TRAINING REPORT

(01 AUG 2011 TO 10 SEPT 2011)

At

BHARAT ELECTRONICS LIMITED

GHAZIABAD
Submitted in partial fulfillment
For
B.Tech (Mechanical Engineering) VI th Semester
Examination
Submitted by:-

MISS SHUBHANGI BADOLA

Of

G B PANT ENGINEERING COLLEGE

PAURI GARWAL

TRAINING REPORT
(01 AUG 2011 TO 10 SEPT 2011)

At

BHARAT ELECTRONICS LIMITED

1.
2.
3.
4.
5.

6.

7.

ACKNOWLEDGEMENT
CERTIFICATE
COMPANY PROFILE OF B.E.L.
GENERAL PROFILE OF B.E.L. GHAZIABAD
ROTATIONAL REPORTS OF VARIOUS SECTIONS
Production control
Management service
Antennae fabrication
Machine shop
Fabrication shop
REPORT ON NUMERICAL CONTROL CELL
CNC (Computer Numerical Control) Machine
DNC ( Direct Numerical Control) Machine
Introduction to programming
Working Procedures of NC Cell
System codes
CONCLUSION

1. ACKNOWLEDGEMENT
First of all I would like to express my gratitude to Mrs VANEETA
BHANDARI, MANAGER HRD department for arranging my
training for duration of six weeks. The training schedule prepared
by her got me to have an insight into working methodology and
procedures at BEL. I want to thank department of HRD for
cooperation from their part.
I offer my sincere gratitude to my guide Mr. D K Khanna Dy.
Manager Machine Shop for his continuous guidance and support. I
take the opportunity to thank Mr. P K S Nair, Dy. Engineer (N C
CELL) for helping me to complete Project.
It will be in debt of my part if I forgot to extend my thanks a lot to
all those visible and invisible hands that helped me throughout my
training period.

SHUBHANGI BADOLA

CERTIFICATE
Dated: 10-09-2011
This is to certify that Miss SHUBHANGI BADOLA,
student of B.TECH (Mechanical Engineering), G B PANT

ENGINEERING COLLEGE PAURI GARHWAL

successfully completed her six week training in BHARAT
ELECTRONICS LIMITED, GHAZIABAD from 01 Aug

2011 to 10 Sept 2011

Project THE STUDY OF CNC MACHINES IN
MACHINE SHOP, SBU R was assigned to her. In this
period she worked hard and made valuable contribution in
developing the project. All her work is genuine and original
and was timely completed.

DY. Manager (M/C shop)

CERTIFICATE
This is to certify that Miss SHUBHANGI BADOLA,
student of B.TECH. (MECHANICAL ENGINEERING) from G
B PANT ENGINEERING COLLEGE PAURI has successfully
completed her summer training in BHARAT ELECTRONICS
LIMITED, GHAZIABAD from 01 Aug 2011 to 10 Sept 2011.
A project was assigned to her. In this period she worked hard and
made valuable contribution in developing the project. All her work
is genuine and original and was timely completed.

R.N.TYAGI
(HRD)

3.
COMPANY
PROFILE
OF
BHARAT
ELECTRONICS
LIMITED

BHARAT ELECTRONICS LIMITED (BEL)

THE INDUSTRY
BEL was established in 1954 as a Public Sector Enterprise
under the administrative control of Ministry of Defence as the
fountainhead to manufacture and supply electronics components
and equipment. BEL, with a noteworthy history of pioneering
achievements, has met the requirements of state-of art
professional electronic equipment for Defense, broadcasting, Civil
Defense and telecommunications as well as the component
requirement of entertainment and medical X-ray industry .Over the
years, BEL has grown to a multi- product, multi-unit and
technology driven company with track record of a profit earning
PSU.
BEL was born to meet the growing needs of Indian Defense
services for electronic systems. Employing the best engineering
talent available in the country, BEL has progressed manufacturing
state-of-the-art products in the field of Defense Electronics like
Communications including encryption, Radars and strategic
components.
Over the years, BEL has diversified to meet the needs of
civilian customers as well and has provided products and network
solutions on turnkey basis to customers in India and abroad.
With the Research & Development efforts, its engineers have
fructified it into a world class organization. The company has a
unique position in India of having dealt with all the generations of
electronic component and equipment. Having started with a HF
receiver in collaboration with T-CSF of France, the companys
equipment designs have had a long voyage through the hybrid,
solid-state discrete component to the state-of-art integrated circuit
technology. In the component arena also, the company established
its own electron valve manufacturing facility. It moved on to
semiconductors with the manufacture of germanium and silicon

devices and then to manufacture of Integrated circuits. To keep in

pace with the component and equipment technology, its
manufacturing and product assurance facilities have also
undergone sea change. The design groups have Cads facility, the
manufacturing has CNC machines and a Mass Manufacture
Facility, and QC checks are performed with multi-dimensional
profile measurement machines. Automatic testing machines,
environmental labs to check extreme weather and other operational
conditions are there. All these facilities have been established to
meet the stringent requirements of MIL grade systems.
Today BELs infrastructure is spread over nine locations with
29 production divisions having ISO-900119002 accreditation.
Product mix of the company are spread over the entire
electromagnetic(EM) spectrum ranging from tiny audio frequency
semiconductor to huge radar systems and X-ray tubes on the upper
edge of the spectrum. Its manufacturing units have special focus
towards the product ranges like Defense Communications, Radars,
Optical & Opto-electronics, Telecommunications, Sound and
Vision broadcasting, Electronic components, etc.
Besides manufacturing and supply of a wide variety of
products, BEL offers a variety of services like Telecom and Radar
Systems Consultancy, Contract Manufacturing, Calibration of test
& measuring instruments, etc. At the moment, the company is
installing MSSR radar at important airports under the
modernization of airports plan of National Airport Authority
(NAA).
BEL has nurtured and built a strong in-house R&D base by
absorbing technologies from more than 50 leading companies
worldwide and DRDO labs for a wide range of products. A team of
more than 800 engineers is working in R&D .Each unit has its own
R&D Division to bring out new products to the production lines.
Central Research Laboratory (CRL) at Bangalore and Ghaziabad
works as independent agency to undertake contemporary design
work on state-of-art and futuristic technologies. About 70% of
BELs products are of in-house design.

BEL was amongst the first Indian companies to manufacture

computer parts and peripherals under arrangement with
International Computers India Limited (ICIL) in 1970s. BEL
assembled a limited number of 1901 systems under the
arrangement with ICIL. However, following Governments
decision to restrict the computer manufacture to ECIL, BEL could
not progress in its computer manufacturing plans. As many of its
equipment were microprocessor based, the company continued to
develop computers based application, both hardware and software.
Most of its software requirements are in real time. EMCCA,
software intensive naval ships control and command system is
probably one of the first projects of its nature in India and Asia.
BEL has won a number of national and international awards for
Import Substitution, Productivity, Quality, Safety etc.
VARIOUS UNITS:
Its corporate office is at Bangalore. Bangalore complex is the
BELs first and largest unit and it accounts for two-thirds of both
the Companys turnover and manpower. This units product range
covers over 300 Defence and Civilian products.
Ghaziabad is the second largest unit of BEL and it specializes in
RADARS, COMMUNICATION EQUIPMENTS &
MICROWAVE COMPONENTS.
In total BEL has got 9 units. These are distributed in all over the
India as:
1. BANGALORE (Corporate Office)
2. GHAZIABAD
3. PANCHKULA
4. MACHILIPATNAM
5. PUNE
6. HYDERABAD
7. CHENNAI
8. KOTDWARA
9. TALOJA

The passionate pursuit of excellence at BEL is reflected in are

pulsion with its customers that can be described in its motto,
mission and objectives:
CORPORATE MOTTO
Quality, Technology and Innovation
CORPORATE MISSION
To be the market leader in Defence Electronics and in other chosen
fields and products.
CORPORATE OBJECTIVES
To become a customer-driven company supplying quality
products at competitive prices at the expected time and providing
excellent customer support.
To achieve growth in the operations commensurate with the
growth of professional electronics industry in the country.
To generate internal resources for financing the investments
required for modernization, expansion and growth for ensuring a
fair return to the investor.
In order to meet the Nations strategic needs, to strive for selfreliance by indigenization of materials and components.
To retain the technological leadership of the company in Defense
and other chosen fields of electronics through in house Research
and Development as well as through collaboration/co-operation
with Defense/National Research Laboratories, International
Companies, Universities and Academic institutions.
To progressively increase overseas sales of its products and
services.
To create an organizational culture, which encourages members
of the organization to realize their full potential through continuous
learning on the job and through other HRD initiatives?

