INTERNSHIP REPORT

MAA FACTORY

Submitted To:

Assistant Manager (AM)

Submitted By:

Hammad Ahmad

UW-11-ME-BSc-028

Institution:

Department Of Mechanical Engineering

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 Acknowledgements

All the praises are for the almighty, Allah who bestowed me
with the ability and potential to complete this Internship. I also pay my gratitude
to the Almighty for enabling me to complete this Internship Report within due
course of time.
Words are very few to express enormous humble obligations to
my affectionate Parents for their prayers and strong determination to enabling
me to achieve this job.
I also appreciate the cordial co-operation from all my concern Managers
in the services group of especially Admin & HR management for providing me
requisite information and knowledge for compilation of my complete
Internship.

PURPOSE

My purpose of internship in P.O.F Industries is so to

acknowledge about theories which I can studied in different subjects, and fulfill
my requirements about practical knowledge which will open my mind and this
particle knowledge will help me my future designing related to engineering
products, machinery and maintenance of these things as well.

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POF Iternship Report:

The Pakistan Ordnance Factories (POF), responsible

for conventional weapons production, is located in WahCantt. POF is a
government organization operating under the Defense Production Division in
Pakistan’s Ministry of Defense. The Pakistan Ordnance Factories is a complex
of arms and ammunition manufacturing factories employing more than 40,000
personnel. POF provided the weapons and ammunitions to the Pakistan Army
and their entire foreign clients. This modern defense industrial complex, which
is the oldest & largest in Pakistan defense production industrial system, has
helped many other defense production setups to flourish. Pakistan has a
reasonably good defense production potential in which Pakistan Ordnance
Factories occupies the central position. POF produce approximately 70 major
products for supply of Army, Navy and Air Force. The main products include
automatic rifle; light medium and heavy machine guns, complete range of
mortar and artillery ammunitions, aircraft ammunition and anti-aircraft
ammunitions, tank ammunition and anti-tank ammunitions, bombs, grenades,
land mines, pyrotechnics and signal stores etc.

The Pakistan Ordnance Factories organization has fourteen large complexes

at Wah:

1. Weapons Factory
2. Machine Gun Factory
3. Small Arms Ammunition Factory
4. Tank Ammunition Factory
5. Medium Artillery Ammunition Factory
6. Heavy Artillery Ammunition Factory
7. Brass Mill
8. Steel Foundry
9. Tungsten Carbide Factory
10.Tungsten Alloy Factory
11.Explosives Factory

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 12.Propellants Factory
13.Filling Factory
14.Clothing Factory for Uniforms

MAA SHOPS:

 Fuze Shop C-12

 Shell Forging Shop B-31

Fuze Shop C-12

Introduction to Fuze Shop:

Fuze Shop C-12-MAA was established in early

1950s for the manufacturing of fuzes, Primers & Switches required for various
service stores. The shop was initially part of Non-Ferrous Group and in early
1980s, it was reallocated to MAA / AA Factory as a result of reorganization of
the factories. The following facilities were created in the shop to meet the
manufacturing requirements of empty parts of the ammo. :-

a. Machining facilities which include Lathe Machines, Milling, Drilling,

Single Spindle Auto & Multi Autos etc.
b. Presses & Furnaces for blanking, drawing, forming & stamping
operations.
c. Die Casting Machines for casting of Zinc Base Alloy and Aluminum
parts.
d. Surface Treatment Plants.

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 A fuze is consisted of 70 components and for making all these
components this shop is divided in to many groups, and from them few are
single spindle auto group, multi spindle auto group, booster group, capstan
group, CNC group, proximity group, secondary group, M 48 group, and surface
treatment group. All these groups manufacture fuze parts then assemble it in
assembly group. The fuzzes prepared in this shop are fuze BDM534, fuze
PIBDM509A2, fuze He 132 mm, fuze V 19, PA2, fuze V9PIAI, fuze VI9PAA2,
fuzePDM557, proximity fuze PFIA, 200mm phalax, fuze PDM739m and multi
option fuze (MOFA). After completion the fuzes are checked in inspection
shop.

Main Groups:

Main Groups according to Lay out are following

 Single Auto group
 Booster
 Capstan
 Multi Auto
 Secondary
 M48
 PIBD
 Tool Room
 CNC
 Proximity Assembly bond
 Assembly bond

Initial Products:
The initial products of Fuze Shop were as follows:
Fuses:
 Fuse # 161 for 2” Mor Bomb
 Fuse # 162 for 3” Mor Bomb

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  Fuse 119 B for 25 Pdr HE
 Fuse 221 for 25 PdrSmk
 Fuse 255 for 40 mm AA/C Ammo.

Primers:
 Primer # 1 for 25 Pdr Blank
 Primer # 11 for 25 Pdr HE
 Primer # 12 for 40 mm AA/C Ammo.
 Primers for 100 mm TK & 90 mm A/T Ammo.

