1

UNIVERSITY COLLEGE OF ENGINEERING TECHNOLOGY

DEPARTMENT OF TECHNICAL EDUCATION

Supervised industrial training

It is submitted that I have completed my supervised industrial training at pakistan machine tool factory.
PMTF is unit of ministry of industries & production where every kinds of tools of various machines are
prepared.Thousands of multinational pakistanis are employed here and earning for their beloved.

Learning outcomes
I have completed my work in manufacturing department and Learn the basic skills required to work in
the manufacturing field. Discover the role of production design, process planning, and the heart of 13
different manufacturing processes. Understand why facility location and plant layout decisions are so
vital and learn how job design helps you accomplish company goals and achieve worker satisfaction.
Find out what makes up the physical work environment and learn how to characterize different types of
production materials. Master product development concepts such as the voice of the customer (VOC),
quality function deployment (QFD), and failure mode and effects analysis (FMEA). Learn how
performance measurements and standardization improve manufacturing operations.

Signature:

Name of student: Muhammad yasir Abbas

Registration NO: BMTF13E028

Signature:

Supervisor name: Engr. Shoaib

Dated: 07-july 2107

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2017

PAKISTAN MACHINE TOOL FACTORY

INTERNSHIP REPORT
MUHAMMAD YASIR ABBAS

UNIVERSITY OF SARGODHA [BS MECHANICAL ENGINEERING AND TECHNOLOGY]

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 UNIVERSITY OF SARGODHA COLLEGE OF
ENGINEERING AND TECNOLOGY

SUBMITTED TO:
DR. Farhat

SUBMITTED BY:

Students of UNIVERSITY OF SARGODHA COLLEGE ENGINEERING AND TECHNOLOGY

Department OF MECHANICAL TECNOLOGY 4rd year. 2013 batch.

Muhammad Yasir Abbas (BSMTF13E028)

Internship Duration

Start Date: 07-APRIL-2017 End Date: 09-jULY-2017

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preface

This report documents the work done during the summer internship at PAKISTAN MACHINE TOOL
FACTORY (Pvt.) Limited under the guidance of PMTF staff. The report first shall give an overview of
the learning during the period of internship with technical details.

We have tried our best to keep report simple yet technically correct. We hope we succeed in our attempt.

Student of University of Sargodha

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Acknowledgments

All the praises for the Almighty, Allah who bestowed us with the ability and potential to complete this
internship. I also pay my gratitude to the Almighty for enabling me to complete this Internship report
within due course of time the internship opportunity I had with Pakistan Machine Tool Factory was a
great chance for learning and professional development. Therefore, I consider myself as a very lucky
individual as I was provided with an opportunity to be a part of it. I am also grateful for having a chance
to meet so many wonderful people and professionals who led me though this internship period.

Simply put, we could not have done this work without the lots of help we received cheerfully from the
whole PMTF. The work culture in PMTF motivates. Everybody is such a friendly and cheerful companion
here that works stress is never comes in way.

I would special like to thank MR. IRFAN and MR. SHAUKAT for providing us a chance to get this great
experience.

Author

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Summery

This report documents my internship experience with PAKISTAN MACHINE TOOL FACTORY.,
during the period APRIL 9, 2017 through JULY 10, 2017. It is intended to establish that this experience
meets the objectives of the Bachelor of Engineering Technology internship. Following an examination of
the internship objectives, PMTF organizational structure, approach, and management philosophy are
overviewed. The major project undertaken during the internship is introduced and its technological basis
briefly discussed. The author's specific work assignments and contributions in Manufacturing Department,
all in project control engineering, are then presented. The supervisor of internship in the POF rotates me
in different departments. Every department is divided into its different sections. I visited every section and
tried to learn employee's practices. A brief history of POF and the basic introduction of the organization
and its different departments has described at the start of the internship report.
Finally, aspects of project management to which the intern was exposed through association and
observation during the internship are discussed. It is thus demonstrated that both the program and personal
objectives are met.

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TABLE OF CONTENTS

CHAPTER #01 COMPANY INTRODUCTION ........................................... 02

1.1 design office,,,,,,,,,,,,,, 01

1.2 production pllaning.....02

1.3 production control ..03

1.4 tool design.. .04

1.5 tool room..05

1.6 cnc shop.06

1.7 light parts..06

1.8 heavy parts07

1.9 machine assembly and store..7

CHAPTER #2 INTERNSHIP EXPERIENCE

2.spechial manufacturing...08

2.1 forging. 08

2.3 heat treatment .. 09

2.4 die-casting . 10

2.5 press and welding shop .. 11

2.6 drilling .11

2.7 press shop.11

2.8 lathe mahine ..12

2.9 milling machine .14

2.10 broaching....15

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2.11 plastic shop16

2.12 heat treatment19

CHAPTER #3 conclusions and reccomendations 20

Reference 22

figures title page

Figure #1 Production planning and control 04

Figure #2 Tool Design 05
Figure #3 Forging 09
Figure #4 Broaching 15

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Introduction

Pakistan Machine Tool Factory (Pvt.) Ltd. (PMTF) is a precision engineering goods manufacturing
enterprise in Pakistan, established in technical collaboration with M/s. Oerlikon Buhrle & Co. of
Switzerland who are the world's renowned manufacturers of Machine Tools. The factory came into regular
production in 1971.

