copy of vaibhav
TRANSCRIPT
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Menon Pistons Limited, Plant II, MIDC Kupwad
Report of In-Plant Training
IN
Menon Pistons Limited, Plant II , Kupwad
By
1.wale!ar "ai#$a% P. &.Ta!ale B$anudas B.
'.Bagwan (u$el . ).*erwade Pramod B.
+.Kulal (anay . .Pat!i (aura#$ .
Submitted in partial fulfillment for confirring
egree of Ba/$elor of Te/$nology 0Me/$ani/al
2f
($i%ai 3ni%ersity
Kol$apur
epartment of Me/$ani/al 4ngineering
T(5s (anay B$o!are 6roup of Institutes,
Mira.
'711-'71'
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Menon Pistons Limited, Plant II, MIDC Kupwad
1. COMP!" P#O$IL%
Location
Menon Pistons Limited, Plant II
&'1, MIDC, Kupwad (loc),
Sangli * +1 +1,
Ma-aras-tra, India.
Mission Core /alues0'
/ISIO!
o be t-e world2s leading pro3ider of auto component manufacturing
total engineering solutions to automobile manufacturers across t-e world.
MISSIO!
o pro3ide inno3ati3e products of world class 4ualit5 at reasonable prices.
6ualit5 Polic50
primar5 responsibilit5 at Menon Pistons Limited is to offer cost effecti3e
4ualit5 products to its customers7
owards -is 8e Commit Oursel3es0
o meet t-e Customer e9pectations of current : future needs.
o co'ordinate and ac-ie3e impro3ements and effecti3eness in areas of
4ualit5 and processes on a continual basis.
o endea3or to upgrade tec-nologies and s5stems and practices to meet
statutor5 and regulator5 re4uirements.
o ac-ie3e -ig-er goals of e9cellence b5 establis-ing ob;ecti3es and targets
at rele3ant and appropriate inter3als and monitor t-eir effecti3eness
periodicall5.
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Menon Pistons Limited, Plant II, MIDC Kupwad
wards Laurels0'
-e $irst Compan5 in India to de3elop #ing Carrier Pistons
(%S /endor ward from Maruti =d5og Ltd in t-e 1>>+'>?
@S-ip * to * =se7 Status b5 C=MMI!S I!DI LD since 1>>?
$aster De3elopment ward from Kirlos)ar Oil %ngines Ltd
ISO:S0 1>+> Certified b5 =/ Suddeutsc-land in
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Menon Pistons Limited, Plant II, MIDC Kupwad
Design and manufacturing acti3ities are continuall5 impro3ed b5 -a3ing in
'-ouse testing facilit5 for t-e 3alidation of t-e product before offering t-e product
to t-e Customer.
MPL -a3e been acti3el5 associated wit- t-eir Customers in carr5ing out
trials using t-eir test facilit5 for arri3ing at mutuall5 acceptable performance
le3els. -e e9perienced Design team of 5oung %ngineers at MPL pro3ides two
dimensional and t-ree dimensional solid modeling facilities and anal5sis utiliEing
t-e Pro'% 8ildfire*< foundation pac)age for t-e Surface modules, ad3ance
Modeling e9tension and t-e rele3ant CD and C% facilities. 8it- t-e
e9perienced team, MPL wor)s as a complete solution pro3ider to its Customers b5
underta)ing t-e product de3elopment from conceptual stage to product realiEation
wit- t-e s-ortest possible lead time. MPL stri3es -ard to pursue Customer
satisfaction t-roug- t-eir Process Control and non destructi3e 6ualit5 c-ec)s as
well as maintenance and impro3ement of t-e 6ualit5 S5stems. (5 use of rigorous
6ualit5 Standards and S5stems at 3arious stages of manufacturing wit- t-e
computeriEed On'Line *Statistical Process Control.ec-ni4ues, MPL ensures t-at
products w-ic- reac- t-e customers are defect free and -a3e been produced wit-
t-e -ig-est International 6ualitati3e Standards.
