industrialtraining report final

8/12/2019 Industrialtraining Report Final

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INDUSTRIALTRAINING

REPORTONAluminium Castings, Clutches and Braes

Su!mitted in the "artial #ul#ilment #$r the a%ard $# Bachel$r $# Techn$l$g&

in 'echanical Engineering

Su!mitted T$( Su!mitted B&

Pr$#) R)*) Tri"athi Anit Garg

+) O) D) R$ll N$) -./

'echanical Engineering

0rd 1ear 'ech) Engg

De"artment $# 'echanical Engineering+INDU COLLEGE O2 ENGINEERING

3A##iliated t$') D) Uni4ersit&, R$hta 5

PRE2ACE


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The im"$rtance $# industrial training needs n$ em"hasis) One $# the

characteristics $# m$dern scenari$ is the increasing ra"idit& $# change)

This intensi#ies the need #$r stud&, ada"tati$n and training) 2$r an

engineering student the "ractical training is as im"$rtant as the

the$retical n$%ledge and s$metimes m$re than the the$r& "art)

The "ractical training n$t $nl& maes a student #amiliar %ith the

atm$s"here and c$ndi t i$ns $# industr& !ut su##i c ient l&

increases h is 6her n$%ledge !& "r$4id ing a sense

$# c$n#idence and m$ti4ati$n) The main $!7ect $# all industrial

trainings is t$ "re"are an indi4idual s$ that he6she can acc$m"lish

his6her tas e##icientl& and e##ecti4el& and can tae u" and handle

7$!s $# higher res"$nsi!i li t& ) Training is an act $# increasing the

n$%ledge and sills $# an em"l$&ee #$r d$ing a "articular 7$!) The

ma7$r $ut c$me $# training is learning) A trainee learns ne% ha!its, re#inedsills and use#ul n$%ledge during the training that hel"s him6her as

im"r$4ed "er#$rmance) Training ena!les an indi4idual t$ d$ his6her

"resent 7$! m$re e##icientl& and !e "re"ared #$r higher le4e l 7$!)

Training is a " l a n n e d " r $ g r a m m e d e s i g n e d t $ i m " r $ 4 e

" e r # $ r m a n c e s a n d ! r i n g a ! $ u t m e a s u r a ! l e c h a n g e s i n

n$%ledge, sill, attitude and s$cial !eha4i$ur $# an indi4idual) I "ers$nall&

#eel "r$ud and ha""& in %riting this training re"$rt that I ha4e c$m"leted m&

training in such a g$$d $rganisati$n %hich taught me s$ man& use#ul things)

AC*NO8LEDGE'ENT


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I #eel immense "leasure in c$m"leting this training and su!mitting this #inal

re"$rt) The %h$le internshi" "eri$d %ith AS* Aut$m$ti4e P4t) Ltd)+as !een #ull $# learning and a sense $# c$ntri!uti$n t$%ards

increasing the "ractical n$%ledge) I %$uld lie t$ than

'r) R)*) ARORA 3C+AIR'AN5 #$r gi4ing me the $""$rtunit& t$c$m"lete m& training in such a g$$d $rganisati$n) A success#ul training

can ne4er !e c$m"leted !& the e##$rts $# a single "ers$n, !ut it als$

demands the hel" and guardianshi" $# s$me c$n4ersant "ers$n %h$

hel"ed the undersigned acti4el& $r "assi4el& inc$m"leti$n $#

success#ul training) During the actual training

'r) De4ender Sharma 3+ead Training De"artment5h a s ! e e n a s $ u r c e $ # i n s " i r a t i $ n t h r $ u g h h i s c $ n s t a n t

g u i d a n c e , " e r s $ n a l i n t e r e s t , enc$uragement and hel") I %$uld lie

t$ c$n4e& m& sincere than t$ him) I als$ tae this $""$rtunit& t$ than

'r) G$4ind *aushi 3Su"er4is$r5and all th$se "e$"le %h$ made this e9"erience a mem$ra!le $ne)

