This report represents the whole topics i had learned during my Industrial training at BITAC. File contains related pictures, description of various shops and related things on machine tools.

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Topics including this report at a glance
1) Machine Maintenance 02-04
2) Fabrication Section 05-07
3) MT (heavy) Shop 08-11
4) MT (light) Shop 12-15
5) Plastic Technology 16-19
6) PCD; IED & IS 20-22
7) HT & PC 23-27
8) Mould & CNC Shop 28-31
9) Foundry Shop 32-34
10) Pattern Shop 35-39

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Machine Maintenance
Machine maintenance refers to keep the active machine running and at the same
time inactive machines are able to be in running mode.
Hand Tools:
There are some tools which are needed for the maintenance.
Hammer
Pipe range
Slide range
Ring range
Screw driver
Cutting pliers
Wrench
Allen key
Flat file
Half file
Round file
Triangular file
Jewellery file
Nose pliers
Pliers
Machines:
Some machines that have to be maintained are given below:
Crank shaft grinding machine
Hand press machine
Hydraulic press machine
Radial drill machine
Column drill machine
Rolling machine
Bending machine
Shearing machine
Vertical lathe machine
Central lathe machine
Hydraulic planner machine
Mechanical planner machine
Horizontal boring machine
Horizontal shaper machine
Vertical shaper machine
Horizontal milling machine

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Rotary table
Surface grinding machine
Internal grinding machine
Thread grinding machine
Power saw machine
Bend saw machine
Small parts:
Small parts of these machines are given below.
Gear
Oil seal
Bearing
Surclip
Nut and bolt
LM bolt
Plane washer
Error:
There are two types of error
1. Mechanical error
2. Electrical error
Mechanical error:
 If there is no particular lubricants in machines parts
 For the leakage of oil seal during operations
 Failure of bearing during operations
 Bearing shapes can cause mechanical error too.
 Break down of gear tooth
 Erosion too gear shaft surface
 Break down of surclip
 For the jam of tailstock
 For the jam of tool post
 For the jam of compound rest
 If the gears inside carriage is failed down during operation
 Exhaustion of key
 If carriage box automate does not work
 Failure of lead screw half nut.
Electrical error:
 Failure of main switch
 If channel board does not work

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 Failure of the machine switch
 Failure of the water pump switch
 Burn down of motor
 Failure of motor bearing
 Damage to the motor shaft key
 If motor and machine pulley belts are loose down.
Gear:
Some gears which are introduced are given.
Bevel gear
Helical gear
Spiral gear
Spur gear
Rack gear
Sprocket gear
Worm wheel gear
Worm shaft gear
Types of bearing:
Ball bearing
Roller bearing
Taper roller bearing
Thrust bearing
Needle bearing
Bush bearing
Lubricants:
Mobile( use only for engines)
Hydraulic oil(use only for hydraulic machines)
Shell beta oil(use only for machines)
Uses: Cutting compound or coolant reduces the corrosion and keeps the job
cool down after machining work

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Fabrication section
Metal fabrication is the building of metal structures by cutting, bending, and
assembling processes. It is a value added process that involves the construction of
machines and structures from various raw materials. A fab shop will bid on a job,
usually based on the engineering drawings, and if awarded the contract will build the
product. Large fab shops will employ a multitude of value added processes in one
plant or facility including welding, cutting, forming and machining. These large fab
shops offer additional value to their customers by limiting the need for purchasing
personnel to locate multiple vendors for different services. Metal fabrication jobs
usually start with shop drawings including precise measurements then move to the
fabrication stage and finally to the installation of the final project. Fabrication shops
are employed by contractors, OEMs and VARs. Typical projects include loose parts,
structural frames for buildings and heavy equipment, and stairs and hand railings for
buildings.
The main operation of the fabrication shop is to assemble all the parts. In this shop
welding does a lot of joining. We saw,
TIG welding
Gas tungsten arc welding (GTAW), also known as tungsten inert gas (TIG) welding,
is an arc welding process that uses a non-consumable tungsten electrode to produce
the weld.
Arc welding:
Arc welding is a type of welding that uses a welding power supply to create
an electric arc between an electrode and the base material to melt the metals at the
welding point. They can use either direct (DC) or alternating (AC) current, and
consumable or non-consumable electrodes.

