Internship Report

On

TO STUDY OF INDUSTRIAL CNC MILLING MACHINES

By

Vaishnavi Revansidha Bandichode

In association with

SONA INDUSTRIES

Department of Mechanical Engineering

Al Ameen Educational & Medical Foundation’s

College of Engineering

Savitribai Phule Pune University, Pune

[2025-26]
 Al Ameen Educational & Medical Foundation’s
College of Engineering

Savitribai Phule Pune University, Pune

This is to certify that,

Vaishnavi Revansidha Bandichode has successfully completed the

Internship entitled “TO STUDY OF INDUSTRIAL CNC MILLING

MACHINE” under my guidance, in the partial fulfillment of Bachelor of

Engineering.

(Mechanical) of Savitribai Phule Pune University, Pune.

Date:
Place: Koregoan

HOD Principal External Examiner

2
 INDEX

SR.NO. TITLE PAGE

NO.
1 Acknowledgements 4
2 Abstract 5
3 Introduction 6
4 Objectives 7
5 Details of Internship 7
6 Company Overview 8
7 Manufacturing Processes 9
8 Milling Machining 11
1. Introduction
2. Process Cycles
3. Equipment’s
4. Tooling
5. Materials
6. Design Rule
7. Cost Drivers

9 Quality Inspection 18
10 Welding & fabrication processes 19
A]MIG Welding
B]TIG Welding
C]SMAW Welding
11 Conclusion 20

3
 1. ACKNOWLEDGEMENT
I take this opportunity to thank all those who have contributed in successful completion of T.E
Mini-Project/Internship work. . I would like to express my sincere thank you to my guide Prof.
Ramkumar Tadgure who has encouraged me to work on this topic and valuable guidance
wherever required.
I also extend my gratitude to Prof.Rajkumar Panchal (HOD of Mechanical) who has provided
to explore the subject with more enthusiasm. I am extremely indebted to SONA INDUSTRIES.
For giving me the opportunity to undertake my summer training at their prestigious SONA
INDUSTRIES. It was an incredibly good learning experience for me to have worked at this
site. I would like to convey my heartiest thanks to Mr.Vishwakarma Sing, General Manager.
I express my immense pleasure and thankfulness to all the teachers and staff of the Department
of Mechanical Engineering, P.G. Moze College of Engineering, and Pune for their cooperation
and support.

Vaishnavi Bandichode

4
 2. ABSTRACT

Internships are educational and career development opportunities, providing practical

experience in a field or discipline. Internships are far more important as the employers are
looking for employees who are properly skilled and having awareness about industry
environment, practices, and culture. Internship is structured, short-term, supervised training
often focused on tasks or projects with defined time scales. Core objective is to expose technical
students to the industrial environment, which cannot be simulated/experienced in the classroom
and hence creating competent professionals in the industry and to understand the social,
economic and administrative considerations that influence the working environment of
industrial organizations. Engineering internships are intended to provide students with an
opportunity to apply conceptual knowledge from academics to the realities of the field
work/training.

5
 3. INTRODUCTION

Milling is the most common form of machining, a material removal process, which
can create a variety of features on a part by cutting away the unwanted material.The milling
process requires a milling machine, workpiece, fixture, and cutter. The workpiece is a piece of
pre-shaped material that is secured to the fixture, which itself is attached to a platform inside the
milling machine. The cutter is a cutting tool with sharp teeth that is also secured in the milling
machine and rotates at high speeds.

By feeding the workpiece into the rotating cutter, material is cut away from this
workpiece in the form of small chips to create the desired shape. Milling is typically used to
produce parts that are not axially symmetric and have many features, such as holes, slots,
pockets, an even three dimensional surface con- tours. Parts that are fabricated completely
through milling often include components that are used in limited quantities, perhaps for
prototypes, such as custom designed fasteners or brackets. Another application of milling is the
fabrication of tooling for other processes. For example, three-dimensional molds are typically
milled. Milling is also commonly used as a secondary process to add or refine features on parts
that were manufactured using a different process. Due to the high tolerances and surface
finishes that milling can offer, it is ideal for adding precision features to a part whose basic
shape has already been formed.

6
 4. OBJECTIVES
Internship provides an excellent opportunity to learner to see understand the conceptual aspects
learned in classes and deployed into the practical world. Industry/on project experience
provides much more professional experience as value addition to classroom teaching.
1. To encourage and provide opportunities for students to get professional/personal experience
through internships.
2. To learn and understand real life/industrial situations.
3. To get familiar with various tools and technologies used in industries and their applications.
4. To nurture professional and societal ethics.
5. To create awareness of social, economic, and administrative considerations in the working
environment of industry organizations.