MPL -as been awarded and Certified b5 t-eir 3alued Customers for t-eir
6ualit5 related acti3ities and -a3e been recogniEed as t-e most @6ualit5 Conscious
and Consistent7 Supplier. ll Plants of MPL -a3e been certified for @ISO:S
1>+>7
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Menon Pistons Limited, Plant II, MIDC Kupwad
Produ/t Range8-
In 1>G?, MPL set up its Second Plant in Sangli w-ic- is around A
Kilometers from Kol-apur and manufactures around A mm featuring Single lfin and Dual lfin Bra3it5 Die Cast
Pistons. MPL manufacture t-ese Pistons on a dedicated manufacturing facilit5 wit-
special purpose C!C Mac-ines to produce comple9 OD Profiles, and
Pin bores wit- O3al (ore, trumpet bore or reliefHs as per t-e re4uirement.
-e complicated Core Profiles featuring on t-ese Pistons are generated appl5ing
FD modeling facilities using Pro'% 8ildfire'< foundation pac)age for surfacemodeling, ad3anced modeling e9tension and ool Design Pac)age for
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Menon Pistons Limited, Plant II, MIDC Kupwad
manufacturing to ac-ie3e targeted sections and effecti3e control on t-e weig-t of
t-e Piston for optimum balance of reciprocating masses. Some of t-e special
features w-ic- are pro3ided in t-e design of t-ese bigger siEe Pistons Diameters of
11A mm to 1JA mm range
wo pieces constructions of Pistons #IC=L%D PISO!S wit-
forged C-rome Mol5 Steel Crown coupled wit- luminium llo5 S)irt -eld
toget-er b5 a Piston Pin w-ere t-e guidance and sealing function are separated
from one anot-er. (ecause of t-is design, t-e s)irts is better s-ielded from -ot
Piston crown and ring one and can, t-erefore, be installed wit- smaller clearances
t-an t-e one'piece Piston, w-ic- -as a positi3e effect on 6uiet running.
'. *ea%y9Medium9Lig$t :ommer/ial "e$i/les wit$ iesel 4ngines.
$ig. Cooled Baller5 Cut Section fig. +SP %uro III Piston
In 3iew of t-e ensuing legislations and t-e )eenness of t-e Bo3ernment to
pro3ide en3ironmentall5 friendl5 ambience, t-e modern Internal Combustion
%ngines need to introduce !ew ec-nologies for compl5ing wit- t-e emission
legislations.
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Menon Pistons Limited, Plant II, MIDC Kupwad
-e new ec-nologies call for design of Pistons to wit-stand increased
specific power output, increased in;ection pressures, -ig- pressure turbo c-arging
wit- after coolers, to compl5 wit- stringent emission regulations w-ile satisf5ing
t-e re4uirements of low fuel and lube oil consumption.
MPL manufactures wide range of Pistons in diameter range of J?mm to 1FA
mm wit- and wit-out @Cooled Baller57 features. -e design and manufacturing
facilities a3ailable wit- MPL enables t-em to design, produce and optimiEe t-e
features suc- as, @ as cast Oil drain Poc)ets7, utot-ermic:utot-ermatic Piston
wit- @control e9pansion7, Steel struts to pro3ide lesser fitting clearances for
reduced noise le3els, Budgeon Pin (ore offset for effecti3e load balancing:noise
control, Cooled Baller5 Pistons
+. Bi-w$eeler 0& (tro!e 9 (mall 4ngine ppli/ations
$ig. /S /ictor:(o9er: $ig. Copeland Pistons
&ero &onda
wide range of Pistons for < Stro)e and + Stro)e %ngines in t-e diameter
range of +A to A mm for powering t-e Scooters, Motor C5cles and #efrigeration
ir Compressors are made from %utectic and &5pereutectic luminium llo5
w-ic- are 3er5 cost effecti3e and pro3ide 3alue for t-e mone5.
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Menon Pistons Limited, Plant II, MIDC Kupwad
-ese Pistons are offered in attracti3el5 pac)ed containers as assemblies
consisting of Pistons, Budgeon Pin. MPL produces about 1.F million pistons
annuall5 of +1mm diameter for #efrigeration ir compressor sealed units. -ese
are manufactured on special purpose mac-ines wit- close tolerance and e9tremel5
good surface finis- to pro3ide H6uiteH running of t-e compressors.
&. 6udgeon pins
$ig. Budgeon pins
-e5 mainl5 manufactured pistons, Pistons rings gudgeon pins. -e5 are
/ander for 1F companies from w-ic- ma;or are automobile companies. -e5
suppl5 pistons for elco, (a;a;, Ma-indra Ma-indra, Kirlos)ar oil %ngines
Coment Diesel %ngines, Cummins India Ltd.
