SUMMER TRAINING REPORT

INTRODUCTON:

COMPANY NAME - HIGH DESIGN TECHNOLOGIES,PUNE

Registered in 2013 ,

 HIGH DESIGN TECHNOLOGIES has gained immense expertise in suppling

&trading of SPM(special purpose machine)
 HIGH DESIGN TECHNOLOGIES has made a name for itself in the list of top
suppliers of in India. The supplier company is located in Bhosari, Maharashtra
and is one of the leading sellers of listed products.
HIGH DESIGN TECHNOLOGIES is listed in Trade India's list of verified
sellers offering supreme quality of etc. Supply the best quality products and
service.

PRODUCTS:

SPM(SPECIAL PURPOSE MACHINE)

1.HEAD PIPE FINE BORING MACHINE

2.SWING ARM FINE BORING MACHINE

3.RADIATORS
GENERAL PROCEDURE OF DESIGN:

In designing a machine component, there is no rigid rule. The problem may be attempted in
several ways. However, the general procedure to solve a design problem is as follows :

1. Recognition of need
First of all, make a complete statement of the problem, indicating the need, aim or purpose for
which the machine is to be designed.

2. Synthesis (Mechanisms)
Select the possible mechanism or group of mechanisms which will give the desired motion.

3. Analysis of forces
Find the forces acting on each member of the machine and the energy transmitted by each
member.

4. Material selection
Select the material best suited for each member of the machine.

5. Design of elements
(Size and Stresses). Find the size of each member of the machine by considering the
force acting on the member and the permissible stresses for the material used. It should be kept
in mind that each member should not deflect or deform than the permissible limit.

6. Modification
. Modify the size of the member to agree with the past experience and judgment to
facilitate manufacture. The modification may also be necessary by consideration of
manufacturing to reduce overall cost.

7. Detailed drawing
Draw the detailed drawing of each component and the assembly of the machine with complete
specification for the manufacturing processes suggested.

8.Production The component, as per the drawing, is manufactured in the workshop.

Following important steps are involved in the procedure of

RAUTING:
 ROUTING IN INDUSTRY
Routing and Scheduling in Production Planning and Control. Routing may be
defined as the selection of path which each part of the product will follow while
being transformed from raw materials to finished products. Path of the product will
also give sequence of operation to be adopted while being manufactured.

STEPS:

 Product analysis determines what to manufacture and purchase.

 Product-analysis is done again to determine materials required for production.
 Fix the manufacturing operations and their sequences.
 Decide the number of units to be manufactured in a batch (lot).
 Estimate the margin of scarp in each lot of production.
 Analyze the production cost.
 Prepare production control forms for effective routing.
 Prepare a separate route-sheet for each order.

Now let's discuss above steps of production in detail:

 Product analysis: Product analysis is the first step in the routing procedure.
This is done to find out what parts (goods) should be manufactured and what
parts should be purchased. This depends mainly on the relative cost. It also
depends on other factors such as technical consideration, purchase policies,
availability of personnel, availability of equipment, etc. Generally, during less-
busy periods most of the parts are manufactured in the factory. However, during
the busy period, many parts are purchased from outside.

 Determine required materials: Product-analysis is done again to find out what

materials are required for production and their quantity and quality.

 Fix manufacturing operations: The next step in the routing procedure is to fix
(decide) the manufacturing operations and their sequences. The detailed
 production procedure is then scheduled (planned). Information required for this
is derived from technical experience and by analyzing the machine capacity.

 Determine size of batch: The number of units to be manufactured in any one

lot (group or batch) should be decided. This is done concerning customers'
orders. Necessary provision should also be made for rejections during the
production process.

 Estimate margin of scrap: The amount of scrap in each lot, should be

estimated. Generally, a scrap margin is between 2% to 5% of production.

 Analyze the production cost: Estimating the cost of manufactured goods is

actually the function of costing department. However, the routing section
provides necessary data to the costing department that enables it to analyze the
production cost.

