Dr.

AMBEDKAR INSTITUTE OF TECHNOLOGY

[An Autonomous Institution, affiliated to VTU, Belgaum and Aided by Government of Karnataka]
Near Jnana Bharathi Campus, Mallathalli, Bangalore-560056.

DEPARTMENT OF MECHANICAL ENGINEERING

INTERNSHIP REPORT
on
Manufacturing and Production
Submitted in partial fulfillment of there requirements for the award of the
Degree of
BACHELOR OF ENGINEERING
In
MECHANICAL ENGINEERING
Submitted By
ABHISHEK.S (1DA21ME001)
DURATION:16/10/2023 to 11/11/2023 (1 Month)

Department of Mechanical Engineering,

Dr.Ambedkar Institute of Technology, Bangalore.

Visvesvaraya Technological University, Belagavi

2022-2023
 Dr. AMBEDKAR INSTITUTE OF TECHNOLOGY
[An Autonomous Institution, affiliated to VTU, Belgaum and Aided by Government of Karnataka]
Near Jnana Bharathi Campus, Mallathalli, Bangalore-560056.

Department of Mechanical Engineering

CERTIFICATE
Certified that the industry internship (Fourth Semester) entitled “LASER SHEET
METAL FABRICATION INTERN”at Magod Laser Machining Pvt Ltd is
carried out by the following bonafied student of Mechanical Engineering in partial
fulfillment for the award of Bachelor of Engineering ,B.E(Mechanical) at
Dr.Ambedkar Institute of Technology, Bangalore, during the academic year
2022-2023

USN STUDENTNAME
1DA21ME001 ABHISHEK S

It is certified that all corrections/suggestions indicated for Internal

Assessment have been incorporated in the project report.The internship
report has been approved satisfying the academic requirements
prescribed for the said Degree.

Dr.T.N.RAJU Dr.MEENAKSHI
HOD Dept. of ME, principal
Dr.AIT-560056. AIT-560056

Sl No. NameoftheExaminer Signaturewithdate

1.
2.
 Dr. AMBEDKAR INSTITUTE OF TECHNOLOGY
[An Autonomous Institution, affiliated to VTU, Belgaum and Aided by Government of Karnataka]
Near Jnana Bharathi Campus, Mallathalli, Bangalore-560056.

Department of Mechanical Engineering

DECLARATION
I am Abhishek.S Currently Pursuing in 3rd year, Bachelor of Engineering student of
Mechanical Engineering, Dr. Ambedkar Institute of Technology, Bengaluru-56, hereby
declare that the internship work entitled “LASER SHEET METAL
FABRICATION INTERN” has been originally carried out by me, under the
guidance of Mr.Ramesh, Production Manager and Mr.GAJENDRA, Store Manager
at Magod Laser Machining Pvt Ltd .

SIGNATURE

Abhishek.S (1DA21ME001)
COMPLETATION CERTIFICATE:-
 ACKNOWLEDGEMENT

 First I would like to thank Manager ,HR, Head, of Magod Laser

Machining Pvt Ltd. for giving me the opportunity to do an internship
within the Organization.

 I also would like all the people that worked along with me Magod
Laser Machining Pvt Ltd (Peenya), with their patience and openness
they created an enjoyable working Environment.

 It Is indeed with a great sense of pleasure and immense sense of

gratitude that I Acknowledge the help of theseindividuals.

 I would like to thank my Head of the Department Dr Raju T.N

for his Constructive criticism throughout my internship.

 I am extremely great full to my department staff members and friends who

helped Me in successful completion of this internship.
 Learning Objectives/Internship Objectives
 Internships are generally thought of to be reserved for college
students looking to gain Experience in a particular field. However,
a wide array of people can benefit from
 Training Internships in order to receive real world experience
 An objective for this position should emphasize the skills you
already possess in the area And your interest in learning more
 Internships are utilized in a number of different career fields,
including architecture, Engineering, healthcare, economics,
advertising and many more.
 Some internship is used to allow individuals to perform scientific
research while others Are specifically designed to allow people to
gain first-hand experience working.
 Utilizing internships is a great way to build your resume and
develop skills that can be Emphasized in your resume for future
jobs. When you are applying for a Training