It is located Off National Highway, about 35 Km from Karachi City near Landhi Industrial Estate and
spread over an area of 226 acres out of which 17 acres are occupied by works. The factory employs about
1900 engineers, technician, workers and another service staff. The layout of the factory is per the best
European standards. This factory is a unit of State Engineering Corporation of Pakistan and is engaged in
the production of Machine Tools, Automotive Transmissions and Axles Components, Gears for
Locomotives, Pressure Die Cast parts and other products.

PMTF has rich experience in Designing and Manufacturing of precision engineering goods and its
facilities include Designing, Machining, Forging, Heat Treatment, Assembly, Die Casting etc.

PMTF is certified to ISO 9001.Quality Assurance System and has excellent Quality Control and Testing
facilities to meet the international quality requirement.

1.1 Design office:

In design office, we saw various things we saw PMTF standards books like zero standard book in which
so many detail about any basic standard of designs and lines and we also saw a 1 standard book in which
detail description about material and we saw and read another standards book of PMTF.

We learn how design person work on AUTOCAD software. In PMTF mostly drawings are converted from
one unit to another or we can say that PMTF convert every drawing on PMTF standards units.

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1.2 PRODUCTION PLANNING

Production Planning may be said to be a technique of forecasting ahead every step in the long process of
production, taking them at right time and in the right degree and trying to complete operations at the
maximum efficiency.

The production planning department of PMTF consist of three section:

Cost estimation
Production pre-planning
Methodology

Cost Estimation
The production planning department estimate the manufacturing cost of the product which includes
material cost, rejection cost, forging cast, normalizing cost and machine hour rate.

Production pre-planning
Production pre-planning section prepare the manufacturing lay-out which include all the operation
required to make the final product. Also, give the operation instruction O.I where necessary. Then make
the material warrant to issue the material.

Methodology
Methodology section does the time and motion study to estimate the production time. Calculate the
standard time and obtain time and difference between them.

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1.3 Production control

Production control is the process that keeps a watchful eye on the production flow and size of resources
along with the location, of any deviation from the present action and to arrange for the prompt adjustment
so that the production may run per the original or revised schedule.

Areas of production control

Sub-dividing the master schedule into manufacturing and subsidiary orders

Routing

Scheduling

Dispatching

Expediting

Inspection

1. Routing
Routing is determining the exact path which will be followed in production. It is the selection of the
path from where each unit must pass before reaching the final stage. The stages from which goods are
to pass are decided in this process.

2. Scheduling
Scheduling is the determining of time and date when each operation is to be commenced or completed.
The time and date of manufacturing each component is fixed in such a way that assembling for final
product is not delayed in any way.

3. Dispatching
Dispatching refers to the process of ordering the work to be done. It involves putting the plan into
effect by issuing orders. It is concerned with starting the process and operation based on route sheets
and schedule charts.

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4. Expediting
Expediting is that branch of production control procedure which regulates the progress of materials
and part through the production process.

5. Inspection
Inspection is the process of ensuring whether the products manufactured are of requisite quality or not.
PMTF has material testing lab to inspect the material supply by the supplier to ensure that the material
quality (hardness, tensile strength, toughness, etc.) is as per requirement. Material testing lab also tests the
chemical composition of material.

1.4 Tool design:

Tool design dept. design every new tool and kept record of old tools. Tool design dept. play an important
role in PMTF. They make four types of tools

Machine tools

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Transmission Tool
Armaments Tools
Die casting Tool

Tool design dept. work on these four types of tools and these four types further divided in many types.
PMTF purchase dies from KTDMC. They make design of fixtures, jigs and gauges, broaching and hoboing
tool are purchased from outside.

1.5 Tool room:

Tool Room dept. divided in many sections.

Milling machines
Lathe machines
Sharpen machines
Grinding machines
EDM (Electric discharge machine) machine
Drilling machine

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In milling section, there are different types of milling machines like shrill machine which is used to cut
the surface, copy milling machine is used to copy the given design form the original copy generally use
to make dies. In lathe section, we saw different operation like turning, boring and facing of tools. In
grinding section, many types of grinding machines like internal, cylindrical and surface grinding. In EDM
section PMTF has two machines for EDM operation. In re-sharpen section mostly hob and brooch and
tools of lathe and milling machine sharpen. In drilling section, various types of drill machine like simple
drilling machine and gang drill machine for many drilling operation at a time.

