INTERNSHIP REPORT

Submitted in partial fulfillment of the requirement for

the award of

BACHELOR OF TECHNOLOGY

IN
MECHANICAL ENGINEERING
Submitted by
GOLLAMANDALA REENA
20A21A0383

DEPARTMENT OF MECHANICAL ENGINEERING

SWARNANDHRA
COLLEGE OF ENGINEERING & TECHNOLOGY
(AUTONOMOUS)
A credited by NAAC with an ‘A’ Grade
Approved by A.I.C.T.E & Permanently affiliated to JNTU, Kakinada
Seetharampuram, Narasapur – 534280, West Godavari Dt., A.P
2020-2024 Batch
 SWARNANDHRA COLLEGE
OF
ENGINEERING & TECHNOLOGY
(Autonomous) Narasapur
DEPARTMENT OF
MECHANICAL ENGINEERING

CERTIFICATE

This is to certify that the “Internship report” submitted by GOLLAMANDALA

REENA (Regd. No: 20A21A0383) work done by him and submitted during 2023 - 2024
academic year, in partial fulfillment of the requirements for the award of the degree of
BACHELOR
OF TECHNOLOGY in MECHANICAL ENGINEERING, at ZF Commercial Vehicle
Control Systems India.
 Student’s Declaration

I, ___________________, a student of the B. Tech Program, Reg. No.

___________________ of the Department of Mechanical Engineering,
Swarnandhra College of Engineering and Technology. I do hereby declare
that I have completed the Internship from 24/11/2023 to 24/02/2024 in ZF
Commercial Vehicle Control Systems India, Department of Mechanical

Engineering in Swarnandhra College of Engineering and Technology.

(Signature and Date)

Head of the department

 CONTENTS
 COMPANY PROFILE

 OVERVIEW OF THE ORGANIZATION

 CNC MACHINING

 INTRODUCTION

 TITLE

 DETAILED EXPLANATION ABOUT MACHINARY

 DETAILED EXPLANATION ABOUT MACHINING PROCESS

 APPARATUS AND COMPONENTS

 CNC PROGRAM

 CAD DESIGN

 CONCLUSION

 FUTURE IMPROVEMENTS

 REFERENCES
 COMPANY PROFILE
ZF is a global technology company that specializes in driveline and
chassis technology, as well as active and passive safety technology for
commercial vehicles and other applications. ZF's commercial vehicle
control systems in India likely involve advanced solutions for optimizing
the performance, efficiency, and safety of commercial vehicles.

ZF Friedrichshafen products include automatic and manual transmissions

for cars, trucks, buses and construction equipment; chassis components (ball
joints, tie rods, cross-axis joints, stabilizer bars, control arms); shock
absorbers and suspension struts; electronic damping systems including
Continuous Damping
Control (CDC), ActiveRollStabilization (ARS); clutches; torqueconverters
; differentials; axle drives; and industrial drives

.
 OVERVIEW OF THE
ORGANIZATION
ZF Friedrichshafen AG, also known as ZF Group, originally Zahnradfabrik
Friedrichshafen, and commonly abbreviated to ZF (ZF = "Cogwheel Factory" =
"Friedrichshafen"), is a global technology company that supplies systems for
passenger cars, commercial vehicles and industrial technology. It is headquartered
in Friedrichshafen, in the south-west German state of BadenWürttemberg.
Specializing in engineering, it is primarily known for its design, research and
development, and manufacturing activities in the automotive industry and is one
of the largest automotive suppliers in the world. Its products include driveline and
chassis technology for cars and commercial vehicles, along with specialist plant
equipment such as construction equipment. It is also involved in the rail, marine,
defence and aviation industries, as well as general industrial applications. ZF has
168 production locations in 32 countries with approximately 165,000 (2022)
employees.

ZF Friedrichshafen is more than 90% owned by the Zeppelin Foundation, which

is largely controlled by the town of Friedrichshafen.
 CNC MACHINING
This research focuses on the utilization of Computer Numerical
Control (CNC) machining techniques for the manufacturing of
crankcases in compressors, aiming to enhance precision,
efficiency, and overall performance. The crankcase, a critical
component in compressor assemblies, plays a pivotal role in
housing and supporting the crankshaft, connecting rods, and
other essential internal components. The traditional
manufacturing processes for crankcases often involve multiple
steps and manual interventions, leading to increased production
time and potential inaccuracies.