 Prepare production control forms: Production Control forms such as Job

Cards, Inspection Cards, Tool Tickets, etc. should be prepared. These forms
should contain complete information for effective routing.

 Prepare route sheet: Route sheet is prepared on a production control form. It

shows the part number, description of the part and the materials required. It is
prepared by a route clerk. Separate route-sheet is required for each part of a
customer's order.

 PRODUCTION SHOP (MACHINES SHOP)

 LATHE MACHINE:
In this article we will study about what is lathe machine – main parts, operations
and working. Almost in every industries of manufacturing lathe machines are used.
It is used to perform various operations to give desired shape and size to the job. If
an engineering students thinks of doing job in any manufacturing industries, than
he or she must have knowledge about the lathe machine. In this post we will
discuss about lathe machine.
What is Lathe Machine?
A lathe is a machine tool which is used to rotate a work piece to perform various
operations such as turning, facing, knurling, grooving etc., with the help of tools
that are applied to the work piece.
Working Principle of Lathe Machine

The function of lathe is to remove metal from a piece of work to give it a desired
shape and size. In a lathe machine, the work piece is rotate against the tool. The
tool is used to remove material from the work piece. The direction of motion of
tool is called feed.
Main Parts of Lathe Machine
The various main parts of lathe machine are
LATHE MACHINE OPERATIONS:
MILLING MACHINE:

What is Milling Machine?

It is a machine which is used to remove metals from the workpiece with the help of
a revolving cutter called milling cutter. It is used to machined the flat, rough and
irregular surfaces and this is done by feeding the workpiece against a rotating
milling cutter.

Main Parts of Milling Machine

The milling machine main parts are:
Vertical Milling Machine
 Horizontal Milling Machine

In this operation, surfaces which are at an angle to the axis of the cutter, is
machined by the rotary cutter Milling machine can perform all other common
operations like turning, facing, fillet making, chamfering, drilling, gear cutting,
planning, slot cutting etc. These are all main milling machine operation.

 TYPES OF MILLING CUTTERS

o Roughing end mill.
o Slab mill.
o End mill cutter.
o Hollow mill.
o Ball mill cutter.
o Involute gear cutter.
 Face mill cutter.
 Wood ruff cutter.

DRILLING MACHINE
The drilling machine is defined as a machine which is used to make a circular
hole, a tool used to drill the holes of different size and other related operations
using a drill bit. The drilling machine is one of the most important machines in a
workshop.

Main Parts of Drilling Machine

 The schematic diagram of the drilling machine is shown in the figure.

The main parts of drilling machines are:

1. Base
2. Column
3. Table
4. Radial Arm
5. Drill head
6. Spindle speed and Feed mechanism.

TYPES OF DRILLING MACHINE

1.Upright Drilling Machine

It is larger in size and stronger than sensitive drilling machine. It is used for
drilling medium and large sized holes. Based on the type of column used it is
classified as a round column and box column upright drilling machines.
 2.Radial Drilling Machine

The schematic diagram of the radial drilling machine is shown in the figure. It
consists of the base, column radial arm, drill head, spindle speed and feed
mechanism.

TYPES OF BITS FOR DRILLING:

 Forstner Bits.
 Three Wing Drills.
 Door Hinge Bits.
 Mortising Bits.
 Spade Bits.
 VARIOUS TYPES OF DRILLING OPERATION:

 TAPPING MACHINE:
Tapping Machine. Taps and dies are tools used to create screw threads, which is
called threading. Many are cutting tools; others are forming tools. A tap is used to
cut or form the female portion of the mating pair (e.g., a nut).

Threading and tapping are the operations used to produce screw threads
.Threading is an operation in which threads are produced on the outside of a
component or we can call them as external threads using a die whereas, tapping is
an operation in which internal threads are produced using a tool called tap.

Different tapping tool types. Tapping tools are divided into four types: straight
flute tap, spiral point tap, spiral fuse tap, and forming tap. Which type you use
depends on what type of hole you want to thread, blind hole or through hole, and
the component material.
What is the difference between threading and tapping?