5. DETAILS OF INTERNSHIP

Organization: SONA INDUSTRIES

Address: KHARADI PUNE
Shop Floor: SOMNATH MALA KHARADI
Department: Manufacturing
Duration of Internship: 04/01/2025 to 02/04/20245

7
 7. COMPANY OVERVEIW

The company specializes in manufacturing all types of CNC machining, Milliling & Industrial
fabrication for various industries. The manufacturing department is responsible for producing
components and assembling the machines.
Their Experties in CNC, VMC heavy duty fabrication and machining also developed over 2000
parts. Their products are high in demands due to their premium quality. They are industrial
equipment supplier in Pune.

CNC Machine Milling Job Works

8
 8. MANUFACTURING PROCESSES
Mechanical manufacturing processes are major of two types one is additive manufacturing and
another is subtractive manufacturing. Subtractive manufacturing is the most widely used
manufacturing process. In this method, the material is removed from a block or bar provided
to get the desired shape and size with controlling its dimensions. this method consists of
different processes like turning, facing, boring, milling, etc. these processes are carried out on
different types of pieces of machinery like lathe machine, CNC machine, VMC machine,
milling machine, drilling machine, etc. these all machines removes material into the chip forms.
The chips formed in different processes having different nature in terms of shape size and
length etc. the scrap chips is the major waste product produced in every mechanical
manufacturing industry.
Manufacturing is the backbone of any industrialized nation. Manufacturing and technical staff
in industry must know the various manufacturing processes, materials being processed, tools
and equipments for manufacturing different components or products with optimal process plan
using proper precautions and specified safety rules to avoid accidents. Beside above, all kinds of
the future engineers must know the basic requirements of workshop activities in term of man,
machine, material, methods, money and other infrastructure facilities needed to be positioned
properly for optimal shop layouts or plant layout and other support services effectively adjusted
or located in the industry or plant within a well-planned manufacturing organization

9
 MANUFACTURING

CNC Bed Milling Machine VERTICAL MACHINE

10
 9. Milling Machining

8. Introduction
9. Process Cycles
10. Equipments
11. Tooling
12. Materials
13. Design Rule
14. Cost Drivers

1. INTRODUCTION
Milling is the most common form of machining, a material removal process, which
can create a variety of features on a part by cutting away the unwanted material.The milling
process requires a milling machine, workpiece, fixture, and cutter. The workpiece is a piece of
pre-shaped material that is secured to the fixture, which itself is attached to a platform inside the
milling machine. The cutter is a cutting tool with sharp teeth that is also secured in the milling
machine and rotates at high speeds. By feeding the workpiece into the rotating cutter, material is
cut away from this workpiece in the form of small chips to create the desired shape..
Milling is typically used to produce parts that are not axially symmetric and have
many features, such as holes, slots, pockets, an even three dimensional surface con- tours. Parts
that are fabricated completely through milling often include components that are used in limited
quantities, perhaps for prototypes, such as custom designed fasteners or brackets. Another
application of milling is the fabrication of tooling for other processes. For example, three-
dimensional molds are typically milled. Milling is also commonly used as a secondary process to
add or refine features on parts that were manufactured using a different process. Due to the high
tolerances and surface finishes that milling can offer, it is ideal for adding precision features to a
part whose basic shape has already been formed.

11
2. Process Cycles
The time required to produce a given quantity of parts includes the initial setup time and the
cycle time for each part. The setup time is composed of the time to setup the milling machine,
plan the tool movements (whether performed manu- ally or by machine), and install the fixture
device into the milling machine. The cycle time can be divided into the following four times:
Load/Unload time - The time required to load the workpiece into the milling machine and
secure it to the fixture,
• Cut time - The time required for the cutter to make all the necessary cuts in theworkpiece for
each operation. The cut time for any given operation is calculated by dividing the total cut
length for that operation by the feed rate, which is the speed of the cutter relative to the
workpiece.as well as the time to unload the finished part. The load time can depend on the size,
weight, and complexity ofthe workpiece, as well as the type of fixture.
• Idle time - Also referred to as non-productive time, this is the time required for any tasks that
occur during the process cycle that do not engage the workpiece and therefore remove material.
This idle time includes the tool approaching and retracting from the workpiece, tool movements
between features, adjusting ma- chine settings, and changing tools.
• Tool replacement time - The time required to replace a tool that has exceededits lifetime and
therefore become t o worn to cut effectively. This time is typically not performed in every
cycle, butrather only after the lifetime of the tool has been reached. In determining the cycle
time, the tool replacement time is adjusted for the production of a single part by multiplying by
the frequency of a tool replacement, which is the cut timedivided by the tool lifetime.
Following the milling process cycle, there is no post processing that is required. How- ever,
secondary processes may be used to improve the surface finish of the part if it is required. The
scrap material, in the form of small material chips cut from the workpiece, is propelled away
from the workpiece by the motion of the cutter and the spraying of lubricant. Therefore, no
process cycle step is required to remove the scrap material, which can be collected and
discarded after the production.

