TRAINING REPORT

Submitted to the Department of Mechanical engineering of

B.G.I.E.T SANGRUR

Providing the Details of Six Months Training

At

YERIK INTERNATIONAL(LUDHIANA)






Submitted To: Submitted By:
Er. Gurmeet Singh Cheema Shubham Garg
100111128504


DEPARTMENT OF MECHANICAL ENGINEERING

BHAI GURDAS INSTITUTE OF ENGINEERING &
TECHNOLOGY
(SANGRUR)

Jan-June (2014)




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ACKNOWLEDGEMENT

I would like to thank the entire yerik international who has provided me this
six months training. I am thankful to the HRD officer of training centre who
organized my training schedule and also the DGMs and AGMs of various shop
departments who have provided me the various knowledge about their respective
shops.
I also thanks to the workers of their respective departments, who were always
ready to clarify our doubts and helped us to increase our knowledge by illustrating us
to the finer points.
I wish to express my deep gratitude to all the concerned persons, whose co-
operation and co-ordination have given me the success to complete my training in
organization.
I hope that my report will reflect our technical knowledge and innovativeness











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PREFACE
Industrial training is part and parcel of every technical course and gives a face or form
to all the theoretical knowledge we gain in our classroom. We get to have a virtual
experience of the processes, methods, objects and phenomenon which used to be just
an imaginary picture in our minds. It also gives an exposure to the environment of the
industries and workshops which are virtual components of our professional life. We
too were provided with this opportunity this summer.
We are thankful to our college administration that handed this invaluable
chance to us and at the same time we pay our regards to the administration of HMT
Pinjore (Machine Tools Division) that proved to be a great supporting force for the
fulfillment of the purpose. The officials and the workers of the firm provided us with
the best of their attention and share ample of knowledge of their concerned field with
us.











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ABSTRACT

Industrial Training plays very much significant role in the course of engineering. It
provides the student during the engineering course a boost to enhance his technical
skills, abilities and creativity. Industrial training backens up the theoretical knowledge
by practical knowledge gained during the course. As is widely said, ounce of
practical is better than the tons of theory. In fact, both these two things are
incomplete without each other. In this report, I have tried my level best to present the
work undertaken by me during my training period in liquid, concise and precise
manner. Engineering means optimum utilization of resources for the achievement of
the desired objectives. Projects and some suggestions given by me in this report under
the guidance of my Industrial Tutor, Mr. Dinesh Rana MR. is a step forward towards
the definition of engineering.




















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TABLE OF CONTENTS

Chapters Contents Page No.

1. Introduction 8

2. Raw Material Procurement 14

3. Manufacturing Infrastructure 16
3.1. Bar Drawing Facility 17
3.2. Forging Facility 19
3.3. Heat Treatment 20
3.4. Machine Shop (forged
components)
21
3.5. Machine Shop (Drawn
Components)
22
3.6. Surface Treatment 24
3.7. Tool Room 25

4. Components Manufactured 26
4.1. Spring Pin 29
4.2. U-bolt 32
4.3. Over running clutch 36
4.4. Top link pipe 37
4.5. Eye bolt 38
4.6. Top link pin 39

5. Hot Forging Shop 40

6. Cold Forging Shop 42

7. Heat Treatment 44
7.1. Annealing 45
7.2. Hardening 46
7.3. Tempering 47
7.4. Induction Hardening 51
8. Non-Ferrous Bush Shop 54

9. Surface Treatment
10.1. Zinc-Plating Shop 59




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10.2. Phosphating Shop 60

11. Projects
11.1. Project 1 62








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C CH HA AP PT TE ER R1 1: :

I IN NT TR RO OD DU UC CT TI IO ON N

1.1 COMPANY PROFILE
The word, YERIK, is the synonym of Gods own creation. This is the feeling behind
all the actions and activities undertaken at YERIK INTERNATIONAL.

YERIK, which is a venture into Steel Industry, has its roots in the companies which
are the trend setters, the pioneers, the leaders, catering to your needs of Agriculture
Machinery, Steel Forgings and other allied Engineering Products for the last 18 years.
The cultures of industrial giants, Resource International & Excell Exports (in which
Mr. M.K. Chopra was a partner) and Preet Forgings Pvt. Ltd., have seeped into the
paraphernalia of YERIK by virtue of the substantial involvement of its proprietor, Mr.
M.K. Chopra into the working and trendsetting activities of these companies, with
him being the mind and soul of the group.

His experience of the world market and scrupulous and conscientious dealing with his
customers since 1990 has finally materialized in the form of YERIK
INTERNATIONAL.

Tanav Chopra who is elder son of Mr. M.K. Chopra, after completing his Masters in
Business Administration (from university of WALES) has joined Yerik. He is
assisting his father in sales & management. Tanav is also a diploma holder in Tools &
Die making.
The group goes global with YERIK, taking care of the Agriculture machinery,
Engineering goods & Hand tool markets of US, Europe, Australia, South Africa,
Middle East & Asia Pacific.

