Internship ReportMuhammad Faran, HITEC University Taxila 1 Internship Report Submitted to: Respected Lt. Col. Shafqat Hussain Supervised by: Respected Maj. Muhammad Shoaib Qazi Submitted by: Muhammad Muhammad Faran 10-HITEC-ME-104 HITEC University, Taxila Cantt Duration: 06 Weeks Internship Report Muhammad Faran, HITEC University Taxila 2 No Title Page No. 1 Abstract 3 2 Acknowledgement 3 3 Introduction to Heavy Industries Taxila 4 4 Modules of Internship 10 5 Pro Engineer Modeling 11 6 CNC Manufacturing Codes 13 7 Pro Engineer Modeled Images & Auto Cad Drawings 20 8 Finite Element Analysis 22 9 Observations 25 Internship Report Muhammad Faran, HITEC University Taxila 3 Abstract: The report describes my six weeks experience and technical activities performed at APC Factory HIT. The report comprises of “Detailed study and modeling of the armored Cover Plate for the fuel cell of Armored Personnel Carrier Vehicle SAAD manufactured at the APC manufacturing facility Heavy Industries Taxila. The plate model was generated using Pro Engineer Software, Creo Parametric 2.0 available in the CAD/CAM section of Factory”. Acknowledgement: My internship at APC Factory gave me a golden opportunity for learning and self development. I consider myself very lucky and honored to have so many wonderful people to lead me in this whole session. My grateful thanks to Honorable Lt. Col. Shafqat Hussain, who allowed me six weeks internship here, I also want to say thanks to Respected Maj. Muhammad Shoaib Qazi, who in spite of being extraordinarily busy with his duties, took time out to hear, guide and keep me on the correct path. A humble ‘Thank you’ sir! Last but not the least I also want to say thanks to the my dear instructors AWM Mr. Mian Abdul Hafeez, AFM Mr. Muhammad Sarfraz, AFM Mr. Dawood Khan & HS-I Mr. Mahfooz-ul-Haq who equipped me with technical knowledge and shared valuable information that helped me so much in the whole session and will help me in the future. Internship Report Muhammad Faran, HITEC University Taxila 4 Introduction to HIT: Heavy Industries or (HIT) Taxila lies 35 km north-west of Rawalpindi/ Islamabad. Heavy Industries Taxila (HIT) is a manufacturing facility which has built the Main Battle Tank “Al-Khalid", Armoured Personel Careers, Al-Zarar Tank. Heavy Industries Taxila formerly known as Heavy Rebuild Factory (HRF) was established in Taxila in the late seventies to undertake rebuild and modernization of Chinese tanks. Heavy Rebuild Factory (HRF) was renamed to Heavy Industries Taxila (HIT) in September 1992. Now HIT consists of six major military factories. Activities of HIT now include the cost effective manufacture of armoured fighting vehicles, armoured personnel carriers and tank guns. Facilities: Heavy Industries Taxila comprises various defense factories and facilities: Heavy Rebuild Factory T-Series To rebuild and modernize tanks/armoured recovery vehicles of Chinese and Eastern European origin. Heavy Rebuild Factory M-Series Heavy Rebuild Factory (M-Series) carries out rebuild of tracked vehicles of US origin. The factory specializes in M113 Series vehicles. APC Factory The M113 Family of vehicles are manufactured in this factory using CNC machines CAD/CAM system and manufacturing technology on MIG and TIG aluminum welding, radiographic inspection, chemical cleaning, coating and painting according to military specifications. Gun Factory The Gun factory has the capability of machining barrels ranging from 105 mm to 203 mm caliber. It manufactures 105mm gun barrels for upgraded T-59 & T-69 tanks. Each barrel is auto-frottage and subjected to high precision work on state of the art machines. Tank Factory Tank Factory is equipped with modern manufacturing facilities, including 7-axis CNC machines, for flexible heavy-duty machining operations and a complete infrastructure for hull and turret manufacture. Development, Engineering