QUALITY POLICY
BEL is committed to consistently deliver enhanced value to our
customers, through continual improvement of our products and
processes.

QUALITY OBJECTIVES
1. Effective and Efficient design and development process,
considering the present and future needs of customers.
2. Enhanced customer satisfaction by on-time delivery of defect
free products and effective life cycle support.
3. Continual up gradation and utilization of infrastructure and
human resources.
4. Mutually beneficial alliances with suppliers.
5. Continual improvement of processes through innovation,
technology and knowledge management.
The management of BEL is convinced of the need for Quality
Enhancement, on a continuous basis, in the company. Need was
felt to impart Education I Training to all the officers on the various
facets of quality management. Accordingly, an institute called
Bharat Electronics Quality Institute (BEQI) was established
in1999.
Regular training programs are conducted for all employees
working in different units of the company. Business Excellence
models being followed by different organizations are studied and
efforts are being made to implement the best possible practices in
the functioning of the organization.
Bharat Electronics Ltd., (BEL), a premier Professional
Electronics Company of India, has established and nurtured a
strong in-house R&D base over the years to emerge and remain as
a market leader in the chosen areas of business in professional
electronics. Each of the nine manufacturing units of BEL is having
its own in- house R&D Division to develop new products in its
field of operations. Besides, there are two Central Research
Laboratories (CRL) located at Bangalore and Ghaziabad, to
address futuristic technologies of interest to BEL.
Main areas of R&D activities at BEL include development of
Military Radars, Naval Systems, Military Communication
Products, Electronic Warfare Systems, Telecommunication
products, Sound and Vision Broadcasting Equipment and Systems,

Opto-Electronic Products, and Electronic Components. CRL

performs the dual role of carrying out blue sky research for the
development of future technologies and supporting the D&E
Divisions of BELs nine units with state-of-the-art core technology
solutions in areas like Embedded Computers and applications,
Radar Signal Processing, VLSI designs, RE & Microwave
Communication Technologies, Software modules etc.
BELs R&D Units have state-of-the-art R&D infrastructure,
facilities, and manpower with relevant technical expertise for
product development. There are about 1000 engineers working in
BEL on various D&E projects. BEL spends around 5 % of
company turnover for the year on R&D every year. HRD Divisions
of BEL take adequate initiatives for the all round development and
expertise up gradation of R&D human resources. State of the art
infrastructures, test equipment, computers & workstations,
Software packages etc. are augmented every year for the R&D
divisions. BEL R&D Units are recognized by the Department of
Scientific & Industrial Research under the Ministry of Science &
Technology, Government of India.
R&D Units of BEL have close interactions with other
National Design Agencies like DRDO, CSIR, C-DOT and a
number of Technical Institutes. BEL jointly works with them to tap
suitable indigenous designs for commercialization. Technological
collaborations with some of the Multinational companies and
subsequent absorption of these technologies also have enhanced
the technological base at BEL. On an average, about 67% of BELs
turnover is from indigenous design, and 33 % of it is through
foreign technology transfers.
List of world class companies with whom BEL has
technological collaborations for different state-of-the-art products
are as given below:
Company
Product
Oerlikon Contraves, Switzerland Naval FC Systems

AWARDS WON BY BEL

R&D Divisions of BEL have been receiving number of
National R&D awards. A list showing the various R&D awards
received by BEL since 1990 is as given below.
1. FICCI Award for Research in Science & Technology 1990
(For the corporate initiative of R&D)
2. DSIR National R&D Award 1992
(For successful commercialization of Public Funded R&D)
(For D&E project handled at BEL-GAD)
3. DSIR National R&D Award 1993
(For in house R&D efforts under Electronics & Electrical
Industries Sector)
(For D&E projects handled at BEL-Bangalore,
Machilipatnam & Ghaziabad)
4. DSIR National R&D Award 1995
(For in house R&D efforts under Electronics Industries Sector)
(For D&E Projects handled at BEL-Bangalore & Ghaziabad)
5. DSIR National R&D Award 1998
(For successful commercialization of Public Funded R&D)
(For D&E projects handled at BEL-Bangalore & Panchkula)
6. Defense Technology Absorption Award 98 1999-2000
(Sponsored by DRDO)
(For D&E projects handled at BEL-Hyderabad)
7. Award for Excellence in R&D for the year 1998 2000-2001
(Sponsored by Ministry of Information Technology, Gol) (For
BEL-Ghaziabads developments of various 1FF Systems)

8. Award for Excellence in Professional Electronics 2000- 2001

For the year 1998.
(Sponsored by Ministry of Information Technology, Gd)
(For BEL-KOTs excellent performance in Production,
R&D & its commitment to Quality & Service)
9. Award for Contribution in areas of Defense R & D 2001-2002
To Col. Retd.) H. S. Shankar, Director (R & D) for
The year 2001-2002
(Sponsored by Society for Defense Technologists SODET)
DESIGN AND MANUFACTURING SERVICES
Bharat Electronics Limited today has an integrated approach and
systems capability, which is a direct result of its commitment to
providing tailor-made solutions to the customers through its
philosophy of quality management.
The company has set up impressive infrastructure and
manufacturing facilities spread over nine ISO 9001 I 9002 certified
modern production units around the country. The infrastructure is
regularly upgraded with the latest and state- of-the-art facilities.
Manufacturing infrastructure is amply supported by the applicable
Quality Assurance infrastructure and skilled technicians. Standards
Division of BEL optimizes the processes on a continuous basis.
Process and QA standards generated by BEL are used as reference
by a number of companies in India.
With the strengths in infrastructure and skilled/experienced
manpower, BEL offers Contract Manufacturing Services for both
domestic and international customers in the following areas:

PCB ASSEMBLY (SMT, through hole, BGA) and Testing

BEL has set up an exclusive Mass Manufacturing Facility and
achieved proficiency in assembly of a wide variety of circuit board
designs including Surface Mount Technology (SMT), Mixed
Technology and Plated I Pin Through Hole Technology (PTH),.
BEL also offers most modern facilities for testing of the products
manufactured.

Precision machining and Fabrication

BEL has the experience and expertise in the manufacture of high
Precision Machined and Fabricated Parts in its state-of-the-art
facilities equipped with latest CNC and special purpose machines.
Products manufactured include chassis, enclosures, panels,
brackets, rack mounts, card cage flanges and covers, large and
medium modular frames and precision machined parts for the
electronic, computer, and electrical products being used in
commercial, Defense, aerospace and telecommunication industries.
Opto Electronic Components and Assemblies
Bharat Electronics offers cost effective services for design and
manufacture of optical and opto-electronic products and
components operating in the UV, Visible and IR spectrum. Optical
components include lenses, prisms, mirrors, windows, wedges etc.
and Optical assemblies include Objective assembly, Eyepiece
assembly, Collimator assembly & Imaging assembly.

Microwave integrated Circuit Assemblies

BEL manufactures a variety of Microwave Components and subsystems using microchip technology which are required for wide
range of applications in communication, radar systems including
airborne and space related subsystems. The facility is also qualified
for the manufacture of C-Band Receiver for satellite systems.
Multilayer PCB Design and Manufacturing

BEL has established an excellent infrastructure to manufacture

variety of Printed Circuit Boards ranging from single sided to 18
layers. The facilities are equipped to manufacture high technology
quick turn prototypes, Quick-to- Market products and undertake
volume production of buried and blind vias, build-up multi layers
(micro vias) and ultra fine lines/spaces.

