INDUSTRAIL

REPORT
LOHIA STARLINGER LIMITED, KANPUR (INDIA)

PREPAID BY

YADBIR SINGH

STUDENT OF MECHANICAL ENGINEERING (3rd year)

BHABHA INSTITUTE OF TECHNOLOGY

KANPUR (D), INDIA

Suncity12300@gmail.com
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ACKNOWLEDGEMENTS

I would like to extend my heartfelt thanks and deep sense of gratitude to all those
who helped me to writing this Report. First, I would like to express my sincere thanks to
my sir Mr. Sarvendra Singh (TCP) of B.I.T, Kanpur. I would also like to express my
thanks to Er. Bupendra Singh Verma, NTPC Faridabad.

This most sincere and important acknowledgement and gratitude is due to my parents,
who have given their moral boosting support and encouragements at some stage of this
endeavor.

Yadbir Singh

Students of Mechanical Engineering

Bhabha Institute of Technology,

Kanpur, India.
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CONTACTS

PAGE NO

1. Introduction……………………………………………………………………………...4

2. Description of visit………………………………………………………………………..5-
6

3. Machine used

4. Bibliography.......................................................................................................................15

INTRODUCATION
About a Company
(Lohia Starlinger limited Kanpur, India)

www.lohiagroups.com
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LOHIA GROUP, promoted by a well known business family of North India, diversified
from traditional business and ventured into manufacture of high-tech machines way back in
mid '70s. LOHIA GROUP, has a long tradition of excellence is currently active in machinery,
mechanical sub-contracting, textiles and engineering plastics. Few of their mastered domains
include Extrusion Plants for polypropylene filament
yarns, Weaving, Winding and Slitting Machinery. The
GROUP enjoys tremendous amount of goodwill and
reputation on account of its quality standards.

LOHIA ENGINEERING WORKS, a firm belonging

to LOHIA GROUP, began with the manufacture of
Schweiter type cone-winding machines, to handle a
variety of yarns. Presently, the GROUP is primarily
engaged in engineering sector with LOHIA
STARLINGER LIMITED as its flagship Company,
under the leadership of its Chairman Mr. Raj Kumar
Lohia.

LOHIA STARLINGER LIMITED incorporated in

1981, is engaged in manufacture of complete range of
machines required by Plastic Woven Fabric Industry and
is an undisputed leader amongst machine manufacturers
of this industry. At present, it is not only enjoying over
60% of market share in India but has also earned a
reputation of world's leading manufacturer of such equipments. Its projects are running
successfully in over 60 countries around the world and this accomplishment has been possible
due to the GROUP's continuous emphasis on quality and innovation. The Company has an
outstanding track record to its credit as it enjoys the status of 'Trading House' and is
accredited ISO:9001:2008 CERTIFICATE BY DNV NETHERLANDS.

Along with LOHIA STARLINGER LIMITED, LOHIA GROUP also comprises of

THREADS (INDIA) LIMITED incorporated in 1983 engaged in manufacture of industrial
synthetic sewing thread and INJECTOPLAST PRIVATE LIMITED primarily engaged in
manufacturing of high performance engineering plastic components for automobile sector.
Besides these there are other companies promoted by the Group that are engaged in various
business activities.

Chairman’s Message
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We at Lohia Group have been active for three decades in

manufacturing industry producing high technology and cost
competitive industrial products for domestic and export markets. We
have continuously invested to create most up-to-date design &
development, manufacturing and related capabilities including human
resources to produce quality products and services for the world
markets. LOHIA STARLINGER LIMITED has achieved status of a
major global supplier of repute for machinery for producing flexible
woven sacks and fabric for a wide range of applications with Mr. Raj Kumar
references in almost 60 countries. We are committed to enhance our Lohia
leadership position by leveraging our core strengths to continuously Chairman, Lohia
innovate to create advantages for all our stakeholders. Group

Mission

• To follow the best practices as a responsible corporate and contribute in sustainable

development of the society including employees.
• To preserve and enhance the integrity in all our business dealings by continuous
monitoring, control and interventions without any compromises and concessions.
• To achieve leading position in each of our business sector by sustainable and
profitable growth creating long term wealth for the shareholders
• To provide total customer satisfaction through quality products and services at
competitive costs.
• To make continuous upgradation in our products through innovation anticipating the
needs of our markets and customers.
• To maximize the exports of our all products by offering quality products and services
at competitive costs combining with our intellectual and trade resources.

Vision
• To enlarge our product portfolio and production capacities in each of our businesses
leveraging our domain knowledge, expertise and resources by fostering global
partnerships and alliances to become leading global player with dominant market
share.
• To be the partner of choice for our customers by providing technology based world
class products and performance enhancing services tailored to meet their
requirements.
• To develop bench mark innovations and technologies to suit the changing
requirements of the customers & the industry by continuous investments in updating
our manufacturing & human resources.
• To provide total customer satisfaction through quality products and services at
competitive costs.
• To attain the leadership in technology, quality, services and costs with integrity and
stability.