Threading and tapping are the operations used to produce screw threads.
Threading is an operation in which threads are produced on the outside of a
component or we can call them as external threads using a die whereas, tapping is
an operation in which internal threads are produced using a tool called tap.

WELDING MACHINE :
Arc welding is a type of welding process using an electric arc to create heat to
melt and join metals. A power supply creates an electric arc between a consumable
or non-consumable electrode and the base material using either direct (DC) or
alternating (AC) currents.

It is a type of welding that uses a welding power supply to create an electric arc
between a metal stick ("electrode") and the base material to melt the metals at the
point of contact. Arc welders can use either direct (DC) or alternating (AC)
current, and consumable or non-consumable electrodes.

Principles of arc welding. Arc welding is a welding process, in which heat is

generated by an electric arc struck between an electrode and the work piece.
Electric arc is luminous electrical discharge between two electrodes through
ionized gas

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

electric arc. The arc is formed between the actual work and an electrode (stick or
wire) that is manually or mechanically guided along the joint. ... Most welding in
the manufacture of steel products uses the second type of electrode.
GAS CUTTING

 Oxy-fuel cutting is a thermal cutting process that uses oxygen and fuel
gas (such as acetylene, propane, MAPP, propylene and natural gas)
to cut through materials.
 WHY ACETYLENEUSE INSTEAD OF PRPANE?
 Welding. Firstly: Propane cannot be used for Gas Welding. When acetylene
burns in oxygen, it creates a reducing zone that cleans the steel surface.
 Propane do not have a reducing zone like acetylene and can hence not
be used for Gas Welding.
 Oxy-fuel cutting is a chemical reaction between pure oxygen and steel to form
iron oxide. ... Pure oxygen is then directed toward the heated area in a fine, high
pressure stream. As the steel is oxidized and blown away to form a cavity, the
preheat and oxygen stream are moved at constant speed to form a
continuous cut.

 What metals can be cut with the oxy fuel gas process?

 Any metal that will rapidly oxidize, such as iron, low-carbon

steel, magnesium, titanium and zinc
 PROCEDURE

 The welder can adjust the oxy-acetylene flame to be carbonizing (aka

reducing), neutral, or oxidizing. Adjustment is made by adding more or less
oxygen to the acetylene flame. The neutral flame is the flame most
generally used when welding or cutting.

 WHICH GAS IS HOTTER BW PROPANE &BUTANE?

 Contrary to the notion that propane burns hotter than butane, the heat
output is identical. Both fuels deliver the same BTUs (British thermal units),
so neither flame is hotter, according to The Adventure Network. One will
not boil water or cook food faster than the other
  PROCESS THAT ARE MADE FROM OTHER INDUSTRIES
1.CNC CUTTING:
CNC machining is a manufacturing process in which pre-programmed computer
software dictates the movement of factory tools and machinery. The process can be
used to control a range of complex machinery, from grinders and lathes to mills
and routers

 What is CNC machine and how it works?

 A CNC, or computer numerical control machine is a high precision tool

that's computer-controlled and makes repeated, accurate movements. It
does so by taking computer-generated code and converting it with software
to electrical signals.
  Why CNC Machining is Important for Manufacturing?
 Computer Numerical Control (CNC) refers to - manipulating traditional
machines by the use of computer systems. ... Since computers are used to
control machines, it means that all major operations of production can be
automated to increase speed and quality of manufacturing.

While CNC machines are expensive and complicated, they quickly pay for
themselves by reducing the workload and preventing errors. The first
majoradvantage of CNC machining is that it improves automation, removing the
need of an operator for all but a few parts of the work

TYPES OF CNC MACHINE:

 Milling Machines
 Lathes.
 Grinders
 Custom-Built Machines
 CNC Router
 3-D Printer

2.JIG BORING
 What is Jig Boring operation?
 Jig boring is used to accurately enlarge existing holes and make their
diameters highly accurate. ... Dedicated jig boring machines are designed to
machine holes with the tightest tolerances possible with a machine tool.

