ANNEXES

PREFACE

My industrial training report represents the outcomes of 22 weeks training period that I had
spent at the Industrial Development Board of Ceylon as an Engineering trainee from 01th of
April 2010 to 17thof August 2010.

Report contains three chapters. Chapter one is dedicated to the Industrial Development Board
current status strengths and weaknesses.

Chapter two describes the training experience that I have gathered. My Training experience
focuses on machinery, manufacturing processes and projects that I have taken part in.

And the final chapter is the “conclusion”. This consists of summary of my overall training
and comments on training establishment and my suggestions to improve the training given by
Industrial Development Board.

At the end of the report 10 annexes are attached and they contain the project reports and
drawings done by my self

Piyanka W.P.G.T (070367R)

Department of Mechanical Engineering
Faculty of Engineering
University of Moratuwa

ACKNOWLEGEMENT

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 ANNEXES

I think I must grateful to the training division specially Mr.Gunawardhana and

Mr.Wijewikrama for tackle my training place problem, Department of Mechanical
Engineering and NITA for taking initiative to deliver us such a successful training period.
Also I thanks to the Industrial Development Board of Ceylon for taking me as an in plant
trainee.

I also want to express my heartiest gratitude to the Engineering Department of IDB Chief
Engineer Mr.Rathnamala, training coordinator Mr.Razool, Workshop Engineer Mr.Premasiri
and Technical Assistant Mr.Dissanayake, and all the machine operators and workers those
who spent their precious time for us.

I also wish to express my sincere gratitude to Mr.Ariyadasa Jayawardhana the Personal

Director for his kindly support and offering a payment for us to complete training at
Industrial Development Board successfully.

A word of big thanks must also go to my fellow colleague who trained with me at Industrial
Development Board for sharing his knowledge and time with my self.

Thank again you all for your generous support toward to myself.

More than all, it is the effort of my family, who made me what I am today. The blessing that
they gave me helped more than in one way to overcome the challenges that I faced during my
entire life. So a very special tribute must also go to my family, since I owe them for
everything they had done.

Piyanka W.P.G.T (070367R)

Department of Mechanical Engineering
Faculty of Engineering
University of Moratuwa

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ANNEXES

Table of Contents
PREFACE.................................................................................................................i
ACKNOWLEGEMENT...............................................................................................ii
List of Figure..........................................................................................................v
CHAPTER 1: INTRODUCTION TO TRAINING ESTABLISHMENT.................................1
1.0.1. Mission of the IDB...................................................................................1
1.0.2. Structure of the Industrial Development Board..................................2
1.0.3. Act of Incorporation Set out the Object of the IDB As Follows:............................3
1.1. FUNCTIONAL DIVISION...............................................................................3
1.2. RELATIONSHIP BETWEEN SME SEECTOR.....................................................4
1.3. IDB SERVICES.............................................................................................5
1.3.1. Planning................................................................................................6
1.3.2. Regional Development..............................................................................6
1.3.3. Entrepreneurship Development....................................................................7
1.3.4. Technical Services....................................................................................7
1.3.5. Engineering Services.................................................................................8
1.3.6. Marketing assistance...............................................................................10
CHAPTER 2: TRANING EXPERIENCE......................................................................11
2.1. MAIN LATHE COMPONENTS AND THEIR IMPORTANCE...................................11
2.1.1. The Lathe Bed Slide Way..............................................................................11
Figure 2.01........................................................................................................12
2.1.2. The Carriage or Saddle.................................................................................12
2.1.3. Headstock.................................................................................................12
2.1.4. The Cross Slide..........................................................................................12
2.1.5. The Compound Slide...................................................................................13
2.1.6. The Tool Post............................................................................................13
2.1.7. The Tailstock.............................................................................................13
2.1.8. Steadies....................................................................................................14
2.1.9. Work Holding Methods................................................................................14
2.1.10. Tool Holding Method.................................................................................15
2.1.11. Production of Chips...................................................................................17
2.2. BASIC LATHE MACHINE PROCESSES..............................................................19
2.2.1. Turning....................................................................................................19
2.2.3. Facing......................................................................................................20
2.2.3. Parting.....................................................................................................20

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ANNEXES

2.2.4. Drilling....................................................................................................21
2.2.5. Boring.....................................................................................................21
2.2.6. Single Point Thread Turning..........................................................................22
2.2.7. Work Carried Out Using the Lathe Machine.......................................................22
2.3. BASIC SHAPING MACHINE PROCESSES..........................................................23
2.3.1. Work Holding............................................................................................23
2.3.2. Tools.......................................................................................................24
2.3.3. Types of Shaping Machine............................................................................24
2.3.4. Operation of the Shaping Machine...................................................................24
2.3.5. Safety on the Shaping Machine.......................................................................25
2.3.6. Work Carried Out Using Shaping Machines.......................................................26
2.4. BASIC MILLING MACHINE COMPONENTS AND PROCESSES.............................27
2.4.1. Rotating the Head.......................................................................................28
2.4.2. Squaring the Vise........................................................................................28
2.4.3. Types of Milling Cutters...............................................................................28
2.4.4. Removing and Installing Milling Cutters...........................................................29
2.4.5. Climb and Conventional Milling.....................................................................29
2.4.6. Calculating Speed and Feed...........................................................................30
2.4.7. Setting Spindle Speed..................................................................................30
2.4.8. Using the Edge Finder..................................................................................30
2.4.9. Using the Micrometer Dials...........................................................................31
2.4.10. Face Milling............................................................................................31
2.4.11. Milling Slots............................................................................................31
2.4.12. Advanced Work Holding.............................................................................32
2.5. GRINDING MACHINES...................................................................................32
2.5.1. Bench Grinder............................................................................................32
2.5.2. Surface Grinder..........................................................................................33
2.5.3. Work Carried Out Using Grinding Machine.......................................................33
2.6. OXY-ACETYLENE CUTTING AND ELECTRIC ARC WELDING.............................33
2.6.1. Oxy-Acetylene Cutting.................................................................................34
2.6.2. Electric Arc Welding...................................................................................35
2.6.3. Work Carried Out At the Welding Section.........................................................37
2.7. ELECTRIC DISCHARGE MACHINE PROCESS....................................................38
2.7.1. Advantages and Disadvantages.......................................................................39
2.7.2. Work Carried Out Using the Lathe Machine.......................................................39

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ANNEXES

CHAPTER 3: CONCLUSION....................................................................................40
3.1 Review of Training Experience..........................................................................40
3.2 Comments on training establishment...................................................................40
3.3 Suggestions..................................................................................................41
ANNEXES.............................................................................................................42
ANNEXES

List of Figure

• Figure 1.01 : structure of

IDB ..................................................................................................02
• Figure 2.01 : Lathe machine
……………………………………………………………………………………………….12
• Figure 2.02 : 3-Jaw chuck
…………………………………………………………………………………………………
…14
• Figure 2.03 : 4- jaw chuck
…………………………………………………………………………………………………..
14
• Figure 2.04 : Face plate
…………………………………………………………………………………………………
……15
• Figure 2.05 : Lathe machine tool
………………………………………………………………………………………..16
• Figure 2.06 : Turning process
……………………………………………………………………………………………..19
• Figure 2.07 : Facing process
……………………………………………………………………………………………….20
• Figure 2.08 : Parting process
………………………………………………………………………………………………20
• Figure 2.09 : Drilling process
………………………………………………………………………………………………21
• Figure 2.10 : Boring process
……………………………………………………………………………………………….21
• Figure 2.11 : Single thread cutting
………………………………………………………………………………………22
• Figure 2.12 : Shaping machine
……………………………………………………………………………………………23
• Figure 2.13 : Head position
…………………………………………………………………………………………………
24
• Figure 2.14 : Milling machine
……………………………………………………………………………………………..27
• Figure 2.15 : Milling machine and Components
………………………………………………………………….27