Anit Garg

CONTENTS

:)PRE2ACE


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;)AC*NO8LEDGE'ENT

0)CERTI2ICATE

)SECTIONS

:.)?UALIT1 ASSURANCE

::)ALU'INIU' CASTINGS

:;)CLUTC+ES

:0)BRA*E ASSE'BL1

:=> !& 'r) *) S) Rathee %ith a

4isi$n t$ achie4e e9cellence in the #ield $# manu#acturing Aut$m$ti4e

C$m"$nents) The c$m"an& has technical c$lla!$rati$n %ith the %$rld leader

in #ricti$n material '6S) AS* Technical C$r"$rati$n, @a"an) 8ith its m$tt$


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$# Cust$mer 2irst the c$m"an& gr$%n $4er the &ears and "resentl& it has

three "lants at di##erent l$cati$ns in Gurga$n, +ar&ana) Thr$ugh its

c$mmitment t$ inn$4ati$n, "r$cess im"r$4ements, ualit& c$ntr$l and

cust$mer ser4ice the c$m"an& has !een a!le t$ "$siti$n itsel# as a e&

res$urce #$r leading OE's) The AS*s "r$ducts are in line %ith the m$st

demanding ualit& standards) All $# AS*s $"erati$n ha4e secured

a""r$"riate ?ualit& Certi#icati$ns and the C$m"an& has recei4ed a n$ $#

ualit& and "er#$rmance a%ards #r$m cust$mers)

The e& aut$m$ti4e OE' d$mestic cust$mers include


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The c$m"an&s sale gra"h is increasing &ear !& &ear) The #$ll$%ing chart

sh$%s that Latest Sales Gra"h


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INR in 'ILLIONS

The #$ll$%ing #e% lines sh$% the success st$r& $# the c$m"an&

:>=>Setting u" $# c$m"an&

:>>


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:>>>?S(>... Certi#icati$nBest ender A%ardF #r$m *inetic '$t$r

;..:Signed TCA %ith AS* Technica C$r" $# @a"anSetting u" $# unit IISetting u" $#

Die Casting #acilit&

;..0Challenge India Su""$rt A%ardF #r$m +'SI

;..Plan t$ set unit I

PLANT LA1OUT


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ORGANISATION


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Organisa t i$n ma& !e de# ined as the "r$cess $# ident i #& ing

and gr$u"ing the %$r t$ !e "er#$rmed, de#ining and delegating

the auth$rit& and res"$nsi!ilit& and esta!lishing relati$nshi" #$r the "ur"$se

$# ena!ling "e$"le t$ %$r m$st e##ecti4el& t$gether in acc$m"lishing

$!7ecti4e) The AS* Aut$m$ti4e 3P5 Ltd) has a 4er& g$$d #uncti$nal

$rganisati$n) An $rganisati$n chart $# the c$m"an& is sh$%n !el$%

Under each head there is $ne seni$r engineer and $ne engineer) Under

engineer there are su"er4is$rs and under su"er4is$rs there are %$rers)

8OR* CULTURE


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ari$us acti4ities $# AS* gr$u" stands t$%ards maintaining /S

and T?' are !eing undertaen in the c$m"an& #$r achie4ing $4erall

e9cellence) S$me $# these are listed !el$%(

H The "lant has !een di4ided int$ 4ari$us $nes %ith each $ne ha4ing a

$nal leader

H The $nal leader is res"$nsi!le #$r /S acti4ities in his $ne

H Peri$dic /S audits are !eing c$nducted !& the c$re gr$u"

H C$nce"t $# TEI has !een intr$duced

H SGIA 3Small Gr$u" In4$l4ement Acti4ities5 teams #$rmed #$r di##erent

acti4ities

PRODUCTS


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AS* Aut$m$ti4e 3P5 Ltd) manu#acture "r$ducts $# man& t&"es and

s"eci#icati$ns acc$rding t$ the need $# OE' cust$mers, !ut still these can

!e di4ided int$ t%$ t&"es

:) 2ricti$n 'aterial Pr$ductsThese are the "r$ducts %hich reuire #ricti$n linings $n their sur#ace)'ain #ricti$n material "r$ducts are(

H Brae Sh$e

H Brae Assem!l&

H Brae Lining

H Clutch Plate

;) Aluminium Castings

Aluminium castings include man& "r$ducts lie(


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H Panels

H +u!s

H N$nAut$m$ti4e

H Cran Case

H Gri"

H Engine Parts


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Gri"s

All the "r$ducts manu#actured !& AS* are n$t $# $ne s"eci#icati$n !ut !ased u"$n the4ari$us di##erent s"eci#icati$n gi4en !& the di##erent cust$mers)