1.6 CNC (computer numeric control)

CNC (computer numeric control) this dept. play a vital role in PMTF, here we make production quickly
and easily. In CNC dept., various types of lathe and milling machine then we saw and learn the process
of making spline on grub machine. And then we saw a machining center.

1.7 Light parts:

Light parts section is generally known to make light parts for the PMTF various operations have been
performed with high accuracy by a skilled and great experienced worker. We saw different job was being
prepared such as head stock of lath machine, Gas meter body, transmission shaft etc. We had a great
experienced.

Light part dept. divided in four sections

Drilling
Turning
Grinding
Milling

In grinding section, final surface finish of part and achieve accuracy and here also various types of grinding
machine like center hole machine, surface grinding machine, cylindrical grinding machine. In milling
section, here various types of milling machines like slotting machine, face cutter machine and many
machines. In turning section here various types of turning machines only difference of size of chuck in

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which part fixed. In drilling section, we learn and saw many terms in drilling like taping, center bore,
center sink.

1.8 HEAVY PARTS:

Heavy parts section deals with the heavy job comparatively than light parts. We had a chance to see the
different machinery working on different jobs including lathe bed, tail stock, carriage etc.

Heavy part dept. divided in three sections

Boring
Drilling
Planning

In boring section, vertical boring machine which moves in x and y axis. In Drilling sections drill heavy
parts and here we saw and learn one more new term reamer. In surface planning section used shrill milling
machines for finish surface and various machines use for planning operation.

1.9 Machine Assembly and Store:

In Machine assembly dept. assemble different parts of machine and after inspection send to dispatch.
Machine assembly dept. divided in different sections like

Lathe section
Milling section
Power saw section
Paint section
Drilling section

In lathe section assemble every little or big part of lathe machine and make C4 lathe after assemble go
to paint and then final inspection. In milling section assemble milling machine and make K4 and K6
milling machine and same operation as lathe section. In power saw section assemble power hack saw. In
drilling section assemble pillar drilling machine.

In this dept. two types of stores

Those parts manufactured in PMTF

Those parts purchase outside placed in separate store.

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Chapter #02

SPECIAL MANUFACTURING:

S.M section called SM-300, SM-300 divided in six sections

SM-302(turning)
SM-303(drilling)
SM-304(Milling)
SM-305(Grinding)
SM-306(Gear cutting)
SM-307(special turning)
In this dept., we saw in detail about gears cutting from hob and broaching and different types of milling
machines (square, shrill vertical) and saw many types of drilling machines and saw hydraulic press. Gear
cutting section have different types of machines gear cutting machines like (spur, spiral bevel and straight
bevel) for both have different machines used. In gear making there are following process:
Hibbing process
Shaping process
Gear shaving
Gear grinding

2.1 FORGING:
In forging dept. material come outside and burn in furnace make red hot coke, furnace temperature 1250-
1300centigrade. And then hammering the red coke piece in hammering the pressure 300PSI and then
forging , here in this dept. there are 2 forging machine both apply different pressure ( one apply 1500 PSI
and other apply 300 PSI ) , forging dies different from other dies PMTF purchase forging dies and after
forging cutting rough material , internal cutting called parsing and external cutting called Trimming
after cutting normalizing material in furnace and if we set temp 925 degree centigrade then normalizing
takes 2 hours and if we set temperature at 650 degree centigrade then normalizing takes 3 hours and in
normalizing process used 5 burners after normalizing material send for short blasting to remove burn stuff
.

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2.2 HEAT TREATMENT:

In heat treatment dept., there are two types of plant old and new in old plant manual working like in old
plant pit type furnace used and arrange charge and after arrange charge in furnace then check temp then
oil quenching and after quenching material testing and check HRC then send to material testing lab. In
new plant sealed furnace in which material after heat treatment auto directly go for quenching and then
come and other process same as old plant then material send for short blasting to remove the burn stuff
and finish the material and after shot blasting material send for sand blasting and go to dispatch after final
inspection.

2.3 DIE CASTING:

In this dept. 11 machines for aluminum die casting and every machine make different parts. Now a days
PMTF die casting dept. make SSGC components like G4, G1.6. G4 have two types of component

G4 upper case
G4 bottom case

Other component G1.6, in G1.6 have 4 types of components

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GM body
Top cover
Side cover front
Side cover rear

Now a day these two types of product making in die casting dept. aluminum melt at 660-680 degree
centigrade for melting aluminum used natural gas and air pressure. In die casting machine cover block
fixed and ejector block move pump pressure must be greater than 100 psi.