The overall working of the group is governed by Mr. Mohinder Chopra, with the help
of the trust worthy and Mr. Yash Pal Trehan (Vice President-Technical) along with a




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vast team of over 800 dedicated Workers and Engineers (some have been trained in
Italy), who give their 100% every second, to the company and its growth.

Beside business activities YERIK group is involved in sports activities. Mr. M.K.
Chopra is President of Ludhiana Badminton Academy which is providing free
coaching to children from the age group of 6-13 years. Academy is also providing
scholarship to needy & poor kids.



1.2 PRODUCT RANGE

1. Forged Top links & Parts

.
Fig. no. 1.2 (a)

2. Pto Adaptors


Fig. no. 1.2 (b)


3. Draw Bars & Stay Straps




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Fig. no. 1.2 (c)



4. Weldons

Fig. no. 1.2 (d)
5. Forged Top Links & Parts
Fig.no- 1.2(e)
6. Stabilizers
Fig. no.-1.2(f)
7. Pins




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Fig. no.-1.2(g)






8. Hitch balls

Fig. no. -1.2(h)


9. Tine bushes

Fig. no. 1.2 (i)

10. Weather caps




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Fig. no. 1.2 (j)





11. Levelling boxes



Fig. no. 1.2 (k)
12. Small parts





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Fig. no. 1.2 (l)


pin























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CHAPTER 2:

RAW MATERIAL PROCUREMENT

The raw material is in form of long cylindrical rods. The raw material is different
types of nuts & bolts. The colour codification for different for different materials are
as follows:


Material

Colour Code
Mild Steel /C-30 No colour
6T/EN-8K White
EN-8D Black
CK-45 Brown
SAE-1541 Yellow
SAE-4140 Sky Blue
SAE-8620 Pink
EN-353 Green
41 Cr 4 Navy Blue
H.D.S. 9% W White, Red
H.C.H. Cr Yellow, Red
O.H.N.S. Yellow, Navy Blue
H.S.S. 16:4:1 (TCV) White, Yellow
H.S.S. 6:5:2 White, Navy Blue
EN-24 Yellow, Green
EN-31 Sky-Blue, Navy Blue
EN-36 Yellow, Black
H.D.S. 5% Cr Sky Blue, Red
EN-45 White, Green
42 Cr Mo2 Smoke Grey
SAE 15B41 Orange










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2.1 RAW MATERIAL SUPPLY
As per the quality policy of every industry the raw material for a manufacturing must
be of excellent quality as per the requirement. These materials are passed through a
metallurgy laboratory for inspection and testing as per requirements. There are
various Indian industries for fulfilling the raw material requirement of the industry.
Some of the majors industries which supply the raw material to are listed as follow:-

1. Garg Industries, Dhandari
2. O.K. Industries Pvt. Ltd.Dhandari
3. Prem Auto Ltd.
4. Surinder Engineering Works

When the raw material is once unloaded in the industry, then the yellow tag is
given to it. Yellow tag is used to show that the material is going under inspection and
testing in the metallurgy laboratory. After the inspection and testing if it is found that
material has a quality and properties as per industrial requirements, then green tag is
given to it and if it fails as per the requirements, then red tag is given to it.
















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CHAPTER 3:


MANUFACTURING INFRA-STRUCTURE


BAR DRAWING FACILITY
COLD FORGING FACILITY
HOT FORGING FACILITY
HEAT TREATMENT FACILITY
Carburising
Hardening
Tempering
Annealing
INDUCTION HARDENING
MACHINING FACILITY
SURFACE TREATMENT
Phosphating
Auto black
Zinc Electro-plating
Painting
TOOL ROOM
FERROUS & NON FERROUS BUSH SHOP







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3 3. .1 1 M MANUFACTURING F FACILITIES

The strength and expertise in the development and manufacture of Components due to
our In-house facilities has explored new horizons to provide a vast range
of components. Almost all the operations are carried out under One-roof.:-

3.1 Bar Drawing Facility





Step Turning Acid Pickling Bar Drawing






Bar Straightening Power Press Band Saw

Fig: 3.1 Processes in Bar Drawing

In a rod or bar drawing, the product must remain straight. In the Bar Drawing Section
the following steps are followed:-

1. Step turning
2. Pickling




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3. Drawing
4. Straightening
5. Cutting
6. Facing & chamfering

There are the following machines in the bar drawing section:-

1. Step turning machines 3
2. Pickings tanks 8
3. Chain draw benches 5
4. Straightening machines 5
5. Cutting machine
Shearing presses 7
Band saws 3
6. Facing & chamfering
Single end chamfering 5
Both end chamfering 3











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3 3. .2 2 F FO OR RG GI IN NG G F FA AC CI IL LI IT TY Y