 DIFFERENCE BETWEEN JIG & FIXTURE

 A jig is often confused with a fixture; a fixture holds the work in a fixed
location. A device that does both functions (holding the work and guiding a
tool) is called a jig.

 Which type of bushes are used in jig to perform more than one operation in
same location?
  Slip Bush. They are used when two or more operations are performed on
the same axis such as drilling and reaming, it is necessary to use two
different guide bushes for different tools.

3. BLACKODISING
 Blackodising Corrosion Resistance is a conversion coating formed by a
chemical reaction produced when parts are immersed in the alkaline aqueous
salt solution operated at approximately 135º C.
 The reaction between the iron of the ferrous alloy and the hot oxide bath
produces a magnitite (Fe3 O4) on the actual surface of the part.
 It is possible to oxidize non-ferrous metals under suitable conditions to form
black oxides.
 It is possible to apply black oxide at room temperature, however it is not
possible to achieve all of the benefits available from the "hot" oxide process.
 The cold black oxide process routinely shows color variation from part to part
and the black material frequently rubs off in your hands.

In order to determine the appropriate after-finish, it must be evaluated which

after-finish to use.
 The following factors should be considered:

 Length of protection required

 Desired finished appearance (gloss/matte)
 Storage conditions (humidity, vapor, temperature)
 Final application

Size: 1000mm diameter*3000mm length

4. POWDER COATING
Powder coating. ... The powder may be a thermoplastic or a thermoset polymer.
It is usually used to create a hard finish that is tougher than conventional
paint. Powder coating is mainly used for coating of metals, such as household
appliances, aluminium extrusions, drum hardware and automobile and bicycle
parts.

 What are the benefits of powder coating?

 Powder Coating gives consumers, businesses, and industries one of the

most economical, longest lasting, and most color-durable quality finishes
available on virtually any type of metal. Powder coated surfaces are more
resistant to chipping, scratching, fading, and wearing than other finishes.

 Is powder coating cheaper than painting?

 The base product for powder coating is also substantially cheaper

than wet paint. ... Mechanical – Powder coating generally produces
a coating twice as thick as standard paint. The real advantage is its
flexibility and ability to bend and yield with the material .

 Is powder coating stronger than paint?

 The benefits of the process of powder coating are numerous. First, powder
coating results in a thick, dense finish on metal products which can be more
durable and longer lasting than conventional painting. Second, powder
coating is typically a one coat finish so the process can be quite quick and
easy

TESTING EQUIPMENTS

1.DIAL INDICATOR
 What is the use of dial indicator?

 Dial indicators are one of the primary measuring tools used in precision
engine building. They are typically used to measure deck clearances,
crankshaft thrust and straightness, lifter travel and other measurements that
 involve the distance between two surfaces or small amounts of component
travel.

 How do you read Mitutoyo dial indicator?

 To read a dial indicator, start by mounting it on a stand to stabilize it and

calibrating the dial by turning the outer face until the hand points to 0. Once
the dial indicator is calibrated, press the spindle on the bottom against the
item you're measuring

 What is the least count of dial gauge?

Dial Indicators

Range Least Count

0-12.7mm 0.01mm

0-12.7mm 0.001mm

0-25mm 0.01mm

0-25mm 0.001mm
 What are slip gauges used for?

 They are used as a reference for the calibration of measuring

equipment used in machine shops, such as micrometers, sine bars, calipers,
and dial indicators (whenused in an inspection role). Gauge blocks are the
main means of length standardization used by industry.

2.HIGHT GAUGE

 What is a height gauge used for?

 A height gauge is a measuring device used either for determining

the height of objects, or for marking of items to be worked on.

 How does a height gauge work?

  A height gauge is a measuring device used for determining the height of
objects, and for marking of items to be worked on. ... Height gauges may
also be used to measure the height of an object by using the underside of the
scriber as the datum
.
 What is the least count of Vernier height gauge?

Height Gauge

Sr Description Least Count

No

1. Vernier Height Gauge – VHG 1 0.02mm

Digital Height gauge – DHG 1 with Metric & Inch

2 0.01mm/0.0005”
readout
MACHINE GENERAL DESCRIPTION

THE BORING SPM IS DESIGNED FOR BORING THE HEAD PIPE OF TWO
WHEELER CHASIS.