SECTIONSThe di##erent secti$ns $# unit III are(

Ra% 'aterial St$re

'achining Secti$n

Drilling Secti$n

2inishing Secti$n

Paint Sh$"

Assem!l& Secti$n

T$$l R$$m

2inished G$$ds St$re

RA8 'ATERIAL STORE

The ra% material reuired in Unit III c$mes #r$m Unit II) 2$r !raes the ra%

material is all c$m"$nents $# sh$e !rae such as !rae sh$e, !rae lining,

!ac "late, retract$r s"ring etc) 2$r clutches ra% material is clutch "lates

and #$r aluminium castings the ra% material is unmachined and

un#inished castings %hich are #inished and "ainted there)

'AC+INING SECTION


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In machining secti$n all the machines reuired t$ d$ !asic

machining $# an& c$m"$nent are a4aila!le)The machines a4aila!le in

machining secti$n are(

Lathe 'achine

Sha"er Sl$tter

Drill 'achine

Reaming 'achine

B$ring 'achine

'illing 'achine

Grinding 'achine

Br$aching 'achine

P$%er +acsa%

DRILLING SECTIONThe drilling secti$n $# the industr& is $ne $# the m$st im"$rtant secti$ns #$r

ualit& as"ects) The di##erent "arts manu#actured !& c$m"an& reuire

man& "recise drilling $"erati$ns) T$ meet the ualit& standards the

drilling secti$n is eui""ed %ith CNC machine t$$ls) The entire

drill machines a4aila!le in drilling secti$n are CNCs) There are :/

CNC drill machines $ut $# %hich ten machines are $# #i9ed

aut$mati$n t&"e and the rest #i4e are used #$e #le9i!le

"r$gramming) The !asic idea !ehind using CNC machines is the

reuired accurac&) Als$ the c$m"uter readil& and easil&"r$grammed, there#$re, the s&s tem is 4er& #le9i!le) The machine can

manu#acture a "art #$ll$%ed !& $ther "arts $# di##erent design)

2INIS+ING SECTION

The #inishing secti$n is #ull& eui""ed %ith the machines and techn$l$g&

reuired t$ c$ntr$l the sur#ace #inish $# the c$m"$nents) The sur#ace

#inishing s"eciall& reuired #$r the castings is d$ne in this secti$n)

8hate4er ma& !e the manu#ac tur ing "r$cess , an a!s$ lu te l&sm$ $t h an d #l at su r# ac e ca n n$ t !e $!tained) There are s$ man&

irregularities "resent $n the sur#ace $# the c$m"$nent %hich n$t $nl& gi4e a

!ad l$$ t$ the c$m"$nent !ut "r$4ide a !ase #$r c$rr$si$n and

scale etc t$ $ccur) T$ sa4e metal #r$m these "r$!lems sur#ace #inishing

is reuired) All the sur#ace #inishing "r$cesses can !e "er#$rmed in the

#inishing secti$n such as


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Grinding

La""ing

+$ning

Bu##ing

Barrel Tum!ling

Barrel R$lling

Su"er 2inishing

Burnishing

P$%der C$ating

P$lishing

PAINT S+OPAS* has a "$siti4e "ressurised "aint sh$" %ith #$ll$%ing #acilities(

Eui""ed %ith humidit& c$ntr$ller Using h&dr$static guns #$r highest

ualit& $# "ainting Baing $# "aint is d$ne in tem"erature c$ntr$lled $4en t$

ensure c$nsistenc& in ualit& $# "r$duct Se4en !ath "retreatment "lant #$r

chr$m$tising

ASSE'BL1 SECTIONThe assem!l& secti$n is the last stage #$r c$m"leti$n $# a c$m"$nent) The

assem!l& secti$n at AS* is a manual $ne) Th$ugh s$me $# the

"r$cesses #$r assem!l& are carr ied $ut aut$maticall& !ut m$st $# the

%$r is d$ne manuall&)

TOOL ROO'The t$$l r$$m is $ne $# m$st im"$rtant secti$n $# an& industr&) At AS* the

t$$l r$$m is eui""ed %ith al l th e t$ $l in g s$ lu ti $n s re u ir ed ) Th e

t$$l r$$m is 4er& ca"a!le t$ su""$rt the c$m"an& g$al

#$ r achie4ing de4el$"ment c$mmitments gi4en t$ its cust$mers !&

"r$4iding related t$$l ing s$lut i$ns %el l %ithin sti"ulated time #rame)