Support And Components Manufacture (DESCOM) Internship Report Muhammad Faran, HITEC University Taxila 5 This production facility has been established to provide engineering support to all the factories of HIT. Equipped with CNC machines, it undertakes manufacture of components, assemblies, tools, dies, gauges and arranges development of spare parts through the vendor industry. It also provides repair and maintenance support to machinery and equipment installed in HIT. Evaluation, Training And Research Organization (ETRO) This is a supporting organization which undertakes Quality Assurance of finished products with quality assurance laboratories which test physical and chemical properties of production materials, calibration facilities are available to ensure accuracy of tools and gauges used in rebuild and manufacturing processes. Mechanical Complex This complex manufactures sugar plants, cement plants, boilers, cranes, road construction machinery, brick-making machinery and other equipment to cater for the needs of Railways and other civilian organizations. Research And Development (R&D) HIT has undertaken R&D projects on required basis wherein it has carried out successful R&D in the following areas: Tank design Tank modernization Infantry fighting vehicles Tank fire-control systems Production: Former: Type 69-II - Main battle tank produced under license. Type 85-IIAP - Main battle tank produced under license. M113 - Armoured personnel carrier produced under license. Current: Main battle tanks (MBT) Al-Khalid Al-Zarrar Artillery MKEK Pinter towed howitzer. Armoured personnel carriers (APC) Talha : Internship Report Muhammad Faran, HITEC University Taxila 6 APC based on M113 chassis with 5 road wheels, accommodates 11 fully equipped troops. 250 delivered to the Pakistan Army by 2006. Saad : APC based on the Talha design. Modified with extended hull and 6 road wheels, 14.5 mm machine gun, improved amour protection and a more powerful engine supplied by Germany's MTU. Accommodates 13 fully equipped troops. Sakb : Armoured command vehicle based on Talha APC. Al-Hamza: Infantry fighting vehicle (IFV) based on the Saad APC, fitted with 25 mm automatic cannon, an export product not in service with the Pakistan Army. Armoured guided missile carriers: Maaz: Based on the Talha APC, armed with the Baktar-Shikan anti-tank guided missile (ATGM) launcher and operated by a crew of 4. There is capacity for 8 extra rounds and the missile firing unit on the roof is retracted into the cabin for reloading. Mouz: Based on the Talha APC, armed with either the RBS 70 or Anza I/II air-defense missile systems. The missile firing unit on the roof is retracted into the cabin for reloading. Auxiliary armoured vehicles: Al-Hadeed : Armoured recovery vehicle (ARV) based on Saad APC. Al-Qaswa : Armoured logistics vehicle (ALV) based on the Talha APC. Armored cars: Muhafiz : Armoured security vehicle based on the Land Rover Defender. Under development: 155 mm Self-propelled artillery gun - Project revealed at IDEAS 2002 defense exhibition. Al-Khalid II - Under development. Internship Report Muhammad Faran, HITEC University Taxila 7 Pictures: (M113P) (Al-Zarrar) (AL-Khalid) (Muhafiz Vehicle) Internship Report Muhammad Faran, HITEC University Taxila 8 Flow Process Steps APC M113P (Saad): The step wise process is given below 1- Material Cutting 2- Finishing 3- Quality Control QC 4- Bottom Plate Fabrication 5- Final Drive left/Right Assembly 6- Box Beam Assembly 7- Storage Lower Nose Plate 8- Auto Weld 9- Top Plate 10- Rear Plate 11- Slide Plate Left /Right 12- Sponson Plates 13- Driver Hatch Assembly 14- Upper Hull Welded 15- Lower & Upper Hull Welded 16- Auto Weld Hull 17- Position Welding 18- Ramp Mating on Hull 19- Hull Inspection 20- Hull Machining 21- Deoxidization 22- Engineering Compartment 23- Bulk Head Assembly 24- Grill Mating 25- Storage Position