Submitted by

KRISHNARADDI R GANGAL
This is a report of my internship program at ACE
Internship Objectives and Report Structure
DESIGNERS.
 The main objective of this internship was to study
the company, the manner in which tasks are
distributed, work is organized and performed.
 My primary focus was on the Component
Manufacturing Division, to learn more about the
ways in which manufacturing is done, components
manufactured and other aspects are relevant to the
operations of the CMD.
The other area of study was the machine Assembly,
particularly the Flow line assembly.
Since my study was based on observation and
interaction with people, this study report contains
details of what I learned during the time I spent in
the company.
Ace Designers had its humble beginnings in 1979
About ACEtoolDESIGNERS
as a machine designing Service Company,
under the leadership of three engineers, Mr.
Ashok V Sathe, Mr. Shrinivas G. Shirgurkar, and
Mr. Benedict Machado.

With 35 years of machine tool experience,

design boards and a few thousand rupees in hand,
the three started Ace in a garage as a machine tool
designing service company, at first, it was a
partnership firm. It became a joint stock company
in the year 1989, and it became a deemed public
company in the year 1996.
At present, Ace Designers Ltd. is the leader in
sales of “CNC Turning Machines” (accounting for
about 40% of the Indian market) and among the
top 3 machine tools manufacturing companies in
India. Ace has focused in providing technical
solutions, including development of special work-
holding devices, test runs to conduct process
capability studies and even automation. 70% of
Ace products are sold to the automotive industry
and the balance to industries like Bearings and
general engineering industry.
The company is ISO 9001 certified.
 The company’s Product Range has developed
Product Range
over the year and it is a ‘Continuous
Improvement Process’ to constantly upgrade
the machines.
 The range includes the following machines:
1. CNC Lathes and Chuckers
 Jobber XL
 LT-2XL / LT-2XL 500 / Super Jobber
 LT-20C / Classic / LT-20XL
 Junior Jobber
 Twin Spindle CNC Chucker
 Centre Lathe (New)
 Auto Lathe CNC
 VTL-30 / VTL-40
2. Special Purpose Machines
 Friction Welder
 Turning And Burnishing Machine
 Piston Ring Turning Machine
 Other Valve Machines
Customers of ACE
The customers of Ace Designers Ltd. are present in
India, the European Union countries, USA, Canada,
Brazil, Egypt, Germany, Spain. In India, Ace meets
customized CNC machine requirements of more than
200 companies, mainly located in South India out of
these about 70% of companies are in Karnataka.
Another 20% of companies are in Andhra Pradesh ( in
Hyderabad). Remaining 10% are spread in Tamil
Nadu, Maharashtra, New Delhi, etc.
The Various Divisions of the Company
To fulfill the requirement of the customers, the
company has distributed itself into 6 major divisions.
Each division is allotted particular task that it must
carry out, which is essential for the successful
operation of the company.
The major divisions of the company are indicated in
the block representation below.
Product Cycle at Ace Designers
 ACE DESIGNERS

TECHNICAL
SERVICE
SHEET ASSEMBLY
GROUP COMPONENT
METAL DIVISION
MANUFACTU
DIVISION
RING DIV PAINTING
DIVISION
COMPONENT
MANUFACTU
RING DIV
Individual Function of Divisions
Technical Service Group
It is the Marketing division’s responsibility is to interact
with the customer. They understand the customer’s needs
and requests, and accordingly advise him with the most
suitable option. The customer’s order is placed and details
are forwarded to the Design division
Design Division
The Design division is given the task of visualizing and
developing a practical concept or idea and give shape to it,
just as the customer would have wanted it to be. The
Division also believes in continuously improving their
designs to by finding better alternatives and low cost
options.
Component Manufacturing Division (CMD)
The CMD is the manufacturing hub of the company.
The CMD is in charge of producing almost all the
critical components of a turning machine. Various
kinds of machining processes are performed here. The
division out sources some manufacturing processes.
CMD is equipped with adequate number of machines
and manpower. The division believes in continuous
improvement in its processes and techniques.
Organizational Chart for CMD
 Operations Performed
Turning
Milling
Drilling
Grinding
Shaping
Broaching
Slotting
Components Manufactured
 The machine components are categorized into the following:
 Purchased components
Manufactured components:
a) In house manufactured components
b) Vendor supplied components
All components manufactured in CMD are
classified into 4-categories as .
AA Class: Bed, Saddle, Top Table, Turret Disc,
Tail Stock, Housing, Spindle, Tail Stock Guide,
Tail Stock Slide etc.
A Class: Axis Bearing Housing, Spindle Spares,
Spindle Covers, Tool Holders, Axis Spacer and
Nut, Spindle Pulley.
B Class: Keeper Plates, Height Plates, Tail Stock
Assembly Elements, Steady Rest Elements, Parts
Catcher Elements, Draw Bars.
C Class: Residual components fall under this
category.
MACHINES IN THE CMD

