Submitted byKRISHNARADDI R GANGAL

Internship Objectives and Report StructureThis is a report of my internship program at

ACE DESIGNERS. The main objective of this internship was to

study the company, the manner in which tasks are distributed, work is organized and performed.

My primary focus was on the Component Manufacturing Division, to learn more about the ways in which manufacturing is done, components manufactured and other aspects are relevant to the operations of the CMD.

The other area of study was the machine Assembly, particularly the Flow line assembly.

Since my study was based on observation and interaction with people, this study report contains details of what I learned during the time I spent in the company.

About ACE DESIGNERSAce Designers had its humble beginnings in 1979 as a machine tool designing Service Company, under the leadership of three engineers, Mr. Ashok V Sathe, Mr. Shrinivas G. Shirgurkar, and Mr. Benedict Machado.

With 35 years of machine tool experience, design boards and a few thousand rupees in hand, the three started Ace in a garage as a machine tool designing service company, at first, it was a partnership firm. It became a joint stock company in the year 1989, and it became a deemed public company in the year 1996.

At present, Ace Designers Ltd. is the leader in sales of “CNC Turning Machines” (accounting for about 40% of the Indian market) and among the top 3 machine tools manufacturing companies in India. Ace has focused in providing technical solutions, including development of special work-holding devices, test runs to conduct process capability studies and even automation. 70% of Ace products are sold to the automotive industry and the balance to industries like Bearings and general engineering industry.

The company is ISO 9001 certified.

Product Range The company’s Product Range has developed over the year and it is a ‘Continuous Improvement Process’ to constantly upgrade the machines.

The range includes the following machines:

1. CNC Lathes and Chuckers Jobber XL LT-2XL / LT-2XL 500 / Super Jobber LT-20C / Classic / LT-20XL Junior Jobber Twin Spindle CNC Chucker

Centre Lathe (New) Auto Lathe CNC VTL-30 / VTL-402. Special Purpose Machines Friction Welder Turning And Burnishing Machine Piston Ring Turning Machine Other Valve Machines

Customers of ACEThe customers of Ace Designers Ltd. are

present in India, the European Union countries, USA, Canada, Brazil, Egypt, Germany, Spain. In India, Ace meets customized CNC machine requirements of more than 200 companies, mainly located in South India out of these about 70% of companies are in Karnataka. Another 20% of companies are in Andhra Pradesh ( in Hyderabad). Remaining 10% are spread in Tamil Nadu, Maharashtra, New Delhi, etc.

The Various Divisions of the Company

To fulfill the requirement of the customers, the company has distributed itself into 6 major divisions. Each division is allotted particular task that it must carry out, which is essential for the successful operation of the company.

The major divisions of the company are indicated in the block representation below.

Product Cycle at Ace Designers

ACE DESIGNERS

TECHNICAL SERVICE GROUP

COMPONENT MANUFACTU

RING DIV

SHEET METAL

DIVISION PAINTING DIVISION

ASSEMBLY DIVISION

COMPONENT MANUFACTU

RING DIV

Individual Function of DivisionsTechnical Service Group It is the Marketing division’s responsibility is to

interact with the customer. They understand the customer’s needs and requests, and accordingly advise him with the most suitable option. The customer’s order is placed and details are forwarded to the Design division

Design Division The Design division is given the task of visualizing

and developing a practical concept or idea and give shape to it, just as the customer would have wanted it to be. The Division also believes in continuously improving their designs to by finding better alternatives and low cost options.

Component Manufacturing Division (CMD)The CMD is the manufacturing hub of the

company. The CMD is in charge of producing almost all

the critical components of a turning machine. Various kinds of machining processes are performed here. The division out sources some manufacturing processes.

CMD is equipped with adequate number of machines and manpower. The division believes in continuous improvement in its processes and techniques.

Organizational Chart for CMD

Operations PerformedTurningMillingDrillingGrindingShapingBroachingSlotting Components ManufacturedThe machine components are categorized into the

following: Purchased components

Manufactured components: a) In house manufactured components b) Vendor supplied components

All components manufactured in CMD are classified into 4-categories as .

AA Class: Bed, Saddle, Top Table, Turret Disc, Tail Stock, Housing, Spindle, Tail Stock Guide, Tail Stock Slide etc.

A Class: Axis Bearing Housing, Spindle Spares, Spindle Covers, Tool Holders, Axis Spacer and Nut, Spindle Pulley.

B Class: Keeper Plates, Height Plates, Tail Stock Assembly Elements, Steady Rest Elements, Parts Catcher Elements, Draw Bars.

C Class: Residual components fall under this category.

MACHINES IN THE CMD

Machining Centers MAZAK MAZATECH FH-6800

Type: Horizontal Machining Centre Specification: X-axis 1050 mm Y-axis 800 mm Z – Axis 880 mm

Index Table rotation up to 3600 Spindle Speed: 7000 rpm maxTable size: 630 mm x 630 mm

Components machined:

Top table Tail stock body ATC bracket Saddle Head stock Housing Carriage Turret disk (Only for VTL lathes)

MAZAK Nexus 600 This machine is newly acquired by the CMD, to assist in the machining of

smaller components, with required very high accuracy and precision It is almost similar to the MAZAK MazaTech FH-600 machine

Type: Vertical Machining Centre Specifications:

Machine capacity:-

No. of Tools: 24 in Drum Type Tool magazine with automatic tool changer

Components machined: Plate Cover Pulley Bearing housings Housing X-nut housing Z-BSB housing

CNC Grinding Machines Hardinge Kellenberger KEL-VARIA UR175/1500 Benefits over conventional grinding machine: All Spindles are finish ground on this machine. Spindle Run outs & face outs is now maintained within 2µ. (Earlier up to

5µ) Roundness of 0.3 to 0.4µ achieved in spindle Taper Accuracy achieved within 5”

Spindle ManufacturingThe spindle is regarded as the heart of the

Machine Tool. It is the most critical component and it requires very high accuracy, or else the machine tool may not meet the standards. In a Turning machine, the spindle is used to provide a link between the driving motor and the work holding component (i.e. Chuck). It is supported by two bearings and coupled to the motor by a V-Belt pulley. At all these places a sufficient taper angle is provided.