Fig. 3.2 Forging Process
Facilities:
Friction Screw & Power Press
Centre Lathes
Drilling
SPMs.
Dia Reduction
Cold Heading Double Stroke &
Single Stroke










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3 3. .3 3 H HE EA AT T T TR RE EA AT TM ME EN NT T
(Carburizing, Hardening, Tampering, Annealing )



Fig. 3.3 Induction hardening & Muffle Furnaces
Facilities:

Oil Fired Salt Bath Furnace
Oil Quenching
Water Quenching
Air Circulated Furnace
Electric Muffle Furnace
Electric Salt Bath Furnace
Tempering Plant Air Circulated
Electric Pre-Heating
Annealing
Induction Hardening






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3 3. .4 4 M MA AC CH HI IN NE E S SH HO OP P

(Forged Components)


Fig. 3.4 Machining Process
Facilities:

Production Lathes
Milling
Threading, Thread Rolling
Polishing
Drilling
Rotary Milling
Tapping










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3 3. .5 5 M MA AC CH HI IN NE E S SH HO OP P

(Drawn Components)

Fig. 3.5 Drawn Components
Facilities:
Grinding
Bore Grinding
Tool Grinder
Slot Making
Drilling
Automatic Cutting
Tapping
Spl. Purpose Coping
Facing
Milling
Nut Forming




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Bar End Turning
Thread Rolling
U-Bolt Bending
Bar Turning
Production Lathes
Copy Turning
Bar Drawing
Wire Drawing
Bar Straightening
Circular Metal Cutting
Descaling & Re-Coiling
Coil Opening




















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3 3. .6 6 S SU UR RF FA AC CE E T TR RE EA AT TM ME EN NT T


Fig.3.6 Painting & Electroplating Process


Facilities:
Zinc Plating Plant
Auto Blackening Plant
Phosphating Plant,
Shot Blasting M/c
Paint Booth













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3 3. .7 7 T TO OO OL L R RO OO OM M


Fig. 3.7 Tool Room

Facilities:
Grinding
Tool & Cutter Grinder
Milling
Shaping
Drilling
Planner
Slotting
Pedestral Grinding
Electric Drill
Tap Resharpening
Surface Plate








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CHAPTER 4:


COMPONENTS MANUFACTURED



For all the components produced, the procedure, before going to machine
shop, is same; which is as follows:

Annealing: The raw material is first of all annealed to refine its grain structure.

Step turning: The first operation is step turning. The long round bar is loaded onto
a platform & is fed to a lathe machine in which a fixture is there to support the tools.
The tooling arrangement is such that four tools are set in circular arrangement. The
rod is sent to the tools which rotate & reduce the diameter of the bar up to a certain
length.

Acid pickling: This operation is done in order to remove any kind of surface
defects on the surface of long round bars. The bars of different diameter are put in
sulphuric acid (commercial grade). The quantity of sulphuric acid required for
different rods of U-bolts is as follows:

Bar thickness Sulphuric acid
(commercial Grade)
11-16 mm 10.0 ltr.
18-20 mm 12.0 ltr.
21-23 mm 15.0 ltr.
24-32 mm 17.5 ltr.
33-45 mm 20.0 ltr.




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The time period for different rods to be acid pickled is 6-8 hours depending on the
diameter.

Cold bar drawing: Then the acid treated bar is sent to the bar- drawing machine.
The reduced end of the bar is put in the die of required diameter. The end is gripped
by a lock. Then the lock is pulled by a very large force which is applied by a big chain
powered by a heavy motor. Thus the bar gets reduced in diameter but is elongated.

Bar cutting: The elongated bar is then cut by using a power- press. The required
length is once set & an obstacle is fixed at that length. Each time the bar strikes that
obstacle the press is actuated and the bar is cut. But this method is conventional one.
The production is not so high in this case, because at a time only one piece can be cut
& also the quality of cut is not good. So a much advanced method is used, which is
automatic power hacksaw. 8-10 bars are loaded on the machine at a time & hacksaw
is started. Due to automation the hacksaw each time cuts equal length & quality of cut
is also good.

Bar straightening: The bar when elongated gets bent & has to be straightened
before machining. So it is sent to the bar straightening machine. The bars are sent into
the machine in whish two skew rollers are there. These rollers are set to rotate and bar
is passed through them. These rollers straighten the bar.




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Fig. 4 Plant 1


List of the product manufactured in plant:
SPRING PIN
U-BOLT
OVER RUNNING CLUTCH
TOP LINK PIPE
EYE BOLT
TOP LINK PIN







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4 4. .1 1 S SP PR RI IN NG G P PI IN N


Fig. 4.1 Spring Pin
This section deals in manufacturing of various types of pins. This section has total 31
machines.