The weapons factory manufactures parts of a weapon, machining of the parts, finishing of the parts, fitting
or assembly of the weapon and proof testing of the weapon in a closed and safe environment. The shops
visited, in our twelve week of internship in the weapons factory, are as follows

Press and Welding Shop

Barrel Shop
Plastic Shop
Woodwork Shop
Machine Shop
Heat Treatment Plant
Assembly and Proofing Shop
CNC Shop

The manufacturing of some weapons was presently taking place but this factory does manufacture,
assemble and test for weapons such as:

SMG - PK1
SMG PK
MP5 P3
MP5 A2
AZB (DMR)
SMG PK (7.62 x 51 mm)
G3A3
MG3
308 Win Sportier

2.4 Press and Welding Shop

The processes that take place from sheet metal to finished byproduct in this shop are Shearing, Blanking,
Bending, Piercing, Stamping and Bending, Piercing and Cutting, Trimming, Bending, Folding Front,
Folding Rear, Final Piercing and Stamping. In this order the processes take place. Some processes are

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repeated using the same machinery but different punch and die or geometry and dimensions. The machines
that perform these processes are as follows:
Welding is a fabrication process that joins materials by causing coalescence. This is often done by melting
the work pieces and adding a filler material to form a pool of molten material that cools to become a strong
joint, with pressure sometimes used in conjunction with heat, or by itself, to produce the weld.

Oxyacetylene Welding and Cutting is relatively inexpensive and simple, generally employing the
combustion of acetylene in oxygen to produce a welding flame temperature of about 3100 C. The flame,
since it is less concentrated than an electric arc, causes slower weld cooling, which can lead to greater
residual stresses and weld distortion, though it eases the welding of high alloy steels. A similar process,
generally called oxy-fuel cutting, is used to cut metals.

Spot Welding is a process in which contacting metal surfaces are joined by the heat obtained from
resistance to electric current flow. Work-pieces are held together under pressure exerted by electrodes.
Typically, the sheets are in the 0.5 to 3 mm 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.

2.5 Drilling Machine

The processes of drilling and boring take place on this machine. The difference between drilling and
boring is that when a hole is made all the way through the work piece it is known as drilling otherwise it
is known as boring. Drill bits of different sizes are present and are fitted into the machine manually per
the requirement of the hole diameter. The work piece is held in place using a vice or using T-slots.

2.6 Press Machine

The press machine uses press tool which mainly consist of a punch and die of the desired geometry. There
are presses ranging from one ton to nine-hundred-ton press load capacity. There are two types of presses
present; Hydraulic and Pneumatic Press. The hydraulic press having greater accuracy due to the
application of load gradually results in accurate processing. Thus, the hydraulic press is preferred instead
of pneumatic when making parts having delicate geometry. The process occurring on this machine are
notching, bending, piercing etc.
To prevent the work piece from breaking in the press machine, annealing is done. This softens the material,
as it is heated and then cooled. After the processes, have taken place they are fed into the tumbling
machine. The vibratory and rotator tumblers clean the work piece and remove the weld marks giving the
work piece a finished look.

2.7 Barrel Shop

In this shop the barrel of G3A3, G3S and 10 mm Pistol is manufactured. The raw material used is 28 mm
diameter Chromium Steel Alloy 32 CRMOV 1210 rods. The machinery used in the manufacturing is as
follows:

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2.7 Lathe Machine

The processes of facing, turning and threading take place on the lathe machine. In this machine the work
piece is rotating and the tool is stationary. The tool is given feed using the carriage and cross slide and
thus work is done on the work piece. Carriage lathe is a slightly different type of lathe machine. This
consists of a separate chuck which can hold a job of up to 45 inches in diameter. This machine is mainly
used for cutting internal as well as external diameters. The jaws of an ordinary lathe machine are set using
a key, controlling the jaws (3 jaws or 4 jaws) of the chuck simultaneously or separately but in the case of
carriage lathe, the work piece is secured via tightening of various nut and bolts along the perimeter of the
work piece. Each part of the lathe machine has a specific duty.

The feed rod is used to start the machine and moves the carriage on the guide ways parallel to the work
piece. The lead screw is used when threading process occurs as this process can properly take place only
when the machine is set on auto. Human error may cause irregular thread forming. Mandrels are used to
hold the job internally to provide stability and support to reduce vibrations produced during process. A
single point cutting tool is mostly used which is held in the tool holder attached on top of the cross slide.
The speed of the chuck can be adjusted per the material of the work piece being worked upon. Coolant
used is soluble oil to prevent over heating (causes wear) and reduce friction between work piece and tool.

2.7.1 Multi-Spindle Lathes

It has more than one spindle and automated control (whether via cams or CNC). They are production
machines specializing in high-volume production. They are usually called automatic chucking machines.
These machines automatically chuck up individual blanks from a magazine. Typical minimum profitable
production lot size on a screw machine is in the thousands of parts due to the large setup time. Once set
up, a screw machine can rapidly and efficiently produce thousands of parts on a continuous basis with
high accuracy, low cycle time, and very little human intervention. These machines can possess from
single, six up to 8 spindles.