8or)ing S-ifts
-ere are F s-ifts per da5. In all t-ree s-ifts production is done
continuousl5. urno3er of compan5 is about 1< to 1? corers per 5ear. Compan5 is
-a3ing ISO0 >AA S'1>+> certificate called =/.
;23NR< PR:TI:4(
G
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Menon Pistons Limited, Plant II, MIDC Kupwad
:$arge Material -
-e raw material re4uired for pistons casting consist of luminum
ingots, re;ected pistons cut off pro;ections, etc.
:$emi/al :omposition -
s per t-e c-emical results in c-emical composition are depends on
t-e re4uired properties of piston li)e -ardness. $or e9ample c-emical composition
of
l-B3TT2N (MPL4 LM-1+91=) is gi%en #elow8
l * G+.J Si * 11.J? $e * A.+
Cu * A.? Mn * A.1? Mg * 1.? n * A.1F i * A.A1
Pb * A.A1 Sn * A.AA
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Menon Pistons Limited, Plant II, MIDC Kupwad
In t-is process molten metal is broug-t collected into -olding
furnace. -is operation is done to -old t-e molten metal maintain re4uired temp
to )eep in melting condition. fter collecting molten metal in -olding furnace t-e
CL%!OL powder is spread o3er it for remo3al of slug i.e. dross, etc. from melt.
6as > :$emistry :$e/!ing -
In molten metal mi9 alrefine powder in it stir it well. -en wait for 1?
to
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Menon Pistons Limited, Plant II, MIDC Kupwad
Parting, ;elting > (torage of /asting -
During casting, runners risers are pro3ided along wit-
ot-er necessar5 pro;ections. -ese pro;ections re4uired to be remo3ed w-ic- is
done in parting felting operation. fter t-is pistons are stored in round buc)et
t-en transferred to furt-er operations.
*eat Treatment -
-e casting produced is -a3ing lower -ardness. 8e re4uire
-ardness up to ?A (. $or t-is purpose t-e -eat treatment is done on casting. t
first solution treatment is done at +GA to +>A NC in pit t5pe electric furnace. -en
t-ese pistons are 4uenc-ed in water to a3oid soft spots due to bubble formation
w-ile castings are rapidl5 dipped in out in water.
fter solution treatment 4uenc-ing, t-e precipitation treatment is
done on casting. $or t-is purpose t-e furnace =sed in bo9 t5pe, electricall5 -eated
furnace. -e temperature ac-ie3ed is 1GA'
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Menon Pistons Limited, Plant II, MIDC Kupwad
PI(T2N M:*IN4 (*2P PR:TI:4(
;oundry
-e foundr5 is t-e beginning of t-e piston. t t-e foundr5 t-e die is
prepared b5 -eating it to operating temperature for appro9imatel5 one -our. -is
process allows t-e die to readil5 accept t-e molten material w-en it is poured.
$ig. Pouring of molten metal in die
T$e die
-e dies used are ? pieces and t-ree pieces. -ese dies are made from cast
iron wit- steel inserts for t-e gudgeon pin -oles and t-e cores. -e cores dictate t-e
placement of t-e gudgeon pin and can be located to gi3e offset pins or s4uare pins.
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Menon Pistons Limited, Plant II, MIDC Kupwad
$ig. Die
1F
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Menon Pistons Limited, Plant II, MIDC Kupwad
T$e pro/ess
-e process starts b5 -eating t-e material to JAA degrees Celsius. -is is
well abo3e t-e melting point of t-e aluminum, but below its boiling point. -ematerial is t-en scooped up wit- a ladle from t-e crucible t-e pot t-at -olds t-e
molten material. -is is t-en poured into t-e die t-roug- t-e spur. -e material is
t-en allowed to cool before it is remo3ed from t-e die and placed into a bin of -ot
water. -is water is used to facilitate a more e3en settling of t-e -ot metal. fter
t-e castings -a3e -ad time to cool t-e5 are placed into a -eat treatment plant
o3ernig-t. -is process tempers t-e casting and ensures t-e piston will -a3e
impro3ed 4ualities. fter it is remo3ed from t-e -eat treatment t-e casting -as its
runner remo3ed. -is process ta)es little time and is full5 automated.