Switches:
 Switch No. 4
Present in-production and view additions of productions
Present In-production Products:
The present production line include the following products
 Fuse V19PA-A2
 Fuse V9P1 A2
 Fuse PD M557
 Proximity Fuse PF-1A

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  Primer # 330
 Hand Grenade ARGES 84
 Switch No. 4
 Fuse Adopter Assy. for 81 mm Smk
 Parts for 60 mm Illuminating
 Projectile Assy. for 20 mm Phalanx

New Stores Being Added in the Production Line:

The Fuse Shop-MAA is endeavoring to establish mass scale
production of the following stores:
 EVT Fuse for 81 mm Illuminating
 Fuse # 6 for 30 mm A/C Ammo.
 Fuse HE-2 A1 for 57 mm AA/C
 Fuse V19P-A2 (Brass Body)
for 120 mm Mor Bomb
 Fuse M739 for 105 mm
through 203 mm Arty. Ammo.
 Fuse HE-I for 37 mm (Re-
activation)
 Time Fuse for 155 mm T4,
DPK1M
Smoke Grenade T-80UD:
 Striker (Steel)
 Strike Sleeve (Steel)
 Striker Head (Steel)
 Delay Holder (Brass)
 Cap Holder (Brass)
 Delay Empty (Brass)

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  Det Sleeve (Empty)
Grenade Hand Target Indication:
 Primer Holder (Brass)
 Striker (Steel)
 Striker Holder (Brass
 Delay Holder (Aluminum Alloy)

Delay Parts for Charge Demolition:

 Delay Carrier (Brass)
 Cap Holder (Brass)
 Disc (Brass)
Fuse Proximity Assembly bond:
In this shop fuses are produced that are very important part of tank
ammunition, aircraft ammunition and other calibers. When fired shell strikes its
target it is the fuse that blasts the shell. Fuses can be set to SAFE or FIRE mode.
Fuses are normally divided into two general classes—mechanical and electrical.
These classes only refer to the primary operating principles. They may be
subdivided by their method of functioning or by the action that initiates the
explosive train—impact, mechanical time, proximity, hydrostatic, or long delay.
Another ‘classification is their position in the bomb—nose, tail, side, or multi-
positioned.

Electrical Fuzes:
Electrical fuses have many characteristics of mechanical
fuses.

They differ in fuse initiation. An electrical

impulse is used to initiate the electrical fuse rather than the mechanical action of
arming vane rotation.
An electrical pulse from the delivery aircraft charges capacitors in the fuse as
the bomb is released from the aircraft.
Arming and functioning delays are produced by a series of resistor/capacitor
networks in the fuse. The functioning delay is electromechanically initiated,
with the necessary circuits closed by means of shock-sensitive switches.

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The electric bomb fuse remains safe until it is energized by the electrical
charging system carried in the aircraft.
Because of the interlocks provided in the release equipment, electrical charging
can occur only after the bomb is released from the rack or shackle and has
begun its separation from the aircraft; however, it is still connected electrically
to the aircraft's bomb arming unit. At this time, the fuse receives an energizing
charge required for selection of the desired arming and impact times.

Mechanical Fuzes:
A mechanical force (in this case, the bomb impacting
the target) drives a striker into a sensitive detonator. The detonator ignites a
train of explosives, eventually firing the main or filler charge. For safe,
effective operation, any fuse (mechanical or electrical) must have the following
design features: It must remain safe in stowage, while it is handled in normal
movement, and during loading and downloading evolutions. It must remain
safe while being carried aboard the aircraft. It must remain safe until the bomb
is released and is well clear of the delivery aircraft (arming delay or safe
separation period). Depending upon the type of target, the fuse may be required
to delay the detonation of the bomb after impact for a preset time (functioning
delay). Functioning delay may vary from a few milliseconds to many hours. It
should not detonate the bomb if the bomb is accidentally released or if the bomb
is jettisoned in a safe condition from the aircraft. To provide these qualities, a
number of design features are used. Most features are common to all types of
fuses.

Maintenance:
Maintenance, repair, and operations (MRO) or Maintenance,
Repair and Overhaul involve any sort of mechanical or electrical device should
it become out of order or broken (known as repair, unscheduled or casualty
maintenance). It also includes performing routine actions which keep the device
in working order (known as scheduled maintenance) or prevents trouble from
arising (preventive maintenance). MRO may be defined as, "All actions which
have the objective of retaining or restoring an item in or to a state in which it

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can perform its required function. The actions include the combination of all
technical and corresponding administrative, managerial, and supervision
actions."