Welding 26- Final Storage Read Line Fuel Cell Grill Assembly Ramp & Door Cargo Hatch Driver Hatch Cover Plate Door 27- Quality Control Internship Report Muhammad Faran, HITEC University Taxila 9 28- Sub Assembly welded 29- ITB 30- STS 31- Track Fitted 32- Engine Installment 33- Final Paint 34- Ready Flow Process Steps of Security Vehicle (Muhafiz): The step wise process is given below 1- Material Cutting 2- Finishing 3- Quality Control QC 4- Bottom Plate Fabrication 5- Side Plate Left/ Right Stowage 6- Rear Plate Stowage 7- Job Plate Stowage 8- Hull Mating 9- Final Stowage Door Retainer Rifle Rack Fire Extension Eng Safety Plate Hull 10- Hull Finishing 11- Door Stowage 12- Door Fitting 13- Bonnet Fitting 14- Cargo Hatch Extension Cover Fitting 15- Driver Compartment Safety Plate 16- Fuel & Governor Box 17- Bumper Assembly 18- Turret Assembly 19- Final Finishing Internship Report Muhammad Faran, HITEC University Taxila 10 20- Quality Control 21- STS Anodizing 22- Hull Painting 23- Hull Chases Mounting 24- Front/ Rear Bumper Fitting 25- Dash Board Fitting 26- Steering/ Gear Box Fitting 27- Electric Fitting 28- Minor assembly Fitting 29- Final Paint 30- Bullet Proof Glasses/ Tyre Fitting 31- AC work 32- Final Inspection 33- Quality Control QC 34- Ready Modules of internship: My internship was divided into three major modules. These modules are listed below and there detail is on next pages. 1. General overview of different Machines and their operations in Factory 2. Pro Engineer Modeling of armored fuel Tank cover plate 3. Analysis using Finite Element Methods software Introduction of machines in Workshop The APC factory has a number of different Machines working the operations regarding manufacturing and bullet proofing of armored personnel carrier vehicles. Most of the machines are CNC operated. Their codes are feed in them by using floppy disks. These codes are generated by using the Pro Engineer software. Workers in the CAD/CAM section model the required jobs in the software and the software generates codes for the working of machines. These codes are then feed in the machines and machines perform operations accordingly. There is an engine assembly section in which engines imported from foreign countries are fitted in the chasses of the Land Rover vehicle and then the vehicle is armoured with aluminium and steel metals Internship Report Muhammad Faran, HITEC University Taxila 11 Pro Engineer Modeling: The project assigned was to model the armoured plate of fuel cell cover. This was modeled in pro engineer and the codes for CNC machines were generated. The plate is manufactured using operations of Profile milling, drilling and cutting. Three codes were generated to avoid the problem of availability of drilling tools. Cutters (Profile millingh)were used in substitute to that issue. G & M codes: Generally G codes are written in and performed by the CNC processor and operate the motion control part of the control, the M codes are MACHINE codes, these operate most of the basic electrical control functions such as Coolant, Tool changers, safety circuits etc, the M, S & T codes are written in a separate PLC processor, both processors usually communicate with each other over a common bus. The tool changer and spindle are both configured to suit particular machine specifics. Al. G CODES CHART M CODES CHART G00 Positioning (rapid traverse) G01 Linear interpolation (feed) G02 Circular interpolation CW G03 Circular interpolation CCW G04 Dwell G07 Imaginary axis designation G09 Exact stop check G10 Offset value setting G17 XY plane selection G18 ZX plane selection G19 YZ plane selection G20 Input in inch G21 Input in mm G22 Stored stroke limit ON G23 Stored stroke limit OFF G27 Reference point return check G28 Return to reference point G29 Return from reference point G30 Return to 2nd, 3rd & 4th ref. point G31 Skip cutting G33 Thread cutting