1

REPORT OF INPLANT TRAINING

AT

CRAFTSMAN AUTOMATION – UNIT -3

[10.06.2015 – 16.06.2015]

SUBMITTED BY

KAVI PRASATH.S

OF

KPR INSTITUTE OF ENGINEERING &TECHNOLOGY

COIMBATORE

2

ACKNOWLEDGEMENT

I hereby declare that the In-Plant Training at Craftsman

Automation would not have been possible without the guidance and help

received from the authorities concerned.I sincerely express my gratitude

to all those who have spared their time and contributed their expertise

for In-Plant Training.

The industrial exposure that I have experienced as a student in

Craftsman Automation , Unit-3 has helped me a lot in improving my

theoretical knowledge and also to understand the working culture &

practical exposure of a large industry . I am sincerely grateful to the

management of Craftsman Automation for giving me an oppurtunity to

undergo one week Inplant Training in your organization . I would like to

express my deepest gratitude towards R.Mohanakrishnan ( Senior G.M –

Admn. & HRD ) for encouraging me in this training . Im also very

thankful to Mr.Sampath for making timely guidance and encouraging

me at various stages during my training . I am also thankful to all the

concerned Senior Engineers for their positive support , coordination &

guidance . And I also thank all the people of the department ,for their

kind co-operation and support.

3

CONTENTS

INTRODUCTION - 4

FIXTURE DESIGN - 5

SPM ASSEMBLY - 7

FOUNDRY - 8

GEAR - 11

BEARING CAP - 13

WIND MILL - 15

CONCLUSION - 16

4

INTRODUCTION

Craftsman Automation started the journey in the year 1986 as a

small scale industry in the southern Indian city of Coimbatore, has grown

to become a leader in precision manufacturing in diverse fields. The years

of experience that Craftsman have in the field of Engineering has

strengthen the commitment, towards the determined customer focus,

culture of quality, and unique emphasis on social responsibility empowers

Team Craftsman Automation.

The close collaboration with international automobile manufacturing

partners for precision engine components including engine blocks, heads

and transmission housings through the years has earned the reputation of

being a reliable world-class automobile manufacturing partner. This

coveted position was achieved through the strategic establishment of

manufacturing units in the automotive hubs in India. Craftsman

Automation has strategically located manufacturing units in automotive

hubs in India to enable ‘just-in-time’ delivery schedules.

Craftsman Automation houses state-of-the-art manufacturing

facilities that include CNC machining lines with comprehensive

production capacity. Craftsman Automation produces heavy parts for the

commercial vehicle, locomotive, wind energy, and healthcare industries.

And its large machining centres , coupled with the fabrication shop, are

capable of producing heavy and large engineering parts machined to

perfection.

5

FIXTURE DESIGN

FIXTURE – Plays a key role in the manufacturing process and it is

one of the work holding device and in craftsman various kinds of

fixtures are manufactured. The designing of fixture is based upon

various theorems such as

3-2-1.

Six degrees of freedom.

Diamond pin theory.

TYPES OF FIXTURES:

Mechanical Fixtures.

Hydraulic Fixtures.

SOME OF FACTORS TO BE CONSIDERED IN FIXTURE:

Loading & Unloading.

Machine swing & travel.

Chip removal.

6

FIXTURE MANAGEMENT SYSTEM

DISCUSSION

DATA SHEET

3D DESIGN

(AUTO CAD)

APPROVAL

2D DRAWING

FIXTURE MANUFACTU

RING

FIXTURE TRAIL

PROVEOUT REPORT

PERIODIC INSPECTION

REWORK

7

SPM ASSEMBLEY

SPM – Special Purpose Machine

The main purpose of Special Purpose Machine is to perform

different operations on a single component using different tools

in a single machine.

Main advantage of special purpose machine is

Reduces machining time.

Increases production rate.

Zero maintanence.

Reduction in cost.

Around 25 Special Purpose Machines are manufactured and also

being used in Craftsman Automation for various machining and

other purpose. And in Craftsman Automation upto 12 axis

movement machines are manufactured.

Some of the SPM are:

Lancing machine.

Honing machine.

Gun drilling.

8

FOUNDRY

Craftsman Automation through its aluminium foundry division

caters to the precision casting needs of the automotive, printing,

textile, marine, engineering, locomotive, power and other

industries. Castings are produced through green sand moulding,

no-bake process, low and high pressure die casting, gravity die

casting.