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ANNEXES

• Figure 2.16 : Types of milling cutters

………………………………………………………………………………….28
• Figure 2.17 : Conventional milling and Climb milling
…………………………………………………………..29
• Figure 2.18 : Face milling
…………………………………………………………………………………………………
…31
• Figure 2.19 : Face milling
…………………………………………………………………………………………………
…31
• Figure 2.20 : Milling slots
…………………………………………………………………………………………………
…31
• Figure 2.21 : Bench grinder
…………………………………………………………………………………………………
32
• Figure 2.22 : Surface grinder
………………………………………………………………………………………………33
• Figure 2.23 : Oxy-Acetylene welding station and components
……………………………………………34
• Figure 2.24 : Equipment used in welding
……………………………………………………………………………35
• Figure 2.25 : Welding power source
……………………………………………………………………………………36
• Figure 2.26 : Electric arc welding station
…………………………………………………………………………….37
• Figure 2.27 : EDM machine
…………………………………………………………………………………………………
38
• Figure 2.28 : Operation of the EDM machine
……………………………………………………………………..38
• Figure 2.29 : Operation of the EDM machine
……………………………………………………………………..38
• Figure 2.30 : Elbow crutch
………………………………………………………………………………………………….
39

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INTRODUCTION TO TRAINING ESTABLISHMENT CAPTER 1

CHAPTER 1: INTRODUCTION TO TRAINING ESTABLISHMENT

The Industrial Development Board (IDB) of Ceylon, in its present form was incorporated as a
statutory body by industrial development board Act No. 36 of 1969 and was affiliated to the
then ministry of industries and scientific Affairs until 1986. The Head office of IDB was
situated at No.16 Gregory‘s Road, Colombo 07.

From1986 to 1994 it came under the ministry of textile and rural industrial development and
the ministry of tourism and rural development. From 1994 on wards it functioned under the
ministry of industrial development till the present government came into power. Since then it
is affiliated to the ministry of rural industries and self employment promotion.

At the inception the IDB consisted of a few divisions, namely finance, establishment,
economic research and documentation and publication. In addition there were special
functional centers which were located at different places in Colombo.

In 1972 the management development and productivity center split into two and one emerged
as the national institute and business management (NIBM).

The act grants the IDB power under section 33(2) (a) establish, maintain and carry on
industrial estate in Sri Lanka. Accordingly the industrial estate run by the former industrial
estates corporation came under the management of IDB.

In 1973 the different section of the IDB which operated from geographically apart locations
shifted to one center place in Katubedda. The technical service institute which was located in
same premises merged with the IDB.

1.1.1. Mission of the IDB

To Provide and facilitate the demand driven quality services to make Sri Lankan enterprises
globally competitive through an island wide network of dedicated and innovative team to
achieve business excellence.

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 INTRODUCTION TO TRAINING ESTABLISHMENT CAPTER 1

HEAD
HEAD
HEAD
HEAD
HEAD
HEAD
HEAD
OF
OF
HEAD
HEAD
OF
OF
TECHNICAL
OF
ENGINEERING
OF
PERSONAL
REGIONAL
HEAD
OF
FINANCE
MARKETING
PLANNING
OF
GENERALOF
INTERNAL
IDB
IDB
CHAIRMANOF WORKSHOP
CITIS
SERVICE
FOUNDRY
DEPARTMENT
DEPARTMENT
DEVELOPMENT
MANAGERDEPARTMENT
DEVISION
DIVISION
AUDIT
DIVISION

1.1.2. Structure of the Industrial Development Board

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INTRODUCTION TO TRAINING ESTABLISHMENT CAPTER 1

Figure 1.01

1.1.3.Act of Incorporation Set out the Object of the IDB As Follows:

The industrial development act no 36 of 1969 clearly spells out the objectives incorporation.
To assist in the encouragement, promotion and development of industries in Ceylon.

• To assist in the proper co-ordination and in the inter-related growth of all

industrial undertaking in the private and public sectors of the economy of the
country.
• To foster industrial research with the object of utilizing the natural resources
of Ceylon, improving the technical process and equipment for local industrial
and discovering processes and methods for the better utilization of waste
products.
• To foster the export of local industrial products to overseas markets.
• To assist such measure in the field of international trade and regional co-
operation as are necessary or conductive to industrial development.
• To provide for services and facilities of every description required by or in
connection with any industrial undertaking or industrial establishment in
Ceylon.
• To advice on matters relating to the promotion and development of industries
in Ceylon.
• To take all such measure as may be necessary for, or conductive to, the
attainment of the object specified hereto. (industrial development act No: 36 of
1969, P5)

1.1.FUNCTIONAL DIVISION

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INTRODUCTION TO TRAINING ESTABLISHMENT CAPTER 1

In order to carry out its services the organizational set up comprises the following divisions.

• Administration
• Finance
• Planning
• Rubber product development and services
• Engineering Services
• Regional development
• Industrial Estate
• Marketing
• Centre for entrepreneurship development and consultancy services
• Centre for industrial technology information (including library) services
• Centre for rubber products development and consultancy services
• Centre for leather products and footwear development

1.1.RELATIONSHIP BETWEEN SME SEECTOR

Small and medium enterprise sectors the small and the medium enterprise (SME) sector in
any country is the key driver of the nation’s economy growth. In terms of generation of
employment, reducing poverty level and reducing urban rural disparities, this sector plays
very vital role.

There is a growing need to focus on the development of regional economy and giving priority
to cluster development as a strategy by moving away piece meal approaches to SME
development.

IDB during its past years of service to the nation has contributed enormously towards the
development of SME’s. The development of the SME sector is a high priority in the agenda
of government too. On its part IDB stands ready to fully support the initiatives and broader
objectives of the industrial policy of the government over the long term.

The promotion of SEM sector forms an integral part of employment generation, poverty
alleviation and the regional development Programs implemented by the government.

Now the war is over, the focus is on development. Post conflict Sri Lanka has embarked on a
massive development drive that embraces all part of the island including the north and the

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INTRODUCTION TO TRAINING ESTABLISHMENT CAPTER 1

east where the people are very enterprising. Such an approach will lead to lasting peace,
harmony and prosperity in our motherland.

SME sector has great potential to generate socio-economic benefits to the country with a low
level of a investment. SME’s have the capacity and to mobilize and divert financial recourses
and to promote balanced regional development.

Now that peace has dawned there is greater impetus on development which can continue
unhindered. The industry faced many bitter challenged due to terrorism and thanks to the
resilient nature of SMEs we are now in a position to envision a better and brighter future.
IDB Industrial Estate in Atchchuveli and Vavuniya which was abandoned during the past
three decades are now being restructured. Difficult time ignite the opportunity to redesign,
reshape and revive business. Tamil Diaspora now has an opportunity to participate in the
rebuilding of the north and east. It is imperative that we move fast in the new era of peace.

The significance of the role that entrepreneurs play in achieving the industrial development
targets and economy prosperity of the country is indispensable. IDB acknowledges the role
played by the entrepreneurs in the social fabric of the country and their services to the
country. It is through the success of SMEs that the targeted economic growth of the country
could be achieved.

1.2. IDB SERVICES

The keeping with the above objects it was incumbent upon the IDB to design suitable service
packages to promote industrialization especially in the small and medium (SMI) sector. The
concept of industrialization was new during the initial phase and knowledge was micro small
and medium entrepreneur advise during the insipient stage the service packages since
inception had some common feature but somewhat varied from time to time depending on the
needs and prevailing industrial environment.