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Spot welding
Resistance spot welding (RSW) is a process in which contacting metal surfaces are
joined by the heat obtained from resistance to electric current. Work-pieces are held
together under pressure exerted by electrodes. Typically the sheets are in the 0.5 to
3 mm (0.020 to 0.118 in) thickness range. The process uses two shaped copper
alloy electrodes to concentrate welding current into a small "spot" and to
simultaneously clamp the sheets together. Forcing a large current through the spot
will melt the metal and form the weld.
In this shop some hand tools are also used such as:
Hammer
File Wrench
Slide Wrench
Ring Wrench
Flat Screw drivers
Star Screw drivers
Pliers Cutting Pliers
Nose Pliers
Allen Key
Flat File
Half Flat File
Round File
Triangular File

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FIG: Fabrication section

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Machine TOOL (Heavy) shop
Heavy machine shop is equipped with manual lathes, conventional drilling
machines, boring mills, honing equipment, hydraulic torqueing machines and a
variety of support equipment and portable line boring equipment.
Lathe Machine:
In a lathe machine, material is removed from a work piece by rotating it when a
cutting tool is moved longitudinally with a depth of cut. Lathe machines are widely
used to work on cylindrical work pieces.
Various operations can be done using lathe. Among them turning, facing, boring,
parting, drilling, reaming, knurling, threading, chamfering etc.
Principle units of lathe:
1.bed 9.carriage
2.motor drive 10.cross slide
3.feed gear box 11.tool post
4.head stock 12.collum
5.tail stock 13.table
6.spindle 14.swivel plate
7.lead screw 15.top slide
8.feed rod 16.switch box
Boring:
Boring is internal turning. Boring can use single point cutting tools to produce internal
cylinder or conical surfaces.
Name of the Machines:
1. Horizontal Boring Machine:
It is the more powerful machine in the heavy machine shop. A horizontal boring
machine or horizontal boring mill is a machine tool which bores holes in a horizontal
direction. There are three main types — table, planer and floor. The table type is the
most common and, as it is the most versatile, it is also known as the universal type.
Operation: Facing, drilling, boring, internal flat cutting, gear cutting etc.
Job: All size gear box, engine head, pump machine, bearing housing, bevel gear,
spur gear etc.

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2. Vertical Lathe & Boring Machine:
At vertical boring machine table can be set in desire angle. Or can be used for jig
boring with the help of dividing head.
Operation: Turning, facing, boring, radius cutting by hand.
Job: Gear box.
3. Jig Boring Machine:
Jig boring machine like a Moore, the spindle is always square to the table and there
is no knee movement.

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Planer:
A planer is a type of metalworking machine tool that uses linear relative motion
between the work piece and a single-point cutting tool to machine a linear tool path.
Its cut is analogous to that of a lathe, except that it is (archetypally) linear instead of
helical.
In this machine shop there are two types of planer machine. They are
1. Hydraulic Planer Machine:
Operation: Surface finish, side cutting, slot cutting, grinding.
Job: Spur gear, bevel gear, v-block etc.

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2. Mechanical Planer Machine:
Its operation is just like hydraulic planer machine. But in this machine there is no
gear in the lever, so no thread cutting in this machine.

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Machine tool (Light) Shop
Light machine shop is mainly equipped with various types of lathe and milling
machines. In light machine shop, small jobs and machine parts are machined.
Machines in light machine shop are:
1) Shaper machines :
There are two kinds of shaper machines.
Vertical and
Horizontal
a) Vertical Shaper Machine:
Vertical shaper machine situated vertically. Here job moves clockwise, table is fixed.
Mainly used for finishing.
b) Horizontal Shaper Machine: Here job is fixed and ram moving to and fro
motion.

