METU NCC: SUMMER PRACTICE GUIDELINE

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Appendix 1: Cover Page

Mechanical Engineering Program

MECH 300

SUMMER PRACTICE
REPORT

Name of Student : Muhammad Hamza Taimoor

ID Number : 2104339
Name of Company : 502 Central Workshop
Date of Submission:
25th August 2019

TABLE OF CONTENTS
1. Introduction……………………………………………………………………………4

2. Main Part………………………………………………………………………………7

• List of recent project products manufactured……………………………...7

• The introduction to 2 latest products under work………………………….8
• Manufacturing and repairing of the Torsion shaft…………………………9
• Manufacturing and repairing of the Muzzle Brake…………………………19
• Quality Control of the products………………………………………………22
• Cost Analysis for both products……………………………………………..22
• Safety rules and regulations in PM & DM shop……………………………23

3. Conclusion……………………………………………………………………………24
4. References……………………………………………………………………………25
5. Appendix………………………………………………………………………………26

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 List of Figures and Tables
Figure 1: APC ABS 70 MOUZ………………………………………………………………..5
Figure 2: Tank Al Hamza (Infantry fighting vehicle)………………………………………..6
Figure 3: Torsion Shaft………………………………………………………………………..8
Figure 4: Muzzle Brake………………………………………………………………………..9
Figure 5: Old Torsion Shafts…………………………………………………………………10
Figure 6: Plain Turning………………………………………………………………………..11
Figure 7: Dispatched Part…………………………………………………………………….12
Figure 8: Turning at Centre…………………………………………………………………..13
Figure 9: Finished from center lathe………………………………………………………...14
Figure 10: Labelled Center lathe…………………………………………………………….15
Figure 11: Labelled Vertical milling machine……………………………………………….16
Figure 12: Labelled Horizontal milling machine…………………………………………….17
Figure 13: Thread milling on horizontal milling……………………………………………..18
Figure 14: Final Thread part with key grooving…………………………………………….19
Figure 15: Old muzzle brake………………………………………………………………….20
Figure 16: Muzzle brake boring………………………………………………………………21
Figure 17: Torsion shaft model view…………………………………………………………27
Figure 18: Torsion shaft model view 2……………………………………………………….28
Figure 19: Torsion shaft orthographic views………………………………………………..28
Figure 20: Muzzle brake model………………………………………………………………29
Figure 21: Muzzle Brake orthographic views……………………………………………….29

Table 1: Cost analysis table for Torsion Shaft……………………………………………..22

Table 2: Cost analysis table for Muzzle Brake……………………………………………..23
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Introduction
The main aim of this internship is to get practical with the manufacturing knowledge
gained during my undergrad in Mechanical Engineering. I took courses regarding
manufacturing and design which in return made things easier for me to understand while
performing my internship in 502 Central Workshop EME. The workshop did not only
have departments related to manufacturing, but it is an organization where maintenance,
quality assurance, non-technical departments, repairments, logistics, accounts and etc
were also under action throughout the working time. I had the opportunity to gain various
experience in departments mentioned above. My manufacturing knowledge became
stronger and a basic knowledge on maintenance and quality assurance was summoned
in my experience list.

The workshop is in Rawalpindi which is a city of Punjab (Pakistan). The workshop comes
under the obligation of the military of Pakistan and is the most influential and old military
manufacturing company. The DG Electrical and Mechanical Engineers (EME), who is a
brigadier himself, has the control over the workshop which means all the department
acceptances, certifications, clearances and any other kind of Performa is under his
signature. Some of the repairing departments are as follows; Tactical Vehicle Repair
Group (TVRG), Air Defense Armament Repair Group (ADRG), Special Vehicles Repair
Group (SVRG) etc. All these repairing departments are run by colonels which in the end
are under the DG. The workshop has a total of 5000 workers in the company amongst
which we have engineers, technicians, inspectors, laborers, directors, supervisors and
deputy directors. Below list shows the number of people in the latter mentioned posts:

• 550 engineers
• Approximately 2000 technicians and inspectors
• Approximately 2400 labor workers
• The rest 50 we have the directors, deputy directors and supervisors.