Services provided at present

These services include

• Industrial information
• Marketing services and assistance
• Investment analysis and feasibility studies

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INTRODUCTION TO TRAINING ESTABLISHMENT CAPTER 1

• Technical assistance and laboratory service

• Engineering assistance
• Workshop and foundry facilities
• Management training and consultancy
• Factory space and comment services
• Entrepreneurship development
• Infrastructure for establishment of industries

1.1.1. Planning

The planning division is vested with the overall responsibility for monitoring the progress of
the activities carried out by the Functional divisions

It offers the following services to assist the industrial community.

• Preparation upgrading of model projects reports

• Preparation, implementation, monitoring and revision of the co-operate plan
• Preparation of the project proposals for foreign funding
• Preparation of statistical abstracts
• Conduction special studies and surveys

1.1.1. Regional Development

The regional development division is responsible for coordinating, monitoring and

supervision of the services rendered by the extension officers through the network of
provincial and district officers.

The division is responsible for the implementation of the programs at regional level in order
to promote balanced regional development. The services offered are

• Identification of regional investment opportunities/potential investors.

• Establishment of new industrial units.
• Assistance to develop existing industries.
• Promoting self employment projects.
• Preparation of model project report for obtaining credit facilities and
coordination.
• Conducting market studies.

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INTRODUCTION TO TRAINING ESTABLISHMENT CAPTER 1

• Preparation of directory of industries.

1.1.1. Entrepreneurship Development

The mandate of the centre for entrepreneurship development and consultancy services
(CEDACS) is to inculcate a new entrepreneurship culture and impart latest managerial skills
in order to encourage the promotion of industries.

With this view in mind CEDACS carry out the following programs

• Entrepreneurship development programs

• Entrepreneurial awareness building workshop/programs
• Business creation programs
• Programs to empower women entrepreneurs
• Technology transfer programs
• Management development programs

1.1.1. Technical Services

Technical services Division (STD) one of the key divisions of the IDB caters to the
technological needs of the industrial community in Sri Lanka. It consists of four units namely
Food, Chemicals, Oils, and Fiber and building materials.

TSD provides technological assistance to entrepreneurs from conception through formulation

to implementation of new industries and expansion, modernization diversification and quality
and productivity improvement.

A teem of specialized technologist provide technological assistance to SMEs through

consultancy and training programs to transfer technology. The TSD is equipped with a
laboratory for products/process development work.

The main activities of the division covers

• Technological demonstration
• Technology transfer workshop

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INTRODUCTION TO TRAINING ESTABLISHMENT CAPTER 1

• Development of products and process

• Preparation of technology packages
• Preparation and upgrading of technological reports
• Resuscitating sick industries and providing technical support for troble-
shooting in industries
• Coordinating activities of production village development programs
• Conducting computer hardware servicing programs

1.1.1. Engineering Services

The engineering division consist of the workshop, foundry and the engineering division at the
head office, Electroplating centre Peliyagoda, common services centre at Mathara and
brassware centre at Pamunuwa.

The main functions cover

• Consultancy and extension service

• Technology transfer training / workshop
• Machinery / equipment / process development
• Expansion of machinery and equipment resources
• Fabrication casting and metal finishing services
• Development of prototype machinery
• Laboratory testing services for foundry sector
• Development of appropriate machinery
• Valuation services
• Electroplating services
• Leather products and footwear development

Considering the vast potential for the development of leather sector in Sri Lanka the centre
provides both technology and training facilities to manufacture quality products with and
export potential. It also provides common services to SMEs engaged in the leather products
and footwear manufacture. The activities of the division covers

• Technology transfer and training

• Skill development
• Common facilities
• Sub-contracting facilities

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INTRODUCTION TO TRAINING ESTABLISHMENT CAPTER 1

• Consultancy and information services

The services offered are footwear design, footwear cutting and clicking, footwear upper
closing, footwear lasting and finishing, upgrading skills.

Rubber product development and services centre provide technical services and information
on rubber and rubber products manufacturing industry expert consultancy and advisory
services.

The laboratories of the centre are equipped with a range of physical and mechanical testing
equipment for quality testing of rubber compounds and finished products.

• Semi commercial activities

• Compounding of dry rubber and rubber latex
• Retail sale of chemicals and other processing agents
• Hiring of portable machinery to execute pilot projects
• Limited facilities for utilization of machinery for special processes
• Sub contracting facilities
• Information technology

Providing access to information technology has taken on paramount importance especially in

the wake of rural empowerment. IT plays a crucial role in accelerating the economic growth
and harnessing of global opportunities. This will facilitate the SMEs to compete with the rest
of the world on a level playing field.

The centre of industrial technology information services (CITIS) comprises of the library,
industrial information unit.

Industrial infrastructure

One of the main constraints in setting up industries in rural sector has been the difficulties
encountered in finding suitable locations to set up the industries and the need to incur heavy
capital expenditure initially on land and infrastructure facilities. In order to facilitate them
industrial estates have been set up throughout of the country under the industrial estate
division with infrastructure facilities such as internal road ways, telecommunication, water
supply, three-phase electricity – street lightning, storm/ rain water drains.

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INTRODUCTION TO TRAINING ESTABLISHMENT CAPTER 1

Industrial estate are located in Ekala, Pallekale, Horana, Pannala, Galigamuwa,Wavulugala,

Pussella, Beleatta, Karandeniya, Matale, Negampaha, Vauniya, Buthala, Lunuvila,
Mihinthale and Kotagala.

1.1.1. Marketing assistance

Yet another major constraints faced by the rural and medium scale industrialist is the market
problem. In order to increase and establish the market share of the existing industries of the
SME sector and the potential entrepreneurs the following services are offerd by the marketing
division.

• Marketing information
• Managing and coordinating sale centers “Laknipayum” in Colombo and “Lakkam
trade center” at he head office katubadda.
• Sub-contracting facilities
• Organizing and conducting exhibition and trade Eras.
• Provision of metal scrap to SMEs and medium light engineering industrialist.

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TRAINING EXPERIENCE CHAPTER 2

CHAPTER 2: TRANING EXPERIENCE

My first week on Industrial Development Board I was assigned to mechanical workshop to

develop my knowledge on machines and machine processes and also to get hands on
experience of them. Basically mechanical workshop can divide into several sections. They
are lathe and milling, cutting, welding.

On the first day workshop engineer Mr.Premasiri assigned me under supervision of Technical
Assistant Mr.Dissanayake to get a good knowledge about manufacturing processes. Since
first week I spent my time in lathe and milling section to gain knowledge about lathe and
milling processes. Then I focused on Shaping Grinding and Welding operations.

First I started learning about milling machine with the help of machine operator. So there he
told me about basic components if a milling machine first. Then I observe those components
and recognized them very well (like lathe Bed, carriage or saddle, tool post, slide ways,
tailstock, chuck, spindle speed selector, and etc). Machine to machine the some of
components vary their positions and the availability.

Then he taught me the importance of those components. So I listed those components and
their importance as bellow.

2.1. MAIN LATHE COMPONENTS AND THEIR IMPORTANCE

2.1.1. The Lathe Bed Slide Way

It cast with a box-like cross section made of gray cast iron. It has two main functions.

• To give the necessary stiffness for resisting the twisting and other stress, which occur in
practice and which if they strained the bed, would destroy the accuracy of lathe.

• To ensure that the lathe-cutting tool moves accurately along a path that is parallel to the
machine spindle axis.