G40 Cutter compensation cancel M00 Program stop M01 Optional stop M02 End of program (no rewind) M03 Spindle CW M04 Spindle CCW M05 Spindle stop M06 Tool change M08 Flood coolant ON M09 Flood coolant OFF M19 Spindle orientation ON M21 Tool M22 Tool M23 Tool M24 Tool M25 Tool clamp M26 Tool unclamp M27 Clutch neutral ON M28 Clutch neutral OFF M30 End program (rewind stop) Internship Report Muhammad Faran, HITEC University Taxila 12 G41 Cutter compensation left G42 Cutter compensation right G43 Tool length compensation + direction G44 Tool length compensation - direction G45 Tool offset increase G46 Tool offset decrease G47 Tool offset double increase G48 Tool offset double decrease G49 Tool length compensation cancel G50 Scaling OFF G51 Scaling ON G52 Local coordinate system setting G54 Work coordinate system 1 select G55 Work coordinate system 2 select G56 Work coordinate system 3 select G57 Work coordinate system 4 select G58 Work coordinate system 5 select G59 Work coordinate system 6 select G60 Single direction positioning G61 Exact stop check mode G64 Cutting mode G65 Custom macro simple call G66 Custom macro modal call G67 Custom macro modal call cancel G68 Coordinate system rotation ON G69 Coordinate system rotation OFF G73 Peck drilling cycle G74 Counter tapping cycle M98 Call sub-program M99 End sub-program Internship Report Muhammad Faran, HITEC University Taxila 13 G76 Fine boring G80 Canned cycle cancel G81 Drilling cycle, spot boring G82 Drilling cycle, counter boring G83 Peck drilling cycle G84 Tapping cycle G86 Boring cycle G87 Back boring cycle G89 Boring cycle G90 Absolute programming G91 Incremental programming G92 Programming of absolute zero point G94 Per minute feed G95 Per revolution feed G96 Constant surface speed control G97 Constant surface speed control cancel G98 Return to initial point in canned cycle G99 Return to R point in canned cycle CNC Manufacturing codes: Plate 1 code: % N15 ( / MFG0001) (use cutter one inch) N20 M6 N25 S7000 M3 N30 G0 X13.28 Y.375 N35 Z1. M7 N40 Z.5 N45 G1 Z-.5 F100 N50 X6.53 N55 G2 X.375 Y6.53 I6.53 J6.53 N60 G2 X6.53 Y12.685 I6.53 J6.53 N65 G1 X13.28 N70 G2 X19.435 Y6.53 I13.28 J6.53 N75 G2 X13.28 Y.375 I13.28 J6.53 Internship Report Muhammad Faran, HITEC University Taxila 14 N80 G1 Z1. N85 G0 Y.875 N90 Z.5 N95 G1 Z-.5 F100 N100 X6.53 N105 G2 X.875 Y6.53 I6.53 J6.53 N110 G2 X6.53 Y12.185 I6.53 J6.53 N115 G1 X13.28 N120 G2 X18.935 Y6.53 I13.28 J6.53 N125 G2 X13.28 Y.875 I13.28 J6.53 N130 G1 Z1. N135 G0 Y1.375 N140 Z.5 N145 G1 Z-.5 F100 N150 X6.53 N155 G2 X1.375 Y6.53 I6.53 J6.53 N160 G2 X6.53 Y11.685 I6.53 J6.53 N165 G1 X13.28 N170 G2 X18.435 Y6.53 I13.28 J6.53 N175 G2 X13.28 Y1.375 I13.28 J6.53 N180 G1 Z1. N185 G0 X6.53 Y13.56 N190 Z.5 N195 G1 Z-1.5 F100 N200 X13.28 N205 G2 X20.31 Y6.53 I13.28 J6.53 N210 G2 X13.28 Y-.5 I13.28 J6.53 N215 G1 X6.53 N220 G2 X-.5 Y6.53 I6.53 J6.53 N225 G2 X6.53 Y13.56 I6.53 J6.53 N230 G1 Z1. N235 M30 % Plate 2 code: :S1500 M3 T1 Internship Report Muhammad Faran, HITEC University Taxila 15 :G0 X9.905 Y.905 N70 Z1. M7 N75 G81 X9.905 Y.905 Z-1.9002 R1. F50 N80 X15.8999 Y1.5524 N85 X18.905 Y6.53 N90 X15.8999 Y11.5076 N95 X9.905 Y12.155 N100 X3.8999 Y11.5023 N105 X.905 Y6.53 N110 X3.8999 Y1.5577 N115 G80 N120 M6 (Use Drill 1.125") :S1500 M3 T2 :G0 X9.905 Y.905 N135 Z1. M7 N140 G81 X9.905 Y.905 Z-.888 R1. F50 N145 X15.8999 Y1.5524 N150 X18.905 Y6.53 N155 X15.8999 Y11.5076 N160 X9.905 Y12.155 N165 X3.8999 Y11.5023 N170 X.905 Y6.53 N175 X3.8999 Y1.5577 N180 G80 N185 M6 (Use degree 45') Internship Report Muhammad Faran, HITEC University Taxila 16 :S7000 M3 :G0 X6.53 Y13.31 N200 Z1. M7 N205 G1 Z-.25 F100 N210 X13.28 N215 G2 X20.06 Y6.53 I13.28 J6.53 N220 G2 X13.28 Y-.25 I13.28 J6.53 N225 G1 X6.53 N230 G2 X-.25 Y6.53 I6.53 J6.53 N235 G2 X6.53 Y13.31 I6.53 J6.53 N240 G1 Z1. N245 M6 (Use cutter 1") :S7000 M3 :G0 X6.53 Y13.56 N260 Z1. M7 N265 Z.75 N270 G1 