I was assigned to the PM & DM workshop which is one of the essential production
workshops of 502. This workshop is the oldest amongst the rest of the workshops as told
by the workshop supervisor under who’s inspection I was assigned.
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Most of the repairment and the production of the military automotive such as APCs
(Armored Personnel Carriers), Tanks such as Al Hamza etc. The visuals below will show
you an APC example ABS 70 MOUZ and the tank Al Hamza. Both the visuals were taken
from [3] by Man in 2011:

Figure 1: APC ABS 70 MOUZ

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Figure 2: Tank Al Hamza

These are two of the few examples of the workshop. There are several more but
confidential due to military reasons. What I tried to explain by all this was that in the PM
& DM workshop, not the whole vehicle is designed and manufactured but some parts of
it because every production and repairment workshop in 502 is assigned on a task to
produce a part or repair a part. During my time of the internship manufacturing and
changing the torsion shaft of the APC vehicle and the repairment of the muzzle brake of
the APC vehicle. As time is unfriendly at the time in Pakistan, military vehicles are being
modified for future reference. The details of this production and repairment section will be
given in the main part of the report which is the next section.

Before moving onto the next section of the report I would like to give brief history of the
502 workshop. It was established by the Britishers in 1927 which was way before the
independence of Pakistan. Before, it was called the Royal EME Workshop but since the
independence it became 502 central workshop EME. Since the independence it has been
serving the country’s military operations. Production and repairment of war vehicles have
been practiced since the independence of Pakistan. The workshop has been serving for
the safety of the country for more than 70 years now and has been dedicated to its aims.
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 MAIN PART
So far, we have discussed the interface of the workshop organization and its history.
Here, in the main part, I will be discussing my experience in the workshop as a
manufacturing intern. I was assigned to the PM & DM workshop which is a production
and repairment workshop of the APC vehicle and various tanks certain parts. As it is a
military organization, there were strict rules regarding usage of mobile phones. The
supervisor strictly objective no phones. Even internet connection was prohibited in the
premises. All the labor work on machines and working elsewhere in the premises was
disallowed on using mobile phones. Only the army engineers captain level and above
were allowed mobile phone. Luckily, I got the allowance for one day only to get pictures
for the 2 products I was assigned on, the related machines used and the technical drawing
table because I had a relative in a major post who made it possible. I was not allowed on
taking any other picture on the premises.

My supervisor informed me on the products manufactured recently before my period

which were a part of the major project for the modification of the weapon system of the
APC vehicle. I saw the ready manufactured weapon system in front of me on the first day
because I had to gather information on the typical latest project products manufactured
there. I was not allowed to take any picture or details on those products as they were
highly confidential and a vital part to the national security. Although, I was only addressed
with certain product names which were the part of the project before my period. The list
is stated below:
• MISC BRACKETS (Missile brackets)
• SEATS
• CARGO HATCH
• TRIPOD
• HOUSING LATCH
• GUNNER PLATFORM
• SUPPORT BRACKET
• SUPPORT RAIL
• SUPPORT PEDESTAL
• MSL RACK (Missile rack)

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The PM & DM workshop consisted of variety of machines and occupied a good amount
of space. There were three types of central lathe machines which were only different
because of their size. Their functioning ability was the same only the size was different.
There were two types of milling machines, vertical and the universal milling machine. Jig
Boring machine was installed in a room, CNC was also installed in a room of cold
temperature all the time, fitting section was also available, and the filtering section was
also present. Every workshop has a manager who keeps track of the functioning of the
machines and the working speed and effort of the laborers on a given assignment. This
prefer person is known as the OIC (Officer in Command) of the workshop. Every
workshop has a supervisor as well who was assigned alongside me as I was the only
intern assigned at the time frame.

During the time I was assigned, only two simple but really essential parts of the APC
vehicle were modified and manufactured. One was the Torsion shaft (MG1A3) and the
other was the Muzzle brake (of M46). The visual of the torsion shaft is given in figure 3
and muzzle brake in figure 4 below:

Figure 3: Torsion Shaft

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 Figure 4: Muzzle Brake

Now that I have introduced the manufacturing products practiced, I will move forward to
the next step which is taking you one by one through the processes done in order to
modify these products through different manufacturing steps. As I mentioned before that
in PM & DM workshop, parts are not designed here from scratch but are modified and
finished here just before the quality assurance inspection. Starting from the next page
you will understand what I am talking about.