2.7.2 Turret Lathes and Capstan Lathes

There are members of a class of lathes that are used for repetitive production of duplicate parts. It -evolved
from earlier lathes with the addition of the turret, which is an index able tool holder that allows multiple
cutting operations to be performed, each with a different cutting tool, in easy, rapid succession, with no
need for the operator to perform setup tasks in between or to control the tool path. First machining of
barrel is done via auto lathe machine and then transferred to the capstan lathe for second machining.

2.8 Milling Machine

Horizontal, vertical and universal milling machines are the types. These machines are consisting of many
parts contributing to making different parts. One such part is the gear train which is used to make spiral
bevel gear. Milling machine may be defined as the type of machine in which the metal is removed by
causing the job to be fed against a revolving cutting tool called the milling cutter, which has one or more
cutting edges.

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The principle parts of milling machine are as follows:

2.8.1 Base
The base of the machine serves as a foundation member for all the other parts which rest upon it. It carries
the column at its one end. In some machines, it works as a reservoir for coolant fluid.

2.8.2 Column
The column is the main supporting frame mounted vertically on the base. It houses all the driving
mechanisms for the spindle and table feed. The top of the column is finished to hold an over-arm that
extends outward at the front of the machine.

2.8.3 Knee
The knee is the part that slides up and down on the vertical way of the column face. The adjustment of
height is effected by elevating screw on the base that also supports the knee. The knee houses the feed
mechanism of the table, and different controls to operate it.

2.8.4 Table
A lead screw under the table engages a nut on the saddle to move the table horizontally by hand or power.
The circular base maybe graduated in the degree.

2.8.5 Over hanging arm

Over hanging arm is mounted on the top of column extending beyond the column face and serves as a
bearing support that may be provided nearest to the cutter. More than one bearing support may be provided
for the arbor.

2.8.6 Spindle
The spindle of the machine is in the upper part of the column and receives power from the motor through
belts, gears and clutches and transmits it to the arbor at the front end of the spindle and it is provided with
a tapered hole into which various cutting tools and arbors may be inserted. The accuracy in metal
machining by the cutter depends on primarily accuracy, strength and rigidity of the spindle.

2.8.7 Arbor
An arbor is considered as an extension of the machine spindle on which cutters are securely mounted and
rotated. The arbors are made with taper shanks for proper alignments with machine spindles having taper
hole on their noses. The taper shank of the arbor conforms to the self-releasing taper.

2.8.8 Gun Drill

Gun drills are straight fluted drills which allow cutting fluid (cutting oil) to be injected through the drill's
hollow body to the cutting face. They are used for deep drilling. Gun barrels are the obvious example;
hence the name. The coolant provides lubrication and cooling to the cutting edges and removes the chips
from the hole. Modern gun drills use carbide tips to prolong life and reduce total cost when compared to
metal tips. Speed of drilling depends on the material being drilled, rotational speed, and the drill diameter.
It is used to drill the barrels 7.73 mm diameter bore. The oil is pumped with a pressure of 50 bar so as
the oil operates as a coolant and lubricant as well to remove the chips discarded/removed during deep
drilling. Reaming is done after drilling to provide a proper finishing to the holes made during drilling.

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2.8.9 Honing
Honing is an abrasive machining process that produces a precision surface on a metal work piece by
scrubbing an abrasive stone against it along a controlled path. Honing is primarily used to improve the
geometric form of a surface, but may also improve the surface texture. Honing process is done using
diamond ledges to create internal slots and internal profile. When the honing tool is inserted into the work
area, the ledges come outwards and when coming back out, the ledges retract into the tool.

2.8.10 Cold Tube Forging Machine

Also, known as hammering, this process is used to make the outer as well as inner profile of the work
piece per requirements. The work piece is rotated at 40 rpm and 4 vibrating hammers perform the cold
forging process while a mandrel (grooving tool) is used to create the internal grooves (12 grooves). The
distance between the hammers is set so the work piece comes out as required. For the case of G3A3 the
8-mm diameter barrel is processed to 7.62 mm

and as its bore decreases its length increases, whereas for the MG weapon the barrel is processed from 8
mm to 7.46 mm along with a 0.03 mm taper on both guns. In the case for G3A3, a force of 250-350 ken
is applied by the hammers whereas in the case of the MG the force applied by the four hammers is 350-
400 king

2.8.11 Serration
A total of 12 teeth are made. The tool mounts in the lathes turret and forms the serrations in successive
strokes along the work piece. At the beginning of the process, the spindle remains stationary while the
tool makes three passes that form the first five teeth in progressive stages of development and a fully
formed sixth tooth. Then the spindle indexes to the next tooth location, where the first five teeth are
increasingly formed and the last tooth is completed. Each time the spindle indexes to the next tooth
position and the turret strokes the part, one tooth is completed. The process continues until the part indexes
full-circle and the serrations are completely formed.