Some of the commonly used materials:

AlSi7Mg A356 (Blue)

AlSi10Mg (Yellow)

AlSi12(Green)

AlSi8Cu3(White)

AlZn10Si8Mg(Brown)

AlSiCu1(Violet)

AlSi6Cu4(319)

Furnace used in foundry unit is oil fired and the type of fuel is

diesel and has a capacity of 250 Kg.

9

STEPS INVOLVED IN FOUNDRY UNIT:

Melting.

Grain Refinement.

Degassing.

Pouring.

Vacuum testing.

TYPES OF CORE USED:

Ammine core.

Cold set core.

Furon core.

SAND PREPARATION:

Green sand - 200Kg

Bentonite - 2.5 Kg/20mix

Water - 2.5 tons (10 secs )

Silica sand.

10

Monthly CAPACITY OF 1500 TONS:

Casting weight ranges from (0.08 – 500Kg)

Highest quality raw materials

Patterns & dies are manufactured both in-house & through key

suppliers.

ALLOYS – Al Si7 Mg 0.3 ST 6, Al Si10 Mg, Al Si12, Al Zn10

Mg, ASTM AA 380, A 356, B 319,ADC 12

A sand testing laboratory ensures the right parameters for

moulding sand to provide consistent quality of moulds .

Parameters measured in testing laboratory:

Moisture - (4-6%)

Strength(Kg/cm2) - (1400-2000/150g)

Permeability - (120-200/150g)

Compactability - (45-50%/100g)

Mould Hardness - (60-90/500kg)

11

GEAR SHOP

Craftsman Automation manufactures and supplies high

quality gears of every shape and size to suit the needs of the

engineering industry customers .Various types of gears are

manufactured in order to meet the requirements.

PROCESS:

SELECTION OF RAW

MATERIAL

TURNING OPERATION

S

HOBBING OPERATION

S

PRIMARY INSPECTION

HEAT TREATMENT

BORE AS PER

REQUIRED DIA

SURFACE GRINDING

OD GRINDING

FINAL INSPECTION

12

TYPES OF GEARS PRODUCED:

Transmission gear parts

Steel mill gear box internals

Multi crowned gear coupling

Worm & worm wheel pairs for printing

machine inker assembly

Gear planet

Gear drive

Compressor gears

Timing gears for earth moving equipments

Pinion for metro rail project

SOME OF THE TYPES OF GEAR BOXES:

Triple output gear box

Three pump gear box

Rotary head gear box

Transfer gear box

Main hoist gear box

13

BEARING DIVISION

Craftsman automation is the single source of bearing cups

for Brakes India. Volvo is the customer of Brakes India

and around 5000 pieces of bearing cups are manufactured

in Craftsman Automation.

PROCESSING OF BEARING CUPS:

BEARING CUPS

BEARING CUP

POLISHING

BORE ROUGHING

DRILLINGBORE

SURFACING

DE-BURRING

14

Material used in Craftsman Automation for the

production of bearing cups is Spheroidal grey cast iron.

INSPECTION:

Before inspection a green mark is checked

Deburring cutter mark

Dent mark

Blow hole

To ensure rust casting & machining surfaces

Free from burr in crank bore

6 blow hole in crank bore

15

WIND MILL

Wind mill one of the source of renewable energy sources,

the major components of a windmill are produced in

Craftsman Automation. Craftsman Automation produces

heavy parts for the commercial vehicle, locomotive, wind

energy, and healthcare industries.

BLASTING &PAINTING

VISUAL INSPECTION

VISUAL FETLLING

CLEANING MASKING

GRIT BLASTING

AIR CLEANING

DROSS FETLING

GRIT BLASTING

BASE COAT

PAINTING

MASKING

INTER COAT

PAINTING

TOP COAT PAINTING

DE-MASKING

COATING INSPECTION

PACKING

16

CONCLUSION

This training program is an excellent opportunity for me

to gain an experience about an industry and the processes

followed in industries. I am very much thankful to the

Craftsman Automation for providing me an opportunity to

gain knowledge about the industrial experience.

Craftsman Automation uses advanced technique machines

which keeps them in their position in this competitive

world. From this training I also learnt the way of work in

an organization ,the importance of being punctual, the

importance of quality assurance and control .Once again I

thank Craftsman automation for encouraging m in this

training program.