REPORT ON

JYOTI CNC AUTOMATION LTD.

G-506&2839, Lodhika, G.I.D.C.
Village, Metoda, Rajkot

SUBMITTED BY
Shikotra Sachin
shikotrasachin@gmail.com

STUDENT OF
SAL INSTITUTE OF TECHNOLOGY AND
ENGINEERING RESERCH
AHEMDABAD (11th to 20th February)
 ACKNOWLEDGEMENT

I am very grateful to respected H.O.D. Mrs.MEGHA PANICKER

and all the staff members of the department of electrical
engineering for their constant encouragement and all those who
helped me directly or indirectly in my endeavour.

I am also very thankful to Mr. Nawaz Ghodi for granting my

industrial training in Jyoti CNC Automation Ltd. and supporting
me throughout my training.

Last but not the least I am very thankful to the company and the
entire department Heads for their constant guidance. I felt very
proud for getting my training in this company.
 Abstract
The industrial training is very essential element, as it plays
important role in an engineer’s life. As we know all that the
industrial training is the right way for understanding the
theoretical concept more effectively. Sometimes it happens that
the simple theory becomes big complication when they are
applied practically.
Hence, it is necessary for engineer to undergo through in-plant
training as it gives practical knowledge about the implemented
theory. As today, the experience of an engineer is considering
more valuable than his education degree. The industrial training
helps a lot.
As we are finally exposed to an industrial environment, the
engineer gains the maximum knowledge regarding the technology
and management system possessed by the company, through
which one can improve its working ability. Clearing all the
doubts, he has a better image of the industrial field, which greatly
influences his future carrier.
I fill very lucky to take an industrial training in ‘Jyoti CNC
Automation Ltd.’ at Rajkot, a Leading CNC Machine
Manufacturing Company.
So, I am glad to present this in plant training report which
contains the contents regarding the concepts of practical training
through which I passed.
 Index

Chapter 1: Introduction
Chapter 2: Foundry shop
2.1 Pattern shop
2.2 Foundry section
Chapter 3: sheet metal shop
3.1 Metal cutting
3.2 Sheet bending
3.3 Welding
3.4 Grinding and Finishing
Chapter 4: Machine-Shop & Electrical Maintance
Chapter 5: Sub-Assembly
Chapter 6: Assembly
Chapter 7: conclusion

 Chapter 1: Introduction

Some times ago we use convectional machining process like

drilling, milling, turning, grinding and etc. All these processes
done by manually and it takes more times or time consuming
processes. In manual operate process causes many defects and
errors. In recent times we use non-convectional machine like
computer numerical controller (CNC). In CNC machines takes
less times to perform and chances of errors is to less, and also get
high finishing products. Jyoti CNC is the first company of
manufacturing of CNC machines in Gujarat. Basically Jyoti CNC
manufacturing 2-axis, 3-axis, 4-axis, 5-axis machines and multi-
axis. The company has wide products like CNC turning, CNC
milling, CNC horizontal machining, CNC vertical machining. In
company there are total six machine unit and two grinding unit.
1. Foundry shop
2. Sheet metal
3. Paint shop
4. Machine shop
5. Sub-Assembly
6 Assembly

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 Chapter 2: Foundry shop
In foundry there are two sections:
1. Pattern section

1. Wooden pattern
2. Aluminum pattern
3. POP pattern
4. Thermocol pattern
But generally wooden pattern are used.
Designing the pattern as per CNC part required.
Design a core component.
Making the core.
Making the pattern.
Painting the core and pattern

In Jyoti CNC casting parts are made in foundry shop. Those

parts can’t be manufactured by machining process it is
manufactured by castings.

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 2. Foundry section

Wooden pattern are made in pattern shop after bring it to foundry

section. In foundry section making mold of pattern. And mold is
generally made of sand. Cope and drag pattern are used and if
parts are hollow then use core. Resin and catalyst is put into crop
and drag through hopper. Catalyst is used for hardness and resin is
used for binder. Hardness of mold is tested in chemical lab. After
making mold cope and drag pattern is removed. And painting
mold to avoid the moisture. To provide strength and hardness
mold is passing through baking process. There are three furnaces.
Two furnace are electric furnace and each capacity is three ton and
another one is holding furnace and it’s capacity is ten ton. Total
capacity is sixteen ton if we made large parts then we use holding
furnace to store molten metal. And it’s temperature is 1450oC.
After making molten metal it is pouring into mold. During pouring
process outer surface of mold is burn because of exhaust gas
removed and can’t create problems. After 2 to 3 days of the
pouring, mold sand will be removed by heavy vibrations. And this
process is called knock out process. And it’s sand is reused and
it’s ratio is 85:15. And other powder particles is collect by dust
collector. In dust collector blower are there and it such powder
particles and store in down way.
After heat treatment process is doing and it takes 8 to 9 hours. And
generally it is stress relieving process. It is not doing for all parts
when it’s require it is use.