 Machining Centers
 MAZAK MAZATECH FH-6800

 Type: Horizontal Machining Centre

 Specification: X-axis 1050 mm
Y-axis 800 mm
Z – Axis 880 mm
Index Table rotation up to 3600
Spindle Speed: 7000 rpm max
Table size: 630 mm x 630 mm

Components machined:
 Top table
 Tail stock body
 ATC bracket
 Saddle
 Head stock Housing
 Carriage
 Turret disk (Only for VTL lathes)
MAZAK Nexus 600
 This machine is newly acquired by the CMD, to assist in the machining of smaller
components, with required very high accuracy and precision It is almost similar to the
MAZAK MazaTech FH-600 machine

Type: Vertical Machining Centre

 Specifications:

Machine capacity:-
 No. of Tools: 24 in Drum Type Tool magazine with automatic tool changer

Components machined:
 Plate
 Cover
 Pulley
 Bearing housings
 Housing
 X-nut housing
 Z-BSB housing
CNC Grinding Machines
 Hardinge Kellenberger KEL-VARIA UR175/1500

 Benefits over conventional grinding machine:

 All Spindles are finish ground on this machine.
 Spindle Run outs & face outs is now maintained within 2µ. (Earlier up to 5µ)
 Roundness of 0.3 to 0.4µ achieved in spindle
 Taper Accuracy achieved within 5”
Spindle Manufacturing
The spindle is regarded as the heart of the
Machine Tool. It is the most critical component
and it requires very high accuracy, or else the
machine tool may not meet the standards. In a
Turning machine, the spindle is used to provide a
link between the driving motor and the work
holding component (i.e. Chuck). It is supported
by two bearings and coupled to the motor by a V-
Belt pulley. At all these places a sufficient taper
angle is provided.
Types of Spindles Manufactured at ACE
CMD
Type of Spindle Machine Tool Model
A2-5 Jobber XL/LT-16 XL
A2-6 Centre Lathe (New)
A2-8 VTL/LT 25/LT 30/ Classic
A2-11 VTL 40/LT-25/ LT-30
The spindles are made of Low Alloy Steel (20MnCr5)
(15Ni2Cr1Mo15) (20MnCr1) (15Ni2Cr1Mo12)
A2-5 Spindle Manufacturing Procedure
STEP 1: Forging
STEP 2: Proof Machining
STEP 3: Turning Before Carburizing
STEP 4: Boring Before Carburizing
STEP 5: Case Carburizing
STEP 7: After Carburizing Turning and Grooving
STEP 8: Hardening, Tempering & Sand Blasting
STEP 9: Hard Turning & Threading
STEP 10: Hard Boring
STEP 11: Keyway Milling
STEP 12: Stabilizing
STEP 13: Finish Grinding
After Proof Machining
Turning Before Carburising After Carburising