3. Equipments
Milling machines can be found in a variety of sizes and designs, yet they still possess the same
main components that enable the workpiece to be moved in three directions relative to the tool.
These components include the following:
1. Base and column - The base of a milling machine is simply the platform that sits on the
ground and supports the machine. A large column is attached to the base and connects to
the other components.
2. Table - The workpiece that will be milled is mounted onto a platform called the table, which
typically has ”T” shaped slots along its surface. The workpiece may be secured in a fixture
called a vise, which is secured into the T-slots, or the workpiece can be clamped directly

12
 .into these slots. The table provides the horizontal motion of the workpiece in the X-
direction by sliding along a platformbeneath it, called the saddle.
3. Saddle - The saddle is the platform that supports the table and allows its longitudinal
motion. The saddle is also able to move and provides the horizontal motion of the workpiece
in the Y direction by sliding transversely along
4. The knee is the platform that supports the saddle and the table. In most milling machines,
sometimes called column and knee milling machines, the knee providesthe vertical motion
(Z direction) of the workpiece. The knee can move vertically along the column, thus moving
the workpiece vertically while the cutter remains stationary above it. However, in a fixed
bed machine, the knee is fixed while the cutter moves vertically in order to cut the
workpiece.

The above components of the milling machine can be oriented either vertically or horizontally,
creating two very distinct forms of milling machine. A horizontal millingmachine uses a cutter
that is mounted on a horizontal shaft, called an arbor, above the workpiece. For this reason,
horizontal milling is sometimes referred to as arbor milling. The arbor is supported on one side
by an overarm, which is connected to the column, and on the other side by the spindle. The
spindle is driven by a motor and therefore rotates the arbor. During milling, the cutter rotates
along a horizontal axis and the side of the cutter removes material from the workpiece. A
vertical milling machine, on the other hand, orients the cutter vertically. The cutter is secured
insidea piece called a collet, which is then attached to the vertically oriented spindle. The
spindle is located inside the milling head, which is attached to the column. The milling
operations performed on a vertical milling machine remove material by using both the bottom
and sides of the cutter.
Milling machines can also be classified by the type of control that is used. A manual milling
machine requires the operator to control the motion of the cutter during the milling operation.
The operator adjusts the position of the cutter byusing hand cranks that move the table, saddle,
and knee. Milling machines arealso able to be computer controlled, in which case they are
referred to as a computer numerical control (CNC) milling machine. CNC milling machines
move the workpiece and cutter based on commands that are preprogrammed and offer very high
precision.The programs that are written are often called G-codes or NC-codes. Many CNC
milling machines also contain another axis of motion besides the standard X-Y-Z motion. The
angle of the spindle and cutter can be changed, allowing for even more complex shapes to be
milled.

13
4. Tooling
The tooling that is required for milling is a sharp cutter that will be rotated by the spindle. The
cutter is a cylindrical tool with sharp teeth spaced around the exterior. The spaces between the
teeth are called flutes and allow the material chips to move away from the workpiece. The teeth
may be straight along the side of the cutter,but are more commonly arranged in a helix. The
helix angle reduces the load onthe teeth by distributing the forces. Also, the number of teeth on
a cutter varies. A larger number of teeth will provide a better surface finish. The cutters that can
be used for milling operations are highly diverse, thus allowing for the formation of a variety of
features. While these cutters differ greatly in diameter, length, and by the shape of the cut they
will form, they also differ based upon their orientation, whether they will be used horizontally
or vertically.