DESCRIPTION OF VISIT
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On Tuesday 24 august 2009 we were going outside the institute Bhabha Institute of
Technology, Kanpur (D) UP, India. This was a small journey to Kanpur city at industry
Lohia Starlinger Limited Kanpur (D).we are 33 students and 2 more people with us.
When we assemble at lohia company then we are going to lohia R&D section of that
company. After that we meets to HR person of that company he give me a sweet speech
for making future engineer. According to him an engineer is person who develops the
nation by improving the technology as well as growing future demand of nation. After
that we are joining with the company of two more section engineer of lohia groups with
help of section engineer.
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During two and three hours visit we good knowledge about machine such as lathe
machine staper machine and many more machine. These machine are total as well as
CNC machine these machine are fully programming based machine. This is short visit
but give much knowledge about a company as well as company term work. Customer's
satisfaction by delivering quality products has been the corner stone of Lohia Group.
The group, therefore, believes in manufacturing of all critical and precision components
in-house. The production facilities of the group companies are equipped with high
precision machine tools and managed by a team of well qualified and experienced
engineers and technicians.

After that we are going to in Kanpur city. Where are celebrate the birthday party of our
friends. This is second’s visit of me in a big company for getting known about company.

This picture of Lohia groups company.

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MACHINE USED

1 LATHE MACHINE
A lathe (pronounced /ˈleɪð/) is a machine tool which spins a block of material to perform
various operations such as cutting, sanding, knurling, drilling, or deformation with tools that
are applied to the workpiece to create an object which has symmetry about an axis of rotation.

Lathes are used in woodturning, metalworking, metal spinning, and glassworking. Lathes can
be used to shape pottery, the best-known design being the potter's wheel. Most suitably
equipped metalworking lathes can also be used to produce most solids of revolution, plane
surfaces and screw threads or helices. Ornamental lathes can produce three-dimensional
solids of incredible complexity. The material is held in place by either one or two centers, at
least one of which can be moved horizontally to accommodate varying material lengths.

Description
The purpose of a lathe is to rotate a part against a tool whose position it
controls. It is useful for fabricating parts and/or features that have a circular cross section.
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The spindle is the part of the lathe that rotates. Various work holding attachments such as
three jaw chucks, collets, and centers can be held in the spindle. The spindle is driven by an
electric motor through a system of belt drives and/or gear trains. Spindle speed is controlled
by varying the geometry of the drive train.
The tailstock can be used to support the end of the work piece with a center, or to hold tools
for drilling, reaming, threading, or cutting tapers. It can be adjusted in position along the
ways to accommodate different length work pieces. The ram can be fed along the axis of
rotation with the tailstock hand wheel.
The carriage controls and supports the cutting tool. It consists of:
• A saddle that mates with and slides along the ways.
• An apron that controls the feed mechanisms.
• A cross slide that controls transverse motion of the tool (toward or away from the
operator).
• A tool compound that adjusts to permit angular tool movement.
• A tool post T-slot that holds the tool post.

Choosing a Cutting Tool

• Cutting tool geometry varies with the type of work to be done.
• 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. Installing a Cutting Tool
Lathe cutting tools are held by tool holders. To install a tool, first clean the holder,
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.
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Positioning the Tool

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 Cut

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 workpiece, 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.
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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 should not extend more that three times its diameter. Then install a roughing or
finishing tool (whichever is appropriate). If you're feeding the saddle toward the headstock
(as in the clip below) 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.
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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 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 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.
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 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.
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 tailstock. Make certain that the tang on the
back of the drill chuck seats properly in the tailstock. 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 into position, and
lock the it in place (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 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 collets.
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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 spindle speeds or by grinding a smaller radius on the nose of the
tool.
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2. 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 is mechanically coupled to the carriage lead
screw. Procedures vary for different machines.

Advanced Work Holding

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
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

An angle plate is a work holding device used as a fixture in metalworking.