Cable assemblies and Wiring Harnesses

BEL specializes in the manufacture of cable assemblies and
builds custom wiring harness required for its electronic equipment
for commercial and military applications.
Design and Manufacturing of Professional Grade Transformers
BEL manufactures a wide range of transformers (power, audio
frequency, modulation, pulse, filament etc.,) coils (audio
frequency, radio frequency, air arc, IF, pot case, molded, etc.,)
Chokes (smoothing, modulation, radio frequency, etc.,) and Subassemblies (HV Units, EHV units, etc.). Most of these products
meet the stringent defense specifications for use in Defence
equipment.

Antenna Manufacturing
Bharat Electronics Limited is engaged in development and
production of various types of antennas for use in Radars,
Communications, TV- Broadcasting, Satellite Communication etc.
The antenna production division also includes a FRP shop capable
of producing antennas with hand-lay-up technology. The R&D and
production efforts are supported by well-equipped microwave
testing laboratory and a microwave outdoor antenna test range.
There is also a facility to produce thin film MIC components that
are extensively used in phased array antennas.
Many foreign companies like AT&T-USA, GE-Medical-USA,
Vishay-Austria,

ECHOSTAR-USA, ENCON International-USA, CREC Products

Inc-Canada.,
Multitone-UK, Elisra, Elta, Ortek, Scitex, ELOP-Israel,
Technology
Rendezvous Inc., USA, ERICSSON,SWEDEN and many more are
using our facility for meeting their outsourcing requirements.
BEL has also established Joint Venture Companies with DeIft,
Holland for Image Intensifier Tube and General Electric Medical
Systems, USA for X-Ray Tubes.

4.
GENERAL
PROFILE
OF
BEL
GHAZIABAD

GHAZIABAD UNIT
Formation

In the mid 60s, while reviewing the Defence requirements of

the country, the government focused its attention to strengthen the
Air Defence System, in particular the ground electronics system
support, for the Air Defence Network. This led to the formulation
of a very major plan ADGES with Prime Minister as the presiding
officer of the apex review committee. At about the same time,
public attention was focused on the report of the Bhabha
Committee on the development and production of electronics
equipment. The Ministry of Defence immediately realized the need
to establish production capacity for meeting the electronics
equipment requirements for its plan ADGES.
BEL was then entrusted with the task of meeting the development
and production requirement for the plan ADGES and in view of the
importance of the project it was decided to create additional
capacity at a second unit of the company.
In December 1970 the government sanctioned an additional
unit for BEL. In 1971, the industrial license for manufacture of
radar and microwave equipments was obtained; 1972 saw the
commencement of construction activities and production was
launched in 1974.
Over the years, the unit has successfully manufactured a wide
variety of equipment needed for Defence and civil use. It has also
installed and commissioned a large number of 1FF systems needed
to match a variety of Primary Radars. More than 3 versions of IFFs
have already been supplied traveling the path from vacuum tubes
technology to solid-state to latest Microwave component-based
system.

Organizational Structure of BEL:

The operations of BEL Ghaziabad are headed by General Manager

with Additional/Deputy General Manager heading various
divisions as follows

Design &Engineering Divisions:

Development and Engineering-R
Development and Engineering-C
Development and Engineering-Antenna

Equipment Manufacturing Divisions:

Radar
Communication
Antenna
Systems
Microwave Components

Support Divisions
Material Management
Marketing and Customer Co-ordination
Quality Assurance and Torque
Central services
Information Systems
Finance and Accounts
Personnel and Administration
Management Services

Design and Engineering:

The pace of development and technological obsolescence in the

field of electronics necessitates a strong Research and
Development base. This is all the more important in the area of
Defense Electronics. BEL Ghaziabad has since its inception laid a
heavy emphasis on indigenous Research and Development. About
70% of its manufacture today relate to items developed in-house.
For the development and production of the Mobile Troposcatter
System and the 1FF equipment, BEL was awarded the Gold Shield
for Import Substitution.
Design facilities are also constantly being modernized and
substantial computer-aided design facilities are being introduced
including installation of mini and micro-computers and dedicated
design application. About 170 graduate and post-graduate
engineers are working on research and development and indication
of the importance R&D has in BELs growth.
Three Design and Engineering groups are product based viz.
Communication, Radar and Antenna; these divisions are further
divided into different departments to look after products of a
particular nature. Each of them has a drawing office attached to
them, which are equipped with latest drafting and engineering
software. The PCB layout and PCB master making is done at
CADDs center. A central Records and Printing section takes care
of the preserving the engineering documents and distribution
thereof. Most of the engineering documents are available online.

Equipment Manufacturing Divisions:

As a supplier to the defense services and professional user,

strict adherence to specifications and tolerances has to be in-built
into the design and manufacturing process. For this. BEL
Ghaziabad has well defined standards and process for as well as
manufacturing and testing activities. Activities are divided into
various departments like Production Control, Works assembly and
QC works. The manufacture and control of production is through a
central system, BELMAC, BELs own homegrown ERP system.
Apart from conventional machines, BEL Ghaziabad has been
equipped with several Computer Numeric Control (CNC)
machines for ensuring repeat occurrences and increased
throughput. A separate NC programming cell has been set up to
develop the programs for execution on the CNC machines.

Microwave Component Group:

Frequencies greater than 1 GHz as Microwaves, Microwave
Integrated Circuits(MIC) used extensively in the production of
subsystems for radar and communication equipment constitutes a
very vital part of the technology for these4 systems and is
generally imported. Owing to the crucial and building block nature
of the technology involved, BEL is currently setting up a modem
MIC manufacturing facility at a planned expenditure of Rs 2crores.
When in full operation, this facility will be the main center for the
MIC requirements of all the units of the company.
The manufacturing facilities of hybrid microwave
components available at BEL Ghaziabad includes facility for the
preparation of substrates, assembly of miniaturized components
viz, directional couplers, low noise amplifiers, phase shifters,
synthesizers etc. involves scalar as well as vector measurements.
For this state of the network analysis are used.

Material Management:
Material Management division is responsible for
procurement, storage binding, issue of purchased parts as well as
raw materials required to manufacture various equipment and
spares. It also takes care of disposal of unused or waste material.
This division is divided into Purchase, Component store, raw
material store, Chemical store, Inwards good store, Custom
clearance cell, Inventory management & disposal.

Marketing and Customer Co-ordination:

This division is responsible for acquisition and execution of
customer orders and customer services. Marketing department
looks after the order acquisition, Commercial department looks
after the order execution, and Shipping takes care of the packing
and dispatch of material to customer Quality Assurance & Torque.
In the area of professional defense electronics, the importance of
Quality and reliability is of utmost importance. BEL has therefore
established stringent processes and modern facilities and systems
to ensure product quality-from the raw material to the finished
product. IGQA Environmental labs, Test Equipment Support and
QA departments are grouped together under this division.
All material for the consumption in the factory passes
through stringent inward goods screening in IGQA department
before being accepted for use Subsequent to manufacture and
inspection, the end product is again put through a rigorous cycle of
performance and environmental checks in Environmental Labs.
The testing, calibration and repair facility of test
instruments used in the factory is under the control of Test
Equipment Support. All the instruments come to this department
for periodic calibration Quality Assurance department facilitates
1S09000 certification of various divisions. All the production
divisions of BEL Ghaziabad are 1S9000 certified. The microwave

division is 1S09001 certified whereas the remaining three divisions

viz. Radar, Communication and Antenna are also 1S09002
certified.

Central Services:
Central Services Division looks after plant and maintenance
of the estate including electrical distribution captive power
generation, telephones, transport etc.

PCB Fabrication & Magnetics:

PCB Fabrication, Coil and Magnetic, Technical literature,
Printing press and Finished goods are the areas under this division.
Single sided PCB blanks-having circuit pattern only on one side of
the board and double-sided-having circuit pattern on both sides of
the board are manufactured in house. However, Multilayered
PCBs, having many layers of circuit are obtained from other
sources.
Magnetic department makes all types of transformers & coils
that are used in different equipment. Coils and transformers are
manufactured as per various specifications laid down in the
documents released by the D&E department.

Information Systems:

IS department is responsible for BELs own homegrown

manufacturing and control system called BELMAC. It comprise of
almost all modules a modern ERP system but is host and dumb
terminal based.

Finance &Accounts:
The F&A division are divided into Budget & Compilation,
Cost and Material Accounts, Bills payable, Payrolls, PF section,
Cash sections.