 Internship, make sure to highlight any special skills or talents that

can make you standard Apart from the rest of the applicants so that
you have an improved chance of landing the.
 Department of Mechanical Engineering
Internship Log Sheet
Student Name : ABHISHEK.S USN: 1DA21ME001
Faculty (Mentor) : Dr.Purushotham Duration : 16/10/2023 to 11/11/2023
No of Credits : 03 Semester: 05
Company Name : Magod Laser Machining Company Supervisor Name : Mahantesh
Pvt Ltd
Date Time In Time Out Hours Activity Log
16-10-23 09:00 AM 05:30 PM 8hr 30 min Visiting magod laser machining pvt ltd the company manager and
Advised about rules and regulation after company and safety and
precaution About the internship
17-10-23 09:00 AM 05:30 PM 8hr 30 min Introduction about the production department and Introduction
about the laser cutting machining and procedure to Cutting metals
using Laser
18-10-23 09:00 AM 05:30 PM 8hr 30 min Introduction about the bending machine and its working principle
19-10-23 09:00 AM 05:30 PM 8hr 30 min Introduction of programming laser cutting machine by using
Magod laser application.
20-10-23 09:00 AM 05:30 PM 8hr 30 min Explaining the brief of inspection using different method
26-10-23 09:00 AM 05:30 PM 8hr 30 min Introduction about the store department what is the requirement
and advantages of store department
27-10-23 09:00 AM 05:30 PM 8hr 30 min Learning the filing process using the grinding machine to remove
step provided to a metal and carry it on the produced materials
30-10-23 09:00 AM 05:30 PM 8hr 30 min Laser machine operator help us to teach how to operate the laser
machine
31-10-23 09:00 AM 05:30 PM 8hr 30 min Inspection of all material using gauges
02-10-23 09:00 AM 05:30 PM 8hr 30 min Introduction about the laser gases which laser machine users to
cut and hammering the Bent Heat treated metals to proper shape.
03-11-23 09:00 AM 05:30 PM 8hr 30 min Introduction about the Compressor and MCB and other
components of laser machine and there role in machine
04-11-23 09:00 AM 05:30 PM 8hr 30 min Brief introduction to billing process.
06-11-23 09:00 AM 05:30 PM 8hr 30 min Introduction about the inspection report and writing the inspection
report
07-11-23 09:00 AM 05:30 PM 8hr 30 min Major part and function of laser machine
08-11-23 09:00 AM 05:30 PM 8hr 30 min Programming loading and unloading using the application
09-11-23 09:00 AM 05:30 PM 8hr 30 min Analyzing and recognition of different types and grades of metals
like aluminium and stainless steel and mild steel
10-11-23 09:00 AM 05:30 PM 8hr 30 min Brief overview of how mechanical industry runs
11-10-23 09:00 AM 05:30 PM 8hr 30 min Final understand how the metal come from the store department
products in production department and packing and loading
I certify that I have worked the hours indicated above.
Student Intern Signature Date
I certify that the Student Intern has worked the hours indicated above.

Company Supervisor Signature Date

Faculty ( Mentor) Signature Date

 TABLE OF CONTENTS

1. Introduction about Company/ Industry

2. Introduction to laser cutting machine

3. Major Parts and Functions of Laser machine

4. Laser Cutting Head

5. Laser Gases and Cutting Gases

6. Bending machine

7. Laser Micro Welding

8. Grinding Process

9. Packaging

10. Idea/Suggestion

11. Conclusion
 Introduction About Industry
Magod Laser, A Laser Based Manufacturing Company in India with facilities at
7 locations - Bengaluru (Jigani, Peenya, Dabaspet), Dharwad, Chennai
(Sriperumpudur), Hosur (TN) and a subsidiary unit Magod Fusion at Pune. They
provide Jobwork Services in Laser Cutting of Sheets & Plates, Laser Cutting of
Tubes & Pipes, 5-Axis Laser Cutting of 3D formed Parts, Laser Welding
(NADCAP Certified), Laser Cladding, Laser Hardening, Laser Drilling, Metal
3D Printing, Die & Mould repair, as well as Design & Product Development
Support to Industries.

The Company was started in 1997 with a vision of making available the latest
manufacturing processes to Indian Industries. Since then the company has
grown and now are they one of the biggest Laser Cutting & Laser Welding
service providers, and has the best NADCAP Certified Laser Welding facility in
India as on date. We bring added value to our customers by sharing our
experiences and giving feedback on the optimum utilization of our services in
terms of design and material planning.
 INTRODUCTION TO THE LAZER CUTTING
MACHINE

In 1965, the first production laser cutting machine was used to drill
holes in diamond dies. This machine was made by the Western
Electric Engineering Research Center. In 1967, the British pioneered
laser-assisted oxygen jet cutting for metals .In the early 1970s, this
technology was put into production to cut titanium for aerospace

Applications.
At the same time CO lasers were adapted to cut non-metals, such as
textiles, because, at the time, CO: lasers were not powerful enough to
overcome the thermal conductivity of metals.