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Torsion Shaft
In figure 3 I showed the finished version of the torsion shafts but in this part I will take you
through the modification of the old torsion shafts into the ones shown in figure 3. During
my time of internship, the main project of the PM & DM was to modify the torsion shafts
and the muzzle brakes of old VPC vehicles into new ones with new dimensions for the
new VPC vehicles designed. Below I have given a visual of the old torsion shafts which
were taken from the old VPC vehicles not in use anymore. It was more like a recycling
manufacturing project:

Figure 5: Old and used torsion shafts

These torsion shafts are used in the engine system of the APC vehicle. As you can see
they are quite old and well used. These shafts are modified to different dimensions and
some additional parameters are applied. Initial length of the shaft was 7ft. First process
was to decrease the length from 7ft to 5ft through cutting process on centre lathe. The
cutting process on lathe is technically call the plain turning which is the process used to
remove excess amount of material from the surface of the shaft. Along with the removal
of the material chips are produced which can be dangerous so you must be careful with
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the turning rpm which was maintained at 750rpm. Along with the turning process we apply
lubrication at the cutting side so that temperature is maintained of else high amount of
friction may cause the product to be hot.

Below now, I have given the visual for another angle for the starting of the turning process.
Here you will have a better view of the turning process applied which shows us that 2ft of
the 7ft is being dispatched. After Figure 7 I have given Figure 8 which shows the 2ft part
dispatched from the initial torsion shaft.

Figure 6: Initial plain turning

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 Figure 7: Dispatched part after cutting

If you see the left end of dispatched part in figure 8 then you can straight imagine that in
order to obtain the similar shape on the right side of the 5ft torsion shaft, we apply facing
which is the process through which the end of a workpiece is made flat. The total length
we now have is of almost 5ft. 1574mm and from this 1574, 1423mm is the center part
where we apply turning again to decrease the diameter from 60mm to 45mm. Below I
have given a visual which shows the described scenario:

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 Figure 8: Turning applied at the center of the bar

Before moving onto the next step, I would like something to the process. As said before,
the torsion bar is used in the engine system of the VPC vehicle so both ends of the shaft
will be of different diameters. We apply turning again on both the ends of the shaft and
achieve one end from 72mm to 57mm and one end from 60mm to 54mm which is not
much of a difference but as you may have noticed that in the modified version the
difference is lesser than the one before the modification. When all this is done, we apply
filling and polishing that removes burs, any undulating surface, roughness and gives a
shiny surface. The polishing is done with the help of emery cloth of fine grades. As I could
only use the phone for one day, I was not able to get pictures of these processes, but I
managed to get pictures of the spare finished torsion shafts. Below is the visual for the
modified but not complete torsion shafts:

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 Figure 9: Finished from central lathe

In the figure above, the shafts in the center are finished ones. After all this I have the
visual Figure 10 (Engineering Lathe, 2009) for the general central lathe machine with
all the labelled parts.
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Figure 10: Labelled Center Lathe [1]

Till now, the Lathe section is handled and a while ago I showed you the modified torsion
shaft. Now, to complete our next modification we will go to milling process. Before starting
off the process I would like to give you a good introduction on the what is milling, types of
milling machines and processes performed through those machines. The milling process
is a general process which technically means the cutting of a workpiece by feeding it
against a cutter with various number of teeth. The cutter is called the milling cutter. A
rough flat workpiece is cut with good finishing. Commonly used milling machines are the
vertical and the horizontal milling machine and even in the PM & DM workshop I saw
both. This time I will give you the schematic of the milling machines before the process
steps. Below I have given the labelled visuals of the vertical and horizontal milling
machine in [2] by Mishra in 2016;

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Figure 11: Labelled Vertical Milling Machine

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 Figure 12: Labelled Horizontal Lathe Machine