Personnel & Administration:

There are at present about 2300 employees at BEL
Ghaziabad, of which more than 400 are graduate and post graduate
engineers. P&A Division is divided into various departments like
Recruitment, Establishment, HRD, Welfare, Industrial Relations,
Security and Ml Room.

Management Services:
This department deals with the flow of information or from
the company. It is broadly classifies into three major sub-sectionsManagement Information System, Industrial Engineering
Department and Safety.

5.
ROTATIONAL
REPORT
OF
VARIOUS
SECTIONS

1. PRODUCTION PLANNING AND CONTROL

Production control
The main goals of the production control are:
1. To improve the profit of the company by better resource
management.
2. To ensure own time delivery product to customer
3. To improve quality of the products
4. To reduce the capital investment
5. To reduce the working capital needs by better inventory
management.
Production control is responsible for producing the product, right
from the stage engineering drawing are received to the stage where
it is store credit as finished products.
Its basic function is to identify the parts /operations to be made the
best way of making them, and the time when they have to make
and to arrange the production resources to the optimum. The
commercial department obtains order for equipment through
quotations. The equipment stop order (ESO) is released by
commercial department.
The management service department, issue the work order for the
quality of the equipment to be made. This is for the calculation of
the cost of the project. Then D&B department develops the
equipment and releases the following engineering documents:
KS Key sheet
GA General assembly diagram
WD Wiring diagram
PL Part list
CL Connection list
Now the production control takes the responsibility of
manufacturing the equipment. Pc decides for items to be purchased

from outside, for items to be manufactured by other companies and

prepares documents for items to be made inside the company.
Documents issued by PC
1.

2.

3.
4.

Process sheet (Fabrication): this process sheet indicates the

process and the sequence of operation to be followed in
various work cells and work centres. Every item timed by
productivity services
Process sheet (Assembly): This is similar to PS (fabrication)
except that, it is used in electronic assembly, PCB
assemblies, cable from the cable assemblies.
Process sheet (Coils): This indicates operational analysis for
transformer and coils.
Schedule for RM, fasteners and PPs: This gives the gross
requirement for raw materials, purchased parts, fasteners etc.
Based on this material control department initiates
procurement action and store requisitions are released with
reference to this schedule.

TOOL PLANNING

Some of the items while under fabrication require the use of some
jigs and fixtures or some special purpose tools. This department
arranges all these items, because the jobs can e made fast and
accurate by using any jig or fixture.
The working format of this department is as follows:
1. Procurement of PPS
2. Procurement of raw material.
3. Writing of process sheet for machines shop
Sheet metal working
Turning shop
Welding shop
Process sheet for assembly
4. Launching of manufactured parts in various shops
5. Assembly activity
6. Testing
7. Dispatch.

2.MANAGEMENT SERVICES
This department deals with the flow of information to or from the
company. It is broadly classified into the major sections:
1. Productivity service
2. EDP section
Productivity service
The basic work of this department can be summarized as:
1. To prepare plans for next five years called Roll-on plan and
evaluate the current roll on plan that has been drawn 5yrs
age.
2. The cost estimation, revenue and budget plans are got
approved by the board of management
3. Standard hour is approved by the department.
4. Report on production value is evaluated for each unit.
Material management
The responsibility given to this section is to obtain raw materials
and items essential towards daily usage of the factory. The division
further consists of two departments:
1. Purchase
2. Components store
BEL as a frontrunner has installed three automatic components
holding machine in its component store. The system is KARDEX
system installed in 2002. This systems aims at;
1. Utilizing vertical space for storing
2. Making the process of searching components, fatigue, less as
well as time saving (components to man instead of man )

3. Also provide facility of inventory control.

Its specifications are:1.

2.
3.
4.
5.
6.
7.

Vertical height of 6mtrs.

Tray length if 1.2mtrs
Horizontal depth of 2.5mtrs.
3 motors
Eight sensors
Sprocket chain drive mechanism
54 components housing trays adjusted to some height
(changeable)

3. ANTENNA
Various antennas types are being fabricated and assembled in this
shop:
a. Radar or communication antennas consists of:
i. Main panel fixture or reflector
ii. Feed fixture assembly
iii. Backup frame
iv. Rotary joint assembly
v. Transportation frame assembly
b. Satellite antennae of different diameter consist of:
Reflector:
a. FRP sandwich type
b. Panel fixture type
Feed:
a. C-Band
b. Ext.C-Band
Feed support assembly
Mount assembly
a. Manually operated or motor controlled operated
b. Remote operated with control unit
Various sections in this shop are:
a. Precision Fitting
b. Dip brazing
c. Welding
d. Painting
e. Fiber reinforced poly urethane molding shop(FRPE)

TYPICAL ALUMINIUM DIP BRAZIG SHOP

DIP BRAZING
Dip Brazing is a process of joining of Aluminum alloy parts by means of flowing a
filler metal between the joint interfaces at a temperature below the melting point
of the base metal. Upon cooling to the solid state it forms a strong metallic bond
throughout the joined area. This process is different from other joining process
e.g. welding, brazing, soldering in following aspect:
a) No distortion
b) Close dimensional accuracy
c) More than scores of joints can be dip brazed in one dip
d) Quick, Leak-proof
Consequently the application has been use in those areas:

Where the job is intricate and conventional manufacturing process is

either very costly or takes a longer cycle time.

No distortion is allowed in the parent item after joining process.

Leak proofing at joints

Joining of thin sheet to a thicker one.

The wave guides, with all the bends and twists, for RF plumbing of any
communication Equipment, are the ideal items for dip brazing.

Parts to Be Dip Brazed Are

Cleaned of oil, grease and freed of excess oxide,
Assembled and jigged along with the necessary filler metal (dry flux).
Heated to approximately 580 deg Celsius for about 45 minutes
Immersed in molten flux at 605 deg Celsius for about 2-3 minutes.
Removed from the molten flux, cooled and cleaned,

 The assembly is now ready for use for further treatment.

One joint or a hundred can be formed during the few minutes the assembly is
submerged in the molten salt.
It is a welding method, which involves welding of material via an unknown salt or
aluminum power exported from U.S.A.
The various stages involved are:
1) Cleaning of raw material: - It involves the surface cleaning of the material
part to be joined.
2) Setting of raw material: - the different parts to be joined of various types
can be set by tag welding or by tightening by wires.
3) Cleaning
Descaling It can be done by treating it with HNo3 + HF in the ratio
of 6:4 (Removal of scales).
Degreasing this can be done by treating it with Tetra-chloro
ethylene (TCE).
4) Reassemble: - Guiding them reassembles the material parts.
5) Application of Filler material: - This filler material of aluminum powder of
same compound is applied on the place where it is to be welded.
6) Pre-heating: - the material is heated to a temperature of 580 oc so that it
may come to plastic state. The time period depending upon the job. Then
due to capillary action, it sweeps into the joints.
7) Dipping in Salt water: - It is put in salt bath, which is at a temperature of
605o c. It is done so that it gets hardened and also external powder is
washed away.
8) Air-cooling: - The job is then air-cooled.
9) Hot water cooled: - It is done in order that the stresses may not develop if
sudden cold water is applied.
10)Further cleaning is done

ADVANTAGES OF DIP BRAZING

LESS DISTORTION:
Large and extremely complex shapes can be brazed with minimal distortion at
relatively lower than welding temperatures. Dip Brazing utilizes uniform
application of heat both in the pre-heating furnace & in molten salt bath and
works in conjunction with high thermal conductivity properties associated with
Aluminum. This uniform application of heat reduces the incidence of distortion.
REDUCED TOOLING COST:
The dip brazing process uses little if any specialized tooling. Fixturing is generally
accomplished with common fixtures that allow for quick and inexpensive
configuration changes.
MATERIAL SAVINGS:
Unlike castings or machined parts, dip brazing can be done at near final
dimension.
IMPROVED STRUCTURAL INTEGRIT:
Dip brazing offers a continuous leak-proof and EMI shielded joint even with a
variety of material thicknesses.
BETTER CONDUCTIVITY:
As the dip brazed joint is made up of aluminum, conductivity is clearly better than
that achieved with an adhesive bonded or mechanically attached assembly.