2.9 Broaching
Broaching is a machining process that uses a toothed tool, called a broach, to remove material. There are
two main types of broaching: linear and rotary. In linear broaching, which is the more common process,
the broach is run linearly against a surface of the work piece to affect the cut. Linear broaches are used in
a broaching machine, which is also sometimes shortened to broach. In rotary broaching, the broach is
rotated and pressed into the work piece to cut an axis symmetric shape. A rotary broach is used in a lathe
or screw machine. In both processes the

cut is performed in one pass of the broach, which makes it very efficient. Broaching is used when precision
machining is required, especially for odd shapes. Commonly machined surfaces include circular and non-
circular holes, splines, keyways, and flat surfaces.
Broaching machines are relatively simple as they only must move the broach in a linear motion at a
predetermined speed and provide a means for handling the broach automatically. Most machines are
hydraulic, but a few specialty machines are mechanically driven.

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2.9.1 Finishing of Barrel

At the end of the machining the work piece goes through a process called Chamber Moping; this process
is used to polish the work piece for a good finished look using an Emery paper.
The clearance and adjustment of bore size of the barrel is done by a process known as Lapping.

2.10 Plastic Shop

In this shop injection as well as jet mold casting is done. The parts manufactured in this shop are:

Forearm
Butt Stock
Butt Plate
Grip
Spacer
Filling Piece
Plate for forearm
Holder for buffer housing
Loading (finished)

The materials used to make these parts are different types of plastics such as B3WG7 (forearm), NODUR
(butt stock) and LOPULINE (butt plate).
The raw material comes in the form of grains in 20-25 kg bags. These grains are fed in to tanks and heated
to 80-900C to remove moisture inside the plastic. Then the grains are loaded into the injection casting
machine where they are heated via heater to 240- 2450C. The melted plastic is injected into the die via
guide ways and lead screw. When the casting sets, the die opens and ejects the casting automatically. The
loading and unloading of different dies are done via the one ton cane provided. Jet molding is also done
but only for small parts. There are some parts that require riveting, like forearm thus, they are done using
the pendulum press. the Woodwork shop. It has the same products as the plastic shop but due to the
unavailability of wood and expense issues plastic is preferred over wood parts.

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2.11 Machining Shop

This shop is one of the biggest shops in the weapons factory. It houses around 152 workers and is divided
into 5 groups. A, B, C, D and E groups; each performing its own function. The components this shop
manufactures in different sections are Hammer, Barrel, Sear, Buffer housing, Bush for front sight, Screw
socket, Extractor, loading lever housing, Recoil spring tube, Firing pin, Check lever, Bolt head etc.

Group A
The machines working in this group are as follows:

Vertical Milling Machine

In the vertical mill the spindle axis is vertically oriented. Milling cutters are held in the spindle and rotate
on its axis. The spindle can generally be extended (or the table can be raised/lowered, giving the same
effect), allowing plunge cuts and drilling. There are two subcategories of vertical mills: the

bed mill and the turret mill.

A turret mill has a stationary spindle and the table is moved both perpendicular and parallel to the spindle
axis to accomplish cutting. Turret mills often have a quill which allows the milling cutter to be raised and
lowered in a manner like a drill press. This type of machine provides two methods of cutting in the vertical
(Z) direction: by raising or lowering the quill, and by moving the knee. In the bed mill, however, the table
moves only perpendicular to the spindle's axis, while the spindle itself moves parallel to its own axis.

Horizontal Milling Machine

A horizontal mill has the same sort of xy table, but the cutters are mounted on a horizontal arbor across
the table. Horizontal milling machines also feature a built-in rotary table that allows milling at various
angles; this feature is called a universal table.

Grinding Machine
It is a type of machining using an abrasive wheel as the cutting tool. Each grain of abrasive on the wheel's
surface cuts a small chip from the work piece via shear deformation. Grinding is used to finish work pieces
that must show high surface quality and high accuracy of shape and dimension. As the accuracy of the
grinding machine is very high so in most applications it tends to be a finishing operation and removes
comparatively little metal while giving high quality finishing to the work piece.

Slotting Machine
A vertically reciprocating planning machine, used for making shaping the sides of opening. It consists of
a reciprocating arm which contains a cutting tool and as it moves up and down it chips off some material
from the inside wall of the work piece. It is mainly used for internal modification.

