INTERNSHIP REPORT

STUDY OF ORION H6600 CNC HMC MACHINE

Submitted By
Arjun Sridhar (14BT1ME009)
Ekhalak Ansari (14BT1ME018)
Studying in the final year B.Tech, Mechanical Engg
at the School of Engineering and Technology-Jain
University, Bangalore.

Carried out at Bharat Fritz Werner Ltd, under the guidance of

Mr. Ramesh Babu
Senior General Manager-MCD
Bharat Fritz Werner Ltd
 CERTIFICATE

Study of Orion H6600 CNC HMC Machine

Submitted by

Arjun Sridhar (14BT1ME009)

Ekhalak Ansari (14BT1ME009)

Studying in the final year B.Tech, Mechanical Engg

at the School of Engineering and Technology-Jain
University, Bangalore.

Mr. Ramesh Babu

Senior General Manager-MCD
Bharat Fritz Werner Ltd
 Acknowledgment

We are very thankful to Bharat Fritz Werner Ltd

for having given us the opportunity to undertake
internship in such a prestigious organisation. We
would like to thank Mr. Ramesh Babu, Sr General
Manager of MCD for guiding and monitoring our
progress over the duration of the internship. We
would also like to thank Mr. Dinesh, Mr. Santosh,
Mr. Harsha, Mr. Abhishek, Mr. Mallikarjun, Manu
and Ravi, all of MCD Division and we would also
like to convey our thanks to Mr. Chetan and
Bhatru of HLD Division, for their invaluable inputs
and support over the course of the internship.

We would also like to thank Mr. Abhijit

Choudhary, Deputy Manager-Talent Acquisition
and Mrs. Nagalakshmi K S, Asst. Manager-HR for
providing us with this wonderful opportunity and
sending us on the right path and for doing the
needful.
 CONTENTS

1. About the Organisation

2. Products
3. Observations
4. Suggestions
5. Summary
 ABOUT THE ORGANISATION

Bharat Fritz Werner Limited, popularly known as BFW,

is India’s largest machine tool builder. One of the
flagship companies of the Kothari Group, BFW was
incorporated in 1961 in collaboration with Fritz Werner
Werkzeugmaschinen GmbH of West Germany. They
have a wide product range. In addition to all commonly
required machine tools, they have built more than 200
special variants. There are more than 30,000 BFW
products across the globe.

Their products find applications in a wide range of

industries. BFW is an ISO 9001:2008 and ISO 14001:2004
manufacturer, with the main manufacturing facility
located outside Bengaluru city. BFW has a fully-fledged
foundry in Hosur that is equipped with furnaces, shot
blasting equipment, sand mixing and reclamation
machinery and an in-house laboratory.

BFW is acknowledged both for its product quality and

environment conservation efforts. It is one of the rare
private sector machine tool companies in India to have
completed 50 years of operation.
 PRODUCTS

BFW have a number of products.

CNC Vertical Machining Center (VMC)

The vertical machining centers are the machining centers
whose spindle axis is vertically oriented. Milling cutters are
held in the spindle and made to 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. A few VMCs manufactured by BFW are
given below:
 CNC HORIZONTAL MACHINING CENTER (HMC)

A horizontal mill has the same, but the cutters are

mounted on a horizontal spindle across the table. Many
horizontal mills also feature a built-in rotary table that
allows milling at various angles; this feature is called a
universal table. Some of the HMCs manufactured by
BFW are as follows:

Series 1 (Orion H5000 I H5500)

Series 2 (Orion H6000 I H6600 I H8000)

Prima 44
 OBSERVATIONS

We were tasked with observing the production and

assembly of an Orion H6600 HMC machine. To obtain a
better understanding of HMCs we’ve listed a few of
them in relative detail below:

H5000, H5500
ORION horizontal machining Centre are designed and
operated to deliver excellent machine precision with the use
of high precision components and work friendly features.
ORION platform has three series, covering upto 1250 x 1000
pallet size horizontal machining centres catering to a wide
range of applications. They have temperature sensors to
continuously monitor abnormal temperature rise. Some of
the special specification of this machine are as follows;
1. Maximum spindle torque 124/50 (126/84) Nm
2. Spindle speed 15000 rpm
3. Spindle boring dia 70 mm
4. No of tool standard 40
5. Maximum tool weight 12 kg
6. Tool changing time 1.4 sec
7. Chip to chip time 2.8 to 3 sec
8. Pallet change time 9 sec
9. Servo driven 180 swing type
10.Machine weight 12000 kg
 11. Compressed air 6 bar
12. Power supply 3 phase 415 v, 50 Hz
13. Pallet type typed holes
14. Load capacity 500-700 kg
15. Index position 360 deg