LOWER COST:
The dip brazed process yields the lowest cost given the superior characteristics
achieved.

DESIGN FREEDOM:

The design engineer will enjoy a greater range of options using the dip
brazed process.

Reduced Tooling Costs

Reduced Design Change cost and implementation time

FATIGUE AND THERMAL PROPERTIES:

The natural shape of the meniscus formed by the filler material is ideally shaped
to resist fatigue. Any stress of the assembly is evenly distributed around the fillet
and disperses the stress uniformly over a large stress area.

2. Painting
After production the work comes for painting which is the last
operation on the job.
He paints used are:
a. Enamel paint
b. Nitro cellulose polyurethane
Enamel paint: It is used in writing work for example, mono.. of
BEL done by enamel paint.
Nitrocellulose and polyurethane: It cant be done by brush as it
dries down very fast so it is done by spray.
The procedure adopted is:
1. Cleaning: cleaning work on the job is done by applying
Tricloro ethylene.

2. The OIC primer is put on it i.e. the red oxide and it is left for
drying for 24 hours.
3. Then primer sur. Is put on it which is of grey colour for 24
hours. It is coated such that the paint may have strong catch
and is left for 24 hours to dry.
4. Then the paint is sprayed over it. It takes 8-24 hours to dry.

Antennae shop also houses Shot blasting machine. This machine is

used for removing rust from heavy rusted assemblies before
painting them. It consists of steel grit, which is sprayed under
pressure to remove rust.

3. Welding
Various types of welding being used are:
Silver brazing with brass base metal (brazed with Ag
because it has lower MP as compared to brass.)
Tungsten inert gas welding (TIG): It uses argon gas and
electric arc Filler material is aluminum.
Arc welding using consumable electrode, which I flux,
coated.

3. Fiber reinforced poly urethane section:

The transmitters and covers of track antennae are manufactured
here. The redum covers of RADAR are made here. It also
makes reflectors for reporter as well as FLYCATCHER
RADAR.

Fiberglass is used as reinforcing material to increase

mechanical strength as well as insulation properties. Carbon
fibers improve the electrical properties of components
The constituents for making reinforced assembly are
fiberglass mats. They are of 3 types:
Winovin mat
Surface mat
Zobistan mat.

For making antennae for RADARS, the procedure is:

Mould which is used for making antennae is covered with the
separator gel which also doubles up to give better surface finish. It
is covered with polyester resin +1% accelerator +1% catalyst
(depends upon climate, room temperature and conditions). It is
then set in mould for about 24hours. After setting it is put in
Curing chamber for Thermosetting, in stage 1 the temperature
maintained is 250C and in stage 2 it is reduced to 125C.

4. RADAR AND MACHINE SHOP

MACHINE SHOP
To meet the requirement of various projects, their manufacturing parts are
processed in machine shop. Different operations are carried out to complete the
job as required. Operations mainly covered under machine shop are:
1. Turning (conventional)
2. Milling (conventional)
3. CNC turning
4. CNC milling
5. Jig boring
6. Grinding
7. Sheet metal work

TURNING
Turning is done on a lathe machine. In turning normally single point cutter tool is
used, job is generally hold in chuck or collet (fixture) that rotates and tool is
allowed to cut the material. Different process performed on lathe machine.

Turning

Facing

Drilling

Boring

Knurling

Taper turning

Thread cutting

Parting off

Chamfering

There are various types of lathes in this section

i.

Centre lathe

ii.

Capstan and turret lathe

iii.

Engine lathe

There make/types are as follows:

1.

SCHAUBLIN 135:
It is a very precise machine and is used to perform high accuracy jobs. It
is centre lathe. 135 specify the height of center.

2.

HMT LATHE:
It is also a very accurate machine and can take heavy load as well. It is
generally used for machining of large sized precise jobs. It is of type H22
is the height of centre. It is also a centre lathe. Job diameter range is 15
440mm. length of the bed is 1.5m and its speed is 40 2300 r.p.m. the
speed depends upon the diameter of the work piece.

3.

GEE DEE WEILER:

It is having a turret a capacity of SIX tools, which can be set as per
required dimensions, with an additional provision of utilizing two more

tools on auxiliary slide. It is used for manufacturing small jobs in large

quantity. Job diameter range: 2 25mm and speed range: 440 3600
r.p.m

MILLING
In cell-22, milling operation is done on milling machines. On milling machines
operations are performed by multipoint cutting tool known as milling cutter.
Generally, cutter hold in arbor and the job hold in the vice/fixture/machine bed
and required machining operations are performed as per drawing.

Milling operation is basically of two types:

i.

Conventional (up) milling

ii.

Climb (down) milling

CONVENTIONAL (UP) MILLING

If the rotation of the cutter and feed of the job is in opposite direction, it is known
as up milling. In this process we can take heavy cut but finishing is not good.

CLIMB (DOWN) MILLING

If the rotation of the cutter and feed of the job is in same direction, it is known as
CLIMB MILLING. In this process we cannot take heavy cut but finishing is good.

TYPES/MAKE OF MILLING MACHINES:

.

SCHAUBLIN:
It is a universal type-milling machine, as it may be adapted to very wide
range of milling operations. Its bed moves in longitudinal, crosswise &
vertically. There is a D.R.O attached to it, which stands for Digital Read
Out. It is a Swiss machine.

Specifications:
Bed movement

2.

Longitudinal

700mm

Crosswise

200mm

Vertical

500mm

Feed range

12 to 1050mm/rev.

Speed range

38 to 1510 r.p.m

PRAGA-GAMBIN:
It is one of the few Indian machines in BEL. It is also a universal milling
machine. It is one of the oldest machines in Cell-22.

Specifications:

3.

Feed range

10 to 160mm/rev.

Speed range

40 to 250 r.p.m

HURON:
It is an omniversal type milling machine. It is a French machine.

Specifications:
Bed movement
Longitudinal

1100mm

Vertical

600mm

700mm

30 to 2050mm/rev.

Bed

1.6 to 820 mm/ rev.

Head

0.8 to 410 mm/ rev.

Head movement
Crosswise
Speed range
Feed range

4.

DECKLE FP 3L:
It is universal type milling machine. It has a fixed bed and has a D.R.O
attached to it. It is a French machine.

Specifications:
Bed movement

5.

Longitudinal

800mm

Crosswise

300mm

Vertical

400mm

Feed range

10 to 500mm/rev.

Speed range

40 to 2000 r.p.m

DECKLE FP2:
It is conventional milling machine. It has a head movement of 45 on both
sides. Both vertical and horizontal work can be done on it.

Specifications:
Bed movement
Longitudinal

400mm

Crosswise

200mm

Vertical

400mm

Feed range

8 to 400mm/rev.

Speed range

40 to 2000 r.p.m

CNC TURNING:

In cell-21 there are three CNC lathes, in which two are from Index, (FRANCE)
and one from Wasino (JAPAN). Index CNC is based on SINUMERIC system and
used for small/medium size large quantity precise jobs. Wasino CNC is based on
FANUC system and is used for large size job.

Specification (WASINO):
Bar capacity
Chuck capacity
Spindle speed range
Feed rate range
Tool station
X-axis turning
Z-axis turning
Spindle power

77 mm (max.)
260 mm (max.)
8 to 3000 r.p.m
0.001 to 400 mm/rev.
12 (in numbers)
330 mm
500 mm
15 KW

Specification (Index-GU 600):

Bar capacity
Chuck capacity
Spindle speed range
Feed rate range
Tool station
X-axis turning
Z-axis turning
Spindle power

10 to 65 mm
200 mm (max.)
25 to 5000 r.p.m
0.001 to 400 mm/rev.
12 (in numbers)
175 mm
700 mm
32 KW

Specification (Index-GS 600):

Bar capacity
Chuck capacity
Spindle speed range
Feed rate range

Tool station
X-axis
Z-axis
Spindle power

9 to 30 mm
100mm (max.)
37.5 to 7000 r.p.m
0.001 to 400 mm/rev.
Turret 1
Turret 2
12
8
95 mm
100 mm
238 mm
128 mm
32 KW

CNC MILLING
In cell-22 there are four types of CNC milling machine. In which two are from
Kitamura (JAPAN) and the other two from Mitsui Seiki (JAPAN). Both are based
on the FANUC 6M system.