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TRAINING EXPERIENCE CHAPTER 2

Figure 2.01

2.1.2. The Carriage or Saddle

This is a flat-shaped casting, planed on its underside to fit the ways of the bed so that it may
slide along.

2.1.3. Headstock

Gear trains enable for driving spindle, feed shaft, lead screw and Gears for changing speeds
are housed in the headstock.

2.1.4. The Cross Slide

This provides,

• Support for the compound slide.

• Movement of the cutting tool at 90 Degrees to the rotating axis of the work piece.
Motion of the cross slide is obtain by a hand wheel, but on the majority of centre
lathes a gear mechanism is fitted to give automatic traverse both towards the spindle
axis and away from it.

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TRAINING EXPERIENCE CHAPTER 2

2.1.5. The Compound Slide

This is mounted on the cross slide and has two main functions.

• To provide location and support for the tool post

• To enable the tool to be place at angle to the axis of the spindle

Compound slide movement is obtained by using a hand wheel, no automatic traverse is

provided. The slide can be rotated about its mounting. The circular scale on the base indicates
the angle through which the slide has turned.

2.1.6. The Tool Post

This has two main functions.

• Positioning the cutting tool

• Securing the cutting in that position

There are two type of tool post,

• Single tool post

• Four way tool post

2.1.7. The Tailstock

This is the counter part of the headstock, and carries the right hand centre for supporting
work when turning centers. It is also used for supporting and feeding drills, reamers, etc.
when it is necessary to use these for drilling work held in the chuck.

Using the lateral adjustment screw can make sideways adjustment of the barrel. By this, the
centre of the barrel can move off centre with the headstock spindle centre. (Live centre)

2.1.8. Steadies

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 TRAINING EXPERIENCE CHAPTER 2

For supporting long, slender work against the pressure of the cut, a steady is used. The fixed
or three jaw steady is clamped to the bed of the lathe and supports the bar, being turned by
means of three jaws set at 120 degrees with each other.

2.1.9. Work Holding Methods

• The self - centering chuck (3 – Jaw Chuck)

• The independent centering chuck (4 – Jaw Chuck)
• Driving plate and centers
• Face plate

The self-centering chuck (3 – Jaw Chuck)

This is the most convenient and most used method of work holding.

Figure 2.02 This can take wide range of diameters. When adjusting jaws move equal
amount light cuts should carry out, because the work may slip in the jaws. In addition, the
work should be firmly round to fix in this chuck.

The independent centering chuck (4 – Jaw Chuck)

Each jaw is individually adjust and moves along its own slot. One
advantage of this four-jaw chuck is that work can be located in the
centre to run true or off centre. One of the most useful applications of
this type is to hold square or rectangular material positioned either
centrally or off centre. Setting time is greatly increased when
Figure 2.03 compared to three-jaw chuck. However, for highly accurate work, this is the most suitable
method.

The faceplate

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 TRAINING EXPERIENCE CHAPTER 2

Figure 2.04

This is used to hold works, which can neither be turned on centers nor held in a chuck. It has
bolt slots for accommodating the necessary clamping bolts.

2.1.10. Tool Holding Method

I have mentioned some components and their importance above as I learned. Then I learned
about machine processes. Thereafter I was learned how to mount a work piece and how to
center it. First I found little bit difficult to mount the work piece correctly and also I learned
how to use surface gauge to center the work piece. Some times work piece is not reasonably
symmetrical.

When it wasn’t symmetrical I had to check the space between surface gauge and the work
piece surface opposite side of the chuck because I couldn’t see continuous equal space
between those two surfaces. I use 3-jaw and 4-jaw chucks to center work piece according to
the irregularities of the surfaces.

Once I mount the work piece I choose a cutting tool to mount on the tool post. When
choosing a cutting tool there are some factors to consider,

Cutting tool geometry varies with the type of work to be done.

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TRAINING EXPERIENCE CHAPTER 2

Figure 2.05

• Facing tools are ground to provide clearance with a center.

• Roughing tools have a small side relief angle to leave more material to support the
cutting edge during deep cuts.
• Finishing tools have a more rounded nose to provide a finer finish. Round nose tools
are for lighter turning. They have no back or side rake to permit cutting in either
direction.
• Left hand cutting tools are designed to cut best when traveling from left to right.
• Aluminum is cut best by specially shaped cutting tools (not shown) that are used with
the cutting edge slightly above center to reduce chatter.

And also when installing a cutting tool there are some instructions to follow,

• Lathe cutting tools are held by tool holders. To install a tool, first clean the holder,
and then tighten the bolts.
• The tool post is secured to the compound with a T-bolt. The tool holder is secured to
the tool post using a quick release lever.

And for the positioning,

In order to move the cutting tool, the lathe saddle and cross slide can be moved by hand.
There are also power feeds for these axes. Procedures vary from machine to machine.

A third axis of motion is provided by the compound. The angle of the compound can be
adjusted to allow tapers to be cut at any desired angle. First, loosen the bolts securing the
compound to the saddle. Then rotate the compound to the desired angle referencing the dial
indicator at the base of the compound. Retighten the bolts. Now the tool can be hand fed
along the desired angle. No power feed is available for the compound. If a fine finish is
required, use both hands to achieve a smoother feed rate.

The cross slide and compound have a micrometer dial to allow accurate positioning, but the
saddle doesn't. To position the saddle accurately, you may use a dial indicator mounted to the
saddle. The dial indicator presses against a stop (often a micrometer as shown in the clip
below).

Feed, speed, and depth of the cut,

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TRAINING EXPERIENCE CHAPTER 2

Cutting speed is defined as the speed at which the work moves with respect to the tool
(usually measured in feet per minute). Feed rate is defined as the distance the tool travels
during one revolution of the part. Cutting speed and feed determines the surface finish, power
requirements, and material removal rate. The primary factor in choosing feed and speed is the
material to be cut. However, one should also consider material of the tool, rigidity of the
work piece, size and condition of the lathe, and depth of cut. For most Aluminum alloys, on a
roughing cut (.010 to .020 inches depth of cut) run at 600 fpm. On a finishing cut (.002 to .
010 depth of cut) run at 1000 fpm. To calculate the proper spindle speed, divide the desired
cutting speed by the circumference of the work. Experiment with feed rates to achieve the
desired finish. In considering depth of cut, it's important to remember that for each
thousandth depth of cut, the work diameter is reduced by two thousandths.

2.1.11. Production of Chips

The production condition of chips in cutting work varies according to the quality of
work material, cutting speed, shape of tool, etc.

Cutting Resistance

In case of cutting work, bigger strength than the work acts. This strength is called
cutting resistance, and the strength, which is equal in size and opposite in direction to this
cutting resistance, acts on the work. This is called cutting force, having effects on the motive
power necessary for cutting, the life of tools, the finished surface and so on.

a) Three Force components

i. Main force component

The force acts in the direction of pushing tools down, is biggest, and
consumes the majority of motive power.

ii. Back force component

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TRAINING EXPERIENCE CHAPTER 2

Is the force pushing back tools from the work, becomes smaller, with bigger
rake angle, and may become minus force.

iii. Feed force component

Is the force to act pushing back tool opposite to feeding direction, and
various according to entering angle of tool.

b) Factors changing cutting resistance

i. Shape of tool tip

Cutting resistance is reduced lineally (up to about 30 Celsius Degree), according

to rake angle becoming larger. However, there is limit in enlarging rake angle, if
the strength of chip of cutting tool is considered.

ii. Cutting speed

In case of high-speed cutting, cutting resistance is reduced with the increase of

cutting speed.

iii. Entering angle of tool tip

Cutting resistance vary according to the entering angle of tool tip. Main force
component are increased, with the decrease of entering angle. Cutting resistance is
increased, with the increase (Cutting Volume) of out Depth x Feed (Cutting Area).

iv. Cutting oil

With the use of adequate cutting oils and agents, friction is reduced by the
lubrication of cutting oil and cutting resistance is reduced.

v. Material

Hard material and tenacious material make cutting resistance bigger. The
quality of tool has no effect on cutting resistance almost.