1. Special purpose facing machine
4
2. Horizontal drilling machine
5
3. Vertical drilling machine
2
4. Horizontal milling machine
3
5. Vertical drilling machine
4
6. Horizontal milling machine (single spindle)
5
7. Tapping machine (horizontal)
1
8. Tapping machine (vertical)
3
9. Grooving machine (SPM)
2




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10. Pneumatic press
1
11. Magna flux crack detection machine
1


The Various Operation performed in manufacturing Spring Pin are
given as.


S. No. Process Description.

1. Step turning.
2. Pickling.
3. Bar Drawing.
4. Straightening.
5. Peel off.
6. a) Auto cutting, Tap hole, Counter sinking & chamfering.
b) Raw grinding.
7. a) Manual cutting.
b) Side facing.
c) Raw grinding.
d) Tap hole drilling.
e) Counter sinking.
f) Chamfering.
8. Stamping .
9. Grease hole drilling.




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10. Cotter slot .
11. Grease slot .
12. Cross hole drill.
13. De burring of cross hole.
14. Tapping .
15. Oil flow test .
16. Visual inspection.
17. Induction hardening.
18. Inspection hardener.
19. Outer dia grinding.




Important Points :-
.
1. Material used:- C K 45.
2. Application :- it is used to hold the leaf spring with bracket, it is
mainly used in heavy automobiles
.












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4 4. .2 2 U U B BO OL LT T


Fig. 4.2 U-Bolts

This section deals with the manufacturing of u bolts. These section has a total
of 29 machines.

1. SPM facing
4
2. SPM turning
5
3. Hydraulic press (vertical)
3
4. Hydraulic press (horizontal)
1
5. Profile threading machine
3
6. Center less grinder
1




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7. Hot bending machine
2
8. Cold bending machine
2
9. Grinding machine
1
10. Air compressor
1
11. SPM for nut assembly
1
12. Stamping machine
2
13. Heater
3

















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The various operations performed in manufacturing U bolts are
given below:-

Sr. No. Process Description.

1. Step turning.
2. Pickling.
3. Bar drawing.
4. Straightening.
5. Blank cutting.
6. End facing.
7. Roll dia turning.
8. Roll dia grinding.
9. Stamping.
10. Thread rolling.
11. Center forging.
12. U forming.
13. Heat treatment.
a) Hardening .
b) Tempering.
14. Surface treatment.
a) Zinc plating .
b) Phosphating.
c) Painting .




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d) Hydrogen de embrittlement ( heated air circulated
furnace).
15. Final inspection.
16. Nut assembly.
17. Packing.







Important Points :-

1. Material used :- M.S., C-45, EN 8K.
2. Daily production :- 2500pcs (local ), 1500pcs(export).
3. Application :- Clamping the leaf spring with axle.

















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4 4. .3 3 O OV VE ER R R RU UN NN NI IN NG G C CL LU UT TC CH H



Fig. 4.3 Over Running Clutch

The various operations performed in manufacturing over running
clutch are given below:-
S.NO. PROCESS DESCRIPTION
1. Forging
2. Rough Machining
3. CNC Machining 1
st

4. Broaching
5. Machining on male part
6. Press Fitting
7. MIG Welding
8. CNC Machining 2
nd





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9. Slotting
10. Drilling
11. Finishing
12. Zinc Plating

4 4. .4 4 T TO OP P L LI IN NK K P PI IP PE E



Fig. 4.4 Top Link Pipe

The various operations performed in manufacturing TOP LINK
PIPE are given below:-
S.NO. PROCESS DESCRIPTION
1. Cutting
2. Reducing
3. Boring
4. Threading




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5. Drilling
6. Buffing
7. Plating



4 4. .5 5 E EY YE E B BO OL LT T



Fig. 4.5 Eye Bolt

The various operations performed in manufacturing EYE BOLT are given
below:-
S.NO. PROCESS DESCRIPTION
1. FORGING
2. CNC MACHINING- 1st
3 3. . C CN NC C M MA AC CH HI IN NI IN NG G 2 2N ND D
4 4. . T TH HR RE EA AD DI IN NG G
5 5. . B BR RI IG GH HT T Z ZI IN NC C P PL LA AT TI IN NG G





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4 4. .6 6 T TO OP P L LI IN NK K P PI IN N


Fig. 4.6 top Link Pin



The various operations performed in manufacturing Top link Pin
are given below:-

S S. .N NO O. . P PR RO OC CE ES SS S D DE ES SC CR RI IP PT TI IO ON N
1. Cutting
2. Machining
3. Drilling
4. Grinding
5. Zinc Plating











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CHAPTER 5
H HO OT T F FO OR RG GI IN NG G S SH HO OP P


In this shop the hot forging is done on the specimen (Rod) by the forging press having
pully mechanism to make the parts.