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2) Lathe:
a) Center lathe machine: The center lathe machine is used to turn and cut
metal. Some common operations are turning, boring, facing, knurling, taper turning
etc.
b) Coppying lathe machine : This machine can copy design and can produce
the exact replica of the given sample.
3) Milling :
a) Vertical milling machine:
Here the table has vertical, longitudinal, and transverse movement and the spindle
has vertical movement.
Operations: Boring, Facing, Drilling, Key cutting, slot cutting etc.

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b) Horizontal milling machine :
In this machine, longitudinal travel of the table is fixed at right angles to the spindle.
Gear Hobbing machine3) :
It’s a special type of milling machine, which is used for gear cutting, cutting splines
and sprockets.The teeth or splines are progressively cut into the workpiece by a
series of cuts made by a cutting tool called hob.
Operations : Spur gear, Worm gear and Helical gears are being cut.

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4) Grinding section :
Grinding is needed for a smooth surface finish of the metal.
a) Cutter grinding machine :
it is used to grind the edge of cutting tools, hence sharpen the tool for the next use.
b) Surface grinding machine: It is used to smooth the surface of any flat
surface of the metal job.
c) Cylindrical grinding machine: It is external grinding, commonly used to grind
the outer diameter of a piece of work often for the purpose to reduce the diameter.
d) Internal grinding machine: It is used to grind the internal surface, i.e. the
bore surface of a hollow work piece.

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Plastic technology
Plastic pipe extruder:
The extruder can turn solid plastic into a uniform melt through the heating, pressure
and shear. The mold includes mixing master batch and the other addictives, blending
resin and smash in the production process. The pressure must be large enough to
viscous polymer extrusion. Extrusion machine complete the above pattern through
the barrel with a spiral track and a screw.
Raw material: Poly propylene
Use: To make any kind of pipe shaped plastic accessories.
Injection Molding Machine:
Generally injection molding machine includes,
Injection device
Clamping device
Hydraulic system
Electrical control system
Capacity: maximum 100kg weighted product.

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Plastic wastage crusher:
There are four blades. Two are fixed and two can rotate.
Cutting edges of the cutters are face to face.
Clearance 0.3
It works on hydraulic system. After cutting the plastic in the cutter they fall down on
the net below the cutter and they have to be cut until they get to pass the net and
here a roller is used.

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Blow molding:
Hopper: Contains raw material.
Barrel: A chamber where raw material is heated.
Mold: To get the shape of the mold according to the purpose and here uses water
chiller to cold the mold at 0-5 c.
Use: To make bottle shaped plastic material.
Vacuum forming machine:
Raw Material:
PVC sheet
Poly carbonate (PC) sheet

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Vacuum forming is usually restricted to forming plastic parts that are rather sallow
in depth. Thin sheets are formed into rigid cavities. Thick sheets are formed into
permanent object. Relatively deep parts can be formed if the formable sheet is
pneumatically stretched.
Use: It is one type of packaging used in medicine company.

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PCD, IED & IS
Production Control Division
Production planning is the planning of production and manufacturing processes in a
company or industry. It utilizes the resource allocation of activities of
employees, materials and production capacity, in order to serve different customers.
Different types of production methods, such as single item manufacturing, batch
production, mass production, continuous production etc. have their own type of
production planning. Production planning can be combined with production control
into production planning and control, or it can be combined and or integrated
into enterprise resource planning.
Production planning is used in companies in several different industries, including
agriculture, industry, amusement industry, etc.