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Broaching
Broaching is a machining process that uses a toothed tool, called a broach, to remove material. There are
two main types of broaching: linear and rotary. In linear broaching, which is the more common process,
the broach is run linearly against a surface of the work piece to affect the cut. Linear broaches are used in
a broaching machine, which is also sometimes shortened to broach. In rotary broaching, the broach is
rotated and pressed into the work piece to cut an axis symmetric shape. A rotary broach is used in a lathe
or screw machine. In both processes the cut is performed in one pass of the broach, which makes it very
efficient.
Broaching is used when precision machining is required, especially for odd shapes. Commonly machined
surfaces include circular and non-circular holes, splines, keyways, and flat surfaces.

Broaching machines are relatively simple as they only must move the broach in a linear motion at a
predetermined speed and provide a means for handling the broach automatically. Most machines are
hydraulic, but a few specialty machines are mechanically driven.

Multi-Spindle Lathes
These have more than one spindle and automated control (whether via cams or CNC). They are production
machines specializing in high-volume production. They are usually called automatic chucking machines.
These machines automatically chuck up individual blanks from a magazine. Typical minimum profitable
production lot size on a screw machine is in the thousands of parts due to the large setup time. Once set
up, a screw machine can rapidly and efficiently produce thousands of parts on a continuous basis with
high accuracy, low cycle time, and very little human intervention.

Drilling Machine
The processes of drilling and boring take place on this machine. The difference between drilling and
boring is that when a hole is made all the way through the work piece it is known as drilling otherwise it
is known as boring. Drill bits of different sizes are present and are fitted into the machine manually per
the requirement of the hole diameter. The work piece is held in place using a vice or using T-slots.

Sand Blasting
It is a process in which the work piece is bombarded with special sand particles which clean any debris
left and polishes the work piece inside and out thoroughly. As a final inspection, the work piece as sent
through a crack detection machine and using X-rays and UV rays the work piece is check for cracks and
defects of any kind or size.

Group B
This section deals with the manufacturing of safety pin, flush header, sight base, locking pin, sight
cylinder, flash hider, sight support, safety pin, screw socket, transmitting piece, holding plate, curved
piece, rotary sight, fore sight holder, trigger lever and sear.
The safety pin is manufactured using milling machine. The coolant used in this machine is soluble oil and
the tool used is the slitting saw cutter. After milling, the part is transferred to the surface grinding machine.
Finishing belt is used to remove any bur still attached with the work piece after

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milling or grinding
The flush header is manufactured on the cam milling machine which uses machine oil and an end mill
cutter is attached to it for working. The rotary sight consists of 3 parts; Side support which is manufactured
in the summer machine (drilling), Side cylinder which is manufactured in the plain milling machine using
a form cutter and the screw socket.
The front side holder is manufactured on the special purpose milling machine which performs 8 processes
on the work piece for the final part to be formed.
The trigger lever is also manufactured using the special purpose milling machine. The sear is manufactured
using the same machine but uses 6 cutters. The trigger lever and the sear have a combined final assembly.
The Honing machine does internal chamfering and removes bur/debris from the drill hole.
The Surface Grinding machine uses magnets to hold and secure the job in one place before grinding. In
certain work pieces, Jigs and Fixtures and needed. The difference between them is that fixtures hold the
work piece stationary at a specific orientation while the Jigs provide a certain amount of movement to the
work piece.

Group C
This section consists of Milling machines and Drilling machines which are used for the manufacture of
the specific parts. The vertical broaching machine is used in the manufacture of L. L. Housing and the B.
S. Housing is manufactured on the vertical milling. Drilling is done as per requirement.
Five types of grinding machines as present her; Surface, Vertical, Cylindrical, Center less and Plunge-cut
Center less grinding machines. Magnetic chucks are used for gripping the work piece/job. But in the case
of cylindrical work piece, chucks and collets are used to hold the work piece. These cylindrical jobs are
grinded using cylindrical grinding machines. Plunge-cut center less grinding machines are used when
specific areas of the work piece need to be grinded.
In center, less grinding machines, the work piece is not held but moves freely between the grinding wheels
moving on guide ways across the machine.

Group D
Group D consists of the manufacturing of springs. There are numerous types of springs that are being
manufactured in this shop both for weapon use and domestic use.
There are four types of springs:

Tension Spring
Compression Spring
Torsion Spring
Form Spring

The wire used to manufacture these springs is either German (used for hard/heavy springs) or English
(used for soft springs) wires. The material is either spring steel alloy or phosphorus bronze that make up
the spring. The machine which manufactures the springs had two stationary cutters allowing for the
circular shape of the spring to be formed, while another adjusts the pitch (distance between two coils) of
the spring. The last cutter is the parting tool which sets the length of the spring and all the cutters are
calibrated as required. Before being fed into the cutters, the wire is made to pass through rollers having
grooves the size of the diameter of the wire.