INTRODUCTION
The manufacturing industry continually seeks innovative
solutions to enhance the efficiency and precision of component
production, especially in critical applications such as
compressors. Among the various components integral to
compressor assemblies, the crankcase plays a pivotal role in
housing and supporting key internal components like the
crankshaft and connecting rods. Traditional manufacturing
processes for crankcases often involve complex procedures and
manual interventions, leading to increased production times
and potential variations in product quality.

MANUFACTURING OF
HINO 160CC
CRANK CASE
USING CNC MACHINARY
 DETAILED EXPLANATION
ABOUT MACHINARY
The CNC machine consists of Different types of Tools. Those different tools are
used for different types of machining process.
For example, milling cutter is used for Milling purpose, Piston bore tool is used
for the boring, etc…. Each tool consists of life which can be simply explained as
the life time of the tool.
After the completion of the tool life the machine displays a message to change
its tool then its Insert should be changed and the tool life should be resettled.
 DETAILED EXPLANATION
ABOUT MACHINING
PROCESS
The machining process consists of three different setups. Each
set-up machines different faces and different operations.
We use AMS CNC’s machines for machining this particular
crank case.
After first setup the bushing process takes place then after the
other process takes place one after the other.
The CNCs were designed based on PLC programming. Then
we use CNC codes for machining according to our
requirements.
The machinery consists of safety light curtain which will give
safety to a machine operator.
At last leak test will be conducted to ensure the part is ok. A
separate machine is available for this process.
 APPARATUS AND
COMPONENTS
The successful implementation of CNC machining for
crankcase production in compressors requires a well-designed
apparatus comprising various components. The following
outlines the key elements essential for this machining process

 CNC Machining Centre

 Cutting Tools

 Work holding Fixtures

 Tool Change System

 Coolant System

 Chip Management System

 CNC Programming

 Measurement and Inspection Tools

 Safety Features

 Material Handling Systems

 CNC Machining Center
The core of the apparatus is the CNC machining center,

equipped with multi-axis capabilities to accommodate the

complexity of crankcase geometries. The machining center

includes a rigid frame, a worktable for securing workpieces,

and a tool magazine for efficient tool changes. The CNC

controller governs the movements of the cutting tools in

accordance with programmed instructions.

 Cutting Tools
High-performance cutting tools are critical components in CNC

machining. End mills, drills, and reamers with

appropriate geometries and coatings are selected based on the

machining parameters and material properties. Advanced tool

materials, such as carbide or ceramic, contribute to extended

tool life and improved cutting performance.

 Work holding Fixtures
Customized work holding fixtures are designed to secure the
crankcase during machining operations. These fixtures ensure
precise positioning and alignment of the workpiece,
minimizing vibrations and maximizing machining accuracy.
Hydraulic or pneumatic clamping systems may be employed
for efficient and secure workpiece fixation.
 Tool Change System
A rapid and efficient tool change system is essential for

minimizing downtime during machining. Automatic tool

changers, integrated into the CNC machining center, allow for

swift and accurate tool swaps, enabling the use of multiple

tools in a single machining operation.

 Coolant System
To dissipate heat generated during machining and to lubricate

cutting tools, a coolant system is incorporated. Coolant helps

maintain stable machining temperatures, improves tool life, and

aids in chip evacuation. Various coolant delivery systems, such

as flood or through-tool coolant, may be employed depending

on the machining requirements.

 Chip Management System
Efficient chip management is crucial for maintaining a clean

machining environment and preventing chip interference with

the cutting process. Chip conveyors, chip augers, or chip bins

are utilized to remove and manage chips generated during

machining operations.

Measurement and Inspection

 Tools
Quality control is paramount in CNC machining.

Measurement and inspection tools, such as coordinate

measuring machines (CMMs), gauges, and probes, are used to

verify dimensional accuracy, ensure tight tolerances, and

perform in-process inspections.

 Safety Features
Safety components, including emergency stop buttons,

interlock systems, and protective enclosures, are integrated into

the apparatus to ensure the safety of operators and comply with

industry regulations.
 Material Handling Systems
Automated or manual material handling systems facilitate the

loading and unloading of workpieces onto the CNC

machining center. This ensures a continuous and efficient

workflow, especially in high-volume production scenarios.

 In-Process Inspection:
Regular in-process inspections are conducted using

measurement tools and probes integrated into the CNC

machining center. This ensures that the machining process is

meeting the specified tolerances and quality standards. Any

deviations or issues can be addressed promptly.