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Next step is shot blasting process. In Jyoti CNC two types of shot
blasting process one is room type shot blasting process and other
one is hanger type shot blasting and is fully automatic and it is
used for small parts. In room type, it is used for large parts and it
takes more time than hanger type. Basically in these process job is
hanging on hydraulic base and balls through on jobs and remove
sand particles.
After completing shot blasting parts is going on grinding and
finishing. In these department if any unnecessary material are
there then remove it by grinding process.
And paint the product to provide resistance against the moisture.
There are two labs.
1. Mechanical labs
2. Chemical labs.
In chemical labs check molten metal content if any material is less
than report in foundry shop.
In mechanical labs check impact test on job. And also finishing
are there.

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 Chapter 3: Sheet Metal Shop

In sheet metal shop four operation is perform:

1. Metal cutting
2. Sheet bending
3. Welding
4. Grinding
3.1 metal cutting :-
In metal cutting there are two types :
1. Laser cutting
2. Plasma cutting
In laser cutting machine is using to cut thin sheet and it’s size is 1
mm to 20 mm. spark gap maintain between sheet and tool is 0.5
mm to 0.8 mm. four types of material is used to cut. When the one
operation done in sheet pallet will be change and it’s happens
manually and automatically, so it reduce loading unloading time
and helps to increase production. Generally four types of material
is used to cut:
1. Aluminium
2. Stainless steel
3. Mild steel
4. CRC (cold roll coil)
Al and SS cut upto 8 mm and MS and CRC cut upto 20 mm. O2 is
used in CRC and MS and N2 is used for Al and SS.

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In sheet metal shop there are two laser cutting machine one is fully
automatically we need to give just program. And in other one
pallet change by hydraulically and it’s manually.
3.2 sheet bending
In sheet bending there are seven types of bending machine each
machine is used for different purpose. There are various types of
bending machine like truebend 5130, truebend 5650, VLVD, EHP.
Once parts is bend then check is by used standard design and if
any defects are there then correct it by manually by using hammer.

3.3 Welding
Once laser cutting operation and bending operation is done then
parts are going to welding section. In welding section there are
different types of welding process is used.
1. MIG
2. TIG
3. Spot welding
4. Stud welding
In MIG welding, electrode is consumable. Copper wire electrode
is fed continuously with the help of welding gun.
In TIG welding, electrode is non consumable, and arc is generated
by tungsten.
Spot welding is done by electric current. And pressure is applied
from both side.

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Stud welding, in these process stud is mounted on the sheet and
pressure is applied.
Drilling process, if we need small holes than we use it. Robot
welding is also used. When we need welding at any complicated
part at that time we use robot welding and also used for heavy
parts.

3.4 Grinding and Finishing

Any welding burrs are on parts and it’s removed by grinding
process. Grinding operation is doing for finishing purpose

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 Chapter 4: Machine shop & electrical
maintenance

There are total seven sections, five are machine shop and two are
grinding shop. Each machine shop doing different different
operation.

In machine shop 5, heavy machine are there, also there are hard
hardening machine if we increase any parts hardness then we use
it. Machine shop 3 &4 only heavy machine are there. And
machining only on large parts like bed, column and etc. In turning
machine there are turret for tool changer and other machines ATC
used. There are two types of ATC one is drum type and second is
chain type. With the help of ATC we can reduce tool changing
time and increase production rate.

There are many different range of ATC. Maximum ATC is 160

tool and minimum is 20 tool. During machining process if any
operation are left perform or rework then we done it manually
because it’s loading and unloading time more and program setting
time is more so that left operation done by manually. Many jobs
are small and saddle table is large so using fixtures and clamping
devices fix it on saddle table.

Machine shop 1,2 & 5 are also perform small types of jobs. When
the parts are small and require to change in every so it takes more
time so that we use automatic pallet changer so that reduce
loading and unloading time. There are total six pallet changer
machine. There are many types of machines like 2-axis, 3-axis, 4-
axis, 5-axis machine. If we need machining at any angle at that

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time we use 5-axis machine, in this machine 4th axis is workpiece
rotating table and 5th axis is tool at any angle.
During machining process tool wear and tool breakage chances is
more so that we use coolant system. Water and cutting fluid
mixture are used as coolant. And its change once in a year.

