training report on Jyoti cnc automation ltd.

JYOTI CNC AUTOMATION LTD.
AASHIT DHARIYAPARMAR (11BME010)
KETAN GOJIYA (11BME013)
MAYUR KACHA (11BME020)
BHAUTIK VADHER (12BME163)
Industrial Training at

Company overview
Foundry shop
Sheet metal shop
Paint shop
Machining shop
Assembly shop

Location
 G - 506, Lodhika GIDC, Village Metoda, Rajkot – 360 021,
Gujarat, India.
Company overview
• India + 37 other countries
• 12.7 % share in domestic metal cutting segment in FY 2012
• 24 products in 81 variants
• 5 units : 3 in Rajkot, India and 2 in Strasbourg, France.
• Their Indian operations are ISO 9001:2008 certified
• manufacture 2,500 machines p.a. in India and 150 machines
p.a. in France.
• In November 2007, Company acquired Huron Graffenstaden
S.A.S.

Products
Entry Level Machines
5 types of Turning
Machines
1 Milling Machine
3 types of 3- Axis
Vertical Machining Centers
High End Machines
•4 types of Turning
Machines
•3 types of 3-AxisVertical
Machining centers
•1 Horizontal Machining
Center
•6 types of 5-Axis Vertical
Machining centres

1. LASER cutting machine
Trumpf machine of Germany having Laser cutting technology.
 It is semiautomatic type and only loading and unloading of sheet
is done, all other operations are done by machine itself according
to program given to it.
2. Bending machine
True band 5050
Trumpf CNC press brake machine
3. Robotic welding machines
4. Grinding equipments

 First sheet is cut by Laser cutting CNC machine which cuts
the sheet to the required size.
 Then sheet is bent to the required shape in bending
machine.
 After bending spot welding is done to attach number of
sheets together.
 Before dispatching the sheet to the assembly unit grinding
of sheet is done.

 7 tank pre-treatment process followed by Cathodic Electro Deposited
(CED) primer coating and conveyor zed baking with powder coating
booths.
 4 powder coating booths for different colours.
 satisfy the aesthetic & protective requirements of customers.
Pre-treatment Plant:
 It has capacity of 2 baskets per hour.
 Each basket with 50 sq mtr of the substrate to be treated.
 Basket size is 3000 × 2500 × 2300 mm.
 Maximum weight per basket is 2500 kg.
Powder coating plant
 It consists of 4 powder coating booths, one baking oven and overhead
conveyor.

Different surface coating processes are as follows:
Process Duration(min) Temperature( °C)
Degrease 5-15 65-70
Rinse 1 Ambient
Rinse 1 Ambient
Derust-1 5-15 Ambient
Derust-2 30-45 Ambient
Rinse 1 Ambient
Rinse 1 Ambient
Activation 1 Ambient
Phosphate 5-15 50-55
Rinse 1 Ambient
D.I. Rinse 1 Ambient
Bake 15 160

FOUNDRY
Casting process is used to make the main body parts of CNC
machine like CNC bed, tail stroke, turn-table, saddle, etc.
Basic process for casting is described below :
Sand Mixing
• First of all, It all starts with the
preparation of sand. They use
85% of recycled sand and 15%
of fresh sand.
• it is prepared by mixing of
special kind of additives viz. Resin
and Catalyst at particular
temperature.
• Special OMEGA company
automatic sand mixer is used in
Jyoti for sand preparation.

Mould Making
• A sand mold is formed by packing sand into each half of
the mold. The sand is packed around the pattern, which is a
replica of the external shape of the casting.
• When the pattern is removed, the cavity that will form the
casting remains.
• Any internal features of the casting that cannot be formed by
the pattern are formed by separate cores which are made of
sand prior to the formation of the mold.
• It takes 45 minutes to get completely mixed and set over the
pattern. In a mould box a pattern is kept over which the
prepared sand is filled up.
• Now that box is carried to the roll over machine
manufactured by OMEGA manufacturers.
• This machine turns the mould box upside down and separates
the mould with the pattern.

• After separation, mould is further carried away to the
painting or coating machine and the separated pattern
returns to be used again for the preparation of similar
kinds of moulds.
• A roller is provided which takes mould from roll over to
the coating machine.
• Coating is carried out either by machine or manually. If
the portion to be coated is less, it is okay to go with
the manual coating and if the portion to be coated is
more, one has to go for machine coating.
• This water based graphite coating helps in easy
separation after the molten metal is being poured.
• The next thing comes to the path is drying of the
mould for which it is kept in the oven.
• After drying upper and lower part is being assembled
which is known as cope and drag assesmbly.

Clamping
Once the mold has been made, it must be prepared for the
molten metal to be poured.
• The surface of the mold cavity is first lubricated to facilitate
the removal of the casting.
• Then, the cores are positioned and the mold halves are
closed and securely clamped together.
• It is essential that the mold halves remain securely closed
to prevent the loss of any material.