In figure 9 I showed you the torsion shafts after the lathe operation and now I will be
discussing the milling operation done to modify the torsion shaft further. As I have learned
in my manufacturing courses that horizontal lathe is more qualitative than vertical relating
to a lot of aspects such as efficiency, tool life, more powerful and even can perform work
equal to 3 to 4 vertical milling machines. Keeping similar aspects in mind, the engineers
of PM & DM workshop also directed the workers to use the horizontal milling machine
(Universal). This brings us to the next step of the process where both the ends of the
torsion shaft were modified by apply thread cutting so teeth can be formed. The teeth
length from both the sides were made till 60mm. During the cutting process we had to be
careful with motion of the feed as precision and ease of mind is needed. If we create a
quick motion, then it may create a rough and an undulating surface and finishing. Along
with that milling keyways was performed at each side of the shaft. Below I have given the
visual where thread milling is done on the horizontal milling machine:
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Figure 13: Thread milling on Horizontal milling machine

Now I have given a closer look to the teeth made through milling process below:

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 Figure 14: Final thread part with key grooving

This was the overall process done in order to manufacture and modify the torsion shaft
of an APC vehicle. Now, we will move forward and step into the modification of another
part of the APC vehicle which was part of the present project.

Muzzle Brake
In this process nothing much was done. The old muzzle brake of the old APC vehicles
was modified through the manufacturing processes for the latest use. For this
modification, only the use of lathe was experienced but as the size of the muzzle brake
is quite much because it is the head of the canon at the top of the APC vehicle. Before

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going to the process applied, I would like to tell briefly about the muzzle brake and what
does it do? How is it useful? The muzzle brake is a very essential part for big guns
especially. More specifically, auto or semi-automatic guns.
It redirects the high-pressure gases which in the end improves the upward movement of
the gun barrel during fire. This creates less pressure on to the shooter or vehicle (APC)
which results in good aim as well. Due to these affective reasons, muzzle brakes are also
used in shooting competitions.

Anyhow, let’s talk about the modification of the muzzle brake of the APC vehicle. Below I
have shown a used, old muzzle brake with a rough surface, improper dimensions and
deficient quality function:

Figure 15: Old Muzzle brake

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Next, what happened was that the muzzle brake had to be renewed and the spacing in
the center was supposed to be tapered for a smoother and finished for quality function.
For the tapering process we used the bigger center lathe for the boring. The workpiece
was centered, and the tool post was moved back and forth for a better and finished boring.
Due to this process, the muzzle brake will fix properly onto the barrel of the APC gun.
Taper turning is applied with a slight reduction in the diameters for a finished surface All
this process is shown in the visual below in figure 16:

Figure 16: Muzzle Brake Boring

These processes were more like of a modification of the weapon system of the VPC
vehicle. These two processes were amongst most accountable projects or you can say
objectives at the time being. I got the chance to learn a lot through out the process. So
far, the manufacturing part is dealt and now I will mention about the quality assurance of
the products under manufacturing.

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Quality Assurance Department
Every workshop in 502 has Quality Assurance Department (QAD) which tests the
functionality of the product. However, there is a specific process that goes through in
order to perfect the quality assurance of the product. At first, the Quality Control
Committee (QCC) checks for the finishing, function and the dimensions of for example
100 products of the same type, they make a report on their quality assurance and then it
is forwarded to QAD that goes through the report first and then check some of the
products by themselves. A product profile is constructed and then forwarded to the OIC
which is the officer in charge of the workshop. He approves the product’s assurance and
then it is forwarded ahead to the military service. Hence these two products were also
inspected in the same manner and were manufactured, modified and forwarded in
groups.

Cost Analysis
Now, I will take you through the cost analysis of the two products. First, I will do the cost
analysis of the torsion shaft and then the muzzle brake. The cost analysis is done with
the addition of two parameters, material cost and the labor cost. Below I have given the
table (Table 1) in which I have given the parameters to calculate the cost of torsion shaft:

Length of shaft (ft) 5

Cost per kg (Rs/kg) 300
Weight of the shaft (kg) 10
Labor cost per hour (Rs/hr) 260
Hours spent to complete the shaft (hrs) 18

These all values were asked from the QAD department and the OIC of the PM DM
workshop. The hours spent are taken in such flow that per day workers had 6 hours of
daily work limit from 8:30am to 2:30pm. Each shaft took in total of 3 days to complete
which made in total of 18hours. Now, for the cost of this product we do simple math. As
discussed before, the cost of a product is established through the addition of the material
cost and the labor cost. For the material cost we use the formulae below:
𝑀𝑎𝑡𝑒𝑟𝑖𝑎𝑙 𝐶𝑜𝑠𝑡 = 𝐿𝑒𝑛𝑔𝑡ℎ ∗ 𝐶𝑜𝑠𝑡 𝑝𝑒𝑟 𝑘𝑔 ∗ 𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑡ℎ𝑒 𝑝𝑎𝑟𝑡 [1]