Types of Spindles Manufactured at ACE CMD Type of Spindle Machine Tool Model A2-5 Jobber XL/LT-16 XL A2-6 Centre Lathe (New) A2-8 VTL/LT 25/LT 30/ Classic A2-11 VTL 40/LT-25/ LT-30 The spindles are made of Low Alloy Steel

(20MnCr5) (15Ni2Cr1Mo15) (20MnCr1) (15Ni2Cr1Mo12)

A2-5 Spindle Manufacturing ProcedureSTEP 1: ForgingSTEP 2: Proof MachiningSTEP 3: Turning Before CarburizingSTEP 4: Boring Before CarburizingSTEP 5: Case CarburizingSTEP 7: After Carburizing Turning and

GroovingSTEP 8: Hardening, Tempering & Sand

BlastingSTEP 9: Hard Turning & ThreadingSTEP 10: Hard BoringSTEP 11: Keyway MillingSTEP 12: StabilizingSTEP 13: Finish Grinding

Turning Before CarburisingAfter Proof Machining

After Carburising Drilling & Tapping

After Carburising

After Finish Grinding Finished Spindles to stores

Assembly DivisionThe Assembly located in Shop-2 is the locations

where value addition upon the components is done, as they take the form of the final machine.

ACE has introduced the concept of Flow line In the year 2002 . This was an inevitable step taken to live up to the ever growing demand of machines by the customers. Previously while following the conventional method It was noticed that such method of assembly would take up to 22 hours per machine. Moreover, there was immense wastage of space as all the elements would be placed collectively around the machine. Manpower was not effectively utilized and scheduling work became even more a difficult task.

models currently assembled on flow line are CUB, COLT, JOBBER XL, JOBBBER Junior,

JOBBER LM, and Super JOBBER. In the station wise activitys are divided in to eight stations .Example. 1st Station Activity: On the first station, a bed is loaded everyday with spindle headstock, saddle and top plate already assembled on it. The operations being done on the first station are as follows:

Start.5SRe tapping of all the holes.Mounting bracket and baffle.Mounting the angle.etc To the 8th station . at last station to the end

Documentation of test details, main elements and pre dispatch inspection .

Case study

Problem selectionIn any industrial concern, the problem of cost

reduction assumes top priority. By the improvement of process the values of capability indices can be increased. The component spacer which is used in assembly of Z-axis and X-axis ball screw is a small one. It is used to fill the space between the ball screw and the bearing on which it is mounted. It is produced on the machine called JOBBER XL.

Introduction to the componentComponent : spacerMaterial: C45Dimensions: in mmInner diameter: 25 mm with tolerance 0. 025 to 0.

050mmOuter diameter 1:35mmLength: 29mm

Calculation performedThe components are divided into 10 sub-groups

and 10 components in each sub-group.The radius of each component are taken in X and

Y directions for about 100 components at the top and bottom surface.

The mean radius of the component is calculated..Based on the values obtained the process is

concluded as stable or not.If the process is not stable suggestions for the

betterment of the process are given.

Inner radius of component spacer

11 to 20

X- topX-bottomY-bottomy-top

53575655

59595958

60555159

62565960

48475051

53535454

42474445

68676666

55575960

60626160

21 to 30

X- topX-bottomY-bottomy-top

66606266

60555562

70616070

60555661

61555659

57585962

50484754

52505252

66565858

46434242

31 to 40

X- topX-bottomY-bottomy-top

60525253

63555362

44484745

64646163

45343445

43343344

61596164

55505054

60525159

35333136

41 to 50

X- topX-bottomY-bottomy-top

43393745

40353439

39333338

59505056

64585865

63656566

54474753

51404052

44454547

43424247

1 to 10 X- topX-bottomY-bottomy-top

50424348

66555565

64586561

45414246

46514846

55575752

61494958

55505157

47424249

65626167

51 to 60 X- topX-bottomY-bottomy-top

47444049

44375645

68666869

58596062

45444647

57555360

60565557

61485658

58514958

56535554

61 to 70 X- topX-bottomY-bottomy-top

54404456

65585560

37343741

57495159

45444445

45454650

52454645

59545452

57576059

56535160

71 to 80 X- topX-bottomY-bottomy-top

62596360

63636465

70686570

58555962

64615864

62606062

54525354

68586067

51484650

61606162

81 to 90 X- topX-bottomY-bottomy-top

54646062

60565865

63626467

70707070

52504949

62636666

51446565

60596060

68645757

55565454

91 to 100 X- topX-bottomY-bottomy-top

62635860

50505151

48393741

62615961

53505047

46394243

52434458

61626161

64636361

63565460

Overall Reaction

This Internship at Ace Designers proved to be a highly successful one. I was greatly benefited from the practical knowledge that I gained from the company. It proved as an excellent opportunity for me to learn the manners and means that are essential for the successful running of an Industry.