Melting of Metal
• Induction furnace is used to melt the
metal.
• Pig Iron, steel scrap, runners and
risers are used as a row material for
melting.
• Generally the temperature of molten
metal goes upto 1430̊C.
• Jyoti has two 3 tons capacity
induction melting furnace and one 10
tons capacity induction furnace for
holding the molten metal.
• According to % ratios of carbon,
silicon and magnesium pig iron, steel
scrap is used in melting.
• Special additives are also used to
achieve particular property.
Dust collector is placed above the

Pouring
• The molten metal is maintained at a
set temperature in a furnace.
• After the mold has been clamped, the
molten metal can be ladled from its
holding container in the furnace and
poured into the mold.
• The pouring can be performed manually
or by an automated machine.
• Enough molten metal must be poured
to fill the entire cavity and all channels
in the mold.
• The filling time is very short in order
to prevent early solidification of any one
part of the metal.
• Inoculate is added at the time of
pouring.

Cooling
• The molten metal that is poured into the mold will begin to
cool and solidify once it enters the cavity.
• When the entire cavity is filled and the molten metal
solidifies, the final shape of the casting is formed.
• It is allowed 24-48 hours of cooling.
• The mold can not be opened until the cooling time has
elapsed. The desired cooling time can be estimated based
upon the wall thickness of the casting and the temperature
of the metal.
• Most of the possible defects that can occur are a result of
the solidification process. If some of the molten metal cools
too quickly, the part may exhibit shrinkage, cracks, or
incomplete sections.

Removal of casting
• After the predetermined solidification
time has passed, the sand mold can
simply be broken, and the casting
removed.
• This step, sometimes called shakeout,
is typically performed by a vibrating
machine that shakes the sand and
casting out of the flask.
• Then runner and risers are removed
by hammering.
• In Jyoti, there is a dust collector
above knock off machine.

Fettling
• After removal of casting it goes into shoot blasting
chamber, in which steel balls of very small diameter
is imparted on the casting.
• Shot blasting removes the any remaining sand,
especially from internal surfaces, and reduce
the surface roughness.
• In Jyoti, there are 2 shoot blasting furnace, one is
automatic and one is manual.

Grinding and Trimming
• During cooling, the material from the channels in
the mold solidifies attached to the part.
• This excess material must be trimmed from the
casting either manually via cutting or sawing, or
using a grinding and trimming process.
• The time required to trim the excess material can
be estimated from the size of the casting's
envelope. A larger casting will require a longer
grinding and trimming time.
• The scrap material that results from this trimming is
either discarded or reused in the sand casting
process. However, the scrap material may need to
be reconditioned to the proper chemical composition
before it can be combined with non-recycled metal
and reused.

Heat treatment process
• Heat treatment process is used to
increase hardness of casting or
for stress relieving.
• In this process, casting is heated
at particular temperature for
particular time and then it is
cooled down.
• Temperature, time and cooling
rate decide the properties of
casting.

Pattern making
• Patterns are made up of many different materials as per
the requirements.
• In general wooden pattern is being used over here which
is cheap in coast as well as long lasting.
• For the complicated parts aluminium metal is being used.
• Thermocole is preferred if the pattern is going to be used
for only once.

Inspection Lab
 Inspection tests
• Strength of sand mold
• Tensile strength of casting
• Metallurgy of casting
• Chemical compositions of scrap.
 Different tools for inspection
• Ultimate tensile strength machine
• Polishing machine
• Impact testing machine
• spectrometer

ASSEMBLY LINES & TYPE OF LAYOUT
Assembly unit is mainly divided into three lines:
1)HMC line
2)TMC line
3)VMC line including ATMs
Fixed position layout is used to assemble
different CNCs. In this, after fixation of leveling
points, all the other mountings are done at
same position.
The sub-assembly required in the machinery is
carried out in different department.

Assembly of DX-150 AND DX-250
Head-stock :
It supports chuck and its
mechanism. It has
system which clamps
and de-clamps of work-piece.

Tail-stock:
It contains the supporting
supporting elements i.e.
i.e. quill
Turret assembly: It is the
part of machine which has
tools to work on job.
Generally it has ten to twelve
tools.

Ball-screw: Ball-screw has bolt-nut which converts its
rotating motion to linear motion.

Electrical panel : It contains lots of electrical and
electronic devices which leads it to automatic.
automatic.

Motors :
There are four different motors.
1) One for revolving of chuck (induction motor)
2) another two for ball-screw (servo motor) (motion in X
(motion in X and Z axis)
3)One motor for revolving of turret. (servo motor)
motor)

Pumps : There are two pumps in DX-250 and DX-150. One is for
hydraulic oil transmission and the other is for coolant circulation.
coolant circulation.
Outer sheet metal body : It provide safety to user and gives good
looks.
Coolant circulation system : This system circulates coolant which
aims to cool down the working area and also directs th removal of

Hydraulic pressurized oil system : There is oil sump which
contain pressurized oil and one pump for circulation. One
circulation. One most important component for hydraulic
hydraulic system is solenoid valve. There are two valves
two valves require for it. Each solenoid valve is electrically
is electrically controlled for oil circulation.