$ig. Cutting e9tra pro;ections
Pin Boring
t t-is stage of t-e piston manufacturing process t-e casting -as t-e gudgeon pin
-ole roug- mac-ined and t-e locating bung mac-ined. -e bung t-is process is
w-ere t-e casting is mac-ined on t-e base to allow placement of t-e casting in
ot-er mac-ines. -is is carried out on a simple lat-e.
1+
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Menon Pistons Limited, Plant II, MIDC Kupwad
$ig. Pin boring
Pin boring is done in con;unction wit- t-e bung turning, as one casting is
remo3ed from -a3ing t-e bung face mac-ined it is placed on t-e pin borer. -e pin
borer is onl5 a roug- mac-ining process w-ic- allows t-e reamer to enter t-e
gudgeon -ole later.
:N: Turning urning of t-e casting is carried out on C!C Computer !umeric Control
mac-iner5. -is e4uipment is t-e most accurate and fastest a3ailable for t-is
application wit- 3er5 tig-t tolerances and e9tremel5 fast spindle speeds.
-e castings are placed in t-e lat-e on a bung and -eld in place b5 a solid rod
t-roug- t-e gudgeon pin -ole. draw bolt is acti3ated in t-e c-uc) w-ic- draws
t-e rod toward t-e c-uc) and -olds t-e piston in place.
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Menon Pistons Limited, Plant II, MIDC Kupwad
$ig. urning
-e lat-e is t-en started and t-e mac-ining c5cle begun. -is c5cle is
programmed into t-e lat-e in a basic language called B'Code t-is code is not t-e
onl5 one a3ailable. B'Code -as basic commands to tell t-e lat-e to mo3e to
certain positions , ", co'ordinates, at particular spindle speeds e.g. S
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Menon Pistons Limited, Plant II, MIDC Kupwad
rilling
Drilling includes all oil -oles in places suc- as t-e gudgeon pin bosses and
oil ring groo3es. Slotting is w-ere slots are placed in t-e s)irt or in t-e oil ring
groo3e.
"al%e relie%ing
-is process is done on a mill and in3ol3es setting t-e mac-ine up for t-e
process, c-oosing t-e correct cutter and completing t-e ;ob. Since t-ere are so
man5 different t5pes of 3al3e relief2s it is impossible to -a3e a specialiEed
Mac-ine set up to do one ;ob.
:ran! relie%ing
Cran) relie3ing is carried out on a specialiEed mac-ine w-ic- scallops t-e
s)irt of t-e piston to t-e re4uired s-ape and dept- b5 using two opposed cutters
Placed on a common s-aft.
6rinding
$ig. Brinding
-is process in3ol3es t-e final siEe being mac-ined on t-e piston. -e
grinder mac-ines t-e s)irt of t-e piston onl5 and in t-e ma;orit5 of cases is cam
ground. Cam grinding ensures t-e piston will grow e3enl5 in t-e bore of t-e
engine.
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Menon Pistons Limited, Plant II, MIDC Kupwad
perfectl5 round piston will e9pand une3enl5 during use because of t-e
une3en placement of material in t-e casting gudgeon pin bosses and ribbing used
for strengt-ening.
6roo%ing -
o locate t-e piston rings on t-e piston t-ere is need to formation of
groo3es. -ese groo3es are formed in two successi3e operations as roug- groo3ing
finis- groo3ing. -is groo3ing is of 1 to + or more in number depending on
design re4uirement of piston.
is$ing ?
fig. piston after dis-ing
Dis-ing is not-ing but to pro3ide t-e ca3it5 in uppermost rigid
portion of piston, w-ic- is useful to increase t-e displacement i.e. cc. suc- dis-ing
is also done in two stages.
;orm Turning -
Suc- operation is called cam or cop5 turning. In suc- operation a
masterpiece or cam made of wear less material follower made of fiber are used
connected wit- turning tool b5 spring connections.
Reaming
-is operation is done for lubrication purpose. Suc- t5pe of drilling is
perpendicular or inclined to t-e piston a9is depending on re4uirement of piston
design. -is operation is done as per re4uirement t-at some pistons re4uire a single
-ole w-ile some re4uire a double -oles parallel one below ot-er.
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Menon Pistons Limited, Plant II, MIDC Kupwad
fig. #eaming
-e final mac-ining process for t-e piston is t-at of reaming. -is process
in3ol3es t-e piston being placed in a bat- of oil and reamed at different siEes to
reac- t-e final siEe re4uired. Since t-e pin boring process is onl5 roug- it is
necessar5 to ream t-e pin bore a number of times to ac-ie3e t-e surface finis- and
siEe re4uired.