Orion series H6000, H6600, H8000

This Orion series mainly deals with improvement of
productivity, providing new methods and ways of
performances that leads to increase in reliability, precision,
stability, economy. There are many series available in this
one that works as per the circumstances applied and given.
The size of the pallet depends on the working application as
it varies from 500*500 to 1250*1000. Some of the features
of constructional elements of this are given below;
1. Cast iron bed structure that supports the entire machine
body
2. LM guide ways that provides linear motion
3. Reduced and minimum possible weight and stiffness of
structure
4. Ball screws that will also have its own rolling movement.
5. Spindle and ball screw cooling system
The rigid single piece of cast structure leads to minimal effect
in temperature variation that in turn improves the safety of
the worker. Motorised spindles are also in use that tends to
easy maintenance and replacement. High speed and torque
motor provide flexibility to the user. They are used for heavy
cuttings. Further it is provided with high speed automatic
tool changer that changes tool in minimum possible time.
ATC arm will provide smooth and reliable tool change.
Some of the applications of this machine are as follows;
1. Cast iron cylinder block
2. Globe valve body
3. Tractor gear box housing
4. Connecting rod

H8800, H10000, H12000

ORION horizontal machining Centre are designed and

manufactured to deliver excellent machine precision with the
use of high precision components and thermo-friendly
features. ORION platform has three series, covering 500 x
500 pallet to 1250 x 1000 pallet size horizontal machining
centres catering to a wide range of applications. Some of the
unique features are as follows;
1. High speed & high torque motor spindle cartridge are
field interchangeable thereby providing flexibility to
user.
2. Servo driven high speed ATC for fast tool change.
3. Efficient chip disposal with chip conveyor inside bed.
4. Swivel type operator panel for easy operation.
Few important specifications are as follows;
1. Spindle speed 6000 rpm
 2. Spindle acceleration time 3 sec
3. Pallet change time 30mm for 180 deg swing type
4. Pallet size 1000*1000 mm
5. Pallet type T-slots
6. Load capacity 3000 kg
7. Rotary table/ index table rotation 360 deg
8. No of tools standard 60
9. Maximum tool length 600 mm
10. Maximum tool weight 30 kg
11. Tool changing time 2 sec
12. Chip to chip time 5.6 sec

Some of the applications are as follows;

1. Gear box housing
2. Large Cylinder block
3. Globe value body
4. Cylinder block for defense vehicle

PRIMA 44
A Prima 44 is a horizontal machining device which plays an
important role in maintaining the working standard and help
in improving the productivity that ultimately boosts the
economy of the working process. It improves the
manufacturing rate and give an extra benefit over other
machines. Prima is generally being made taken into
consideration the future scope. It relates to improved
reliability, production, performance, economy etc.
Some of the properties of this machine are specified as
follows;
1. Proper chip disposal
2. Maintained Coolant flow
3. No effect of chips on machine elements
4. Good power and torque produced
However the specifications and requirements also depends
on the customer demand and economy as well. As on
demand, some of the specifications of the machine elements
that are generally followed are as follows;
1. Pallet size 500*400 mm
2. Load capacity 400 kg
3. Spindle type BT40
4. Spindle speed 6000-8000 rpm
5. Feed rate 1-20000 mm/min
6. No of tools 24,40,60
7. Tool change time 2.2 sec
8. Chip to chip time 5.9 sec
9. Rotary table 360 ͦ
Some of the applications of this machine are as follows;
1. Connecting rod
2. Cylinder block
3. High speed machining

PRIMA 54 and PRIMA 55

The PRIMA series of Horizontal Machining Centers has been
designed to create a prominent impact on shop floor
dynamics by increasing productivity, competitiveness and
profitability. It has many innovative & first in class features as
under, each of them contributing to enhanced reliability,
performance & productivity.
Some of the unique important features are as Follows;
1. Chip disposal through stainless steel chute right below
the cutting zone.
2. Fully enclosed machining area
3. Maximum spindle power upto 18.5 kW & torque upto
235 Nm
4. Overhead shower wash with copious coolant flow.
5. Hydraulic power pack
6. BT 40 spindle taper
7. 24 tools tool magazine
8. Roller type guide ways and precise ball screws for linear
axes
9. Tool life management
10. Coolant gun
11. Automatic pallet changer (rotary type)
12. Chiller for clean coolant system

Some of the important specifications are as follows;

1. Spindle taper BT40 type
2. Spindle power 11-15 kw
3. Spindle speed 6000 to 8000 rpm
4. Spindle torque 105-191 Nm
5. Feed rate 1-20000 mm/min
 6. No of tools 24,40,60
7. Maximum tool length 300 mm
8. Tool change time 2.2 sec
9. Chip to chip time 5.9 sec
10. Automatic pallet changer 180 deg swing type
11. Weight of machine 8500 kg
12. Compressed air 6 bar
13. Power supply 415v,50 Hz,3 phase
14. Pallet size 630*500 mm
15. Load capacity 500 kg
16. Index position standard 360 deg

Some of important applications are as follows;

1. Cylinder block
2. Connecting rod
3. Globe valve body
4. Tractor housing gear box (hsg)