Lubrication system :
This system is require to reduce friction and increase efficiency.
increase efficiency.
Lubrication is provided in two X and Z axis ball-screw and L.M.
screw and L.M. through metering cartridge.
Lubrication is also provided in tailstock sleeve.

STEPS OF ASSEMBLY
 Base assembly
set the bad on level pad
3 point leveling system by spirit level
 Attach the L.M. guide ways on base with nut and bolts

Set the guide ways linearly using AUTO-COLLIMETER
check the parallelism of it by means of straight
edge(linear dial)
This is very important test as saddle is mounted
on it. So, it must be perfect.
Z-axis ball screw assembly mounting
X-axis saddle and ball screw mounting
After that saddle is mounted on CNC bed with
the help of hoists available in assembly unit.
Tail stock assembly
L.M. guide is fixed and same process is carried
out as saddle ball screw assembly

Head stock assembly
fixed by hoist and alignment is done by dial gauge
gauge
squareness test is carried out for x-axis bolt-screw.

hydraulic oil system is fitted with its all mountings like oil
sump with nitrogen gas accumulator, solenoid valves, pipe.

 THERE ARE SEVERAL TESTS USED IN ASSEMBLY,
AS DESCRIBED BELOW.
 GEOMETRICAL TEST
 SQUARENESS TEST
 LASER TEST
 BALL BAR TEST
 PRACTICAL TEST
 COOLANT TRIAL
 ELECTRICAL FINAL TEST
 FINAL INSPECTION
 PRE DISPATCHED INSPECTION

Shop and sub-section
 Machining shop is located at Unit-1 of company
premises.
 Total 7 Sub Sections :
Machining shop-1
Machining shop-2
Machining shop-3
Grinding shop-1
Grinding shop-2
Raw material inlet & dispatch area
A quality control and measurement laboratory.

PROCESSES
 The components made from casting process, are machined
to give them accurate size and shapes.
Following operations are carried out on raw parts to give
them desired finish and accuracy:
Turning
Facing
Milling
Grinding
Drilling
Boring etc.

Parts being machined
 Following parts are machined at the machining unit:
• Bearing covers
• Tool sockets
• Jigs& fixture parts
• Main spindle shaft
• Work table
• Bed of CNC machines
 Some of the parts are imported from the outside vendors

Machining shops features
Main attractions of machine shops at Jyoti:
 5 phase CNC machining centre
 Head positioning changer and multi tool ATC.
 One of the best Horizontal Machining center having
APC with 60 tools ATC.
 Programming Controller by ‘Siemens pt. Ltd.’ or ‘Fanuc’
 Higher quality & productivity machines

Unique Features
 Due to uneven mass its
difficult to locate m/c on
3 points
 4 point location is tedious
and requires patience
 Easy to locate on 3 point
moreover leads to no
stress or twisting

Unique Features
 TRIM :
 Use of high torque integral
servo motor
 Replacements of complex
mechanical components like
worm and worm wheel
 Torque transmission is direct
to motor hence perfect

Machine companies and models
 Although a significant amount of mother machinery at machining unit is
from foreign companies, many of the machines are manufactured by Jyoti
itself.
 Some other manufacturing companies of mother machines are:
 Huron pvt. Ltd.
 Nicola correa
 DMC ltd.
 SNK machines
 Here are some model no. of machines used at machining shop:
• VMC -640
• DX-250
• ATM-160
• VMC-430
• AM-430

Horizontal turning CNC m/c centers

Grinding shops
 All the critical parts are finished using various CNC grinding machines.
 It gives finest accuracy finishes to the machine parts that is in perfect tune with
mission of the company.
 Grinding Shops consists of:
Cylindrical grinding CNC m/c
Rotary horizontal-spindle surface grinding
Rotory vertical-spindle surface grinding CNC m/c.

References
1. http://www.jyoti.co.in/company_profile.aspx?pg=abt&sub=comp
2. http://www.jyoti.co.in/category.aspx
3. http://www.jyoti.co.in/foundry.aspx?pg=str&sub=fdry
4. http://www.jyoti.co.in/mfg_excellence.aspx?pg=str&sub=mfg
5. http://www.jyoti.co.in/sheet_metal_shop.aspx?pg=str&sub=sms
6. http://www.jyoti.co.in/paint_shop.aspx?pg=str&sub=paint
7. http://www.jyoti.co.in/research_dev.aspx?pg=str&sub=rd
8. http://www.jyoti.co.in/training.aspx?pg=str&sub=training
9. http://www.jyoti.co.in/qlty_assurance.aspx?pg=str&sub=qlty

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