The detail of hot forging shop

1. Part Name : Clevises
Material : Mild Steel
Machine : Hot Forging Machine

2. IInd machine of hot forging power press to make forged lashing bracket for D-
ring.
Part Name : Forged Lashing Bracket for D-ring
Material : Mild Steel
Machine : Hot forging machine

3. IIIrd forging press machine is the make forged lashing rings.
Part Name : Forged Lashing Rings
Material : Mild Steel
Machine : Hot Forging Power Press






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4. IV machine is to make fringes by hot forging press
Part Name : Fringes
Material : Mild Steel
Machine : Hot forging press.









































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CHAPTER 6

C CO OL LD D F FO OR RG GI IN NG G S SH HO OP P

Various machines in the card forging shop as below:-
1. Trimming machine
2. Cold heading machine
3. Trimming cum reducing machine
4. Cold heading machine (Single stage)
5. Power press
6. Power Press
7. SPM for facing
8. SPM for facing
9. Power press
10. Power Press
11. Power Press
12. Motor Stamping machine
13. Tool Grinding
14. Tool Grinder
15. Tool Grinder
16. Power Press
17. Centre lathe for coiling
18. Centre Lathe
19. Thread rolling machine
20. Vertical drilling machine




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21. Vertical drilling machine
22. Vertical drilling machine
23. Vertical drilling machine
24. SPM for facing
25. Thread rolling machine
26. SPM for roll dia turning
27. SPM for roll dia turning
28. SPM for Stud Facing
29. SPM for Stud Facing
30. Caustic Soda Drum
31. Saw Dust Drum
32. Fire Brick Cutter
33. Trimming machine
34. Header (Single stage)














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CHAPTER 7


H HE EA AT T T TR RE EA AT TM ME EN NT T


Heat treatment is an important operation in the manufacturing process of many
machine parts and tools. Only by heat treatment is it possible to impart the high
mechanical properties to steel required for the normal operation of modern machinery
and tools.

Heat treatment of various items is done in this section. Heat treatment is
defined as an operation of heating and cooling of metal in the solid state to induce
certain desired properties of steel by changing the size and shape of the grain of which
it is composed or by changing its micro-constituents. It is generally employed for the
following purpose:-.

1. To improve machinability.
2. To change or refine grain size.
3. To relieve the stress of the metal induced during hot and cold working.
4. To increase resistance to wear, heat and corrosion.
5. To produce a hard surface on a ductile interior.

The heat treatment processes used here are:-

1. ANNEALING




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2. HARDENING
3. TEMPERING

7 7. .1 1 A AN NN NE EA AL LI IN NG G







Fig. 7.1 Annealing Furnace


Annealing is one of the most important widely- used
operations in the heat treatment of the steel . The purpose of annealing is to
obtain softness, improve machinability, increase or restore ductility and
toughness relive internal stresses, refine grain size and to prepare steel for
subsequent heat treatment. Slow cooling is required in annealing to enable the
austenite to decompose at low degree of super cooling so as to form
pearlite+ferrite structure in hypoeutectoid steel.










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7 7. .2 2 H HA AR RD DE EN NI IN NG G










Fig. 7.2 Induction Hardening

Hardening is heat treatment process in which steel is heated to a temperature
above the critical point, held at this temperature and then quenched in water ,oil ,or
molten salt baths. Hardened steel is in a stressed condition and is very brittle so that it
cannot be employed for practical purpose after hardening steel must be tempered to
reduce the brittleness relive the internal stress caused by hardening and to obtain
predetermined mech. Properties. Hardening temperature& time depends upon
chemical composition and resence of carbon contents. The more carbon and alloying
admixtures in a steel and the more intricate and large the part being hardened the
slower it should heated to avoid stresses due to temperature difference between the
internal and external layer of metal , warping , and even cracking.








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7 7. .3 3 T TE EM MP PE ER RI IN NG G









Fig. 7.3 Muffle Furnace
Tempering leads to the decomposition martensite
into a ferrite-cementite mixture and strongly affects all properties of steel. At low
tempering temperature the hardness changes only to a small extent and the true tensile
strength and bending strength are increased. A further increase in tempering
temperature reduce the hardness true tensile strength, propotional limit and yield point
while the relative elongation and reduction of area are increased. The cooling rate
after tempering has a great effect on the residual stresses. The slower an article is
cooled, the less the residual stresses will be. The properties of steel after hardening
followed by tempering are always higher than that of annealed steel.

The various heat treatment processes being given to various categories of jobs involve
the following procedure.





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1. The given pieces of jobs are tied together with an ordinary piece of wire just for
the purpose of holding the group of pieces so that they could be properly dipped in
the tank.

2. Now the various are suspended in the preheated tank for the preheating purpose.
Temperature involves is about 400 degree celcius. The pre heater consist of three
electrode and a thermocouple for detecting the temperature of the bath. Panel
consisting of regularity temp. Controls the whole process.