Z-1. F100 N275 X13.28 N280 G2 X20.31 Y6.53 I13.28 J6.53 N285 G2 X13.28 Y-.5 I13.28 J6.53 N290 G1 X6.53 N295 G2 X-.5 Y6.53 I6.53 J6.53 N300 G2 X6.53 Y13.56 I6.53 J6.53 N305 G1 Z1. N310 M30 % Internship Report Muhammad Faran, HITEC University Taxila 17 Plate 3 Code: % N5 G90 G94 N10 G40 G49 N15 ( / PLATEPART2) N20 M6 N25 S1500 M3 T1 N30 G0 X1.41 Y7.905 N35 Z1. M7 N40 G81 X1.41 Y7.905 Z-.8112 R1. F50 N45 Y9.155 N50 G80 N55 M6 N60 S1500 M3 T1 N65 G0 X9.905 Y.905 N70 Z1. M7 N75 G81 X9.905 Y.905 Z-1.9002 R1. F50 N80 X15.8999 Y1.5524 N85 X18.905 Y6.53 N90 X15.8999 Y11.5076 N95 X9.905 Y12.155 N100 X3.8999 Y11.5023 N105 X.905 Y6.53 N110 X3.8999 Y1.5577 N115 G80 N120 M6 N125 S1500 M3 T2 Internship Report Muhammad Faran, HITEC University Taxila 18 N130 G0 X9.905 Y.905 N135 Z1. M7 N140 G81 X9.905 Y.905 Z-.888 R1. F50 N145 X15.8999 Y1.5524 N150 X18.905 Y6.53 N155 X15.8999 Y11.5076 N160 X9.905 Y12.155 N165 X3.8999 Y11.5023 N170 X.905 Y6.53 N175 X3.8999 Y1.5577 N180 G80 N185 M6 N190 S7000 M3 T2 N195 G0 X6.53 Y13.31 N200 Z1. M7 N205 G1 Z-.25 F100 N210 X13.28 N215 G2 X20.06 Y6.53 I13.28 J6.53 N220 G2 X13.28 Y-.25 I13.28 J6.53 N225 G1 X6.53 N230 G2 X-.25 Y6.53 I6.53 J6.53 N235 G2 X6.53 Y13.31 I6.53 J6.53 N240 G1 Z1. N245 M6 N250 S7000 M3 N255 G0 X6.53 Y13.56 N260 Z1. M7 Internship Report Muhammad Faran, HITEC University Taxila 19 N265 Z.75 N270 G1 Z-1. F100 N275 X13.28 N280 G2 X20.31 Y6.53 I13.28 J6.53 N285 G2 X13.28 Y-.5 I13.28 J6.53 N290 G1 X6.53 N295 G2 X-.5 Y6.53 I6.53 J6.53 N300 G2 X6.53 Y13.56 I6.53 J6.53 N305 G1 Z1. N310 G0 X3.8999 Y11.4398 N315 G1 Z-.55 F100 N320 G3 X3.9624 Y11.5023 I3.8999 J11.5023 N325 G3 X3.8999 Y11.5648 I3.8999 J11.5023 N330 G3 X3.8374 Y11.5023 I3.8999 J11.5023 N335 G3 X3.8999 Y11.4398 I3.8999 J11.5023 N340 G1 Z1. N345 G0 X.905 Y6.4675 N350 G1 Z-.55 F100 N355 G3 X.9675 Y6.53 I.905 J6.53 N360 G3 X.905 Y6.5925 I.905 J6.53 N365 G3 X.8425 Y6.53 I.905 J6.53 N370 G3 X.905 Y6.4675 I.905 J6.53 N375 G1 Z1. N380 G0 X3.8999 Y1.4952 N385 G1 Z-.55 F100 N390 G3 X3.9624 Y1.5577 I3.8999 J1.5577 N395 G3 X3.8999 Y1.6202 I3.8999 J1.5577 Internship Report Muhammad Faran, HITEC University Taxila 20 N400 G3 X3.8374 Y1.5577 I3.8999 J1.5577 PRO ENGINEER MODEL IMAGES: By using Creo Parametric 2.0 fuel cell’s cover plate was modeled. This helped us to understand drawing reading concepts from paper. We translated the dimension readings from paper and then drew the model according to the dimensions given in the drawing sheet. A separate drawing sheet was also generated using Auto Cad 2007. The model from Pro Engineer was imported into Auto Cad. Internship Report Muhammad Faran, HITEC University Taxila 21 Internship Report Muhammad Faran, HITEC University Taxila 22 Finite Element Analysis: The designed part was tested using Finite Element Methods (FEA). This testing helped us to understand the strength and durability of the part. The method uses Mechanics of Materials theory. For analysis the cover plate was fixed for all degree of freedom constraints at the coordinates where bolts are tightened. A projected force momentum was applied at 10mm above in Y-axis from the center of plate. The results for deformation produces in the plate and stress were observed. The values of deformation stress were in range of safe design as proved by Von Mises theory. Following are the graphics attached from FEA Analysis. Ansys 14.0 software package was used for the analysis purposes. Internship Report Muhammad Faran, HITEC University Taxila 23 Internship Report Muhammad Faran, HITEC University Taxila 24 Internship Report Muhammad Faran, HITEC University Taxila 25 Observations: The model of plate was generated on pro engineer and then analyzed using Ansys 14.0 software. The results were very satisfactory and the plate showed a very little deformation on the impact of bullet striking. This confirms that the plate manufactured have a high factor of safety and is reliable.