Finished Spindles to stores

After Carburising After Finish Grinding
Drilling & Tapping
Assembly Division
The Assembly located in Shop-2 is the locations where
value addition upon the components is done, as they take
the form of the final machine.
ACE has introduced the concept of Flow line In the year
2002 . This was an inevitable step taken to live up to the
ever growing demand of machines by the customers.
Previously while following the conventional method It was
noticed that such method of assembly would take up to 22
hours per machine. Moreover, there was immense wastage
of space as all the elements would be placed collectively
around the machine. Manpower was not effectively
utilized and scheduling work became even more a difficult
task.
models currently assembled on flow line are
CUB, COLT, JOBBER XL, JOBBBER Junior, JOBBER
LM, and Super JOBBER. In the station wise activitys
are divided in to eight stations .
Example. 1st Station Activity: On the first station, a
bed is loaded everyday with spindle headstock, saddle
and top plate already assembled on it. The operations
being done on the first station are as follows:
Start.
5S
Re tapping of all the holes.
Mounting bracket and baffle.
Mounting the angle.etc
To the 8th station . at last station to the end
Documentation of test details, main elements and pre
dispatch inspection .
Case study
Problem selection
In any industrial concern, the problem of cost reduction
assumes top priority. By the improvement of process the
values of capability indices can be increased. The
component spacer which is used in assembly of Z-axis and
X-axis ball screw is a small one. It is used to fill the space
between the ball screw and the bearing on which it is
mounted. It is produced on the machine called JOBBER
XL.
Introduction to the component
Component : spacer
Material: C45
Dimensions: in mm
Inner diameter: 25 mm with tolerance 0. 025 to 0. 050mm
Outer diameter 1:35mm
Length: 29mm
Calculation performed
The components are divided into 10 sub-groups and 10
components in each sub-group.
The radius of each component are taken in X and Y
directions for about 100 components at the top and
bottom surface.
The mean radius of the component is calculated..
Based on the values obtained the process is concluded as
stable or not.
If the process is not stable suggestions for the betterment
of the process are given.
Inner radius of component spacer
1 to 10 X- top 50 66 64 45 46 55 61 55 47 65
X-bottom 42 55 58 41 51 57 49 50 42 62
Y-bottom 43 55 65 42 48 57 49 51 42 61
y-top 48 65 61 46 46 52 58 57 49 67

11 to X- top 53 59 60 62 48 53 42 68 55 60
20 X-bottom 57 59 55 56 47 53 47 67 57 62
Y-bottom 56 59 51 59 50 54 44 66 59 61
y-top 55 58 59 60 51 54 45 66 60 60

21 to X- top 66 60 70 60 61 57 50 52 66 46
30 X-bottom 60 55 61 55 55 58 48 50 56 43
Y-bottom 62 55 60 56 56 59 47 52 58 42
y-top 66 62 70 61 59 62 54 52 58 42
31 to X- top 60 63 44 64 45 43 61 55 60 35
40 X-bottom 52 55 48 64 34 34 59 50 52 33
Y-bottom 52 53 47 61 34 33 61 50 51 31
y-top 53 62 45 63 45 44 64 54 59 36
41 to X- top 43 40 39 59 64 63 54 51 44 43
50 X-bottom 39 35 33 50 58 65 47 40 45 42
Y-bottom 37 34 33 50 58 65 47 40 45 42
y-top 45 39 38 56 65 66 53 52 47 47
51 to 60 X- top 47 44 68 58 45 57 60 61 58 56
X-bottom 44 37 66 59 44 55 56 48 51 53
Y-bottom 40 56 68 60 46 53 55 56 49 55
y-top 49 45 69 62 47 60 57 58 58 54
61 to 70 X- top 54 65 37 57 45 45 52 59 57 56
X-bottom 40 58 34 49 44 45 45 54 57 53
Y-bottom 44 55 37 51 44 46 46 54 60 51
y-top 56 60 41 59 45 50 45 52 59 60
71 to 80 X- top 62 63 70 58 64 62 54 68 51 61
X-bottom 59 63 68 55 61 60 52 58 48 60
Y-bottom 63 64 65 59 58 60 53 60 46 61
y-top 60 65 70 62 64 62 54 67 50 62
81 to 90 X- top 54 60 63 70 52 62 51 60 68 55
X-bottom 64 56 62 70 50 63 44 59 64 56
Y-bottom 60 58 64 70 49 66 65 60 57 54
y-top 62 65 67 70 49 66 65 60 57 54
91 to 100 X- top 62 50 48 62 53 46 52 61 64 63
X-bottom 63 50 39 61 50 39 43 62 63 56
Y-bottom 58 51 37 59 50 42 44 61 63 54
y-top 60 51 41 61 47 43 58 61 61 60
 Overall Reaction
This Internship at Ace Designers proved to be a
highly successful one. I was greatly benefited from the
practical knowledge that I gained from the company.
It proved as an excellent opportunity for me to learn
the manners and means that are essential for the
successful running of an Industry.