:ir/lipping -
Circlipping is done for well fitting of t-e pin in bore. small tool is fitted
eccentricall5 on mac-ine spindle. 8-en mac-ine spindle rotates, t-e tool comes in
contact wit- t-e piston bore groo3e is made on bore. t t-is stage t-e piston is
cleaned, fitted wit- t-e appropriate gudgeon pin, stamped wit- t-e pistonsH o3ersiEe
and an5 ot-er mar)ings, and t-en sent to dispatc-. ctuall5 in t-is operation t-e
s-ape of cam is gi3en to wor). -is s-ape is li)e tapered pro3ides o3alit5. So
t-at to a3oid ;amming of piston inside t-e c5linder during e9pansion at time of
combustion. &ence in t-is s-ape t-e O.D. is ma9. t open end perpendicular to
pin bore -ole.
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Menon Pistons Limited, Plant II, MIDC Kupwad
$ig.Circlipping
Burnis$ing -
It is super finis-ing operation. &ere t-e rollers mounted on
spindle s-afts are act t-e tool for finis-ing bore. Kerosene is used as coolant for
t-is operation. < or F microns material is remo3ed in t-is operation.
in Plating '
During t-is operation first anodiEing is done t-en after tin plating is
done. (5 performing t-is operation we pro3ide t-in plating of tin on piston as per
our re4uirement. =suall5 t-is t5pe of plating is done for KO%L, #OCK%,
B#%%/%S pistons. $or anodiEing t-e solution contains0
8ater Q sulp-uric acid Q o9alic acid
-is o9alic acid is used to maintain t-e temperature of solution. lso plating is
done for KO%L pistons in t-is acetic acid is used is solution.
%.g. pistons are coated wit- grap-ite powder t-en -eated.
Dispatc- fter cleaning, inspection, punc-ing t-e pac)ing dispatc-ing is done send
t-e piston storage.
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Menon Pistons Limited, Plant II, MIDC Kupwad
:(4 (T3
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Menon Pistons Limited, Plant II, MIDC Kupwad
(u#@ero treatment8
-e subEero treatment is carried out at 'JA NC to 'GANC. Due to subEero
treatment, t-e retained austenite get transformed to Martensite. If t-e 4uenc-ed
steel is -eld at room temp for some time before cooling less austenite I transformed
to Martensite i.e. t-e austenite gets stabiliEed. -ere fore, t-e subEero treatment
s-ould be done immediatel5 after -ardening.
PIN M:*IN4 (*2P
fter doing -eat treatment on pin a lot of gudgeon pin stored for furt-er
mac-ining in pin storage department. Menon piston produces 1GJ no. of pins of
3arious companies including &ero &onda, KO%L, Le5land +AA, and ata indica
J?, %scort sF1
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Menon Pistons Limited, Plant II, MIDC Kupwad
Centerless grinding is t-e met-od of grinding e9terior c5lindrical, tapered
formed surface on wor) pieces t-at are not -eld rotated on centers.
-e wor) is placed upon t-e wor) rest latter, toget-er wit- t-e
regulating w-eel is feed forward, forcing t-e wor) against t-e grinding w-eel. -e
a9ial mo3ement of t-e wor) past t-e grinding w-eel is obtained b5 tilting t-e
regulating w-eel at a slig-t angle from -oriEontal. n angular ad;ustment of A to G
or 1A degree is pro3ided in t-e mac-ine for t-is purpose.
%C&!ICL SP%CI$ICIO!S $O# C%!%#%L%SS B#I!DI!B
MC&I!%...
D%SC#IPIO! MOD%L SL'J?
Brinding range diameter
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Menon Pistons Limited, Plant II, MIDC Kupwad
d3antages of Center less Brinding0
1. s a true floating condition e9ist during t-e grinding process less metal to be
remo3ed.