A cutter that will be used in a horizontal milling machine will have the teeth extend along the
entire length of the tool. The interior of the tool will be hollow so that it can be mounted onto
the arbor. With this basic form, there are still many different types of cutters that can be used in
horizontal milling, including those listed below.
1. Plane (helical) mill
2. Form relieved mill
3. Double angle mill
4. Staggered tooth mill
Another operation known as a straddle milling is also possible with a horizontal milling
machine. This form of milling refers to the use of multiple cutters attached to the arbor and used
simultaneously. Straddle milling can be used to form a complex feature with a single cut.
For vertical milling machines, the cutters take a very different form. The cutter teeth cover only
a portion of the tool, while the remaining length is a smooth surface, called the shank. The
shank is the section of the cutter that is secured inside the collet, for attachment to the spindle.

14
Also, many vertical cutters are designed to cutusing both the sides and the bottom of the cutter.
Listed below are several commonvertical cutters.
1. Flat end mill
2. Ball end mill
3. Chamfer mill
4. Twist drill
5. Reamer
6. Tap
All cutters that are used in milling can be found in a variety of materials, which will determine
the cutter’s properties and the workpiece materials for which it is best suited. These properties
include the cutter’s hardness, toughness, and resistance to wear. The most common cutter
materials that are used include the following:
1. High-speed steel (HSS)
2. Carbide
3. Carbon steel
4. Cobalt high speed steel
The material of the cutter is chosen based upon a number of factors, including the material of
the workpiece, cost, and tool life. Tool life is an important characteristicthat is considered when
selecting a cutter, as it greatly affects the manufacturing costs. A short tool life will not only
require additional tools to be purchased, but will also require time to change the tool each time
it becomes too worn. The cutterslisted above often have the teeth coated with a different
material to provide additionalwear resistance, thus extending the life of the tool. Tool wear can
also be reduced by spraying a lubricant and/or coolant on the cutter and workpiece during
milling. Thisfluid is used to reduce the temperature of the cutter, which can get quite hot
duringmilling, and reduce the friction at the interface between the cutter and the workpiece, thus
increasing the tool life. Also, by spraying a fluid during milling, higher feed rates can be used,
the surface finish can be improved, and the material chips can be pushed away. Typical cutting
fluids include mineral, synthetic, and water soluble oils.

5. MATERIALS
In milling, the raw form of the material is a piece of stock from which the work- pieces are cut.
This stock is available in a variety of shapes such as flat sheets, solid bars (rectangular,
cylindrical, hexagonal, etc.), hollow tubes (rectangular, cylindrical, etc.), and shaped beams (I-
beams, L-beams, T-beams, etc.). Custom extrusions or existing parts such as castings or
forgings are also sometimes used. Milling can be performed on workpieces in variety of
materials, including most metalsand plastics. Common materials that are used in milling
include the following:

15
• Aluminum
• Brass
• Magnesium
• Nickel
• Steel
• Thermoset plastics
• Titanium
• Zinc
When selecting a material, several factors must be considered, including the cost, strength,
resistance to wear, and machinability. The machinability of a material is difficult to quantify,
but can be said to posses the following characteristics:
• Results in a good surface finish
• Promotes long tool life
• Requires low force and power to mill
• Provides easy collection of chips

6. DESIGN RULE
6.1 Workpiece
1. Select a material that minimizes overall cost. An inexpensive workpiece may
result in longer cut times and more tool wear, increasing the total cost
2. Minimize the amount of milling that is required by pre-cutting the workpiece
close to the desired size and shape
7. COST DRIVERS
As the need of computerization increments fundamentally, a control framework
should be effectively programmable, adaptable, dependable, vigorous and savvy.
In this paper a survey on the utilization of programmable rationale regulator
(PLC) in our present market is examined. Examinations on the uses of PLCs in
energy research, designing investigations.
7.1 Material cost
The material cost is determined by the quantity of material stock that is required
and the unit price of that stock. The amount of stock is determined by the
workpiecesize, stock size, method of cutting the stock, and the production
quantity. The unitprice of the material stock is affected by the material and the

16
workpiece shape. Also, any cost attributed to cutting the workpieces from the
stock also contributes to thetotal material cost.
7.2 Production cost
The production cost is a result of the total production time and the hourly rate.
The production time includes the setup time, load time, cut time, idle time, and
tool replacement time. Decreasing any of these time components will reduce
cost. The setup time and load time are dependent upon the skill of the operator.
The cut time, however, is dependent upon many factors that affect the cut length
and feed rate. The cut length can be shortened by optimizing the number of
operations that are required and reducing the feature size if possible. The feed
rate is affected by the operation type, workpiece material, tool material, tool size,
and various cutting parameters such as the axial depth of cut. Lastly, the tool
replacement time is a direct result of the number of tool replacements which is
discussed regarding the tooling cost.