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Industrial Engineering Division
Industrial engineering is a branch of engineering which deals with the optimization of
complex processes or systems. Industrial engineers work to eliminate waste of time,
money, materials, man-hours, machine time, energy and other resources that do not
generate value. According to the Institute of Industrial Engineers, they figure out how
to do things better. They engineer processes and systems that improve quality and
productivity.
The thematic scope of the Division of Industrial Engineering and Logistics covers the
design and management of the supply chain, namely production and logistic systems
to generate goods and services, as well as the necessary techniques for solving
efficiently its derived problems. The Division undertakes research activities on these
topics and transfer of the research results. This is done through consulting and
elaboration of studies, models and software.
Fields of activity
Supply chain design
Capacity planning
Aggregate planning
Design and task assignment of assembly and production lines
Activity programming
Working time management
Task assignment to employees taking into account learning and forgetting
effects
Urban logistics
Port logistics
Reverse logistics
Green logistics
Simulation of production and logistic systems
Generator assignment and electrification of isolated areas
Quantitative techniques
Lean management

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Inspection Section
An inspection is, most generally, an organized examination or formal evaluation
exercise. In engineering activities inspection involves the measurements, tests,
and gauges applied to certain characteristics in regard to an object or activity. The
results are usually compared to specified requirements and standards for
determining whether the item or activity is in line with these targets, often with
a Standard Inspection Procedure in place to ensure consistent checking. Inspections
are usually non-destructive.
Inspections may be a visual inspection or involve sensing technologies such
as ultrasonic testing, accomplished with a direct physical presence or remotely such
as a remote visual inspection, and manually or automatically such as an automated
optical inspection.

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HEAT TREATMENT
Heat treatment is the controlled heating and cooling of metals to alter their physical
and mechanical properties without changing the product shape. Heat treatment is
sometimes done inadvertently due to manufacturing processes that either heat or
cool the metal such as welding or forming.
Heat treatment involves the use in heating or chilling, normally to extreme
temperature, to achieve a desired temperature such as hardening or softening of a
material. Heat treatment techniques include
Annealing
Case hardening
Precipitation strengthening
Tempering
Normalizing &
Quenching
In this process, various furnaces are used:
1. Semi muffle gas furnace:
Carburizing temp:950 to 1000 degree Celsius
Hardening temp:750 to 800 degree Celsius
Annealing temp: 600 to 650 degree Celsius.

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2. Sol bath furnace:
Hardening temp: 1000 degree Celsius.
3. Electric super furnace:
This furnace is used for precision making. Hardening temp is 850 to 1300
degree Celsius.

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Other instrument used in this section:
Tempering machine(temp:150 to 550 degree celsius)
Arban press machine
Job quenching tank(for cooling the job by water,oil,air)
Hardness tester machine
Grinding machine &
Tool box.
Carburizing compound:
Coal (58%)
Mineral coalter (25%)
Sodium carbonate (2%)
Barium arbonate (15%)&
Blackstrap molasses.
Carburizing compound is arranged layer by layer with job and placed in the furnace.

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Protective coating
An industrial coating is a paint or coating defined by its protective, rather than its
aesthetic properties, although it can provide both.
The most common use of industrial coatings is for corrosion control of steel
structures such as offshore platforms, bridges and underground pipelines. Other
functions include intumescent coatings for fire resistance. The most common
polymers used in industrial coatings are polyurethane, epoxy and moisture-cure
urethane. Another highly common polymer used in industrial coating is
a fluoropolymer. There are many types of industrial coatings including inorganic zinc,
phosphate, and Xylan and PVD coatings.
A typical coating system may include a primer, an intermediate coat, and a top coat.
The 4 main stages of a three coat system is given below:
 Abrasive Blasting: This roughens and cleans the surface and prepares the
surfaces for Primer.
 Primer: This wets the substrate, creating a base for the Intermediate coat. These
primers can consist of Inorganic Zinc Silicate, Epoxy Zinc or even general Epoxy
Polyamide
 Intermediate: Provides system thickness build, and prevents permeability.
Intermediates can consist of general Epoxy Polyamide, amongst others.
 Top coat: Provides Chemical Resistance and adds aesthetic value to the
surface.
In BITAC, there are five types of coatings
Hard chrome plating (1 hour working time)
Nickel plating (10 hour working time)
Copper plating (2-3 days working time)
Zinc plating (1 hour working time) &
Bright chrome plating
Tools used for protective coating:
Polishing machine
Hard chrome plating tank
Chemical filter machine
Rectifier machine
Hot water tank
Nickel plating tank
Copper plating tank &
Bright chrome plating tank.
All protective coating procedures are same. So, here nickel plating with bright
chrome plating is described.