Lasers are used for many purposes. One way they are used is for cutting
metal plates. On mild steel stainless steel, and aluminum plate, the laser
cutting process is highly accurate, yields excellent cut quality, has a very
small kerf width and small heat affect zone, and makes it possible to cut
very intricate shapes and small holes.
But how does light cut through a steel plate?
The laser beam is a column of very high intensity light, of a single
wavelength, or cork. In the case of a typical CO2 laser, that wavelength is
in the Infra-Red part of the light spectrum, so it is invisible to the
human eye. The beam is only about ¾ of an inch in diameter as it travels
from the laser resonator, which creates the beam, through the machine’s
beam path. It may be bounced in different directions by a number of
mirrors, or “beam benders”, before it is finally focused onto the plate.
The focused laser beam goes through the bore of a nozzle right before it
hits the plate. Also flowing through that nozzle bore is a compressed gas,
such as Oxygen or Nitrogen Focusing the laser beam can be done by a
special lens, or by a curved mirror, and this takes place in the laser
cutting head. The beam has to be precisely focused so that the shape of
the focus spot and the density of the energy in that spot are perfectly
round and consistent, and centered in the

Major Parts and Functions of Laser Machine

1. Laser Unit (Resonator)

Generates Laser Beam. This unit consists of

 RF Generator-Excitation (Energize) of Laser Gases and

Generation of high frequency from 0 to 10 KHz

 Chiller Unit It is cooling the laser unit

2. Motion Unit (x Slide)
The X and Y slides are moved in the linear guides (Single Direction) and
are driven by three phase current servo motors by means of a rack and
pinion drive. This unit consists of

 Control Panel-A set of Operational keys Laser

Cutting Head
 Switch cabinet (CNC Controller)- This is the function of CNC
controller is logical and power section, electrical power supply of the
drives etc

3. Laser Cutting Head

Is the central component of the system. It is used for cutting in laser
Machine. It is a laser beam guide way, accommodation of the lens and
cutting gas Supply, laser beam focusing
 Conveyor
Disposal of slag (waste) and small parts which fall through the

 Pallet
It supports to work piece for laser cutting

 Dust Collector
It collects all dust from machine while cutting. Installation of the Central
Lubrication, Pneumatic Control Connections for cutting gas and compressed-
air preparation.

 Nozzle

Single layer nozzles are used for melting and cutting, that is, nitrogen is used
as an auxiliary gas, and it is usually used to cut stainless steel, aluminum
alloy, brass, etc
 Laser Gases and Cutting Gases
LASER GASES
We use majorly 3 types of gases to generate laser. The specifications are
Gas. Quality Grade
Carbon Dioxide (CO2) 99.996 4.6
Helium (He) 99.995 4.6
Nitrogen (N2H 99.999 5.0

CUTTING GASES
To cut different material, we saw different gases depending upon
the cutting quality required by the customer. The different types of
gases and the specifications are

Gas Quality Grade

Oxygen(O2) 99.5 2.5
Nitrogen (N2). 99.0 3.5

IDENTIFYING THE GASES

For identifying the gigs each gas cylinder is coated with different color

Oxygen Black
Nitrogen Bottom whitish green top Aluminium
Helium Brown
Argon Dark Green
Carbon Dioxide Bottom Black & Top White
Materials used for Gas Pipeline

The gas pipeline, in which the gas is flowing, is made up of Copper or

Stainless or Flexible Pipe or Brass

Process of Cutting
We have following processes depending upon the cutting Quality

Process Type of Cutting Identification Material

1. Process-1 Oxygen cuttings Edges are black MS – 10 Bar

2. Process 2 Nitrogen cutting Edges are Shining SS,AL- 30 Bar

Oxygen cutting Nitrogen cutting

Description of the Process Cooler
The process cooler is a cooling plant, ready for connection, comprising a
refrigeration circuit including all fittings and control equipment required
for automatic operation
The process cooler is designed for the cooling of water in a temperature
range from +15°C to +33°C The heat extracted from the water is give
the surrounding air via the refrigeration circuit through action of the
fans.