The t$$l r$$m %$rs t$ eliminate t$$l related ?ualit& Pr$!lems,

Pr$ducti$n Pr$!lems, Brea d$%n Pr$!lems

In e9isting and du"licated t$$ling !& ad4ancement thr$ugh

design

?UALIT1 ASSURANCEThe ualit& assurance de"artment "la&s an im"$rtant r$le in an& c$m"an& as

in case $# AS*) The main #uncti$n $# ualit& assurance de"artment is t$


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4eri#& the ualit& $# an& "r$cess $r "r$duct as "er AS* standards) The ne9t

#uncti$n is the de4el$"ment that include

H T$ de4el$" the 4end$r

H G$$d c$mmunicati$n %ith the 4end$r

H I# necessar& sh$t $ut the "r$!lem in a "articular c$m"$nent at a 4end$rs

end

AS* is the Indias #irst c$m"an& t$ !e a%arded the ?S >... certi#icate $#

a""r$4al in its categ$r&, #$ll$%ed !& an$ther landmar $# achie4ing

certi#icati$n TS :>(;..; this ensures that the ualit& standard $# AS*

can match u" %ith the !est in %$rld) S$me $# the ma7$r achie4ements $#

ualit& de"artment are(

H :>>< Best end$r A%ard #r$m *inetic '$t$rs

H :>>= ISO(>..; Certi#icati$n

H :>>> ?S(>... Certi#icati$n

H ;..< TS(:> Certi#icati$nH ;../ C$mmendati$n Certi#icate 2$r ?ualit& and Deli4er& #r$m +'SI

ACTIITIES PER2OR'ED B1 ?UALIT1

DEPART'ENTH Recei"t Ins"ecti$n

H In "r$cess Ins"ecti$n

H 2inal Ins"ecti$n

H end$r De4el$"ment

H Cust$mer C$m"laint

H 'aintain and Im"lementati$n $# ?ualit& S&stem

H Internal Audit

DIE CASTINGSThe die castings manu#actured !& AS* ha4e e9cellent sur#ace #inishes that are

c$nsistent dimensi$nall& %ith the "recisi$n #eatures and minimum dra#t) AS*


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Aut$m$ti4e P4t) Ltd) "r$duces e##icientl& engineered and high "ressure aluminium

castings) Die casting all$&s are generall& n$n #err$us and there are a large n$

a4aila!le %ith a %ide range $# "h&sical and mechanical "r$"erties

t$ c$4er alm$st e4er& a""licati$n a designee might need)

The #le9i!le aut$mati$n techn$l$gies a4aila!le at AS* include(

H ?uic change t$$ling #$r standard machines

H '$dular #i9tures and 7igs

H +igh s"eed ca"a!ilit&, multi #uncti$nal, e9cellent ualit& and %ell

"r$cessed design

H Internet s&stems transmitting in#$rmati$n !et%een engineering and

management

H In "r$cess gauging and em!edded ins"ecti$n de4ices #$r ualit& c$ntr$l

H Rec&cle s&stems #$r achie4ing green "r$ducts and a health& %$r

en4ir$nment

*e& die casting s"eci#icati$ns include(

H 'aterials Aluminium and Aluminium All$&s

H Al - g ma9) %eight and >/. s cm ma9) sie

H 2inishes S"ra& Painting

H C$m"lete range $# sec$ndar& $"erati$ns J CNC machining, drilling,

assem!l& ser4ices

H All #act$ries ?S( >... and TS :> certi#ied

H In h$use m$uld6t$$l design and #a!ricati$n ca"a!ilities

H Central melting #urnace $# ca"acit& #r$m =. t$ . t$nnes

The casting $# these "r$ducts is "re"ared in Unit II and these are !r$ught

here #$r #inishing) +ere at Unit III the castings #r$m ;.g t$ ;)/. g $#

%eight are dul& machined, #inished and "ainted) 'achining

$# casting in4$l4es !asic $"erati$ns lie turning, milling, sl$t

cutting, drilling etc and the $"erati$ns are "er#$rmed $n the

machines a4aila!le in di##erent secti$ns $# unit) A#ter c$m"leti$n $#

machining %$r the castings are sent t$ the #inishing secti$n)

