INTERNSHIP REPORT

Pakistan Ordnance Factories

Muhammad Rehan
Electrical Engineer
Rehanraza0106@gmail.com

COMSATS UNIVERSITY ISLAMABAD, WAH CANTT

Internship Report

Medium Artillery Ammunition Factory (MAA)

 
Introduction:
The word MAA is an abbreviated form of Medium Arms Ammunition, and this factory is one of
the huge factories among fourteen factories of Pakistan Ordinance Factories (POF). The
purpose of this factory is same as SAA factory, but the difference is that in MAA factory they are
manufacturing medium ammunition and in SAA factory they are manufacturing small type
ammunition.

There are some different shops in MAA like C-12, C-10 which I visited during my internship. A
brief introduction of the products and the shops is as under:
 
Products MAA Factory:
The major products of MAA factory are:

 Fuze PDM-557(point detonator mechanism) for 150 mm (how) HE and 105 mm HE-/ TA
 (tank ammunition).
  Fuze V9 P1-A2 for 60 mm(MOR bomb) HE-SMK
  Fuze V19 P1-A2 for 81 mm(MOR bomb) HE-SMK
  Proximity PF-1A for 130 mm FC and RC (full charge and reduce charge).
  Brass Cartridge Cases (20 mm-130 mm)
  Shell 105mm (how smoke, how HE & HE TK)
  Shell 25 PDRHE
  Shell 30mm API
  Shell HE (23mm, 30mm, 37mm, 81mm)
  Shell 81mm signal red (ILLUM)
  Shell 81mm smoke
  Primer No. 11 & Primer No. 12 (M)

  Primer PIMK-III
 Mortar bombs (81mm & 105mm)

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MAA Factory C-10 Shop:

Products:
 Brass Cartridge cases (20mm-130mm)

Manufacturing Process:
Steps involved in the manufacturing process of products are as under:

 Brass Disc:Brass is an alloy of copper and zinc (70% Cu and 30%Zn). Raw material for
brass is imported from LME (London metal exchange) then it is sent to brass mill where
it is melted and discs are made.

 Cupping:Cups are cut from the brass metal strip on a press which applies a force a 2
ton pounds to cut the cup and the remaining strip is sent back to brass mill where it is
melted and reused.

 Annealing:Annealing is a heat treatment process whereby a metal is heated to a
specific temperature and then allowed to cool slowly. Generally annealing is carried out
for releasing the internal stresses arising in the metal during forging and cooling of work
piece. It is used for equalizing the granular structure of the forged metal and improving
 the various mechanical properties. Cups are annealed and their quality is checked. 
st
 1 Draw:In this operation cups are drawn in such a way that the length is increased
 and its wall thickness is decreased.
 Annealing:Cups are annealed again and their quality is checked.

 Indentation: Indenting is done on the bottom of the case where cap is to be placed
after indenting depth of anvil is checked.
nd
  2 Draw:Cups are drawn again.
 Annealing:Cups are annealed again and their quality is checked.

 Final Draw: Cups are drawn again.

 Annealing: Cups are annealed again and their quality is checked.

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 Trimming: Extra length from the case is removed; mouth tool is used to cut which
 operates with cam follower mechanism.
  Heading: After pinch trimming, head is made flat on the bottom of the case.
 Annealing: Cups are annealed again and their quality is checked.

 Tapering:Overall the whole case is tapered in this operation.

 Head Turning:Its head is being turned off.

 Mouth Boring:mouth boring is done i.e. a hole is made on the mouth.

 Inspection:Finally, it is sent for inspection to QC (quality control) and IDA.

Machines:
 Hydraulic presses:

The hydraulic press depends on Pascal's principle: the pressure throughout a

closed system is constant. One part of the system is a piston acting as a pump,
with modest mechanical force acting on a small cross-sectional area; the other
part is a piston with a larger area which generates a correspondingly large
mechanical force. Only small-diameter tubing (which more easily resists
pressure) is needed if the pump is separated from the press cylinder.

 CNC Machines:

It stands for computer numerical controlled machine. These

machines are interfaced with computers. All CNC machining
begins with a part program, which is sequential instructions or
coded commands that direct the specific machine functions.The
most basic function of any CNC machine is automatic, precise,
and consistent motion control. The applications of CNC include
both for machine tool as well as non-machine tool areas.