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 TRAINING EXPERIENCE CHAPTER 2

2.2. BASIC LATHE MACHINE PROCESSES

Then I learned about basic machining processes like Turning, Facing, Parting, Drilling, and
Boring, Thread cutting.

2.2.1. Turning

The lathe can be used to

reduce the diameter of a
part to a desired
dimension. First, clamp
the part securely in a
lathe chuck. The part
Figure 2.06 should not extend more
that three times its
diameter. Then install a roughing or finishing tool. If you're feeding the saddle toward the
headstock use a right-hand turning tool. Move the tool off the part by backing the carriage up
with the carriage hand wheel, then use the cross feed to set the desired depth of cut. In the
clip below, a finish cut is made using the power feed for a smoother finish. Remember that
for each thousandth depth of cut, the work diameter is reduced by two thousandths.

2.2.3. Facing

A lathe can be used to create a smooth, flat, face

very accurately perpendicular to the axis of a
cylindrical part. First, clamp the part securely in a
lathe chuck. Then, install a facing tool. Bring the
tool approximately into position, but slightly off
of the part. Always turn the spindle by hand

Figure 2.07 before turning it on. This ensures that no parts

interfere with the rotation of the spindle. Move
the tool outside the part and adjust the saddle to

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 TRAINING EXPERIENCE CHAPTER 2

take the desired depth of cut. Then, feed the tool across the face with the cross slide. The
following clip shows a roughing cut being made; about 50 thousandths are being removed in
one pass. If a finer finish is required, take just a few thousandths on the final cut and use the
power feed. Be careful clearing the ribbon-like chips; they are very sharp. Do not clear the
chips while the spindle is turning. After facing, there is a very sharp edge on the part. Break
the edge with a file.

2.2.3. Parting

A parting tool is deeper and narrower than a

turning tool. It is designed for making narrow
grooves and for cutting off parts. When a parting
tool is installed, ensure that it hangs over the tool
holder enough that the holder will clear the work
piece (but no more than that). Ensure that the
parting tool is perpendicular to the axis of
rotation and that the tip is the same height as the
Figure 2.08
center of the part. A good way to do this is to
hold the tool against the face of the part. Set the
height of the tool; lay it flat against the face of the part, then lock the tool in place. When the
cut is deep, the side of the part can rub against sides of the groove, so it's especially important
to apply cutting fluid. In this clip, a part is cut off from a piece of stock.

2.2.4. Drilling

A lathe can also be used to drill holes accurately

concentric with the centerline of a cylindrical part. First,
install a drill chuck into the tail stock. Make certain that
the tang on the back of the drill chuck seats properly in the
tail stock. Withdraw the jaws of the chuck and tap the
chuck in place with a soft hammer. Move the saddle
forward to make room for the tailstock. Move the tailstock

Figure 2.09 into position, and lock it. (Otherwise it will slide backward
as you try to drill). Before starting the machine, turn the spindle by hand. You've just moved
the saddle forward, so it could interfere with the rotation of the lathe chuck. Always use a

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center drill to start the hole. You should use cutting fluid with the center drill. It has shallow
flutes (for added stiffness) and doesn't cut as easily as a drill bit. Always drill past the
beginning of the taper to create a funnel to guide the bit in. In this clip, a hole is drilled with a
drill bit. Take at most one or two drill diameters of material before backing off, clearing the
chips, and applying cutting fluid. If the drill bit squeaks, apply solvent more often. The drill
chuck can be removed from the tail stock by drawing back the drill chuck as far as it will
easily go, then about a quarter turn more. A pin will press the chuck out of the collet.

2.2.5. Boring

Boring is an operation in which a hole is enlarged

with a single point cutting tool. A boring bar is used
to support the cutting tool as it extends into the hole.
Because of the extension of the boring bar, the tool
is supported less rigidly and is more likely to
chatter. This can be corrected by using slower
Figure 2.10 spindle speeds or by grinding a smaller radius on the
nose of the tool.

2.2.6. Single Point Thread Turning

External threads can be cut with a die and internal

threads can be cut with a tap. But for some
diameters, no die or tap is available. In these
cases, threads can be cut on a lathe. A special
cutting tool should be used, typically with a 60
degree nose angle. To form threads with a
specified number of threads per inch, the spindle
Figure 2.11
is mechanically coupled to the carriage lead
screw. Procedures vary for different machines.

In addition to that I learned little bit of advanced work piece holding techniques,

Some parts require special techniques to hold them properly for lathe work. For instance, if
you wish to cut on the entire outside diameter of a part, then the part cannot be held in a
chuck or collet. If the part has a hole through it, you can press it on to a lathe arbor (a slightly

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tapered shaft), and clamp onto the arbor rather than the part itself. The hole must have an
adequate aspect ratio or the part will not be firmly supported. If the part has a very large hole
through it, a lathe arbor may not be a practicable solution. You may instead use the outside of
the jaws to hold the inside diameter of the part. If the part has a very complex geometry, it
may be necessary to install the part onto a face plate. The face plate is then attached to the
spindle.

2.2.7. Work Carried Out Using the Lathe Machine

I was given some parts used in clay mixing machine to finish. I have finished all the parts that
were given to me within few weeks. There I learned to cut a taper angle, learned to cut
threads and carried out a break drum cutting operation too. All the drawings are attached to as
annexes.

In addition to that I involve repairing a lathe machine having a problem with its self action
unit. In the self action unit a inspected all the gear wheels because first I thought it was due to
metal dust stuck within the gear wheels. But it wasn’t the issue. Issue was guide ways of a
gear wheel displaced to wards a side. So they were contact with each other generating friction
between those two. So I had to realign and clean all the iron partials inside of the self action
unit.

2.3. BASIC SHAPING MACHINE PROCESSES

Figure 2.12
The main function of the shaping machine is the production of flat surfaces, which are
obtained by combining a line tool cut with a perpendicular feed. To understand how this
machine generates a plane surfaces, it is easiest to consider the surface parallel to the machine

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table. The ram of shaping machine moves the cutting tool backward and forward in straight
line. Each time the tool moves backward the tool lifts clear of the work piece and the work
piece moves across in a path perpendicular to the tool movement. The work remains
stationary during the forward (Cutting) stroke of the tool, and only moves across by one
cross-traverse increment during the return (Non-cutting) stroke. The appearance of the
machined surface is of a succession of closely spaced, straight line cuts. For this reason, it is
often referred to as a ruled surface.

2.3.1. Work Holding

There are several ways of holding the work piece on a shaping machine. The most
usual is to use a swivel vise. In order to produce accurate work, it is essential that the fixed
jaw and the upper surfaces of slides of the vice be accurately aligned with the machine
worktable. After the vise has been positioned for a particular job, it should be checked for
alignment. Large job may be mounted directly on the machine table using clamps or dogs.
Surfaces may be machined perpendicular to each other using the side of the table. The side of
the table is often provided with a ‘V’ for holding cylindrical too.

2.3.2. Tools

One of the great advantages of the shaping machine for jobbing- shop work is the fact
that it uses cheap, single point tools similar to lathe tools. Further, these tools can be ground
off-hand when it is necessary to change their shape to suit a particular job, or to re-sharpen
them. Some typical shaping machine tools, in which the similarity to lathe tools is evident.