 CNC Program
CNC programming is essential for creating the toolpaths,

defining machining parameters, and generating the CNC code

that controls the machining center. It enables the optimization

of toolpaths for efficiency and precision.

HERE THERE WILL BE THREE SETUPS

PROGRAM FOR FIRST SET-UP

O0650 ;
(651/652/653) ;
(20. 08. 2020) ;
;
G0 G91 G28 Z0. ;
;
M12 ;
G04 X2. 5 ;
G17 G40 GB0 ;
M98 P90 ;
M01 ;
#560 =1 ;
M01 ;
;
N1 (FLANGE FACE MILLING) ;
IF [#560 NE 1] GOTO9999 ;
M50 ;
/#851 =#4114 ;
G91 G30 Z0. ;
M06 T02 ;
M01 ;
T01 ;
M98 P1001 ;
M98 P51 ;
M01 ;
M98 P1002 ;
M98 P51 ;
G0 Y0. 0 ;
M05 ;
#610 =#610+2 ;
IF [#610 GE #650] GOTO301 ;
#560 =2 ;
G0 G28 G91 Z0. ;
M01 ;
;
N2 (DIA 11 DRILL) ;
M12 ;
IF [#560 NE 2] GOTO9999 ;
M50 ;
;
M6 T01 ;
M07 ;
M01 ;
T06 ;
M98 P1002 ;
M98 P50 ;
M01 ;
M98 P1001 ;
G90 G0 G54 G43 X0. 0 Y66. 0 Z50. H01 M01 ;
M08 ;
M08 S3500 S2000 ;
G81 G99 Z-29.2 Z-29.5 R3. F450. F550 ;
G80 G0 Z50. ;
G00 X0. Y0. ;
G01 X35. F5000. ;
G01 Z5.0 ;
G01 Z-5.8 Z-6.4 Z-6.3 F300. F380. ;
G00 Z50. ;
M09 ;
M05 ;
G0 G28 G91 Z0.0 ;
M01 ;
#611 =#611+2 ;
IF [#611 GE #651] GOTO302 ;
#560 =3 ;
M01 ;
;
N3 (MOUNTING HOLE CHAMPER) ;
M12 ;
IF [#560 NE 3] GOTO9999 ;
/ M50 ;
M6 T06 ;
M07 ;
M01 ;
T04 ;
M98 P1001 ;
M98 P5001 ;
M01 ;
M98 P1002 ;
M98 P5001 ;
#560 =4 ;
M01 ;
G0 G91 G28 Z0. ;
#616 =#616+2 ;
IF [#616 GE #656] GOTO307 ;
;
;
N4 (SPIGOT OD) ;
IF [#560 NE 3] GOTO9999 ;
;
M50 ;
M6 T4 ;
M01 ;
T3 ;
M98 P1001 ;
M98 P53 ;
M01 ;
;
N45 ;
M98 P1002 ;
M98 P53 ;
M09 ;
M01 ;
#613 =#613+2 ;
IF [#613 GE #653] GOTO304 ;
G0 G28 G91 Z0. ;
#560 =5 ;
M01 ;
;
N5 (PRE BUSH BORE) ;
IF [#560 NE 5] GOTO9999 ;
M50 ;
M6 T03 ;
M01 ;
T05 ;
G04 X0.5 ;
M98 P1002 ;
M98 P56 ;
M01 ;
;
M98 P1001 ;
M98 P56 ;
M09 ;
M01 ;
#612 =#612+2 ;
IF [#612 GE #652] GOTO303 ;
;
G0 G28 G91 Z0. ;
#560 =6 ;
M01 ;
;
;
N6 (GROOVING) ;
M12 ;
IF [#560 NE 6] GOTO9999 ;
M6 T5 ;
M01 ;
M08 ;
T2 ;
M98 P1002 ;
M98 P54 ;
M01 ;
M09 ;
M98 P1002 ;
M98 P54 ; 32
X300. ;
M09 ;
M05 ;
M01 ;
#614 =#614+2 ;
IF [#614 GE #654] GOTO305 ;
;
N7 (PROGRAMME END) ;
G91 G28 Z0. ;
G91 G28 Y0. ;
G0 Y100. ;
G0 X100. X-200. ;
M13 ;
M47 ;
M30 ;
;