 Furnaces:

A furnace is a device used for heating. It is essentially a thermal

enclosure and is employed to process raw materials at high
temperatures.All furnaces have the components: Refractory chamber,
hearth, burners, chimney, charging and discharging doors. Different
types of furnaces are present there like Electric furnace and gas fired
furnace

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MAA Factory C-12 Shop:

It is also known as the Fuse shop. Its brief description is as under:

Products:

 Fuze PDM-557(point detonator mechanism) for 150 mm (how) HE and 105 mm HE-/ TA
 (tank ammunition).
  Fuze V9 P1-A2 for 60 mm(MOR bomb) HE-SMK
  Fuze V19 P1-A2 for 81 mm(MOR bomb) HE-SMK
  Proximity PF-1A for 130 mm FC and RC (full charge and reduce charge)
  Fuze PDM-739 mm & PDM-493 mm
  Fuze HE-2A1 & HE-137 mm
  Fuze PIBD-M509 A2
 Miscellaneous Ammo. Parts

Manufacturing Process:
It involves these steps:
st
 1 operation
  Inspection
nd
 2 operation (if req.)
  Inspection
  Surface Treatment
  Inspection
  Assembly
  Testing
 Dispatch

Machines: There are total of about 850 machines in C-12 shop. They are divided as:

  Single Spindle Auto Machining Group

  CNC Machining Group
  Semi Auto Machining Group
 Surface Treatment Group

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MAA Factory C-12 Maintenance Shop:

Maintenance is done in a way as assigned by the ISO.

ISO (International Standards Organization):

It stands forInternational standard organization. ISO requirements:
  Quality
  
Safety
  
Health
 
Environment

Types of Maintenance:
There are two types of maintenance:

1. Preventive Maintenance
2. Corrective Maintenance

Preventive Maintenance:

Where equipment is maintained before break down occurs. This type of maintenance has many
different variations and is subject of various researches to determine best and most efficient
way to maintain equipment. Recent studies have shown that Preventive maintenance is
effective in preventing age related failures of the equipment. It is done in two steps:

o Schedule A: Lubrication of the machinery is being done once in a year.

o Schedule B:Almost done in the same way as all the components are assembled to
make a machine again, just like overhauling. It is also performed once in a year.

Corrective Maintenance:

In schedule B the maintenance which is required when an item has failed or worn out, to bring
it back to working order. Corrective maintenance is carried out on all items where the
consequences of failure or wearing out are not significant and the cost of this maintenance is
not greater than preventive maintenance.

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MAA Factory C-17 Shop:

C-17 shop in MAA factory is a maintenance shop also known as base workshop. There
are different machines present in this shop. A brief introduction is given below.

1. Boring Machine:
In machining, boring is the process of enlarging a hole that has already
been drilled (or cast), by means of a single-point cutting tool (or of a
boring head containing several such tools), for example as in boring a
gun barrel or an engine cylinder. Boring is used to achieve greater
accuracy of the diameter of a hole, and can be used to cut a tapered
hole. Boring can be viewed as the internal-diameter counterpart to
turning, which cuts external diameters. Boring machine can handle
typical parts like pumps etc.

2. Radial Drilling Machine:

A drill is a tool fitted with a cutting tool attachment or driving tool
attachment, usually a drill bit or driver bit, used for boring holes in
various materials or fastening various materials together with the use of
fasteners. The attachment is gripped by a chuck at one end of the drill
and rotated while pressed against the target material. This may be slicing
off thin shavings (twist drills or auger bits), grinding off small particles (oil
drilling), crushing and removing pieces of the work-piece, countersinking,
counter boring, or other operations.The arm of the radial drill machine
can rotate about 360° and table about 45°.

3. Horizontal Turning Machine:

A turning machine in which the spindle axis is parallel to the ground is
known as horizontal turning machine. Turning is a machining process in
which a cutting tool, typically a non-rotary tool bit, describes a helical tool
path by moving more or less linearly while the work-piece rotates. The
tool's axes of movement may be literally a straight line, or they may be
along some set of curves or angles, but they are essentially linear (in the
nonmathematical sense).

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MAA Factory C-31 Shop:

It is basically a shell machining shop.