7.3 Tooling cost

The tooling cost for machining is determined by the total number of cutting tools
required and the unit price for each tool. The quantity of tools depends upon the
number of unique tools required by the various operations to be performed and
theamount of wear that each of those tools experience. If the tool wear exceeds
the lifetime of a tool, then a replacement tool must be purchased. The lifetime of
a toolis dependant upon the tool material, cutting parameters such as cutting
speed, and the total cut time. The unit price of a tool is affected by the tool type,
size, and material

10. QUALITY INSPECTION

3. Select the size of the workpiece such that a large enough surface exists for the
workpiece to be securely clamped. Also, the clamped surface should allow clear-
ance between the tool and the fixture for any cuts.
6.2 Features
• Minimize the number of setups that are required by designing all featureson one
side of the workpiece, if possible
• Design features, such as holes and threads, to require tools of standard sizes
• Minimize the number of tools that are required

17
• Ensure that the depth of any feature is less than the tool length and thereforewill
avoid the collet contacting the workpiece
• Lower requirements for tolerance and surface roughness, if possible, in orderto
reduce costs
• Design internal vertical edges to have a corner radius equal to that of a standard
tool. If another component with an external sharp edge must fit, then drill a hole to
provide a relief area
• Avoid very long and thin features
• Use chamfers rather than a corner radiusfor outside horizontal edges
• Avoid undercuts

1. TYPES OF INSPECTION
Pre-production inspection:

Pre-production inspection is vital to decrease the quality risk where the inputs can be inspected
prior to the production stage. An experienced inspector takes some random samples and
examines those just to make sure that the raw materials meet the particular standards as well as
checks whether the development team has clearly communicated with the manufacturing team
for the requirements.

In-process inspection:

In-process inspection occurs when the first product that got out of the line is inspected for
conformity. If any kind of issue is raised at this step, the factory can immediately take some
corrective actions and avoid delays. This inspection happens as it takes an expert technician to
reliably detect errors on unfinished products.

Final inspection:

Final inspection is also known as pre-shipment inspection where the total quantity of products
can be counted, and samples of finished products can be drawn in a truly random manner. This
is the most popular quality inspection which takes place once all the products are finished and
ready for shipment and the outcomes of final inspections are more reliable.

18
 11. WELDING & FABRICATION PROCESS
Welding Processes:
1. MIG Welding (Metal Inert Gas): MIG welding, also known as Gas Metal Arc Welding
(GMAW), is commonly used for welding structural components of hydraulic baling press
machines. It involves using a consumable wire electrode and an inert shielding gas, such as
argon or a mixture of argon and carbon dioxide.
2. TIG Welding (Tungsten Inert Gas): TIG welding, or Gas Tungsten Arc Welding
(GTAW), is another commonly used process for hydraulic baling press machines. It utilizes a
nonconsumable tungsten electrode and an inert shielding gas to produce high-quality welds.
TIG welding is suitable for thinner materials or applications that require precise and aesthetic
welds.
3. SMAW Welding (Shielded Metal Arc Welding): SMAW welding, also known as stick
welding, is a manual welding process that uses a flux-coated electrode. It can be used for
heavyduty applications where high strength is required, such as welding thick structural
components of the baling press machine.
Welding Techniques:
1. Butt Joint Welding: Butt joint welding involves joining two metal plates or components
in a straight-line configuration. It requires proper edge preparation and weld bead placement
to ensure a strong and uniform connection. .
2. Fillet Welding: Fillet welding is commonly used for joining components at right angles,
such as the corners of the baling press machine. It requires careful control of the weld size and
profile to achieve adequate strength. .
3. Groove Welding: Groove welding involves creating a groove or bevel in the metal
components to be joined, which provides space for the weld filler material. It is often used for
thicker materials or when high strength is required.

19
 12. CONCLUSION
In review, it can be concluded that this internship has been an excellent and rewarding
experience. I have been able to meet and network with so many people that I am sure will be
able to help me with opportunities in the future. One main thing that I have learned through
this internship is time management skills as well as self-motivation.
I learned that I needed to be organized and have questions ready for when it was the correct
time to get feedback. From this internship and time management I had to learn how to motivate
myself through being in the office for so many hours and also experienced the industrial work
culture.
Addition to this, the hands on experience in manufacturing process, linking and application of
the best of my theoretical knowledge to the real time applications at the field have motivated
me to explore the hidden abilities within me and increased the confidence to handle the things
on own.

20