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Menon Pistons Limited, Plant II, MIDC Kupwad
Center less grinding
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Menon Pistons Limited, Plant II, MIDC Kupwad
Center less grinding Frd0
$ig. Centerless grinding
s t-e O.D. I.D. c-amfering is done gudgeon pin again tends to
center less grinding Frdtime to remo3e t-e material wit-in range of 1+ to +
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Menon Pistons Limited, Plant II, MIDC Kupwad
Suc- a powder emits greenis-'5ellow lig-t under t-e influence of
ultra3iolet lig-t gi3es a better contrast to detect a flaw, since gudgeon pins are
placed on copper rod magnetiEed in circular met-od as current pass t-roug-
copper rod for a w-ile, according to s)in effect alternati3e current .C flow from
surface of t-e component. &ence magnetic pole is formed at t-e crac) or flaw
w-ic- causes t-e magnetic powder to concentrate on t-is area t-e flaw gets
easil5 detected. 8-en flow gets magnetiEed in circular manner t-en lengt-wise
crac)s are easil5 detected.
If an5 defects are obser3ed in pin surface t-en pins get re;ected,
ot-er pin passing successfull5 send for furt-er operation i.e. lapping:super
finis-ing.
Lapping:super finis-ing0
Lapping is t-e operation of siEing finis-ing a small diameter -ole
alread5 -ardened b5 remo3ing 3er5 small amount of material b5 using a lap. It is
abrading process t-at is used to produce geometricall5 true surface, correct minor
surface imperfections, impro3e dimensional accurac5 or pro3ide a close fit
between two contact surfaces.
In lapping mac-ine t-e laps practicall5 called ad stones are placed
in se4uence total G no laps are placed out of w-ic- last F laps are for finis-ing
purpose. Laps are placed in two saddles containing + laps eac-. %3er5 lap tends
pressure on t-e pin pneumaticall5. dial placed on t-e c5linders indicated
pressure in eac- c5linder in bar.Budgeon pins are placed wit- t-e -elp of rollers.
/ibration speed of laps acceleration of rollers maintained proportional to get
desired result. During lapping operation material up to A to ?T will remo3ed.
FA
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Menon Pistons Limited, Plant II, MIDC Kupwad
$or super finis-ing oil in;ected on t-e gudgeon pi w-en t-e5 roll on t-e
rollers i.e.&onilo'>G1 during rec5cling oil it is filtered F times. Due to t-is oil we
get -ig- 4ualit5 of surface finis- on t-e pin. -is is t-e last operation on gudgeon
pin, after t-is operation pin are c-ec)ed under 3isual detection.
/isual inspection0
During 3isual detection pins are cleaned b5 using clot- detected
t-e defects li)e crac)s or dept- cuts on t-e surface of t-e gudgeon pin, if an5
defects are not obser3ed on t-e surface of t-e pin will get re;ected. If an5 defects
are not obser3ed on pin t-en pins sends for furt-er detection in standard room to
c-ec) dimensions of t-e pin are or not.
Standard room detection0
-ese air conditioning rooms speciall5 build for c-ec)ing
dimensions 3er5 accuratel5 on -ig-l5 calibrated gauges li)e surtronics FQ, air plug
gauge optical flat etc.
In surtronic FQ mac-ine surface finis- of pin will c-ec)ed, pin was
placed on t-e / bloc) and rotated in contact wit- t-e -oriEontal member w-ose
deflection are indicated on t-e dial, since less deflection results as desired finis-ing
is ac-ie3ed.
Outer diameter will c-ec)ed wit- t-e -elp of air plug gauge. Pin
passed t-roug- t-e circular plate as t-e pressure is applied on air 3al3e air get
e9perience bac) pressure -ence t-is c-ange will obser3ed on t-e dial connected to
air plug. $latness of t-e pin will c-ec)ed wit- t-e -elp of optical flat ultra3iolet
ra5s, in t-is met-od pin 3erticall5 placed on t-e optical flat plate ultra3iolet ra5s
passed from t-e area of contact t-e appearance of t-e ultra3iolet ra5 on screen will
indicated t-e actual surface of t-e pin. Since t-e speed am flatness measuring c-art
was pro3ided for anal5Eing t-e appearing s-ape on t-e screen during c-ec)ing.
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Menon Pistons Limited, Plant II, MIDC Kupwad
OOL #OOM OOL C#I(
In t-is department or s-op, all e4uipment re4uired for production on
mac-ine is stored. -e5 issued as per re4uirement. In t-is s-op, no. of e4uipment
li)e spigot, clamp, clamp rod, clamp pin, BO'!OBO gauges, center plate, ;ig
plate, fi9ture, mandrills, locators, 3arious roug-ing finis-ing tool groo3ing
forming tool. In t-is s-op Master cam re4uired for form turning also stored.