Specification (Mitsui Seiki VR3A):

X-axis travel

750 mm

Y-axis travel

450 mm

Z-axis travel

450 mm

Spindle speed range

60 to 6000 r.p.m

Feed rate range

0.1 to 4000 mm/rev

Rapid Transverse

12000 mm/ min.

Specification [Mycenter-4 (Kitamura)]:

X-axis travel

914 mm

Y-axis travel

508 mm

Z-axis travel

571 mm

Spindle speed range

60 to 4000 r.p.m

Feed rate range

0.1 to 5000 mm/rev

Rapid transverse

10000 mm/ min.

Specification [Jigcenter-7 (Kitamura)]:

X-axis travel

1100 mm

Z-axis travel

850 mm

Z-axis travel

460 mm

Spindle speed range

50 to 3500 r.p.m

Feed rate range

0.1 to 5000 mm/rev

Rapid transverse

10000 mm/min.

JIG BORING:
Jig boring operations are preformed to get close tolerance on different types of
holes/bore and counter bore as per requirement. These machines are also very
accurate and give repeatability very precise in microns.
There are two types of jig boring machines, both are Swiss made Henri Hauser.
They are very temperature sensitive. They work at 202C.

Specification:
Henry Hauser(Type I)
X-axis travel

700 mm

Y-axis -

500 mm

Rapid transverse

1200 mm/ min.

Feed range

0 to 4000 mm/ min.

Speed range

60 to 600 r.p.m

X-axis travel

400 mm

Y-axis -

250 mm

Z-axis

400 mm

Speed range

60 to 3000 r.p.m

Accuracy

upto 0.1 microns

Henry Hauser(Type I)

6. FABRICATION SHOP
Fabrication Shop is one of the mechanical workshops in the company. There are
several kinds of machine used for different kind of operation.For sheet metal
work first of all the work is done on sheering machine. Shearing machine cuts the
sheet. It firstly bends the sheet & then breaks the sheet by application of heavy
force through a ram.
After cutting the sheet the work piece is sent to punching machine. In this
machine punch can make holes of any shape. This punching machine is a CNC
machine, which has twenty-tool station. The program is feed into the machine
manually, by floppy or by compact disc. After punching, job is sent forward for
other operations. After punching if there is any bending work in that job then it is
sent to bending machine where bending work is done.
In circular saw the waste material is cut of the original piece. Now after
performing such operation the level of the sheet get wreck so before performing
more operations. It is sent to leveling machine in which there are rollers, which
are moving in opposite directions. The sheet is inserted in the machine and
machine levels the surface.
In Fabrication Shop there are various kinds of machine but mainly the work is
done on some machine and they are:
1. Shearing Machine (PC-1).
2. CNC-LVD Punching Machine.
3. NPB- Bending Machine.
4. 120 T- Bending Machine
5. Leveling Machine.
6. Tapping Machine.
7. Circular Saw.

8. Radial Drilling Machine. ( AUTO MULLER )

The brief description and working of the machine is given below:

1.

Shearing Machine (PC-1):-

Shearing Machine is one of the most important machines of the fabrication shop,
because the work starts from this machine as it cuts the sheet. This machine
works on hydraulic pressure. The ram is fixed and it slides horizontally and cut
the sheet. Actually this machine do not cut, it bends the sheet and then breaks by
the action of ram. As the sheet bends and the work done in great accuracy so
clearance must be taken in account before cutting the sheet .The clearance is
the 3% of the thickness of the sheet. For holding the sheet firmly, when we press
the button first the hammer press the and then the ram perform its work. For the
long life of the cutter the ram do not act from both side, instead of that it starts
cutting from one side just like scissor.
Specification:Maximum sheet thickness
Aluminum

0.5 - 6 mm

Mild steel

0.5 - 4 mm

Stainless steel

0.5 - 3mm

Maximum length of the sheet

3mm

Number of strokes per minute

18-28

Distance of frame cutting slide

30HP

Voltage of motor

415V

Approximate weigh

7 tones

2.

CNC-LVD Punching Machine: -

This machine is a CNC turret machine in which there are 20 tool stations in a
turret, which acts as there programming. In this machine there are four ways to
feed the program, first way is simple manual programming, second by magnetic
tape/reel, third way is by floppy and fourth by compact disc. Programming is
based on trigonometry. X & Y indicates the desired length & width of the sheet.
Working of the machine is simple the data is fed into machine by any one of the
method & the sheet is inserted in the machine. The machine automatically works
and finally completes the job. For holding the job firmly there are two vices, which
are movable and which moves the sheet. Their jaws are operated by oil
compression.
Specification: Company
Model
CNC control
Electric consumption
Maximum punch tonnage
Working Area
Maximum sheet thickness
Maximum punch dia
Maximum work piece weight
Position Accuracy
Average repeatability
Number of tool stations

No. Of index station

Inhibited clamp zone

Maximum speed

Nibbling

LVD Belgium
Delta 1000 thick turret 3 indexes
Fanuc 180i
23.4 KW
200 KW
1275 mm
6 mm
88.9 mm
80 Kg
0.1 mm
0.05 mm
20
7A type (up to 12.7 mm)
7B type (dia 12.7 to 31.7 mm)
2C type (dia 31.7 to 50.9 mm)
4D type (dia up to 88.9 mm)
3(D type)
220 mm (X direction)
80 mm (Y direction)
75 mm/min for X & Y direction
106 mm/min for X & Y movement
400 mm/min (+/- 5 %)

Punching
Noise level

3.

for X= 1mm
And y=0 (without sheet)
200 mm/min (+/- 5 %)
for X = 25 mm
And Y = 0 (without sheet)
90 to 100 dB

NPB Bending Machine:-

In this machine the tool is fixed between the jaws and the die is selected as per
our need. It is also an automatic machine. Its an air compressor operated
machine in which applying air pressure does the work.
The die is selected and fitted at the die holder. The job, which is to bend, is
placed on the die, which is fixed on the bed. The most important feature of this
machine is that in this machine the ram do not move, instead bed move upward
and downward and the bending work is done.
This is a kind of automatic machine; so the power of stroke, length of stroke and
the dimension of the job is numerically control where the angel of bending is
dependent on the die.
4.

120T Bending Machine:-

This is simple kind of press, working on hydraulic principle. Its tonnage is 120
tones and is completely manual operated machine. It has two hydraulic cylinders,
which are attached with the hydraulic pistons. There is oil tank behind the
machine, which is filled with oil and is used as a fluid for hydraulic piston.

As this is a manually operated machine, so the stroke length, the die and
bending angle all are set manually. The bending angle is set by die and stroke
length is set up by scale, which is situated on the machine. To hold the job firmly
there is also clamp, which holds the job. In this machine the bed is stationary and
the ram moves upward and downward.
5.

Tapping Machine:-

Tapping machine in its simplest kind consists of AC motor in which the spindle is
fitted from which a belt is fitted from motor spindle to chuck spindle on the both
spindle. There are some steps for the belt, by means of that the speed of
machine is controlled.
An important feature of this machine is that the chuck of this machine can be
rotated clockwise when the moving chuck is pressed upward. By using this
machine we can tap from 2 mm to 10 mm.
6.

Leveling Machine:-

Leveling Machine is used only for leveling the surface of sheets, when the
surface of the sheet gets wrecked after performing the operation such as cutting,
punching etc.
In this machine there are rollers, which are fitted, parallel and moving in opposite
direction, when sheet is inserted in machine the rollers press the sheet by which
the sheet gets leveled.
In this machine the thickness of the sheet must be pre entered and the sheet of
roller must also be set.

FS Circular Saw:-

7.

Circular saw, as the name indicates is a saw, which is circular in shape. It has
two types of cutting saw used as per need. Both cutters cannot be fitted on the
machine simultaneously. The blade is ejected and changed when we need.

The cutters used in the machine are of two types:

Diamond edge cutters

Diamond edge cutter is a simple cutter, in which small particles of
diamond are fixed on the edge of the cutter. This type of cutter is used to
cut acrylic or non-metal sheets varying thickness from

0.5 mm to 5 mm.