3. After preheating the pieces are now ready for any further heat treatment process.
Now for hardening purpose the material are again suspended in hardening furnace
whose temperature about 830 to 880 degree Celcius. The bath consists of salt
neutral in character and melts to liquid form under heating. The soaking time
consist of for 9mm.thick object are 15 min. then for quenching the materials are
dipped in oil tank till the material gets cooled to room temp. The quenching media
consist of various type depending upon the material composites and properties, for
e.g. :- for mild steel they use water and for hot die steel they use air as a medium
for cooling purpose.

4. Tempering is carried out in order to remove brittleness of the material .Tempering
consist of heating it about 555 to 720 degree celcius, range differ for different
material





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5. . The soaking time is about 20 min.


6. Then the piece is clean with the help of caustic soda and hydrochloric acid. They
use caustic soda to remove grease, oil etc.

7. Next the surface finished process of phosphating \ auto black \ zinc plating is
carried out.


8. The thickness of coating is about 10 microns. Special care has to be made for the
U-bolt increases after heat treatment process .The gap has to be reduced manually
by means of hammer.

PROCEDURES FOR HEAT TREATMAENT

1. TITLE:-Procedure for control of heat treatment process.

PURPOSE:-To ensure that the process is carried out under controlled conditions by
qualified operators to ensure that specific requirements are met.

SCOPE:-This process covers all the items requiring heat treatment.





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RESPONSIBILITY:-Section in charge is responsible for implementation to this
procedure. H.O.D works and plant in charge are overall responsible for
implementation of this procedure.

2. TITLE:-Procedure for material storage and material handling at shop floor.

PURPOSE:-To ensure proper handling, damage free movement and proper storage of
material during process.

SCOPE:-It covers all the activities related to the material handling and storage for all
the material being processed at shop floor.

RESPONSIBILITY:-All section in charge and plant in charges are responsible for
effective implementation of this procedure in respective areas H.O.D works is overall
responsible.
SR. NO. MATERIAL HARDENING /
NORMALIZING
TEMPERING
1. EN-8D/C-45 830-860 550-660
2. EN-15/SAE-1541 840-870 550-660




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3. EN-18/14Cr4 850-880 550-700
4. EN-14/SAE-4140 850-880 550-720
5. EN-45 870-930 400-550
6. EN-353/SAE-8620 780-820 150-200




7.4 I IN ND DU UC CT TI IO ON N H HA AR RD DE EN NI IN NG G








Fig. 7.4 Induction Hardening

Surface hardening is a selective heat treatment in which the surface layer of a metal
are hardened to a certain depth while a relatively soft core is maintained.




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TYPES OF INDUCTION HARDENING

A. Hardening with high frequency induction heating
B. Harding with electrical contact resistance heating
C. Hardening with electrolytic heating
D. Oxyacetylene flame hardening.

The principle purpose of surface hardening is to increase the hardness and wear
resistance of the surface of metal articles. At the same time, the reliability in operation
of a machine component is increased, as well as its fatigue limit.


At YERIK INTERNATIONAL a high frequency current about 200 Hz is
passed through a cooper inductor block, which acts as a primary coil of transformer,
the block is placed around but does not touch the surface to be hardened. The heating
effect is due to the induction eddy current and hysteresis loss in the surface material
.The heated jobs are then quenched immediately by spray of water delivered through
numerous of small holes in the block. A depth case of approximately 3mm. is
obtained in about 5 sec.






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ADVANTAGES OF INDUCTION HARDENING


1. It enables the time requirement for heat treatment to be sharply reduced ,thereby
increasing the labor productivity.

2. Article may be heated with practically no scaling so that the metal allowance for
subsequent machining may be reduced.

3. Deformation due to heat treatment is considerably reduced.















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CHAPTER 8

N NO ON N F FE ER RR RO OU US S B BU US SH H S SH HO OP P










Fig. 8.1 Aluminium Bronze Bushes

Cell-1

1. SPM Lathe
2. SPM Lathe
3. SPM Lathe
4. SPM Lathe
5. Grinding machine
6. Grinding Machine





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Cell-2

1. SPM Lathe
2. SPM Lathe
3. SPM Lathe
4. SPM Lathe
5. Grooving machine

Cell No.-3

1. SPM Lathe
2. SPM Lathe
3. SPM Lathe
4. SPM Lathe

Cell No. 4

1. Drilling machine
2. SPM Lathe
3. SPM Lathe
4. SPM Lathe
5. SPM Lathe
6. Facing Machine
7. Grooving Machine




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8. Reaming machine
PROCESS FOR MAKING NON FEROUS BUSH SHOP

1. Make core from the core sand for the bush
2. Then place the core in the die
3. Pour the molten brass in the die
4. After cooling of the bush the runner and riser are break with the help of
hammer.
5. The milling operation is done on the bush.

There are different-2 sizes of bush of different diameter and different length.
These are machine and in the machining section. There are four cell- Cell No. 1,
2,314 for making bush of different sizes.

i) Spring Bush
ii) Bell Crank Bush Big
iii) Bush for King Pin.