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A flow chart is given below:
Job Finishing Polishing
Chalk powder
Binding one head of
the job by copper
wire
To clean the job by
using calcium
carbonate
Wash out by water
The job will be binding by
the wire in the middle
position of the nickel
chemical tank
Anode will be fitted
both side of the job
Supply the current
through the rectifier
Keep it for 10-12
minutes
Increase or decrease
the voltage
according to the job
Off the current
supply after 10-12
minutes
Take of job & wash
out by hot water
Wiping the job by
dry cloths
Polishing the job for
brightness
To remove radish color,
bright chrome plating is
used for 2-3 minutes

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Moulding & CNC Machine
MOULDING:
Pantrograph milling machine:
A pantograph is a mechanical linkage connected in a manner based on
parallelograms so that the movement of one pen, in tracing an image, produces
identical movements in a second pen. If a line drawing is traced by the first point, an
identical, enlarged, or miniaturized copy will be drawn by a pen fixed to the other.
Using the same principle, different kinds of pantographs are used for other forms of
duplication in areas such as sculpture, minting, engraving and milling
FIG: Pantograph milling machine

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Uses of pantograph
 Drafting
 The original use of the pantograph was for copying and scaling and line
drawings. Modern versions are sold as toys.
 sculpture and minting
 Acoustic cylinder duplication
 Medal
 Monograms, seals

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Computerised numerical controlled Machine (CNC)
Milling is the machining process of using rotary cutters to remove material from a
work piece advancing in a direction at an angle with the axis of the tool. It covers a
wide variety of different operations and machines, on scales from small individual
parts to large, heavy-duty gang milling operations. It is one of the most commonly
used processes in industry and machine shops today for machining parts to precise
sizes and shapes
CNC wire cut EDM
The tool electrode in wire EDM is simply a wire. In wire electrical discharge
machining (WEDM), also known as wire-cut EDM and wire cutting, a thin single-
strand metal wire, usually brass

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FIG: CNC wire cut EDM
Die sink EDM
The wire-cut process uses water as its dielectric fluid, controlling its resistivity and
other electrical properties with filters and deionizer units. The water flushes the cut
debris away from the cutting zone. Flushing is an important factor in determining the
maximum feed rate for a given material thickness. Along with tighter tolerances, multi
axis EDM wire-cutting machining centres have added features such as multi heads
for cutting two parts at the same time, controls for preventing wire breakage,
automatic self-threading features in case of wire breakage, and programmable
machining strategies to optimize the operation.

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FOUNDRY
List of furnaces of foundry in BITAC:
1. Cupolas
2. Tilt furnace
3. Pit furnace
4. Electric furnace

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Cupolas
Parts: Air door, slug gate, metal gate, charging door,
Mainly used for Cast iron. The mixture of iron, coke, lime and a little alloying element
are used as charge.
Crucible Furnace
Crucible furnace is also known as pit furnace. Crucible is mainly a pot which is kept
inside the furnace with metal inside it and by using gas as fuel desirous amount of
heat is produced to melt the metal.
Tilt Furnace
Mainly a type of crucible furnace which has a benefit of tilting the crucible so that
molten metal can easily take out from the furnace
Electrical Furnace
The main benefit of an electric furnace is here we can produce exact degree of
temperature that is needed in foundry. So, perfect temperature for the work can be
produced. The main difference with other furnace is there have a coil around the pot
where metal is kept. That coil passes the electricity through it and heated the pot to
its required temperature.
Mold Sand Mixture:
sand 90%
sodium silicate gel 7%
saw dust 1.5%
coal dust 1.5%
Coal dust is mainly used for cleaning purpose. In nonferrous alloys coal dust is
avoided as in creates blow hole inside the mold during casting.
Mold coat r used inside the cavity of mold.
Partisan sand is used in between cope and drag parts.