&oriEontal Spindle, #eciprocating able0'
Brinder0
-e spindle of mac-ine is -oriEontal and table reciprocates. -is grinder
is used to grind t-e s-an) of tool wit- respect to its tip Magnetic s-uc) is used to
-old tool on t-e mac-ine.
ool Cutter Brinder0
On t-is mac-ine operation li)e s-an) radius, nose radius of tool is
gi3en to tool. ool is fi9ed on fi9ture and fed it again, t-e cone s-aped grinding
w-eel. -e angle re4uire is gi3en b5 fi9ture plate to tool we get re4uired radius.
$or c-ec)ing form of tool li)e a form tool used form turning. -e magnified s-ape
is inspected on screen re4uired s-are is obtained. -e magnification obtained up
to 1A. (5 using optical profile because dis-ing operation depends upon form tool.
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Menon Pistons Limited, Plant II, MIDC Kupwad
6=LI" CO!#OL
MPL stri3es -ard to pursue Customer satisfaction t-roug- t-eir Process Control
and non destructi3e 6ualit5 c-ec)s as well as maintenance and impro3ement of t-e
6ualit5 S5stems. (5 use of rigorous 6ualit5 Standards and S5stems at 3arious
stages of manufacturing wit- t-e computeriEed On'Line *Statistical Process
Control. ec-ni4ues, MPL ensures t-at products w-ic- reac- t-e customers are
defect free and -a3e been produced wit- t-e -ig-est International 6ualitati3e
Standards.
MPL -as been awarded and Certified b5 t-eir 3alued Customers for t-eir
6ualit5 related acti3ities and -a3e been recogniEed as t-e most @6ualit5 Conscious
and Consistent7 Supplier. ll Plants of MPL -a3e been certified for @ISO:S
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Menon Pistons Limited, Plant II, MIDC Kupwad
-e list count of instruments is A.AA1mm 1 micron, w-ic- is 1:1A t-of
L.C. of dial gauge. -e instrument dial is generall5 related wit- fi9ed scale
respecti3e readings are c-ec)ed on dial gauge reading, t-e reading of instrument
c-ec)ed. Compared wit- dial gauge reading. -e dial gauge to be c-ec)ed is
wit-in tolerance t-en it accepted ot-erwise re;ected.
#oug-ness ester Mac-ine0'
-is is full5 automatic, surface te9ture measuring mac-ine. a5lor'
&obson, Limited ma)es t-is mac-ine. On t-is mac-ine, part to be c-ec)ed i.e. pin
is mounted. -e st5le w-ic- -a3ing sensor at its end is mounted. -e lengt- is
measured is feed to mac-ine. fter some period, w-en st5lus is mo3ed o3er t-e
Surface of t-e pin t-e result is directl5 printed out wit- grap-. 8e
directl5 get 3alues suc- as #a, #MS, CLS 3alue wit- t-eir respecti3e grap- from
w-ic- we compare standard result.
Profile te9ture testing mac-ine0
On t-is instrument, we c-ec) t-e piston for o3alit5, taper, its diameter
etc. it is 3er5 sensiti3e, w-ic- respond 4uic)l5 to c-ange. It is as simple dial
indicator. -e piston -eld between st5lus pointer measurements are ta)en.
Pin O.D. comparator0
s discussed earlier, t-e pins c-ec)ed b5 t-ese instruments also
taper, o3alit5 of pin is also c-ec)ed wit- t-e -elp of t-is de3ice. -e comparator
used for t-is is pneumatic comparator. -is ring gauge is used for t-is purpose.
-e tolerance is wit-in A.AA< mm. -e least count of mac-ine is A.AA1 mm. -e
-undred inspection is done on t-is mac-ine.
CO!CL=SIO!
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Menon Pistons Limited, Plant II, MIDC Kupwad
s @Industrial Case stud57 is introduced in t-e s5llabus, its
good mo3e as it will -elp t-e students to interact wit- industr5. So t-at students
can get actual practical )nowledge rat-er t-an t-eoretical one.
In industr5 I -a3e studied 3arious mac-ines, t-eir operations,
t-eir wor)ing. It was a nice e9perience to stud5 t-e management s)ills. lso t-e
wor)ing aspects, problems occurring in industr5 -ow t-e5 are o3ercome.
I can conclude t-at t-e 3ocational training program pro3ides
opportunit5 to learn more more t-ings w-ic- can not be studied in boo)s.