KOLA FRAME ASSY COMPONENT: BOTH SIDE DIA 45.75 rough& 45.9
finish BORE.

MACHINE BASE:
THE MACHINE BASE IS FABRICATED FROM MS PLATES WITH A 25 MM
TOP PLATE. THE TOP PLATE IS DULY

MACHINED AND JIG BORED ON A VMC. MANUAL SCRAPPING IS DONE

FOR MAINTAINING THE ASSEMBLY FACE

LEVELS AND PARELLALITY SUITABLE BASE LEVELLING PADS IS

PROVIDED AT THE BOTTOM OF THE BASE

SPINDLE AND SLIDE :

PRECISION ANGULAR CONTACT SPINDLE ASSEMBLY IS MOUNTED A
LM SLIDE UNIT WHICH IS OPERATED BYA
BALL SCREW ASSEMBLY. A CNC SERVO MOTOR DRIVES THE
BALL SCREW FOR FORWARD AND REVERSEMOVEMENT OF THE
SLIDE UNIT.

COOLANT ASSEMBLY:
200 LTR COOLANTTANK IS PROVIDED WITH THE MACHINE. THERE
ARE 2 PUMPS (160LPM) RAJMANE MAKE

ARE PROVIDED ONE FOR CUTTING COOLANT AND 1 FOR BED

CLEANING

ELECTRICAL:
ELECTRICAL SYSTEM CONSISTS OF A MAIN CONTROL PANEL,
OPERATOR PANEL AND TRANSFORMER.THE MAIN CONTROL PANEL
HOUSES THE CNC DRIVES SPINDLE DRIVES, POWER SUPPLY UNIT,
MAIN POWERSWITCH, CONTACTORS, and MCB'S FOR OPERATION THE
CONTROL PANEL IS MOUNTED ON REAR SIDE OF THEMACHINE.

THE OPERATOR PANEL IS MOUNTED ON THE FRONT SIDE OF THE

MACHINE. THE MAIN MACHINE OPERATING BUTTONS AND LAMP
INDICATIONS AND MMI ARE MOUNTED ON THE OPERATOR PANEL
THE MAIN CNC IS MOUNTED IN THE OPERATOR PANEL.

THE OPERTATOR PANEL DETAILS ARE ATTACHED HERE WITH.

DETAILED ELECTRICAL CIRCUIT AND CNC LADDER LOGIC IS

ATTACHED HERE WITH.

HYDRAULIC SYSTEM:
THE HYDRAULIC SYSTEM CONSISTS OF HYDRAULIC TANK (40LTR
CAPACITY, VANE PUMP (6 LPM), YUKEN

MAKE VALVES, FILTERS & PRESSURE RELIEF.

SYNCHRONISED ACTUATION OF VALVES ENABLES THE MACHINE TO

BE OPERATED IN MANUAL AND AUTOCYCLE.
DETAILED HYDRAULIC CIRCUIT, BILL OF MATERIAL AND VALVE
LAYOUT IS ATTACHED HEREWITHA

FOLLOW THE INSTRUCTIONS GIVEN BELOW FOR

MACHINE STARTUP:
1) CONNECT OF 3 PHASE CONNECTIONS, NEUTRAL AND EARTHING AT
THE BOTTOM INNER SIDE OF THE MAIN CONTROL PANEL.

2) FILL THE HYDRAULIC TANK WITH 40 LTRS OF HP ENKLO 68 OIL,

SEE LEVEL ON THE LEVEL INDICATOR PLS USE NEW SEALED BARREL
OIL FOR REFILLING, AS THE OIL SHOULD BE CLEAN WITH MAX DIRT
SIZE OF 5 MICRONS. (REQUIREMENT OF PUMP).