Grinding shop

Grinding operation is used for finishing purpose. Grinding shop 1

&2 Are many types of grinding machines like vertical, horizontal,
angle, hollow grinding.

Machines in grinding shop 1 are like these: ELS, keil bergor,

centre grinding, studded machine, Homart-150.
Machines in grinding shop 2 are HMT, LBG, 400 VG, soloco,
CINCINATTI MILACRON.
Grinding wheel is used abrasive particles. There are two types one
is simple grinding and another is angle grinding.

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Electrical maintenance

There are many motors are used for lubricating, CNC operating,
cooling, axis movements electrical motor are used

There are mainly 2 types motors are used in CNC machines

1) Servomotors – for axis operation, CNC operation
2) Induction motors – for lubrication, cooling and auxiliary
supply

In servo motors are connected with encoders. Encoder deal with

the machines operations as par input.
In CNC machines also construed with scale type encoders which
works on according to machines programs if program details are
done they cut off the supply to the servo motors and whole
machine is stopped.

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 CHAPTER 5: SUB-ASSEMBLY

In electrical sub-assembly assembled the electrical equipment or

devices in penal-box. Different types of connections and different
types of devices together in main panel.

1) FRC CIRCUIT : to maintain and operates the panels and plc

circuit
2) TIMERS: in emergency cut off, the timers provides the time
for savings the data and protects the loss of data.
3) MCBS : to protects the overvoltage or overcurrent problems
4) BUSBAR: to provides differnts types of connection yo the
main bus bars.
5) CONTACTORS: to provides the differnts supply with
machines specification like hydraulic, cooling, lubricating,
etc.
6) FREQUENCY MODULATOR: this device modulated the
frequency and provide with regulated frequency for the
operation.
7) AVS: this device maintain the voltage to the provide by
GEB. This device filter the output and removes unnecessary
signals.

In penal box mainly three types of wire are used for opration of
CNC machines

1) Blue wire: for the power electronics devices supply it oprate

with 24volt dc supply.
2) Red wire : for the single phase connection in panel-box. It
operate with 230-240 volt ac supply
3) Black wire : for the three phase connection in panel-box. It
operate with 400-440 volt ac supply

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 CHAPTER 6: ASSEMBLY

In assembly department, all the parts are assembling there. Casting

base are bring from foundry department and assemble other parts
on it. Alignment of guide ways to fit LM and if any problem to
slide LM on guide ways then check surface of guide ways by
collimator. Headstock and tailstock fitted on base. And apron are
fitted on guide ways and ball screw’s variation is not more than 10
microns. After assemble all parts casing on it. And controller
fitted. Generally two types of controller used one is siemens and
another is fanuc controller. There are two department inside one is
small scale machines and another is heavy duty machine. There
are many series like DX, PX, VMC, HSX, NX and many more.
After assemble all parts of CNC than testing on it.
Squareness test, in this test checking saddle alignment.
Geometry test. In this test checking all dimensions of machines
like saddle, ballscrew, tailstock, headstock.
Laser calibration, in this test only one can be calibrated.
Ball bar test, checking all axis and dimensions checking of x and z
axis.
Then after doing practical test and inspect the job.
In jyoti CNC has no any inventory he makes machine as per
customer requirement.

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Assembly step of VMC:
1. Base assembly
2. Z axis LM headstock and spindle mounting
3. Saddle assembly
4. Squareness testing and Y-axis ball screw mounting
5. Column alignment
6. CRC guarding
7. Lubrication interfacing
8. Electrical interfacing
9. ATC mounting
10. Power and commissioning
10. stroke setting
11. Geometric test
12. SS guarding
13. laser lubrication and ball bar testing

There Are Several Tests Used In Assembly, As Below

• Geometrical Test
• Squareness Test
• Laser Test
• Ball Bar Test
• Practical Test
• Coolant Trial
• Electrical Final Test
• Final Inspection
• Pre dispatched inspection

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 CHAPTER 7: CONCLUSION

At the end of the training I learned the way of conducting each

manufacturing steps in industry and the co-operation between
superiors and workers, i also got brief idea on hierarchy of the
company, and hence it was very exciting experience to be a
part of that company for a while.

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