In the # in i sh ing sec t i$n # i rs t $ # a l l the c$m"$nents a re

cleaned #$r all t&"es $# chi"s and !urrs rem$4al) Then it isc$m"letel& cleaned #$r all t&"es $# #$reign materials lie dust, dirt,

greases, $il etc) a#ter cleaning the c$m"$nent is "ainted in "aint

sh$") Cleaning and "ainting $# casting is a l$ng "r$cess and c$m"leted in

#$ll$%ing stages

STAGE I 2INIS+ING


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$# surr$unding medium and als$ t$ im"r$4e their a""earance) The "r$cess $#

c$ating %ith "aints and 4arnishes is carried $ut in three stages(

"re"arati$n $# the sur#ace t$ !e c$ated,

"ainting and

Dr&ing %ith #inishing)

SUR2ACE PREPARATIONThe castings %ith clean sur#aces are #irst "re"ared !& a""l&ing

"r imers lie $il 4arnish, Ole$ !itumin$us, %ater s$lu!le and nitr$

s$lu!le "rimers) The "rimed sur#ace is then treated %ith #iller, %h$se la&er

sh$uld !e as thin as "$ssi!le) Oil 4arnish #illers and uic dr&ing "&r$9&lin

#illers are c$mm$nl& used)

PAINTINGPainting is d$ne !& a""l&ing $ne $r se4eral la&ers $# "aint) Oil and enamel"aints and 4arnishes are used #$r this "ur"$se) Nitr$ enamels dr& in 0. t$


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'echanical S"ra&ingIn this meth$d the "aint is deli4ered t$ a s"ra& gun !& a "um")

Air S"ra&ingIn this meth$d the "aint is s"ra&ed !& a 7et $# c$m"ressed air %hichcarries the "aint mist t$ the sur#ace t$ !e "ainted) The meth$d is ca"a!le

$# c$ating 0. t$ =. $# sur#ace "er h$ur, !utl$sses are high 3.C is #$rced thr$ugh a

n$le at a "ressure $# ; t$ < N6mm and s$ s"ra&ed) The meth$d

all$%s the use $# highl& 4isc$us "aints, %hich cuts the s$l4ent

reuirements dr&ing time) The "r$ducti$n rate can !e /. J ;.. m $# sur#ace

"er h$ur and "aint l$sses am$unt t$ ;/ J /.K)

Electr$static S"ra&ingIn this meth$d, a negati4el& charged s"ra&er deli4ers "aint %hich

gets int$ the sur#ace $# a "$siti4el& charged metal "art !eing "ainted) The

charging is !eing "r$4ided !& a high 4$ltage c$nstant current s$urce)

The "aint l$sses are less than /K) The meth$d maes it "$ssi!le t$

im"r$4e %$ring c$nditi$ns, t$ "r$4ide #$r #airl& high "r$ducti4it&

3/. m $# sur#ace "er h$ur5 and #$r the "$ssi!ilit& $# de4el$"ing a #ull&

aut$mated "ainting "r$cess

DR1INGA#ter !e ing "a in ted , the "ar t s underg$ dr& ing ) The ual i t& $#

"a in t c$a t ings de"end $n the meth$d $# dr&ing) Dr&ing is a c$m"le9

chemical "r$cess in4$l4ing e4a"$rati$n $# the s$l4ent and $9idati$n $r

"$l&meriati$n $# the c$ating #ilm) Dr&ing can !e natural $r arti#icial) The

natura l $ r a i r d r& ing i s carr ied $ut a t a tem"era ture $# := t$

;/C $4er a l$ng t ime ) The arti#icial dr&ing maes it "$ssi!le t$

s"eed u" s$lidi#icati$n $# the c$at and als$ t$ greatl& im"r$4e its ualit&)The m$st c$mm$n meth$d $# arti#icial dr&ing is !& c$n4ecti4e heating) The

dr&ing is carried $ut in a cl$sed cham!er %hich is airheated !& gas,

electricit&, $r steam t$ tem"erature $# // t$ ;;.C $r !& means $# a

re#lect$r eui""ed %ith !ans $# s"ecial electric lam"s) The latter meth$d

taes $nl& #r$m $ne #$ ur th t$ $ne hal # as muc h ti me as h$t air


23/28

dr& ing meth$ d) O ther dr&i ng m eth$ ds uti l ie high #reuenc&

current 3inducti$n heating5 and in#rared ra&s)