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The springs are soft and cannot take loads, thus they are then tempered. This is done to obtain the elastic
property of the spring. The German wire is tempered at 2400C for 30 minutes whereas the English wire
is tempered at 1900C for 20 minutes. Buffer spring rings or break rings are added to enhance the load
bearing capacity of the spring. The buffer spring for a G3A3 rifle can withstand a load of 90 ken without
the break rings but when the rings are added it can withstand a load of up to 450 king Four break rings are
fitted into the buffer spring. These springs are used in the butt of the weapon to absorb recoil when firing
the weapon. Wires having a diameter ranging from 0.5 mm to 1.0 mm are used in fuses. Another product
made in this group is the blade and sackbut. The parts are casted and certain machining processes are done
on them. They are then assembled by way of a locking pin on the end of the blade handle. The sackbut
tube is casted and certain machining is done and finished in this group.

Group E
In this group 70 component are manufactured mainly using milling operations but drilling and riveting is
also done. The extra portion of the rivet is removed via milling machine.
The side bar of an MG3 machine gun in manufactured in this group.
The main casing of the POF EYE is manufactured here from aluminum and then it is anodized to prevent
rusting etc. (black appearance) The bolt head of an MG3 machine gun is also manufactured using milling
machine and has 54 operations done on it before it is finished.

2.12 Heat Treatment Plant

In this shop, heat treatment, phosphate, painting, annealing, brazing and tempering is done.
The heat treatment done consists of carburizing, hardening, tempering, annealing and brazing. This is done
using a cyanide salt bath. The salt content is C3, C5 and GS540 salts. It is done at 9100C for 150 minutes.
This process is also known as case hardening; meaning that carbon content is increased in the work piece
0.1 mm to 0.5 mm deep in the layer. This process is mainly used for mild steel. As hard jobs break easily
under pressure/stress they are annealed. This means heating and then cooling of the job so the job softens
so it does not break under stress easily.
Tempering is done at 1400C - 1500C for 2 4 hours. Then direct hardening is also done in a similar salt
bath consisting of C3 and GS660 salts at 7700C 8000C for 10 30 minutes.
Brazing is done by applying brazing paste or copper paste on the joining areas of the work pieces and then
heated. The paste melts and forms a joint fusing the work pieces together. The brazing is done at 11500C.
This is done on a conveyor type furnace where the belt moves at a speed of 5 m/s. At the same time
annealing also takes place a 650 8500C. Annealing is also done in pit type furnace as well as in the
vertical annealing furnaces where coils are placed of the side walls of the furnace.

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CHAPTER # 03

Conclusion:

I have a great experience while working in the Pakistan Machine Tool Factory. It fulfills my personal as
well as my study requirements. Tool factory makes tools related to armed forces and other machine tools.
The weapons factory manufactures parts of a weapon, machining of the parts, finishing of the parts, fitting
or assembly of the weapon and proof testing of the weapon in a closed and safe environment. PMTF has
rich experience in Designing and Manufacturing of precision engineering goods and its facilities include
Designing, Machining, Forging, Heat Treatment, Assembly, Die Casting etc.

Recommendations

The industries in the PMTF operate in an environment of global competition. For these suppliers of raw
materials and semifinished goods, quality is a requirement, rather than a differentiator. Successful
companies are able to manufacture high-quality products at the lowest possible cost. In this cost-
constrained business environment, in-house process control groups are becoming smaller or even being
eliminated. Hence, the industries are becoming increasingly dependent on suppliers of process control
systems, even for ongoing optimization. At the same time, even though process control systems can give
companies a technological advantage, new process control technologies will not be implemented unless
they will have an immediate effect on current operations.

The development of improved process control technologies depends on cooperative efforts by

multidisciplinary teams. The capabilities required to develop and implement new process control
technologies vary significantly depending on the specific process science involved and on the maturity of
the technology. Success depends on the integration of several technologies, which may include the
following:

process control science and engineering

computer science and software engineering
signal processing engineering
measurement science
process engineering
manufacturing

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Variability and quality. Advanced sensors and process controls are necessary to monitor process
variations so that high-quality operations can be maintained at lower cost.

Environmental constraints. Innovative, robust sensory devices, including innovative sensor materials
and coating technologies, are necessary to monitor process parameters and provide information in
extreme high-temperature and chemically corrosive environments.

Service. Process controllers are necessary to provide proactive maintenance capabilities, such as
measurements of performance degradation, fault recovery, self-maintenance, and remote diagnostics.

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REFERENCE

PAKISTAN MACHINE TOOL FACTORY ANNUAL REPORT

MANUFACTURING TECNOLOGY BY RS KHURMI

PAKISTAN ORDINACE FACTORY ANNUAL REPORT

PMTF.COM

https://en.wikipedia.org/wiki/Machine_too

https://www.boschrexroth.com/en/xc/.../factory...machine-tools/references/index

https://forum.wordreference.com Italian Italian-English

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