The machining operation done on spring bush in Cell No.1

Cell No. 1
Operations Machines
1. Internal diameter SPM Lathe
turning (rough)




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2. Internal Diameter SPM lathe
turning final
3. Outer Diameter Turning SPM lathe
facing, chamfering and
inner diameter chamfer
4. 2
nd
side facing SPM lathe
5. Grinding Grinding Machine
6. Packing Manually


SPRING BUSH
Operations
1. Internal Diameter turning rough
2. Internal Diameter tuning final
3. Outer diameters turning
4. 2
nd
side facing
5. Oil grooving

Cell No.3
Bell Crank Bush Big
1. Internal Diameter turning rough
2. Internal Diameter reaming
3. Outer Diameter turning
4. Facing




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5. Grinding
Cell No. 4
Bush for king Pin
1. Internal diameter turning rough
2. Internal diameter turning final
3. Outer diameter turning final
4. Side facing
5. Grinding
6. Oil grooving
7. Stamping























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CHAPTER 9

SURFACE TREATMENT

9 9. .1 1 Z ZI IN NC C P PL LA AT TI IN NG G S SH HO OP P







Fig.10.1 Electroplating Barrel

The products are transferred from machine shop to zinc plating shop for zinc
plating. The procedure for zinc plating is as under
1. Caustic is done to removed the Grease on the products
2. Wash in the cold water tank
3. H.C.L. tank
4. Electrolysis Electrolysis i.e. Zinc-plating is done in tank in which there are
two zinc plates and the one barrel which is reveled by the gear and the products are to
which zinc planting is done are placed in it. After that they are take off from the tank
and wash, them check with Gauge for the correct quality ( Salt in the tank like boric
acid etc.) There are small 2 holes in the barrel for go salt solution in the barrel for zinc
platting.

In this way the zinc plating is done.




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9 9. .2 2 P PH HO OS SP PH HA AT TI IN NG G S SH HO OP P

After the heat treatment is done, nut, bolt are phosphating or auto black. There
are number of tanks in which dilute solution for auto black
or for phosphating. We discuss below the process how the phosphating
is done.

PROCEDURE OR STEPS FOR BLACK PHOSPHATING

1. Degreasing So that Grease on the product should be removed
2. Cold water
3. Cold water
4. Acid pickling (HCL acid)
5. Cold water
6. Cold water
7. Cold water
8. Blackening by black Fast (BF 100)
9. Cold water
10. Oil coat (OC 20)
11. Oil coat (OC 20)







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PROCEDURE OR STEPS FOR GREY PHOSPHATING


1. Degreasing So that Grease on the product should be removed
2. Cold water
3. Cold water
4. Acid pickling (HCL acid)
5. Cold water
6. Cold water
7. Cold water
8. Blackening by grey Fast (BF 99)
9. Cold water
10. Oil coat (OC 20)
11. Oil coat (OC 20)




















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PROJECT -1 :-

Aim of the Project
To reduce set up time in formation of stud using cold forging and hence improve the
production.
Research methodology
1. To study the whole cycle of stud formation using cold forging
2. Analyse the whole process
3. Suggest ways to improve the whole cycle and increase the efficiency of machine.

INTRODUCTION
Cold forging Cold forging deforms metal while it is below its recrystallization point.
Cold forging is generally preferred when the metal is already a soft metal, like
aluminum. This process is usually less expensive than hot forging and the end product
requires little, if any, finishing work. Sometimes, when aluminum is cold forged into
a desired shape, it is heat treated to strengthen the piece. This is called "tempering.

The Cold Forging Process
Despite the word "cold," cold forging actually occurs at or near room temperature.
The most common metals in cold forging applications are usually standard or carbon
alloy steels. One of the most common types of cold forging is a process called
impression-die forging, where the metal is placed into a die that is attached to an
anvil. The metal is then hit by a descending hammer and forced into the die.




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Depending on the product, the hammer may actually be dropped on the metal
numerous times in a very rapid sequence.
Cold Forging Considerations We choose cold forging over hot forging for a
number of reasonssince cold forged parts require very little or no finishing work,
that step of the fabrication process is often dispensable, which saves money. Cold
forging is also less susceptible to contamination problems, and the final component
features a better overall surface finish. Other benefits of cold forging include:
Easier to impart directional properties
Improved interchangeability
Improved reproducibility
Increased dimensional control
Handles high stress and high die loads
Produces net shape or near-net shape parts

Some possible disadvantages include:
Easier to impart directional properties
Improved interchangeability
Improved reproducibility
Increased dimensional control
Handles high stress and high die loads
Produces net shape or near-net shape parts




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The metal surfaces must beclean and free of scale before forging occurs
The metal is less ductile
Residual stress may occur
Heavier and more powerful equipment is needed
Stronger tooling is required