PROGRAM FOR SECOND SETUP

06511 (M1336511) ;
(19.08.2020) ;
;
M130 ;
M61 ;
G04 X3.0 ;
;
#550=#4115(PRG NUMBER MAGRO) ;
IF[#551 NE #550] GOTO 303 ;
;
;
M131 ;
;
M98 P1000 ;
G04 X3.0 ;
;
G91 g28 z0. ;
IF[#634 GE #5341] GOTO 304 ;
#560=10 ;
M09;
M53 ;
M01 ;
;
;
;
N20 (M/HOLE DRILL) ;
IF[#562 NE 20] GOTO 999 ;
T3 M6 ;
M08 ;
M52 ;
M98 P1001 ;
M98 P5001 ;
M01 ;
M98 P202 ;
M01 ;
N35 ;
M98 P1001 ;
M98 P202 ;
G0 G91 G20 Z0. ;
M09 ;
#630=#630+2 ;
#631=#631+2 ;
IF[#630 GE #530] GOTO 300 ;
IF[#631 GE #531] GOTO 301 ;
#562=40 ;
M01 ;
;
/ M00 ;
;
N40 (E/C FACE MILLING) ;
M01 ;
;
N60 (6.75 DRILL) ;
IF[#562 NE 60] GOTO 999 ;
T06 M6 ;
M52 ;
M98 P1001 ;
M98 P5003 ;
M01 ;
N65 ;
M52 ;
M98 P1002 ;
M98 P5003 ;
M53 ;
G0 G91 G28 Z0. ;
#635=#635+2 ;
IF[#635 GE #535] GOTO 306 ;
IF[#636 GE #536] GOTO 307 ;
#562=80 ;
M01 ;
;
N80 (SPOT FACE) ;
IF[#562 NE 80] GOTO 999 ;
M61 ;
G04 X2. ;
T9 M6 ;
M08 ;
M98 P1001 ;
M98 P5005 ;
M01 ;
N85 ;
M98 P1002 ;
M98 P5005 ;
G0 G91 G28 Z0. ;
M99 ;
;

PROGRAM FOR THIRD SETUP

06511 (E/C SIDE AND H/F SIDE) ;
(651 AND 652 ONLY) ;
(06. 10. 2023) ;
G40 G80 ;
M12 ;
M01 ;
#561 =1 ;
;
;
N1 (B. B E/C BORE COMBINATION) ;
IF [#561 NE 1] GOTO9999 ;
G91 G28 Z0. ;
M12 ;
M50 ;
T2 M6 ;
T03 ;
M01 ;
M98 P11 ;
M98 P100 ;
M01 ;
M98 P12 ;
M98 P101 ;
M01;
;
;
;
#561 -2 ;
;
#609 =#609+2 ;
IF [#609 GE #649] GOTO300 ;
#610 =#610=2 ;
IF [#609 GE #649] GOTO301 ;
M01 ;
/#561 =2 ;
;
N2 (H/F MILLING) ;
IF [ #561 NE 2] GOTO9999 ;
IF [ #561 NE 2] GOTO9999 ;
G91 G28 Z0. ;
M12 ;
;
M50 ;
T03 M6 ;
T9 ;
M01 ;
M98 P32 ;
M98 P200 ;
M01 ;
M98 P31 ;
M98 P200 ;
M01 ;
#561 =3 ;
#611 #611+2 ;
IF [#61 1 GE #651] GOTO306 ;
/#561 =3 ;
M01 ;
;
;
M01 ;
N3 (PISTON BORE) ;
IF [#561 NE 3] GOTO9999 ;
G91 G28 Z0. ;
M12 ;
M50 ;
T9 M6 ;
M01 ;
T10 ;
M98 P31 ;
M98 P300 ;
M01 ;
M98 P32 ;
M98 P300 ;
M01 ;
#561 =4 ;
#618 =#618+2 ;
IF [#618 GE #658] GOTO308 ;
/#561 =4 ;
M01 ;
;
N4 ;
(H/F DRILL) ;
IF [#561 NE 4] GOTO9999 ;
G91 G28 Z0. ;
M12 ;
M50 ;
T10 M6 ;
T11 ;
M01 ;
M98 P32 ;
M98 P400 ;
M01 ;
M98 P31 ;
M98 P400 ;
M01 ;
#561 =6 ;
#606 =#606+2 ;
IF [#606 GE #644] GOTO309 ;
/#561 =6 ;
M01 ;
;
GOTO6 ;
;
N5 (E/C FACE DRILL) ;
(SCT 12931) ;
G91 G28 Z0. ;
M12 ;
M50 ;
T4 M6 ;
M01 ;
M98 P12 ;
T11 ;
M98 P80 ;
M98 P11 ;
M98 P80 ;
M01 ;
/#606 =#606+2 ;
IF [#606 GE #651] GOTO31 ;
;
;
;
N6 (H/F TAPPMING) ;
IF [#561 GE 6] GOTO9999 ;
G91 G28 Z0. ;
M12 ;
M50 ;
T11 M6 ;
T00 ; /
T2 ;
/ M98 P11 ;
/ M98 P79 ;
M01 ;
G91 G28 Z0. ;
M98 P31 ;
M98 P500 ;
M01 ;
M98 P32 ;
M98 P500 ;
M01 ;
#561 =65 ;
#605 =#605+2 ;
IF [#605 GE #645] GOTO310 ;
/#561 =65 ;
M01 ;
;
N65 (S/F DRILL) ;
IF [#561 NE 65] GOTO9999 ;
M50 ;
T6 M6 ;
T07 ;
M01 ;
M98 P21 ;
M98 P600 ;
M01 ;
IF [#607 GE #647] GOTO304 ; /#561 =66 ;
M01 ;
;
;
N66 (S/F TAP) ;
IF [#561 NE 661] GOTO9999 ;
M50 ;
T7 M6 ;
T02 ;
M01 ;
M98 P22 ;
M98 P700 ;
M01 ;
M98 P21 ;
M98 P700 ;
M01 ;
#561 =8 ;
#605 =#608+2 ;
IF [#608 GE #648] GOTO305 ;
/#561 =8 ;
M01 ;
;
;
;
;
GOTO8 ;
;
N6 (SPOT FACE) ;
M50 ;
T05 M6 ;
M98 P11 ;
T1 ;
M98 P4087 ;
M01 ;
M98 P12 ;
M98 P4087 ;
/#608 =#608+2 ;
/IF [#608 GE #648] GOTO200 ;
M01 ;
;saz
;
N7 (CHAMFER) ;
M50 ;
T1 M6 ;
T2 ;
M98 P41 ;
M98 P800 ;
M01 ;
M98 P42 ;
M98 P800 ;
M01 ;
;
/ M00 ;
;
N8 (PROGRAMME END) ;
M09 ;
G91 G28 Z0. ;
G01 G28 Y0. B0. ;
M13 ;
G0 B-30. B-40. ;
X100. ;
M30 ; N9999
;
CAD DESIGN
CONCLUSION
In conclusion, the utilization of CNC machining for crankcase production in