2.3.3. Types of Shaping Machine

Shapers are mainly classified as standard, draw-cut, horizontal, universal, vertical, geared,
crank, hydraulic, contour and traveling head. The horizontal arrangement is the most
common. Vertical shapers are generally fitted with a rotary table to enable curved surfaces to
be machined. The vertical shaper is essentially the same thing as a slotter (slotting machine),
although technically a distinction can be made if one defines a true vertical shaper as a
machine whose slide can be moved from the vertical. A slotter is fixed in the vertical plane.

Very small machines have been successfully made to operate by hand power. As size
increases, the mass of the machine and it’s the power requirements increase, and it becomes
necessary to use a motor or other supply of mechanical power. This motor drives a

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mechanical arrangement (using a pinion gear, bull gear, and crank, or a chain over sprockets)
or a hydraulic motor that supplies the necessary movement via hydraulic cylinders.

2.3.4. Operation of the Shaping Machine

Figure 2.13

A shaper operates by moving a hardened cutting tool backwards and forwards across the
work piece. On the return stroke of the ram the tool is lifted clear of the work piece, reducing
the cutting action to one direction only.

The work piece mounts on a rigid, box-shaped table in front of the machine. The height of the
table can be adjusted to suit this work piece, and the table can traverse sideways underneath
the reciprocating tool, which is mounted on the ram. Table motion may be controlled
manually, but is usually advanced by automatic feed mechanism acting on the feed screw.
The ram slides back and forth above the work. At the front end of the ram is a vertical tool
slide that may be adjusted to either side of the vertical plane along the stroke axis. This tool-
slide holds the clapper box and tool post, from which the tool can be positioned to cut a
straight, flat surface on the top of the work piece. The tool-slide permits feeding the tool
downwards to deepen a cut. This adjustability, coupled with the use of specialized cutters and
tool holders, enable the operator to cut internal and external gear tooth profiles, splines,
dovetails, and keyways.

The ram is adjustable for stroke and, due to the geometry of the linkage, it moves faster on
the return (non-cutting) stroke than on the forward, cutting stroke. This action is via a slotted
link or whit worth link.

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2.3.5. Safety on the Shaping Machine

We have already referred to safety in chapter 02. The shaper is not any more
dangerous than other machine, but as some people will get in to trouble in the most innocent
situations if may be worthwhile to issue a few words of advice. Most of the other machine
tools have their chief source of danger in members which rotate, the only rotating hazards on
the shaper is the squared shaft which projects from the side of the machine for setting the
stroke, and this can be dangerous if after setting a stroke we forget to remove the handle from
it before starting up. It is also a good precaution not to lean anywhere near this, as the rotating
squared end could wind up in the loose clothing. The ram is the only other real source of
danger, and accidents can occur both by forgetfulness and by knowingly taking chances.

On modern, moisturized, gear driven machines, the danger from an obstruction to the
ram is greater than it was on the earlier belt-driven types, since a belt would often save a
serious situation by slipping off. A train of gearing from a high-speed motor, however, is not
so obliging. The ram, therefore, should always be considered as a source of danger, and this
should never be forgotten, neither should a known risk be entertained. After setting or
resetting a job, make sure that neither the tool nor any portion of the ram will foul anything
on the table before starting the machine. Better still; pull the machine round by hand to make
sure. There is sometimes a temperate to change the stroke or the setting of the ram while the
machine is running. This is taking a known risk and should be avoided. Special care is
necessary when a fine setting to the forward end of the stroke is necessary for shaping up to
an obstruction, and the machine should be pulled round several times before it is started up.

Many mishaps occur through work being insecurely clamped and supported against
the force of the cut and it should be remembered that the tool at the beginning of each stroke
exerts a considerable shock force. Stops should always be used when jobs are clamped direct
to the table and clamping should be arranged to come on to solid metal. Faulty clamping and
setting up, as well as being dangerous, lead to inaccurate results due to work either moving or
distorting. Even if a job is well clamped, it may be pushed off the table, or the tool broken, by
winding in to a large cut that was not checked or has jumped on due to a loose head slide.

The collection of the cutting chips on a shaping machine is a problem that has never
been solved, and when dealing with hard steel particularly it is advisable not to stand at the
front of the machine. Also, sweep the floor often if you value the leather on your shoe soles.

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2.3.6. Work Carried Out Using Shaping Machines

In my training at the IDB I Frequently used this machine to complete works assigned to me.
Among them I shaped some parts that use in clay mixing machine. There were key ways and
taper angle to cut so I performed those operations also using the shaping machine. I have
attached all the drawings of the parts, carried out by my self. Clay mixing machine is one of
the on going project in IDB these days. It was the main project and also there are some other
projects too. Purpose of making those products is to improve the productivity of the local
industries as well as the self employment. I was very lucky to contribute my effort and
knowledge to empower self employees in the country because I believe it’s the true
development of this country.

2.4. BASIC MILLING MACHINE COMPONENTS AND PROCESSES

Figure 2.14

1.Face milling cutter

2.Spindle
3.Spindle head
4.Column Figure 2.15
5.Table
6.Saddle
7.Knee
8.Base
9.Spindle switch
10.Spindle speed gear lever

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11.Spindle speed control lever

12.Oil tank

Milling machines are very versatile. They are usually used to machine flat surfaces, but can
also produce irregular surfaces. They can also be used to drill, bore, cut gears, and produce
slots. The type of milling machine most commonly found in student shops is a vertical
spindle machine with a swiveling head. Although there are several other types of milling
machines, this document will focus only on the vertical milling machine.

A milling machine removes metal by rotating a multi-toothed cutter that is fed into the
moving work piece. The spindle can be fed up and down with a quill feed lever on the head.

The bed can also by feeding the x, y, and z axes manually. In this clip the z axis is adjusted
first, then the y, than the x.

Once an axis is located at a desired position and will no longer be fed, it should be locked
into position with the Gibb locks.

Most milling machines are equipped with power feed for one or more axes. Power feed is
smoother than manual feed and, therefore, can produce a better surface finish. Power feed
also reduces operator fatigue on long cuts. On some machines, the power feed is controlled
by a forward reverse lever and a speed control knob.

2.4.1. Rotating the Head

The head of a vertical milling machine can be tilted from side to side and from front to back.
This allows for versatility of the machine, but these adjustments can drift.

2.4.2. Squaring the Vise

Work on a milling machine is most often held in a vise clamped onto the bed. To make
features aligned with the edges of the stock, it's necessary to align the vise with the feed axes
of the mill. To do this, mount the vise on the bed and secure it with T-bolts, but only lightly
and do adjustments of the orientation of the vise to make it align. Then tighten down the T-
bolts be careful not to change the vise orientation. Recheck the alignment of the vise.

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2.4.3. Types of Milling Cutters

Figure 2.16
In vertical mills, milling cutters with solid shafts are usually used. Milling cutters with keyed
holes are predominantly for use in horizontal mills. End mills are designed for cutting slots,
keyways and pockets. Two fluted end mills can be used to plunge into work like a drill. End
mills with more than two flutes should not be plunged into the work. Ball end mills can
produce a fillet. Formed milling cutters can be used to produce a variety of features including
round edges.

2.4.4. Removing and Installing Milling Cutters

To remove a tool, move the quill to the highest position and lock it in place. Then, engage the
brake while loosening the draw bar with a wrench. Ensure that the draw bar's threads are still
engaged in the collet. Tap on the end of the draw bar to release the collet from the spindle. If
the threads of the draw bar are not engaged, the milling cutter will fall, and could be
damaged. Finally, unscrew the drawbar from the collet.