INTRODUCTION TO PROJECT SET UP TIME Setup Time is defined as the
time to change from the last item of the previous order to the first good item of the
next order. It is also known as changeover time. IN GENERAL TERMS it is The
time between the last good part off the current run and the first good part off the next
run.
IT INCLUDES
1 Preparation. 30%
2 Removing and
mounting.
5%
3 Measurements,
calibration and
settings.
15%
4 Trail runs and
adjustments.
50%
The present set up includes formation of stud using cold forging on single header
machine .This machine works on a simple principle in which the rotational force of a
motor is transformed into a translational force vector. Therefore the energy in a




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mechanical press comes from the motor. Mechanical presses are generally faster than
hydraulic or screw presses. Unlike some presses, in a mechanical press, the
application of force varies in both speed and magnitude throughout the distance of the
stroke. When performing a manufacturing operation using a mechanical press, the
correct range of the stroke is essential.These types of presses are commonly used in
forging manufacture, and sheet metal working. A mechanical press is often a good
choice for impact extrusion, since a fast, quickly repeatable application of force over a
limited distance is what is needed for that type of manufacturing operation. The
eccentric press uses a motor to drive an eccentric shaft, rotating in a connecting rod.
The connecting rod moves a ram in a slider joint one dimensionally. The eccentric
shaft itself is round, therefore it may completely rotate within the connecting rod. The
center of the drive is not the center of the overall shaft. As the motor rotates, the
center of the drive remains stable but the overall center of the shaft changes. This
causes the shaft to change position, providing motion.


The rotation of shaft causes the header to move forward which has a die fixed in its
mouth .




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Raw material is loaded onto a platform and it is automatically feeded into the slot
where die is fixed in the base of machine. The system is controlled by a cam
mechanism which drives its 114
power from the shaft itself with the help of bevel gears. When the ingot is placed into
the mouth the header strikes and the metal piece is forged with the help of the die. In
the slot side a ejector pin is provided which ejects the work piece once it is forged.
This ejector is operated with the help of cam which derives its


power from main shaft. The system is such that in 2 strokes of header only 1 single
piece is formed. This is done so because sometimes the work piece gets stuck in the
header so that can deform the whole work piece and can harm the machine itself. The
cam system is also adjusted according to that.




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With the current set up around 17 pieces are manufactured per minute. The main
problem arising with this set up is that the production rate is too low. So to increase
the production rate following remedies are provided. 116
REMEDIES
PROPOSAL 1
First solution to this problem is to provide an ejector pin on the inner side of the
header that can strike the work piece that gets struck into the header if any. This
ejector pin will work wiyh the help of a cam operated system driving power from the
machine itself . This proposal if implemented precautiously after taking due




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limitations into consideration can increase the production to about 35 work pieces in a
minute.
PROPOSAL 2 "SMED" (Single Minute Exchange of Dies)
Setup includes preparation, replacement, location and adjustment activities.It is easy
to experience a reduction of set-up time from hours to minutes by following a simple
process called "SMED" which means "Single Minute Exchange of Dies." This process
was developed in Japan by Shigeo Shingo during the 1950's. Firstly we should
determine which activities are internal and external. External elements of work can be
completed while the machine is still running e.g. get the next tool, get all your clamps,
get lifting equipment in place, put equipment away, etc. Internal elements of work can
only be done while the machine is stopped e.g. change the tool, adjust the machine
depth, sharpen a tool (which requires the machine to be stopped), etc. Incredible
reductions is total setup time have been realized simply by making internal activities
external activities. The following four-step approach may be used to reduce setup
time:
EXAMPLE FIGURE
1. Classify each setup step as either Internal or External. Internal steps are those done
while the process is inactive. External steps are done while the process is operating.
2. Convert Internal steps to External steps. We want to reduce the time the process is
non-operational, so we need to reduce the time associated with the Internal steps. The
quickest way to do this is to do as many of these steps as we can while the process is
operational. For example, if we can collect the money from the customer as their
burgers are being cooked, then the total cycle time is reduced.




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3. Reduce time for remaining Internal steps. There are some Internal steps that cannot
be donewhile the process is operational. We now want to concentrate on reducing the
time required to complete those steps that require the process to be delayed. For
example, since the burgers cannot be cooked until we know what the customer wants
to order, we will try to reduce the time it takes to place the customer order.
4. Eliminate adjustments. Adjustments, as discussed in the Analyze stage, can be
reduced through effective process control. Designed Experiments may be used to
understand the causes of process variation that precede the adjustment. As you can see
from the diagram once you can define an internal or external element, you can
separate them. This will allow us to complete all external elements for the next set-up
while the machine is still running the current parts. When the current run is finished,
everything required for changeover to the next part is available and ready.
CONCLUSION :-
This proposal if implemented precautiously after taking due limitations into
consideration can increase the production to about 35 work pieces in a minute.