The most important feature of this machine is that it is used only for cutting
non-metals.

Metal edge cutters

This is a type of cutter in which the blades are made up of metal such
as high carbon steel (HCS), high-speed steel (HSS) and other kinds of
hard metals. This cutter is used to cut the sheets of varying thickness of 5
mm to 50 mm, and it also cuts non-metals.

8.

Radial drilling machine:-

Radial drilling machine in its simplest kind consists of motor, which is attached
with drill chuck, and the chuck is hanging on the shaft, which is attached with drill
chuck, and the chuck is hanging on the shaft, which can move in the angles. This
machine can drill up to 29 mm diameter.

This machine is called Radial drilling machine because it can move 360 degree.
To set it in any position there is a magnetic lock which the shaft and do not allow
it to move.

6.
REPORT
ON
NUMERICAL
CONTROL
CELL

NUMERICAL CONTROL
INTRODUCTION
Numerical control machines are those which are capable of being controlled by a
series of formatted data, called NC part program, and thus produce desired
output without the need of human intervention. The NC part program can be
changed at any time to get different desired outputs.

DEFINITION:
Systems in which action are controlled by direct insertion of numerical data at
same time. The system must automatically interpret at least some portion of
numerical data.
OR
Simply as, control of machine tool by means of numbers.

NEED OF NC
Human being has always tried to reduce his efforts in carrying out various tasks
to make life more and more comfortable. For this machines have been designed
right from sharpened stones to turbines and computers. In this series of efforts,
machine tools like lathe and milling machines etc. were designed and automated.
During World War II, it become clear that fixed type of automation,
offer by existing mechanically automated machines, was insufficient to handle
complex and small batch requirement of aircraft parts. In 1948, John T Parson
demonstrated the concepts of NC to U.S. Air force. The first prototype of NC was
developed and demonstrated at MIT in 1952.
Present competitive word demands that a variety of quality products
be produced at high rate of production at a minimum of cost. NC machine
enables us to meet this challenge by providing a solution, which can be termed
as FLEXIBLE-AUTOMATION.

ADVANTAGES OF NC:
NC machines are today serving a host of industry in a variety of applications.
Some are indicated as below:

High productivity, low WIP (work in progress).

Accuracy and consistency.

Low operator fatigue.

Reduce human error.

In process, measurement not required.

Flexibility in manufacturing.

LIMITATION:
As is with any other system of technology around the world, NC technology also
suffers from limitation, some of which are enumerated as below;

High capital and revenue cost of machines.

Complicated and costly maintenance.

Temperature, humidity and dust controlled environment required.

Highly skilled programmers and machine operator required.

COMPUTER NUMERICAL CONTROL (CNC)

MACHINES
Since 1970, CNC based MCUS have been increasingly replacing the hardware
MCUS and currently only CNC systems are manufactured. The diode was
replaced by transistor in 60s giving rise to more reliable, relatively smaller than
MCU. Also microprocessors replaced large sized hardware circuitry in NC
machines, which made arithmetical and logical operations easier. But in practice
CNC machines have been continued to be mentioned NC in general. CNC
machines certainly offers better and easy machining. The best thing about CNC
is that for some further modifications, we need not require a new hardware but
we can simply upgrade the software and modify it as required.

DIRECT NUMERICAL CONTROL (DNC)

DNC is the first step towards the factory of future. It is a manufacturing system in
which a central computer communicates with the controllers of several machine
tools by a direct connection in real time. Its essential functions in addition to
NC/CNC are:
(1)

To use memory of the central computer for storing part programs

meant for several NC/CNC machines.

(2)

To transfer or download directly the part programs from central

computer to individual MCUS of machines.

(3)

To provide downloading in real time on shop floor.

(4)

To stabling two way communication i.e., in addition to down loading

central computers can also receive messages and other manufacturing
information in real time.

WORKING PROCEDURE OF NC CELL

The NC cell works with a model practice.
1.

Receiving of drawing with programming request.

2.

Updating of master file.

3.

Study of drawing and deciding the process of manufacturing on CNC.

4.

Selection of tools (normal), special tools (if required).

5.

Writing the program and tools lay Out (TLO).

6.

Feeding the program into computer and taking out of tape.

7.

Handling over the blue print of TLO, punched tape, Pre-machining and
post machining details and drawing as and when required to the CNC
MACHINING CELL.

8.

Taking out the list off on the machine getting it approved for the
production.

9.

Updating program if required and if any change in drawing.

However it may be added that one set of documents is sent to production Control
Engineer in advance which help him in getting time study done in advanced and
also he can know about pre and post machining operation details.

WHAT IS PROGRAMMING?
The NC machine tool moves as directed by a program punched on a NC tape.
While machining a part using a NC machine tool, the tool path and other
machining conditions are programmed. This program is called a part program.
The part program tells the NC the tool path and auxiliary motions of the machine
tool. This is written on the process sheet. The program on this process sheet is
punched on a paper tape (or taken on any other suitable medium).

COMPOSITON OF PROGRAM
A program is divided into a main program and a sub-program. Normally the NC
operates according to the main program, but when a command calling a subprogram is encountered in the main program, control is passed to the subprogram and when the command in sub-program says to return to the main
program, control is return to the main program. Total of 95 main and subprograms may be stored in the NC memory.
BLOCK:
Program is composed of several commands, each command is known as block.
WORD:
Block is composed of one or more words. Word has an address followed by
number. Address is the letter, which prescribes the meaning of the numerical
value following the address.
Example:

X -- 100

Address

Numerical value

WORD

INPUT FORMAT:
Input format used by the system -6M is known as the variable block format since
the number of words in a block and the number of characters in a word can be
changed. Input can be in inch or metric system.
For example:
X L +0 5 3
3 digits below the decimal point
5 digits above decimal point
Leading zero suppression
With sign
Absolute or incremental
Address

DECIMAL POINT PROGREAMMING:

FANUC 6T can take the input numerical values with decimal point.

ABSOLUTE AND INCRMENTAL PROGRAMMING:

The distance of tool travel in each axis may be commanded by either by
incremental or absolute command. Using incremental command traveling
distance in the block is directly programmed while in absolute command the end
location of the tool within a block is represented by coordinate values in the work
coordinate system and the coordinate values are also programmed.

SYSTEM CODES
1. PREPARATORY CODES (G CODES)
2. AUXILLARY CODES
(a) M CODES
(b) TOOL CAMMAND (T)
(c) SUB-PROGRAM (L)
(d) TRAVERSE INFORMATION (X, Z)
(e) SPINDLE SPEED (S)
(f) FEED INF. (F)
(g) OTHERS (A, B+, B-, I, K, R, N)
PREPARATORY CODES
*G00 : This code is for positioning is for positioning the tool. For each axis the
point is programmed by the address X, Y, Z or U, V, W. in FANUC-6T only X and
Z-axis are programmed.
G00 X--- Z--any movement in X and (or) Z axis will result in movement with given rate of
feed under address F.
G01 X--- Z--- F---

*G02/03: These codes are for circular interpolation/movement. Starting point is

point where tool presently stayed or it is determined by previous block. End point
of arc or circle is determined by given axis value. The interpolation parameters
determine circle center by using I and K with sign over a range of 0 t0 360
degrees.
G02 / G03 X--- Z--- R--- I--- K--- F---

*G04 : It is used for dwell, when the previous block is completed and the next
block is about to start.
G04 (or P) Time in seconds

*G27 / G28 / G29:

A point fixed on the machining plane is called the

reference point and by reference point return function the tool is positioned at this
point. G27 checks whether the tool is positioned at this point. By G28 the tool is
positioned at the reference point automatically. The end point of this command is
called the intermediate point. By G29, the tool is positioned at the command point
via all intermediate point.
G27/G28/G29 X--- Z---

*G31: This code commands linear interpolation; input of skip signal during
execution of this command interrupts the rest of block and executes the next.

