rollers are clamped firmly to the body. This is a very useful
device for testing the angles of conical work-pieces.

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Conclusion
We the interns hereby conclude our report by successfully completing the internship of 30
days in HMT Machine tools Ltd., Bangalore complex.
During the course of the internship we learnt about various departments in HMT and how
they function, we also learnt various industrial processes, machining operations,
departmental work and the roles of managers and workers in their respective departments.
We thank the heads, managers and workers of various departments who allotted their time
to teach and guide us through various processes happening in their respective departments,
which has helped us to understand how industries work. We also thank
Mr. Venugopal M, Manager (Training) for scheduling and co-ordinating with us during
the internship.
Special thanks to Mr. GOPAL KRISHNA for guiding us through the internship.

Thank you.

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