To install a tool, place the desired milling cutter in a collet that fits the shank of the cutter.
Insert the collet into the spindle. Ensure that the key way on the collet mates properly with
the key in the spindle. While holding the tool with one hand, start the threads of the draw bar
into the collet by hand. Use a wrench to tighten the drawbar down with one hand while
holding the brake.

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2.4.5. Climb and Conventional Milling

Conventional
Climb Milling
Milling

Figure 2.17

When milling, one should be aware of the difference between conventional, and climb
milling. In conventional milling, the work piece is fed into the rotation of the cutter. This type
of cut requires lower forces and is preferred for roughing cuts. In climb milling, the work
moves with the rotation of the cutter. This produces a better finish. It is not recommended if
the work piece cannot be held securely or cannot support high forces.

2.4.6. Calculating Speed and Feed

Cutting speed refers to the speed at which the tool point of the cutter moves with respect to
the work measured in feet per minute. Feed is the rate at which the work moves into the
cutter measured in feed per tooth revolution. Feeds and speeds affect the time to finish a cut,
tool life, finish of the machined surface and power required of the machine.

The cutting speed is mostly determined by the material to be cut and the material of the tool.
To find the right speed for any task, refer to the Machinery's Handbook or other reference. To
calculate the proper spindle speed, divide the desired cutting speed by the circumference of
the tool expressed in feet. The feed rate depends on the width and depth of cut, finish desired
and many other variables. To calculate the desired feed setting from the feed rate, multiply
feed per tooth per revolution by number of teeth and rpm of the spindle.

2.4.7. Setting Spindle Speed

Spindle speed is varied by changing the geometry of the drive train. On many modern
machines, it can be adjusted continuously with a hand crank. The spindle must be turning to
make the adjustment. A dial indicator reads the speed in rpm. The spindle speed dial indicator
shown above has two scales, one for low range, and one for high range. The machine is

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switched between ranges with a lever. Sometimes, the spindle must be rotated slightly to
allow the gears to mate properly.

2.4.8. Using the Edge Finder

Before doing precise work on a milling machine, one must locate the edges of a part
accurately. An edge finder is designed to help you do this. An edge finder is composed of two
concentric cylinders, spring loaded together. To use it, offset the two halves slightly so that
there is a wobble as it spins. Then, move the part into the tool slowly. The edge finder will
center up, and then break out of concentricity suddenly. At that point, reset the dial indicator
or digital readout for that axis of the machine to a value equal the radius of the edge finder.
Repeat the process at least once.

2.4.9. Using the Micrometer Dials

Most milling machine manual feeds are equipped with dial indicators. If you know how far
you want to feed the bed, you can set the dial indicator to that number (in thousandths of an
inch). Just turn the locking ring counterclockwise to free the dial indicator, set the dial, and
lock in the setting. Be certain that the backlash in the mechanism driving the table is taken up
prior to setting the dial indicator.

Many modern machines have digital readouts. These are preferred since they measure the bed
position directly so you need not be concerned with backlash. They also read out bed position
in metric units if desired.

2.4.10. Face Milling Figure 2.18

It is often necessary
to create a flat face
on a large part. This can be done best with a facing cutter.
Select a cutter about one inch wider than the work piece
so that the facing can be accomplished in one pass.

Figure 2.19

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2.4.11. Milling Slots

End mills are designed to cut square slots. They will

produce a slot to within two one thousandths of an
inch in one pass. If greater accuracy is required, use an
end mill a little smaller than the desired slot. Measure
the slot produced and opens it to the desired
dimension with a second pass. The following clip
shows and end mill cutting a slot. Note that the depth
of cut is approximately equal to the diameter of the
cutter.
Figure 2.20
2.4.12. Advanced Work Holding

To hold round stock more securely in a vise, use a v-block. The work can be held vertically
or horizontally. Round stock often cannot be held securely in the vise without damaging the
work. A collet block is designed to hold round stock. Square collet blocks allow the part to be
indexed to put in features at 90 degree increments. To mill features at 60 degree increments,
use a hexagonal block.

A work piece can be set up easily when the desired features are parallel with or perpendicular
to the work piece edges. When the features are at an angle to the edges, more ingenuity is
required. Here, an angle plate is used to set the position of a vise within a vise. Thus a slot
can be milled into a work piece at any desired angle.

Some parts don't fit well into a vise. These parts can be secured directly to the bed of the
machine with hold down clamps. It is good practice to create a gap between the bed and the
work with parallels. The clamps should be tilted down slightly into the work.

To create circular features on a mill, a rotary table can be installed onto the bed. The table
allows the work piece to be rotated. A dial indicator allows precise control of the angle of
rotation.

2.5. GRINDING MACHINES

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At the IDB training I was also able to use grinding machines. There were two types of
grinding machines. They are Bench grinder and Surface grinder.

2.5.1. Bench Grinder

A bench grinder is a type of bench top grinding machine used

to drive abrasive wheels. A pedestal grinder is a larger version
of a bench grinder that is mounted on a pedestal, which is
bolted to the floor. These types of grinders are commonly used
to hand grind cutting tools and perform other rough grinding.
Depending on the grade of the grinding wheel it may be used
for sharpening cutting tools such as lathe tools or drill bits.
Alternatively it may be used to roughly shape metal prior
Figure 2.21
to welding or fitting. A wire brush wheel or buffing wheels can be interchanged with the grinding
wheels in order to clean or polish work-pieces. Grinding wheels designed for steel should not be used
for grinding softer metals, like aluminum. The soft metals get lodged in the pores of the wheel and
expand with the heat of grinding. This can dislodge pieces of the grinding wheel.

2.5.2. Surface Grinder

Surface grinding is used to

produce a smooth finish on
flat surfaces. It is a widely
used abrasive
machining process in which
a spinning wheel covered in
rough particles (grinding
wheel) cuts chips of metallic
or non metallic substance
from a work piece, making a
face of it flat or smooth
Figure 2.22

2.5.3. Work Carried Out Using Grinding Machine

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Mostly I used bench grinding machine to sharpen tools and etc. when I use
grinding tool I used eye protecting glasses too. Because some heated small
metals particles can cause damages to our eyes.

Also I used surface grinding machine to get a shining surfaces to metal parts.
When we want precise measurements to our work piece these machines very
helpful achieve those precise dimensions.

2.6. OXY-ACETYLENE CUTTING AND ELECTRIC ARC WELDING

Within the last few weeks of my training I was granted an opportunity to work in welding
section. In the welding section mainly there are two types of categories used to perform
cutting and welding. They are,

2.6.1. Oxy-Acetylene Cutting

Within the first week of welding section I learned about oxy-acetylene cutting process. First I
started learning oxy-acetylene cutting fundamentals. At the begging I was familiar with all
the components used in oxy-acetylene cutting like torch, regulators, hoses, striker, etc. and
some basic steps like, how to fire up the torch, how to keep hoses when cutting the metal,
importance of holding breath till the cutting finished and how to control oxygen and
acetylene percentages to get the required flame. Also studied about the safety equipments that
will mention in another section and few safety procedures to follow when cutting metals as I
mentioned bellow,

a. Make sure the regulators are tight

b. Never use oily rags around cylinders and regulators
c. Check hoses and make sure mixing knob is off before lighting the torch.
d. Make sure regulators are in the proper settings. (15 psi max. acetylene 40 psi max.
oxygen)
e. Light acetylene first then mix oxygen

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Equipments used in gas

2.6.2. Electric Arc WeldingFigure 2.23 welding

Once I got experience of oxy-acetylene cutting I started learning electric arc welding. Same
as above mentioned I learned basics, familiar with equipments and started practicing it.
Regarding the electric arc welding section I found that there are so many safety issues while I
was practicing. Cables and other equipments are damaged. Safety equipments are broken. No
replacement for those broken equipments. Also there were no any notices regarding the safety
steps so I prepared a one and put it in the notice board to enlighten others about safety.