A LEVEL SWITCH IS PROVIDED FOR THE OIL LEVEL, WHICH GIVES

INPUT TO THE CNC SYSTEM WHEN

THE OIL LEVEL IS LOW(NORMALLY INPUT IS OFF)

3) FILL CUTTING OIL WATER MIXTURE IN THE COOLANT TANK. A

LEVEL SWITCH IS PROVIDED FOR THE

OIL LEVEL, WHICH GIVES INPUT TO THE CNC SYSTEM WHEN THE OIL
LEVEL IS LOW(NORMALLY INPUTIS OFF)

4) SINGLE PHASE PREVENTOR SHOULD BE ON. WHEN ELECTRICAL

CONNECTION IS OK IT GIVES A SIGNALTO THE SYSTEM.

5) FILL THE 32 NO OIL IS THE LUBRICATION TANK.

A LEVEL SWITCH IS PROVIDED FOR THE OIL LEVEL, WHICH GIVES

INPUT TO THE CNC SYSTEM WHENTHE OIL LEVEL IS LOW(NORMALLY
INPUT IS OFF)

AFTER ALL THE ABOVE OPERATIONS ARE OVER THE MACHINE IS

READY FOR START UP.

START UP:
a) SWITCH ON THE MAIN POWER ON SELECTOR SWITCH ON THE MAIN
CONTROL PANEL (REAR SIDE OF MACHINE).THE MAIN POWER LAMP
WILL GLOW ON THE OPERATOR PANEL

b) RELEASE THE EMERGENCY BUTTON ON THE OPERATOR PANEL

AND THE CYCLE START BOX.

C) PRESS THE CNC ON BUTTON ON THE OPERATOR PANEL. THE CNC

SYSTEM DISPLAY WILL BE TURNED ON.

d) ROTATE THE SELECTOR SWITCH ON THE CNC MOP TO 'REF

POSITION & PRESS X+ & Z+

BUTTON ON THE MOP. THE CNC WILL PERFORM ITS HOMING AND
THE X & Z AXIS POSITION ON THE MOP DISPLAY WILL TURN 'O' WITH
A #SIGN AT THE END.

e) ONCE HOMING IS DONE PRESS THE HYDRAULIC ON GREEN

ILLUMINATED PUSH BUTTON TO START THE HYDRAULIC MOTOR.
THE LAMP WILL GLOW GREEN IF THE HYDRAULIC MOTOR IS ON.

f) THE MACHINE IS NOW READY TO PERFORM ANY OPERATIONS IN

MANUAL MODE AND AUTOMODE.

CNC PANEL BUTTON OPERATION

1. SBK:

SINGLE BLOCK RUNNING . This functions only in auto mode. When this
selection is 'ON' its Green LED is on andthe machine performs the set programme
one line at a time and stops till the Cycle start signal isgiven again

2 +X: when the machine is in Jog mode pressing this button the LH/X-axis will
move reverse away from the fixture Machine should be in JOG mode for this
function.
3 .+Z: When the machine is in Jog mode pressing this button the RH/Z-axis will
move reverse away from the fixture. Machine should be in JOG mode for this
function.

4.-X: When the machine is in Jog mode pressing this button the LH/X-axis will
move towards the fixture. Machine should be in JOG mode for this function.

5. SPDL CCW :Pressing this button will switch on the RH spindle. Machine
should be in JOG mode for this function.

6. SPDL CW: Pressing this button will switch on the LH spindle. Machine should
be in JOG mode for this function.

7.-Z: When the machine is in Jog mode pressing this button the RH/Z-axis will
move towards the fixture Machine should be in JOG mode for this function.

8 . CHUCK CLAMP: Pressing this button the LH Ref Cyl will move reverse.
(Reference cylinder acts as a Loading Coil, either clamp or unclamp coil should be
ON for main clamp to operate.). Machine should be in JOG mode for this function.

9.CHUCK UNCLAMP:

Pressing this button the LH Ref Cyl will move forward to job referencing position.
(Reference cylinder acts as a Loading Coil, either clamp or unclamp coil should be
on for main clamp to operate.) Machine should be in JOG mode for this function.