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FIG: process of foundry

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PATTERN
A pattern is a shaped form of wood or metal around which sand is packed in the
mold. When the pattern is removed the resulting cavity is the exact shape of the
object to be cast.
The pattern must be designed to be easily removed without damage to the mold. It
must be accurately dimensioned and durable enough for the use intended. Either
one time use or production runs.
Pattern materials:
Wood - common material because it is easy to work, but it warps
Metal - more expensive to make, but lasts much longer
Plastic - compromise between wood and metal
Types of Pattern
One Piece/Solid Pattern. Used for simple shape low quantity
production. Made of wood and these are expensive.
Split Patterns. Two piece patterns made such that each part forms a
portion of cavity for casting.
Match-plate pattern. Two piece constructed by securing each half on
the opposite sides of a single plate.
Cope & Drag Pattern. Two piece constructed by securing each half on
the cope and Drag
For making a pattern, we need various tools. They are given bellow;
Steel tape
Steel roll
Cut pencil
Eraser
Scriber
Tri-square
Hand jaw
Hand planer
Scissor
Divider

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Inset and outset calipers
Wooden file
Steel and wooden clamp
Spoke shape
In pattern shop we saw many machines for making pattern. They are described
below;
Wood jigsaw machine:
A jigsaw power tool is a jigsaw made up of an electric motor and a reciprocating
saw blade. A jigsaw with a bevel function on the sole plate allows cutting angles of
typically up to 45 degrees relative to the normal vertical stroke for cutting miter joints.
In the past, what are now usually called scroll saws were often referred to as jig saw.
A power jigsaw may also be referred to, by some manufacturers, as a "bayonet saw"
or sabre saw
Wood turning lathe:
Woodturning is a form of woodworking that is used to create wooden objects on
a lathe. Woodturning differs from most other forms of woodworking in that
the wood is moving while a stationary tool is used to cut and shape it. Many intricate
shapes and designs can be made by turning wood. There are two distinct methods
of turning wood: spindle turning and bowl or faceplate turning. Their key difference is
in the orientation of the wood grain, relative to the axis of the lathe.

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Band saw machine
A band saw is a power tool which uses a blade consisting of a continuous band
of metal with teeth along one edge to cut various work pieces. The band usually
rides on two wheels rotating in the same plane, although some band saws may have
three or four wheels. Band sawing produces uniform cutting action as a result of an
evenly distributed tooth load. Band saws are used for woodworking, metalworking, or
for cutting a variety of other materials. They are particularly useful for cutting
irregular or curved shapes, but can make straight cuts. The minimum radius of a
curve that can be cut on a particular saw is determined by the width of the band and
its kerf.
Wood jointer machine
A jointer is a woodworking machine used to produce a flat surface along a board's
length. The jointer derives its name from its primary function of producing flat edges
on boards prior to joining them edge-to-edge to produce wider boards. The use of
this term probably arises from the name of a type of hand plane, the jointer plane,
which is also used primarily for this purpose

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Mortiser machine
A mortiser or morticer is a specialized woodworking machine used to cut square or
rectangular holes in a piece oflumber(timber), such as a mortise in a mortise and
tenon joint.
Bobbin sander machine
This is also known as inside finishing machine. The inside portion of the pattern have
to be finished for making the best quality mold to get the accurate job we want to
produce.
Design Considerations of a Pattern
Shrinkage allowance. Pattern must be slightly larger, generally 2%,
exact amount depend upon the material being used.
Draft. Friction, horizontal movement during removal may damage the
mold.
Machining allowance. Depends on the casting process and mold
material.
Core Allowance. If a core is used, it must compensate shrinkage.
Distortion Allowance. Irregular shape

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