The angle plate is made from high quality material (generally spheroidal cast iron) that has
been stabilized to prevent further movement or distortion. Slotted holes or T bolt slots are
machined into the surfaces to enable the secure attachment or clamping of workpieces to the
plate, and also of the plate to the worktable.
Angle plates also may be used to hold the workpiece square to the table during marking out
operations.
Adjustable angle plates are also available for workpieces that need to be inclined, usually
towards a milling cutter.
A jig grinder is a machine tool used for grinding complex shapes and holes where the
highest degrees of accuracy and finish are required.
The jig grinder is very similar to a jig borer, in that the table positioning and spindles are very
accurate (far more so than a manual milling machine or lathe). It is almost exclusively used
by tool and die makers in the creation of jigs or mating holes and pegs on dies. There are
usually many peripheral elements to a large jig grinder, including separate hydraulic motors,
air compressors, and various cooling systems for both the hydraulic circuit and supplying
coolant to the work and machine itself.
The machine operates by a high speed air spindle rotating a grinding bit. The air spindles are
removable and interchangeable to achieve varying surface speeds. Some spindles are fixed
speed (60000 rpm), others are adjustable (30000-50000 rpm), and still others are very high
speed (175000 rpm). The machines have a standard X-Y table with the notable exception of
knee travel. All axes are indexed to .0001" via a vernier scale on the handwheels, with higher
accuracy available with the use of measuring bars. The machine head has two vertical travels,
one rough head adjustment and the other a precise spindle adjustment. The spindle to which
the detachable air spindle mounts also rotates at a variable speed and can typically outfeed .
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100" while running, again with an accuracy of .0001" on the handwheel or greater, for very
precise hole, peg and surface grinding. A well-kept jig grinder will reliably position work to a
higher degree of accuracy than is possible with handwheels alone. These features are all
critical in positioning a hole and peg system a precise distance from a reference surface or
edge.
The most important factor on a jig grinder is the dual-spindle configuration. The main spindle
is roughly positioned with between 1" or 2" of travel for setup, and then the .100" of outfeed
is used during machine operation to outfeed into the work. A spacer bar may be used between
the grinder and main spindle, allowing large (9" radius or larger) work to be completed. The
main spindle has a wide range of speeds to ensure proper grinder feed rates are maintained.

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3.Planing and shaping

This section covers several machining operations that are used to machine straight and open
external or internal surfaces:

Planing and shaping:

These operations are used to machine straight open mainly external surfaces with a single-
point cutting tool.

Broaching
Broaching is used to machine straight and open basically internal surface of complex cross-
section shapes by means of a special tool called a broach

• Planing and shaping are similar operations, which differ in the kinematics of the
process.

• Planing is a machining operation in which the primary cutting motion is performed by

the workpiece and feed motion is imparted to the cutting tool.

• In shaping, the primary motion is performed by the tool, and feed by the work piece

Broaching is a machining operation which uses a toothed tool, called a broach, to remove
material. The broach is used in a broaching machine, which is also sometimes shortened to
broach. It is used when precision machining is required, especially for odd shapes. Broaching
finishes a surface in a single pass, which makes it very efficient. Commonly machined
surfaces include circular and non-circular holes, splines, and flat surfaces. Typical workpieces
include small to medium sized castings, forgings, screw machine parts, and stampings. Even
though broaches can be expensive, broaching is usually favorable to other processes when
used for high-quantity production runs.[1]
Broaches are shaped similar to a saw, except the teeth height increases over the length of the
tool. Moreover, the broach contains three distinct sections: one for roughing, another for
semi-finishing, and the final one for finishing. Broaching is a unique machining process
because it is the only one to have the feed built into the tool. The profile of the machined
surface is always the inverse of the profile of the broach. The rise per tooth (RPT), also
known as the step or feed per tooth, determines the amount of material removed and the size
of the chip. The broach can be moved relative to the workpiece or vice-versa. Because all of
the features are built into the broach no complex motion or skilled labor is required to use it
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4.Cutting tools
Technically, grinding wheels are a subset of cutting tools, as grinding is a true metalcutting
process. Each grain of abrasive functions as a microscopic single-point cutting edge (although
of high negative rake angle), and shears a tiny chip that is analogous to what would
conventionally be called a "cut" chip (turning, milling, drilling, tapping, etc.). However,
among people who work in the machining fields, the term "cutting" is most often understood
to refer to the macroscopic cutting operations, and grinding is mentally categorized as a
"separate" process. This is why the terms "cutting" and "grinding", or "machining" and
"grinding", are often used in contradistinction in shop-floor practice, even though technically
grinding is a subset of cutting. Consequently, the term "cutting tool" is often used to refer to
all cutters used in "regular" (non-grinding) machining, and thus to exclude grinding wheels.

Cutting tools must be made of a material harder than the material which is to be cut, and the
tool must be able to withstand the heat generated in the metal-cutting process. Also, the tool
must have a specific geometry, with clearance angles designed so that the cutting edge can
contact the workpiece without the rest of the tool dragging on the workpiece surface. The
angle of the cutting face is also important, as is the flute width, number of flutes or teeth, and
margin size. In order to have a long working life, all of the above must be optimized, plus the
speeds and feeds at which the tool is run.
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BIBLIOGRAPHY

• All the material (lohiya groups) has been copied from the www.lohiyagroups.com
website.

• A picture of whole report has collection of my friends as well as sir Sarvendra singh.

• Machine parts are collects from the text books. K.M. MODI.