10.TL STK FOR:

Pressing this button the main clamp will clamp the job. Machine should be in JOG
mode for this function.

11.TL STK FOR:

Pressing this button the main clamp will declamp the job. Machine should be in
JOG mode for this function.

12. TRT INDEX:

mauge input interlock is on pressing this button will give gauge input bypass signal
to perform the next cycle. Machine should be in AUTO mode for this function.
13.CLNT ON/OFF:

N/OFF the bed flushing coolant pump. This function operates in any mode.

This button switches ON/OFF the bed flushing coolant pump.

14. SPDL STOP:

This button switches off any spindle that is running. Machine should be in JOG
mode for this function.

15.

CNC ON: This switches ON the CNC System. Nothing will operate until CNC is
on.

16.CNC OFF:

This switches OFF the CNC System.

17. Hydraulic ON:

This switches On the Hydraulic System. Hydraulic switches on only if the CNC
homing condition is ok.

18. Cycle Start:

This switches will start the machine Auto cycle, if all conditions are ok.

19. Cycle Stop:

This switches will will hold the Auto cycle that is running.

20. Tool set Reset :

This is a lock type selector switch which resets the running count for tool change.

21. SPINDLE OVERRIDE:

This selector can vary the spindle RPM. Range 50% to 120% of rpm set in
program. If RPM set in program is 1000 then RPM can be varied from 500 to
1200.
22. FEED OVERRIDE:

This selector can vary the feed set in the program. Range 0% to 120% of feed set
in program. If feed set in program is 100mm/min then feed can be varied from 0 to
120mm/min.

23.

MODE SELECTION :

AUTO : The machine will run as per the selected program.

JOG: All operations on the machine can be performed using the push buttons on
the panel

X1: The selected axis can be moved with 0.001mm increment using the hand
wheel "D". To select the axis press +X/+Z

X10 : The selected axis can be moved with 0.01mm increment using the hand
wheel "D". To select the axis press +X/4Z.

X100: The selected axis can be moved with 0.1mm increment using the hand
wheel "D". To select the axis press +X/+Z.

REF: The servo homing functions in this mode only.

MACHINE OPTIONS SELCTION SWITCHES

1) DOOR BYPASS OPTION: If selector is in OFF position then the machine
cycle won't work until the door limit switch signal is received.

2) AIR GAUGE BYPASS OPTION :

If selector is in OFF position then only 1 machine cycle will work, next cycle will
work only! after air gauge OK input is received from the air gauge.

3) PROGRAMM SELECTION LH RH & BOTH:

selector switch is on LH ih spindle cycle start, if selector switch in middle means

both cycle should run, and selector switch os on RH rh spindle cycle run.
MACHINE OPERATION MODES
1) MANUAL MODE JOG MODE)

2) AUTO MODE

 PLEASE ENSURE THE FOLLOWING CONDITIONS FOR OPERATION

IN ABOVE MODE:

A) MAIN POWER ON LAMP IS ON

B) SERVO HOMING

C) HYDRAULIC MOTOR IS ON

MANUAL MODE:

IN THIS MODE ALL THE MACHINE OPERATIONS CAN BE PERFORMED

BY USING THE RESPECTIVE BUTTONS ON THE OPERATOR PANEL PLS
NOTE THAT NO OPERTATION THE MACHINE LIKE SPINDLE ON/OFF
AND SLIDE FWD / REV WILL BE PERFORMED UNTIL THE JOB IS
CLAMPED (JOB CLAMP LAMP IS ON/ PRESSURE SWITCH IS ON.) GREEN
LAMP ON TOWER LAMP WILL GLOW

AUTO CYCLE:

IN THIS MODE THE JOB MACHINING WILL BE PERFORMED AS PER THE

G & M CODE PROGRAMM AS SELECTED.

TOWER LAMP CONDITION:

HOME : GREEN LAMP

ORANGE LAMP: CYCLE RUNNING

RED: ALARM CONDITION

MACHINE MODE SELECTOR TO BE IN AUTO MODE

1) PLACE THE COMPONENT IN THE FIXTURE.