CLUTC+ESA clutch is the de4ice used in transmissi$n line !et%een the engine and gear!$9 %hich transmits the r$tar& m$ti$n $# engine sha#t t$ the gear !$9

sha#t at desire) It is the de4ice %hich maes $r !reas c$ntact

!et%een the engine and gear !$9) Clutch Plates

2RICTION 'ATERIAL 2OR CLUTC+ES'ainl& the #ricti$n materials #$r clutches are $# three t&"es(

'ill!$ard T&"e

'$ulded T&"e 8$4en t&"e

'ILLBOARD T1PEThis is $nl& as!est$s sheet treated %ith certain im"regnants) 2r$m this sheet

are then #acing discs cut acc$rding t$ di##erent sie reuirements) This is the

chea"est a4aila!le t&"e and is uit satis#act$r&

'OULDED T1PEThis is made !& mi9ing as!est$s #i!res %ith a suita!le !indingmaterial , heating t$ a certain %ell de#ined tem"erature and then

m$ulding in dies under "ressure) 'etallic %ires are als$ s$metimes used t$

im"r$4e %earing ualities) This t&"e $# #acing is m$re dense and ca"a!le $#

taing hea4ier %$ring l$ads) +$%e4er there is $ne disad4antage that each

clutch #acing has t$ !e m$ulded se"aratel&

8OEN T1PEThis t&"e c$nsists $# a cl$th im"regnated %ith certain !inders) Thecl$th ma& either !e %$4en lie $rdinar& cl$th %ith %ra" and %e#t $r !&

%inding the #i!res in circum#erential directi$n $nl&) In the s$lid %$4en

4ariet&, the cl$th is %$4en 7ust t$ the reuired thicness) In case $#

laminated 4ariet&, the la&ers $# cl$th $ne u"$n the $ther are held

t$gether !& a !inder) Stitches are "r$4ided in additi$n t$ the !inder)


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CO''ON CLUTC+ 2ACING 'ATERIALSOrganic #ricti$n materials are the m$st c$mm$n t&"es $# clutch #acing

materials) These are(

H Leather ( Dr& leather $n ir$n has c$e##icient $# #ricti$n $# .);-)H C$r ( C$r $n dr& steel $r ir$n has c$e##icient $# #ricti$n $# .)0;)

H 2a!ric ( G$$d ualit& #a!ric materials ha4e c$e##icient $# #ricti$n $# a!$ut

.)


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:) The !rae must !e str$ng en$ugh t$ st$" the 4ehicle %ithin a minimum distance

in an emergenc&) But this sh$uld als$ !e c$nsistent %ith sa#et& and 4ehicle must n$t

sid);)The !rae must ha4e g$$d anti#ade characteristics) This reuirement

demands that the c$$ling $# !rae sh$uld !e 4er& e##icient)

CO'PONENTS O2 BRA*EThe !asic c$m"$nents $# a !rae are(

H Brae Drum $r C$4er

H Brae Sh$e

H Brae Lining

H Retract$r S"ring

H Ad7uster and E9"ender etc

This t&"e is m$ulded directl& #r$m the mi9, %hich c$ntains as!est$s #i!res, t$gether

%ith resin "$%ders and #illers) The a4erage c$e##icient $# #ricti$n %ith this t&"e $# liningis .)< and tem"erature resistance 4aries #r$m . N6m'a9)

Ru!!ing S"eed := m6s 'a9)

Tem"erature


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2ricti$n C$e##icient .). g6cc

+ardness 3R$c%ell L Scale5 >.

Gr$ss Braing Strength


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The as!est$s #ree disc "ad material is Rane -:- +)

BIBILIOGRAP+1

A Te9t B$$ $# Pr$ducti$n Techn$l$g& !& P) C) Sharma

Aut$m$!ile Engineering !& Dr) *ir"al Singh

Elements $# 8$rsh$" Techn$l$g& !& S) *) +a7ra Ch$udhar&

Industrial Engineering and 'anagement !& Dr) O) P) *hanna


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industrialtraining report final

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