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Then, for the labor cost we apply the formulae given below where we take the product of
the labor cost per hour and the total hours taken to complete the product:

𝐿𝑎𝑏𝑜𝑟 𝐶𝑜𝑠𝑡 = 𝐿𝑎𝑏𝑜𝑟 𝐶𝑜𝑠𝑡 𝑝𝑒𝑟 ℎ𝑜𝑢𝑟 ∗ 𝑇𝑜𝑡𝑎𝑙 𝑡𝑖𝑚𝑒 𝑡𝑎𝑘𝑒𝑛 𝑡𝑜 𝑐𝑜𝑚𝑝𝑙𝑒𝑡𝑒 𝑡ℎ𝑒 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 [𝟐]

Now just putting the corresponding values from Table 1 into [1] and [2] we get the Torsion
shaft cost as Rs.19680. This was the cost of the torsion shaft and now I will do the cost
analysis of the muzzle brake in the same manner and all the other products are inspected
in the same way using the same procedure. In the Table 2 below I have given the same
parameters for the muzzle brake with the corresponding values:
Length of Muzzle brake (ft) 2.5
Cost per kg (Rs/kg) 300
Weight of the Muzzle brake (kg) 40
Labor cost per hour (Rs/hr) 260
Hours spent to complete the shaft (hrs) 12

By placing all these values into the equations [1] and [2] we achieve the cost of the
muzzle brake which becomes Rs.33120.

Safety Rules and Regulations at PM & DM workshop

The safety rules and regulations in the PM & DM workshop are quite straight forward and
are recommended to follow very strictly. The moto of the workshop is that work is more
important than product which means that the safety of the faculty is of much importance
than the material. The workers were obliged to wear a suit of a certain thick material which
would keep you safe from any sharp connection or any hot substance. Such dress is
called a dungaree. Along with this, helmet was always mandatory to wear and gloves
which would keep the worker’s hands safe from the chip’s excretion. Wearing gloves is
every industry’s obligation that needs to be followed. A safety assurance committee was
under the command to weekly take a tour to the workshop which can be amongst any
day of the 5 working day. This surprising appearance would keep the workers under
pressure and would prefer to stay under obligations.

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 Conclusion

So, this was my 20 working days experience one of the Pakistan most influential and
prestigious military organization. It is quite understandable why the rules and regulations
in 502 very strict. As it is a part of the national security therefore, things are kept private
and confidential. Due to my education in a very influential university and the knowledge I
gained, I managed to get a good grasp on not only the principles of manufacturing but
also the tasks where business is on the play. The 2 essential parts of VPC vehicle were
discussed in the report and their corresponding modification through various
manufacturing process due to the presence of the relating machines in the PM & DM
workshop. Torsion Shaft and the Muzzle Brake of the VPC vehicle were the parts modified
for the modern and fresh use. It was a helpful and a challenging experience which would
help in pursuing a manufacturing engineering master’s degree if I make such a choice in
the coming future.

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 References
[1] Engineering Tutorials. (2009). Working Principle of Lathe Machine - Engineering Tutorials. [online]
Available at: http://engineering.myindialist.com/2009/working-principle-of-lathe-machine/#.XV_Pv-gzbIX
[Accessed 23 Aug. 2019].

[2] Mishra, P. (2016). What is Milling Machine - Operation, Parts and Types. - Mechanical Booster. [online]
Mechanical Booster. Available at: https://www.mechanicalbooster.com/2016/12/what-is-milling-machine-
operation-parts-types.html [Accessed 23 Aug. 2019].

[3] Man, T. (2011). Pakistan Army APC Inventory. [online] Pakistan Defence. Available at:
https://defence.pk/pdf/threads/pakistan-army-apc-inventory.87330/ [Accessed 23 Aug. 2019].

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 Appendix

Figure 17: Torsion shaft model view

Figure 18: Torsion shaft model view 2

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Figure 19: Torsion shaft orthographic views

Figure 20: Muzzle Brake model

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Figure 21: Muzzle Brake views
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