2) PRESS JOB CLAMP PUSH BUTTON ON THE CYCLE START BOX.

3) CLAMP CYCLE:

A) THE SIDE REF FWD SOLN COIL WILL BE SWITCHED ON

B) SIDE REF FWD PRESSURE SWITCH WILL BE SWITCHED ON AFTER

THE CYLINDER STROKE ENDS

C) THE MAIN CLAMP CYLINDER FWD COIL WILL BE SWITCHED ON

D) THE MAIN CLAMP ARM WILL MOVE FWD CLAMPING THE JOB.
AFTER THE CLAMP REACHES ITS CLAMP POSITION THE CLAMP PROXI
WILL BE ACTIVATED ALONG WITH THE CLAMP PRESSURE SWITCH.

E) AFTER THE MAIN CLAMP PROXI AND PRESSURE SWITCH ARE ON

THE SIDE REF REVERSE COIL WILL BE ACTIVATED AND THE SIDE REF
CYLINDER WILL MOVE TO THE PARKING POSITION ACTIVATING ITS
REVERSE PROXI. AT THIS POINT THE SIDE REF PRESSURE SWITCH
SHOULD BE OFF.

F) THIS WILL COMPLETE THE CLAMP CYCLE, AND THE MACHINE IS

NOW READY FOR PERFORMING THE AUTO BORING CYCLE.

4) BOTH SPINDLES WILL MOVE FORWARD AFTER THE FEED START

POSITION IS REACHED THE SPINDLE ROTATION WILL BE SWITCHED
ON.

5) THE SPINDLES WILL MOVE FWD INSET FEED FOR BORING & AFTER
THE REQUIRED DEEPTH IS REACHED THE SPINDLE WILL HOLD AT
THE FINAL POSITION AS PER THE DWELL SET.

6) THE SPINDLE ROTATION WILL STOP

7) AND BOTH AXIS WILL RETURN TO HOME POSITION.

8) COUNTER INCREMENTS TO THE NEXT DIGIT

9) AUTO CYCLE IS COMPLETE.

10) REMOVE THE MACHINED JOB AND PLACE A NEW JOB FOR
MACHINING.
THE CYCLE TIME AND THE JOB COUNT IS DISPLAYED AT THE LEFT
BOTTOM CORNER OF THE SCREEN.

DAILY MAITAINENCE
1) CHECK THE LUB OIL LEVEL.

2) CHECK THE FUNCTIONING OF THE EXHAUST FAN OF THE CONTROL

PANEL

3) CHECK THE FUNCTIONING OF THE AC UNIT.

4) CHECK THE SYSYEM AND CLAMP PRESSURE SET.

5) CHECK FIXTURE PARTS FOR DAMAGE AND WEAR.

6) CHECK THE COOLANT OIL LEVEL IN THE TANK.

WEEKLY MAINTAINANCE

7) CHECK THE HYDRAULIC OIL LEVEL.

8) CHECK THE FUNCTIONING OF ALL MOTORS FOR VIBRATION AND

TEMPERATURE.

9) CHECK THE TIMING BELT TENSION.

10) CLEAN THE CONTROL PANEL FAN AND AC FILTERS.

11) CHECK THE HYDRAULIC OIL TEMPERATURE.

12) THE RELAY FUNCTIONING

QUARTERLY MAINTANANCE

1) CONTROL PANEL TEMPERATURE SHOULD BE AT AMBIENT TEMP.

2) CHECK FOR ABNORNAL SOULD IN PUMP & MOTORS & SPINDLES.

3) CLEAN THE HYDRAULIC RETURN LINE FILTERS.

4) CLEAN THE HYDRAULIC SUCTION STRAINER,

5) CHECK ALL SLIDES, SHOULD BE FREE FROM SCRATCHES AND
VIBRATION DURING OPERATION.

6) CHECK THE SPINDLE PLAY AND RUN OUT.

7) CHECK FOR HYDRAULIC LEAKAGES.

8) TIGHTEN THE BALL SCREW LOCK NUTS.