Products:
  Shell 105mm (how smoke, how HE & HE TK)
  Shell 25 PDRHE
  Shell 30mm API
  Shell HE (23mm, 30mm, 37mm, 81mm)
  Shell 81mm signal red (ILLUM)
  Shell 81mm smoke
  Primer No. 11 & Primer No. 12 (M)
 Primer PIMK-III

Manufacturing Process:
It is further divided into groups:

 Die Casting Group:Processes involved in Gravity die casting plant are:

  o 
Melting Furnace (temp. of 750-800 C)
 
 Forging to make Al fins
 
 Inspection (both in QC and IDA)
 
 Annealing
 
 Anodizing
 
 Assembly of cartridge holder tail and Al fins

 Multi Auto Group: It contains 6 spindle multi auto machines. The processes
involved are:
 
 Forged shells from B-31
 
 Facing on Lathe

  st 
1 Auto Machining
  nd 
2 Auto Machining
 
 Grinding
 
Inspection

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 CNC Machining Group:

It stands for computer numerical controlled machine. These
machines are interfaced with computers. All CNC machining
begins with a part program, which is sequential instructions
or coded commands that direct the specific machine
functions. The most basic function of any CNC machine is
automatic, precise, and consistent motion control. The
applications of CNC include both for machine tool as well as
non-machine tool areas.

 Primer Group:
  
Parting
 
 Base Plate manufacturing
 
 Then send to B-31
 
 Breezing is done
 
 Brought back to C-31
 
 CNC Machining
 
 Inspection

 Finishing Group:
  
Phosphating
 
 Finishing by Embry Paper
 
 Painting and Varnishing
 
 Kept in furnace for 20 min for proper painting
 
 Inspection

 Assembly Group:
Assembly of body and tail is carried out.

 Inspection Group:
Final dimension of components inspect by first QC and then IDA and finally manufactured part
is dispatched.

 Dispatch:
Then the products are sent to filling factory.

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MAA Factory C-35 Shop:

It is basically a tool room i.e., in this shop tools are being manufactured for whole of the
shops of MAA factory. Some of the machines being used here are as under:

 Capstan lathe:

A type of lathe fitted with accessories set up for rapid production of

identical parts. The distinguishing feature is the self-indexing capstan
or tool head which holds several previously positioned tools that
perform in succession various cutting operations, such as turning,
drilling, counter boring and threading. The capstan is mounted on a
slide, the base of which is clamped to the lathe bed at a convenient
distance from the headstock.

 Turret lathe:

The turret lathe is a form of metalworking lathe that is used for

repetitive production of duplicate parts, which by the nature of their
cutting process are usually interchangeable. It evolved from earlier
lathes with the addition of the turret, which is an index able
toolholder that allows multiple cutting operations to be performed. It
is due to the toolpath's being controlled by the machine, either in jig-
like fashion, via the mechanical limits placed on it by the turret's slide
and stops, or via electronically-directed servomechanisms for
computer numerical control (CNC) lathes.

 Electric discharge machine (EDM):

EDM, sometimes colloquially also referred to as spark machining,is a

manufacturing process whereby a desired shape is obtained using
electrical discharges (sparks). Material is removed from the work
piece by a series of rapidly recurring current discharges between two
electrodes, separated by a dielectricliquid and subject to an electric
voltage. One of the electrodes is called the tool-electrode, or simply
the ‘tool’ or ‘electrode’, while the other is called the work piece-
electrode.

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 Jig boring machine:

Jig borer is a type of machine tool invented at the end of World War I to
make possible the quick-yet-very-precise location of whole centers. It
was invented independently in Switzerland and the United States. It can
be viewed as a specialized species of milling machine that provided tool
and die makers with a higher degree of positioning precision
(repeatability) and accuracy than those general machines had previously
provided.It was generally used to enlarge to precise size smaller holes
drilled with less accurate machinery in approximately the correct place
(IE with the small hole strictly within the area to be bored out for the
large hole).

 CNC milling machine:

A milling machine is a machine tool used to machinesolidmaterials.

Milling machines are often classed in two basic forms, horizontal and
vertical, which refer to the orientation of the main spindle. Both types
range in size from small, bench-mounted devices to room-sized
machines. Milling machines move the workpiece radially against the
rotating milling cutter, which cuts on its sides as well as its tip.
Workpiece and cutter movement are precisely controlled to less than
0.001 in (0.025 mm), usually by means of precision ground slides and
leadscrews or analogous technology. Milling machines may be manually
operated, mechanically automated, or digitally automated via computer
numerical control.

 Cylindrical grinding machine:

The cylindrical grinder is a type of grinding machine used to shape the

outside of an object. The cylindrical grinder can work on a variety of
shapes; however the object must have a central axis of rotation. This
includes but is not limited to such shapes as a cylinder, an ellipse, a cam,
or a crankshaft. Cylindrical grinding is defined as having four essential
actions:
  The work (object) must be constantly rotating
  
The grinding wheel must be constantly rotating
  
The grinding wheel is fed towards and away from the work
 
Either the work or the grinding wheel is traversed with the respect to the other.

While the majority of cylindrical grinders employ all four movements, there are grinders
that only employ three of the four actions.
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