I listed some of them bellow,

• Always wear proper clothes when welding.

• Place ground lead on material before turning machine on.
• Check cables for cuts in the insulation.
• Never stand in water when welding.
• Never weld near flammable objects.

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Equipments used in arc welding,

Figure 2.24

• Welding Power source

• Electrode holder
• Ground clamp
• Welding cables and connectors
• Accessory equipments (chipping hammer, wire brush)
• protective equipments (helmet, gloves, etc)

Welding power source

Figure 2.25

Welding may utilize either alternating current (AC) or direct current (DC), but in either case,
the power source selected must be of the constant current type. This type of power source
will be deliver a relatively constant, the welding beads produced will be uniform in size and
shape.

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Whether to use an AC, DC, or AC/DC power source depends on the type of the welding
to be done and the electrodes used. The following factors should be considered,

i. Electrode selection- using a DC power source allows the use of the greater range of
electrode types. While most of electrodes are designed to be used on AC or DC, some
will work properly only on AC.
ii. Metal thickness – DC power source may be used for welding both heavy sections and
light gauge work. Sheet metal is more easily welded with DC because it easier to
strike and maintain the DC arc at low currents.
iii. Distance from work – if the distance from the work to the power source is great, AC
is the best choice since voltage drop through the cables is lower than DC. Even
though welding cables are made in copper or aluminum, the resistance in the cables
becomes grater as the cable length increases.
iv. Welding position - because DC may be operated at lower currents, it is more suitable
for overhead and vertical welding than AC. AC can successfully be used for out of
position work if proper electrodes are selected.
v. Arc blow- when welding with DC, magnetic fields are set up throughout of the
weldment. In weldments that have varying thickness and protrusions, this magnetic
field can affect the arc by making it stray of fluctuate in direction. This condition is
especially troublesome when welding in corners. AC seldom causes this problem
because of the rapidly reversing magnetic field produced.

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TRAINING EXPERIENCE CHAPTER 2

2.6.3. Work Carried Out At the Welding Section

At the welding section I was able to get hands on experience with oxy acetylene and electric
arc welding processes. Then I was assigned to cut metal patters to make a ribbon for the clay
mixing machine. It was a very hard process. I had to weld those pieces to a shaft and bend to
get the required shape. So I took help from another experienced welder. There he told me
how the welding should perform and how the to bend those metal parts to get the correct
shape. I followed his advice but it was very difficult me to complete it. So with his help
finally I was able to complete it.

2.7. ELECTRIC DISCHARGE MACHINE PROCESS

Electrode
Figure 2.27
Figure 2.26 Figure 2.29
Kerose
ne bath

Figure 2.28

Tabl
Operational
tower

Electric discharge machining (EDM), sometimes colloquially also referred to as spark

machining, spark eroding, burning, die sinking or wire erosion, is a manufacturing process
whereby a desired shape is obtained using electrical discharges (sparks). Material is removed
from the work piece by a series of rapidly recurring current discharges between
two electrodes, separated by a dielectric liquid and subject to an electric voltage. One of the
electrodes is called the tool-electrode, or simply the ‘tool’ or ‘electrode’, while the other is
called the work piece-electrode, or ‘work piece’.

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 TRAINING EXPERIENCE CHAPTER 2

When the distance between the two electrodes is reduced, the intensity of the electric field in
the volume between the electrodes becomes greater than the strength of the dielectric which
breaks, allowing current to flow between the two electrodes. This phenomenon is the same as
the breakdown of a capacitor. As a result, material is removed from both the electrodes. Once
the current flow stops, new liquid dielectric is usually conveyed into the inter-electrode
volume enabling the solid particles to be carried away and the insulating proprieties of the
dielectric to be restored. Adding new liquid dielectric in the inter-electrode volume is
commonly referred to as flushing. Also, after a current flow, a difference of potential between
the two electrodes is restored to what it was before the breakdown, so that a new liquid
dielectric breakdown can occur.

2.7.1. Advantages and Disadvantages

Some of the advantages of EDM include machining of:

 Complex shapes that would otherwise be difficult to produce with conventional cutting
tools

 Extremely hard material to very close tolerances

 Very small work pieces where conventional cutting tools may damage the part from
excess cutting tool pressure.

 There is no direct contact between tool and work piece. Therefore delicate sections and
weak materials can be machined without any distortion.

Some of the disadvantages of EDM include:

 The slow rate of material removal.

 The additional time and cost used for creating electrodes for ram/sinker EDM.

 Reproducing sharp corners on the work piece is difficult due to electrode wear.

 Specific power consumption is very high.

2.7.2. Work Carried Out Using the Lathe Machine

At the end of the training period I obtained a chance to follow bit

about EDM Machines. In the IDB workshop there is a one EDM
machine. So once I got the opportunity I learned about the process
and the operation I was able to link to an undergoing project. It was
Figure
2.30
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TRAINING EXPERIENCE CHAPTER 2

about cutting mold to a plastic guard of the elbow crutch. Mold is use to make the plastic
guard through the injection molding process. So we took a steel cube as the work piece and
mount it on the EDM machine table. Then mount the electrode (tool) on the EDM machine
and turn on the machine. The cutting was performed inside the kerosene bath. All the work
piece particles dissolve in the kerosene and electrode sank into the work piece.

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CONCLUSION CHAPTER 3

CHAPTER 3: CONCLUSION

3.1 Review of Training Experience.

During my twenty two weeks of training at Industrial Development Board I worked in IDB
workshop function under the Engineering department. At the IDB workshop I learned
practical applications of mechanical engineering. I was able to gain fair amount of knowledge
about the machine and machine processes above mentioned. Most of the time I have done
studies by my self. During my training period I was able to participate in few of on going
projects.

More importantly during my training experience I had to work with various people from chief
engineer to workers of the IDB. I learned the way to move with them quite easily and at the
end of training they became very good friends of mine. When we were carrying out projects
we had chance to discuss with machine operators and workers. I think I gained more
knowledge from them than the workshop engineer and chief engineer.

Industrial development board gave us opportunity to involve in their new project carried out.
I think these were vital opportunities that we were able to work with different people and to
apply our knowledge.

3.2 Comments on training establishment

I think that the Industrial development board has the capacity of giving a useful training for
the mechanical engineering undergraduates. Facilities available at there are acceptable.
Machines operators, workers and fitters and IDB management gave their best to us. These
people are little bit busy in a working time of a day. But we were able to interact with them
frequently. Though they had some problems with IDB administration they guided us towards
the correct path.

Normally IDB is not profit oriented but its duty is to help small and medium
industries and promote self employment. But today for many reasons they haven’t been able
to achieve those objectives. So IDB has become a semi government company that destroys
the public money. But there was a time IDB functions to achieve the company objectives. But
unfortunately to day that has changed. But I believe the present authorities will find a way to
recover those burning problems and fulfill the country needs.

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CONCLUSION CHAPTER 3

3.3 Suggestions

I think it is better to give a training schedule at the beginning of the training period to each
trainee. I think training division has to point out this to IDB management.

I also think our industrial training should be shift to level 4 semesters 2 because it will helpful
to trainees to find there jobs.

Finally must say my training at Industrial development board of Ceylon was successful and I
met my most of the expectations during my training periods I must grateful to the effort
taken by the training division with NAITA deliver us a industrial training for our future
benefits.

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ANNEXES

ANNEXES
Annexes contain reports and drawings that I have prepared during training period.

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