*G33: This is used for thread cutting, giving screw end point (is incremental
command) or screw end point (in absolute command) and the thread lead are
given by z and F respectively.
G33 X--- Z--- F---

*G34: It is used for variable lead thread cutting, commanding an increment or a

decrement for a lead per screw revolution enables variable thread lead cutting to
be performed, K specifies an increment or decrement in the following command
G34 X---Z--- F--- K---

*G40/G41/G42: These are tool nose radius compensation codes. As we

assume machining behind the tuning axis G41 code is used when tool is left to
workpiece and tool be to traverse left to right as tool carriage traverse when
producing L.H. threads. The code G42 is used when tool is left to workpiece and
tool is to traverse right to left as tool carriage traverse when producing R.H.
threads. Using CRC codes the workpiece contour is programmed. The control
calculate the path for tool tip radius center (equidistant* calculation) and the
intersection points of these equidistant paths at acute transition. The benefit of
using CRC codes is that there is no contouring error left. CRC codes may be
used for inside and outside contouring obtuse and acute angles and at acute and
tangential transition. These codes are effective in a block and programmed with
or without path data and with codes G00/G01. The codes G41 and G42 are
deactivated by using G40 code.

*G20/G21:

these are codes for determining the input system that is the data

supplied are in INCHES or METRIC system. For data input in inch code is G70
otherwise it is G71. We are using the metric data input system.

*G90/G91:

these are code for absolute or incremental data input. When

using G90, absolute data input all data refers to the fixed zero point of workpiece.
All X values are recognized as diameter. G91 is used for incremental data input
means that each dimension corresponds to distance to be traversed. Incremental
data are preferred in the subroutine programming. All X values are recognized
as radius.

MISCELLANEOUS FUNCTIONS M
*M00: it makes possible in order to make a measurement or some other
similar purpose. This is unconventional stop and operational in all automatic
modes.

*M02: with use of this code (end of program code) program return to program
start is written in last block.

*M03/M04/M05: these all are spindle control command. M03 is used for
spindle for spindle rotation in clockwise direction. M04 is used for spindle rotation
in counterclockwise direction. M05 is used for spindle rotation stop.

*M17: this code is for end of subroutine is written in last block of the
subroutine.

*M30: this code is used for end of program and is similar to M02.
*M19: this code is used for oriented spindle stop. Orientation of spindle is given
under address S. Spindle always orient in C.C.W direction. This code is used
when drilling or milling is required on periphery of workpiece (this is done with
help of driving attachment).
The command is given as M19 S90 LF. This will result in orientation of spindle by
90 degree.

*M08/M09:

both of these codes are used to control coolant. M08 is used for

to on coolant associated with tool. Whereas M09 is used for to off coolant
associated with tool.

PATH DATA

X AND Z AXIS COMMANDS:

The address for the axis commands X and (or) Z determines the axis which is to
be traversed in accordance with the associated digital value. Both axes can
move simultaneously or individual according to path data is fed. When using G90
(absolute programming code) input data treated as diameter values for x-axis by
the control. Whereas using G91 (incremental programming code) the input
values for X axis refer to the radius.

T WORD TOOL COMMAND

T CODE:
The tool command determines the tool (tool no.) required for a particular
machining section and also relevant tool data (tool offset number). Tool command
is given as below
T mm- -- -Tool command address =T
Tool number 00 to 99 (1 or 2 decades) = mm
Tool offset number (to select: 01 to 16) = n
(To cancel: 00)

TOOL OFFSET
As we know that different tools (i.e. for drilling, turning, boring etc.) are made
under different designation and length. Even tool used for similar operation are
not of same length. So when these tools are fitted to turret (too magazine) their
cutting edge projections are different. So a given program zero is not suitable for
all tools as some were short to workpiece and some dig into the workpiece with
respect to their size. Therefore it is necessary either to set different zeros for
different tools or to give an instruction initially that this much length tool travels
less or more to approach the workpiece without damaging or being short to it.

The distance it has short or more then ZERO set with respect reference tool is
known as tool offset. According to distance tool offset are given number from 01
to 16. it is find out on machine with help of an equipment (accessory) provided by
manufacturer. Tool offset consists of:
X. Tool length offset x-axis
Z. Tool length offset z-axis

CHAMFER AND RADIUS COMMAND

To insert a radius or a chamfer can be inserted automatically by using B code.
The instruction is given as:
N10 X (1). Z (1). B_..
N12 X (2). Z (2).

Means insertion of chamfer.

N12 X (2). Z(2). B+..

N12 X (2). Z(2).. means insertion of radius.
+ writing is optional
This code is given with path data of sharp corner [ X (1), Z (1) ] which is to be
rounded or to be chamfered with B code and followed by the position coordinates [ X (2), Z (2) ] at which tool to reach. The inserted radius/chamfer must
not be bigger than the smaller one of the both distances.

PROGRAM NUMBER:

This control can store program in its memory. The program number is used to
differentiate one program from another.

SEQUENCE NUMBER;
A sequence number can be specified with a number (1-9999) following the
address. It is placed at the head of the block. The order of the number is arbitrary
and need not be consecutive.

OPTIONAL BLOCK SKIP:

With a slash followed by the number (/n)
(n=1 to 9) programmed at the beginning of a block. With the optional block skip
switch n on the machine operators panel set ON, information of the block with /n
of the number corresponding to switch number n are ignored.

PROGRAM ZERO POINT AND COORDINATE SYSTEM:

While programming, a program zero point and a coordinate point must be
determined. Usually, program zero point is placed at an arbitrary position on the
workpiece and the coordinate system is called the work coordinate system.

START POINT AND REFERENCE POINT:

A tool moves from the start point and the program also starts from the start point,
but the NC must know the coordinate values of the start point.
The reference point is the fixed position of the machine tool. A tool may return to
this point rather than the start point to cut down the idle time.

S.NO

GCODE

FUNCTION

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22

G00
G01
G02
G03
G04
G10
G20
G21
G22
G23
G27
G28
G29
G30
G31
G33
G34
G36
G37
G40
G41
G42

23

G50

24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46

G68
G69
G70
G71
G72
G73
G74
G75
G76
G80
G83
G84
G85
G87
G88
G89
G90
G92
G94
G96
G97
G98
G99

POSITIONING
LINEAR INTERPOLATION
CIRCULAR INTERPOLATION (CW)
CIRCULAR INTERPOLATION (CCW)
DWELL
OFFSET VALUE SETTING
INPUT IN INCH
INPUT IN MM.
STORED STROKE LIMIT ON
STORED STROKE LIMIT OFF
REFERENCE POINT RETURN CHECK
RETURN TO REFERENCE POINT
RETURN FROM REFERENCE POINT
RETURN TO 2ND REFERENCE POINT
SKIP CUTTING
THREAD CUTTING
VARIABLE LEAD THREAD CUTTING
AUTOMATIC TOOL COMPENSATION X-AXIS
AUTOMATIC TOOL COMPENSATION Z-AXIS
TOOL NOSE RADIUS COMPENSATION CANCEL
TOOL NOSE RADIUS COMPENSATION LEFT
TOOL NOSE RADIUS COMPENSATION RIGHT
PROGRAMMING OF ABSOLUTE ZERO POINT
MAXIMUM SPINDLE SPEED SETTING
FEED PER MINUTE
FEED PER REVOLUTION
FINISHING CYCLE
STROKE REMOVAL IN TURNING
STROKE REMOVAL IN FACING
PATTERN REPEATING
PEEK DRILLING IN Z-AXIS
GROVING IN X-AXIS
THREAD CUTTING CYCLE A
CANNED CYCLE FOR DRILLING CANCEL
FRONT DRILLING CYCLE
FRONT TAPPING CYCLE
FRONT BORING CYCLE
SIDE DRILLING CYCLE
SIDE TAPPING CYCLE
SIDE BORING CYCLE
CUTTING CYCLE A
THREAD CUTTING CYCLE B
CUTTING CYCLE B
CONSTANT SURFACE SPEED
CONSTANT SURFACE SPEED CANCEL
INITIAL LEVEL RETURN
R POINT LEVEL RETURN

The practical training aims at familiarizing the students with the

working condition in a professional firm as well as to apply their
theoretical knowledge acquired in the institute into practice.
This training was helpful to me in various direct and indirect ways,
like understanding of machines as well as procedure followed in
manufacturing a product. A good insight into inspection and
Quality check of products.
This training has added a whole new dimension to my observation
and practical approach as well as introducing me to Organizational
Hierarchy.

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