Maintenance types:
Generally speaking, there are two types of
maintenance in use.
1. Preventive maintenance:
Where equipment is maintained before
break down occurs. This type of maintenance has many different variations and
is subject of various researches to determine best and most efficient way to
maintain equipment. Recent studies have shown that Preventive maintenance is
effective in preventing age related failures of the equipment. For random failure
patterns which amount to 80% of the failure patterns, condition monitoring
proves to be effective.
2. Corrective maintenance
Where equipment is maintained after
break down. This maintenance is often most expensive because worn equipment
can damage other parts and cause multiple damage.
Preventive maintenance is maintenance performed in
an attempt to avoid failures, unnecessary production loss and safety violations.
As equipment cannot be maintained at all times, some way is needed to decide
when it is proper to perform maintenance. Normally, this is done by deciding
some inspection/maintenance intervals, and sticking to this interval more or less
affected by what you find during these activities.
Corrective maintenance is probably the most commonly used approach, but it is
easy to see its limitations. When equipment fails, it often leads to downtime in
production. In most cases this is costly business. Also, if the equipment needs to
be replaced, the cost of replacing it alone can be substantial. It is also important
to consider health, safety and environment (HSE) issues related to
malfunctioning equipment.

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 C-35: TOOL ROOM

INTRODUCTION:-

In this shop tools, gauges and equipment for other shops are
manufactured and maintained. Fixed and adjustable tools, both types are
produced. Tools are made on lathe, milling and auto machines. Initially material
is in soft state, after machining it is hardening by heat treatment (usually
quenching). Usually, tools are made up of high speed steel. The percentage of
carbon and some other specific metals like manganese, chromium etc. describes
the properties of steel. Grinders are made by casting of silica and alumina. In C-
35, following material is used for the production of tools;

 Super HSS.
 HSS Flat.
 HSS sqr.
 HSS 18% W.
 0.55% Carbon Flat Misc.
 OHNS Rods/Flats (3% Ni/Cr Rods).
 MS Flat (18% Flat).
 1% Carbon Flat Misc. Size.
 Vital Flat.
 MS Plate.

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OPERATIONS:-

Following major operations are carried out on tools:-

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  Surface grinding.
 Cylindrical grinding.
 Internal grinding.
 External grinding.
 Centre-less grinding.
 Cutter grinding.
 Drill bore, counter bore, and counter sinking.
 Back relieving and internal relieving.

MACHINES:-

 CNC Lathe Machine.

 CNC Milling Machine.
 Capstan Lathe Machine.
 Milling Machine (with magnetic chuck).
 Grinders.
 Circular Saw Machine.

PRODUCTS:-

 TOOLS:-
 Tap for Shell 30MM HE.
 Circular Farm Tool (30MM Case).
 Heading Tap Tool (30MM Case).
 SK/T469 Farm Tool (30MM Shell/Case).
 Knurling Tool (30MM Shell).
 SK/T199 Reamer (30MM Shell).
 WB607/T50 Reamer (30MM Shell).
 WB607, 0-1/T-66 Drill.
 SK/T230 Farm Tool (30MM Shell).
 GAUGES:-
 16/G5289 LBNGTH Gauge (25 PDR).
 Length Gauge (30MM Shell).
 AM G71132/G.29A Gauge (30MM Shell).
 SNAP Gauge (30MM Shell).
 R & D:-
 Mine Body Upper.

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 Mine Body Lower.
 Fuze Base (EVT).
 Adapter Booster (Head M-147).
 Roller for Flow Forming.
 Collector 30MM.
 Copy Plate.
 Fuze Body EVT.
 Adapter Booster (Head M-148).
 Copy Plate for 81MM Shell.

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 C-10: CARTRIDGE CASE MANUFACTURING SHOP

INTRODUCITON:-

In this shop, cartridge case is manufactured by drawing process. A brass

disc of specific size is drawn into cup and after four draws it forms the shape of
cartridge. After that machining, washing, stamping and stress removing is
worked out. The case is filled with propellant material as the purpose of
cartridge case is to propel the shell.

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STEPS INVOLVED IN MANUFACTURING OF CARTRIDE CASE IN
C-10:-

 Brass Disc.
 Cup.
 1st Draw.
 Annealing.
 2nd Draw.
 Annealing.
 3rd Draw.
 Annealing.
 Final Draw.
 Trimming.
 Heading.
 Head Turning.
 Tapering.
 Head Turning.
 Machining (CNC Lathe).
 Stamping.
 Washing.
 Shot Blasting (Stress Removing).

PRODUCTS:-

 Round 105MM.
 Round 25 PDR.
 Round 40MM.
 Round 37MM.
 Round 30MM.
 Round 20MM.
 Round 105MM APFSDS.

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Conclusion:

During this week of internship, I conclude that theory can tell us

how to do, but practical is a totally different and actual thing. During our
education this is the responsibility of our institute & our self to arrange this type
of industrial visits so, when we enter into our profession we are skilled engineer
& by this internship ,we can acknowledge every theory, which we can learned
in our course.

Signature AM

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