CNC LASER MACHINE Control Panel

BENDING MACHINE

INTRODUCTION

This investigation is all about working and designing of bending

machine. This bending machine can bends a Small plate, rods, pipes,
tubes. This kind of metal has its own particular thickness. The bending
machine planner
Will think about various components including kind of metal, roller
bender types, the kind of power supply and Bending machine size. The
bar is bending with the assistance of pressure driven power, in light of
the fact that
The energy of hydraulic power is vast, so with the assistance of
hydraulic driven power we can bend the bar. Actually, bending is
procedure of plastically deforming a metal bars, tubes etc and changing
its shapes. Bending is adaptable process by which a wide range of shape
can be achieved. Its produces shapes like v shape, u shape, And circular
shapes can also be achieved. These Machines are to work easily and
effectively.
BENDING PROCESS

Sheet metal bends are formed using metal bending. Metal bending is a
process by which metal can be deformed when applying force to the
subject, which causes it to bend at an angle and form the anticipated
shape, which often results in it being in a ‘V’ or a ‘U’ shape.

WORKING PRINCIPLE OF BENDING MACHINE

A bending machine is a machine used to bend and shape
There are many types and functions of bending machines, which can
either serve as a press or a bending machine.
Some bending machines can process sheet metal directly without the
need for clamping tools, while others require clamping tools to assist
with bending.
The metal sheet is secured by the clamping device and remains in place
throughout the entire processing process.
The bending machine uses the bending tool to shape the metal plate and
create the desired profile.
The body and tools of the bending machine must be made of special
materials to ensure that they can withstand the pressure applied during
processing without being damaged.
2. Laser Micro Welding

This method uses a focused laser beam to melt and join materials
together. It is precise and ideal for joining small or heat-sensitive
components, such as in the electronics and medical device industries.
Laser micro welding is incredibly precise, allowing for the accurate
placement of welds in tight spaces and on small components. This level
of precision is especially valuable in industries like electronics, medical
devices, and aerospace.
WORKING PRINCIPLE OF MICRO WELDING
Laser micro-welding, bonding and forming have similar features, that is,
the main change of the small components after laser irradiation took
place mainly in the shape change of the components, while no materials
are added on or subtracted from the substrate.

Laser micro-welding has almost the same processing principle as laser

welding for macro components, by which the materials are welded
together directly without reducing or adding materials, except that the
size range is much smaller than the latter.

The micro scale of spot welding is the smallest, utilized in high tech industries
like electronics, medical, bio implant, and telecommunications devices, with a
material range of . 0005” to . 005” thickness.
Common applications of micro welding include but are not limited to

 Medical devices
 Aerospace industry
 Heat exchanges.
 Metal boxes.
 Bellows.
 Jewelry,
 Die manufacturing.
 Electronics
Grinding Process
A material removal process in manufacturing
Grinding is an abrasive machining process that uses a grinding wheel or
abrasive belt as the cutting tool. It is commonly used to remove from a
workpiece, to produce a smooth finish on the surface of the workpiece,
or to remove burrs from the surface.

A grinding machine uses an abrasive product — usually a rotating wheel

— to shape and finish a workpiece by removing metal and generating a
surface within a given tolerance. A grinding wheel is made with abrasive
grains bonded together. Each grain acts as a cutting tool, removing tiny
chips from the workpiece
Packaging.

The terms “wrapping” and “packing/packaging” refer to different

aspects of preparing a product for storage, transportation, or
presentation. Wrapping typically refers to the process of covering or
enclosing a product with a material such as paper, plastic, or fabric,
often for decorative or protective purposes helping the employees of
company we learned how to package material by using rapper
Ideas/ Suggestions for laser cutting machine for time
saving
1. The Steps must given in center of the edge rather than giving it in
corner if it is given in corner it cannot be easily spoted and if is
grinned the corner shape might become radius and piece might get
rejected. So it would be better if the step is given in center.
2. time can be saved if the programmers programs in such a way that
unnecessary steps for materials which are large enough that can not
fall down through the pallets should not be given and this not only
saves time but also give good surface finish. so that material rejection
chances will be less.
3. Using double headed laser machine that can save the time for cutting
same designed / shaped materials consecutively

Conclusion

 There are many useful applications and uses for Laser Cutting in
the current manufacturing market.
 Many new innovations are on their way and new uses for this
versatile cutting process are cropping up year.
 Laser cut garments have flooded the high street. It’s easy to forget
that they haven’t always been so readily available. This is more
than a trend: it is also underpinned by the adoption of new
technologies.
 Consumers are becoming more interested in textures and
appreciative of technique, Happily. Laser cutting technologies
were more readily available to garment and fabric manufacturers.
 Laser cutting no longer had to be outsourced to bespoke
companies, but could be a process integrated into clothing
production.
Thanking for Magod lasers for giving this opportunity