compressors represents a critical advancement in manufacturing technology. The

precision, efficiency, and versatility offered by CNC machining contribute

significantly to the production of high-quality crankcases with applications across

diverse industries.

The comprehensive process, starting from CAD design and CAM programming

to the final assembly and quality control, ensures that CNC-machined

crankcases meet stringent requirements for dimensional accuracy, reliability,

and performance. The advantages, such as precision, repeatability, and the

ability to handle complex geometries, make CNC machining a preferred choice

for producing these crucial components.

We can conclude that By using the CNC machines we have lots of uses such as

 Efficiency

 High Production

 Safety

 Improves Accuracy

 Uniform Product and Design Retention

 Low Maintenance

 Capable of producing even the most complex parts

FUTURE IMPROVEMENTS

 Integration of Industry 4.0 Technologies

 Artificial Intelligence (AI) and Machine Learning (ML)

 Additive Manufacturing Integration

 Energy Efficiency and Sustainability

 Automated Inspection and Quality Control

 Multi-Tasking Machining Centres

 In-Process Monitoring and Feedback

 Education and Training Programs

REFRENCE
 PAS da Rocha R. Diagne de Silva e Souza, M E. de Lima Tostes,
Prototype CNC machine design, 9th IEEE/IAS International
Conference on Industry Applications (INDUSCON), 2010, 1-5.
 R E Breaz G, Racz O C, Bologa, Oleksik V S. Motion control of
medium size CNC machine-tools: a hands-on approach, 7th
International Conference on Industrial Electronics and Applications
(ICIEA), 2112-2117, 2012, 8-20.
 CNC Programming, Michael Mattson, Delmar Cengage Learning,
2010.
 Managing Computer Numerical Control Operations, Mike Lynch,
Society of Manufacturing Engineers, 1995.
 Hace A, Jezernik K. The open CNC controller for a cutting machine,
IEEE International Conference on Industrial Technology, 2003;
2(1231-1236):10-12.