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ON
PRESSING & WELDING
TECHNOLOGY
AT
ACKNOWLEDGEMENT
Industrial training is an indispensable part of our engineering curriculum. It
provides the students an opportunity to gain experience on the pragmatic
applications of their knowledge. My training at Caparo Maruti Ltd, Gurgaon has
been very fruitful. I am sure that the experience I gained here will help me
towards making me a competent and proficient engineer.
I would like to convey my sincere gratitude to MR.VIRENDER SINGH ,who
entrusted me with the responsible project work and provided me with timely and
proper guidance whenever required. This enabled me to gain experience in not
only the technical and practical aspects of industry but also in human relations,
teamwork and also provided great insights into the actual working of an
industry. Without his efforts this training would not have been as great learning
experience as it been.
I would also like to thank MR. RATAN YADAV (AGM, HR), who ensured
a proper work environment.
I take this opportunity to thank my training incharge MR.UMESH KUMAR
and my H.O.D MR.KULDEEP SINGH for their constant advice.
I hereby also declare that the contents in this report are true to the best of my
knowledge.
TABLE OF CONTENTS
S.NO.
TOPIC
1.
Introduction
Compan
2.
y profile
Welding shop
3.
Resistance welding
3.1
Spot welding
3.2
Projection welding
3.3
Seam welding
4.
Arc welding
4.1
Stud welding
5.1
6.
6.1
IT GUN
7.
9.
Project assigned
10.
Learning
INTRODUCTION
Caparo Maruti Limited is a joint venture of Maruti Udyog Limited.
Caparo group belongs to Lord Swaraj Paul. It is a U.K based company.
It has 19 plants all over India , amongst them 3 are the joint ventures
with Maruti Udyog Limited.
Caparo maruti is a medium scale industry. It consists of 400 employees
in Gurgaon plant. It makes 21sub components out of which 7 are made
only at press shop and remaining by the help of welding process.
There are 2 shops in this plant a. PRESS SHOP
b. WELD SHOP
In press shop there are 4 mechanical presses (800T, 400T, 400T,400T)
and one hydraulic press.
The processes involved in this shop are a. Drawing
b. Trimming
c. Piercing
d. Side bending
In weld shop there are 4 welding processes involved
a. Spot welding (using IT Gun)
b. Projection welding
c. Stud welding
d. MIG welding
COMPANY PROFILE
A.
WELDING
HEAT
1.
2
3
MELTING
OF METAL
CURRENT
GAS
CHEMICAL
REACTION
JOINING
OF METAL
NO FILLER MATERIAL
FIG . 1
FIG. 2
1.
RESISTANCE WELDING
It is the process of joining metal pieces together by raising the temperature of
the pieces to fusion point and applying a mechanical pressure to join them. In
this, the pieces to be joined are held together and a strong electric current of
high amperage and low voltage is passed through them. This current comes
across a certain resistance in passing from one piece to other and it is this
resistance offered to the flow of current which results in raising the
temperature of the two pieces to fusion or melting point at their junction. The
mechanical pressure applied at this moment completes the weld.
FIG. 3
I2 = Current in amperes,
R = Resistance of the work in 0hms,
T = Time the current flow in cycles
( 50 CYCLES IN ONE SECOND)
4. Time of application - It can also be described as cycle time and is the sum
total of the following time periodsa. Weld time It is the time period during which the current flows
through the metal pieces to raise their temperature.
b. Squeeze time or forging time- It is the time period during which the
forge pressure is applied to the metal pieces to squeeze them together
to form the weld.
c. Hold time- It is the time period during which the metal pieces are
held together under forge pressure for a short while to enable the
weld to solidify. It can therefore, be called cooling time also.
d. Off-time- After cooling of weld the electrode pressure is released and
the metal pieces removed for the next operation cycle. The time
period between this release of electrodes and the start of next welding
cycle is called off-time.
5. Contact area of electrodes - The weld size depends on the contact area of
the face of the electrodes. It can be varied by selecting suitable set of
electrodes to provide the desired area of contact at their tips.
OFF
HOLD
DN SLOPE
WELD
S
Q
U
UP SLOPE
EEZE
CURRENT
TIME
Pr
es
su
re
No Nugget
Nugget Dia
(Strength)
Small
Larg
e
eld
W
d
oo Explosion
G
Current
FIG. 5
Splash
B - will have
Good Weld
Less Spatters
Optimum Nugget Dia
1 (a).
The principle of spot welding- in which a transformer core is having primary and
secondary winding. One end of the secondary winding is connected to the upper
electrode carried in the movable copper or bronze arm A and the other end to the
lower electrode mounted on the fixed arm B. In operation the metal sheets S1
and S2 are held and pressed between the electrodes and a strong current at low
voltage is switched on. Due to the resistance offered by the sheet metal to the flow
of this current the temperature at the contact surfaces rises to fusion point and
the weld is completed under the contact pressure of the electrodes.
WELD SPOTS
CHIESEL
NUGGET DIA
UTM
SPOT SHOULD NOT FAIL
FIG.6
NG
OK
UPPER ELECTRODE
PIN
SPRING
LOWER ELECTRODE
PIN
NUGGET
FIG. 7
1(c).
STUD WELDING
LIFT
STUD
BASE METAL
LIFTING
ACTION
PLUNGE
LIFTED CONDITION
EXCITATION
OF COIL
PILOT ARC
VOLTAGE
WELDING
PULSE
PILOT ARC
WELDING
CURRENT
MELT CONDITION
HEATING
TEMPERATURE
FIG. 8
STUD WELDING (FLASH WELDING)
FIG. 9
PLUNGE
POINT
15
30
50
M.S.
100
200
400
1(d). MULTI SPOT WELDING (MSW) It is similar to spot welding but as the name suggests it is used for doing multiple
spots at the same time. There are number of cylinders having magnetic slips in
them which creates magnetic field.
FIG. 10
1(e).
It is a non integral type welding. It consists of a kick less and a coaxial cable. The
nugget produced is of very high diameter. The cost production is less because it
uses only 1 IT gun in place of 2.
PSW WELDING
SYSTEM
Welding gun
Transformer
Controller
FIG. 11
2. GUN WELDING
The specific use of this method is in welding of irregular surfaces, such as
fabrication of automobile bodies. The electrodes are actuated either
hydraulically or pneumatically. The equipment consists of a transformer,
flexible leads connecting the transformer to the welding gun, the welding gun
unit comprises of two electrodes and a trigger switch.
E
B
FIG.12
The water is coming from cooling towers with a flow rate of 6 to 8 liters/ minute.
The force produced by trigger is 200kg.
The major components of gun are1.
2.
3.
4.
5.
6.
7.
8.
firing card
control card
trigger switch
transformer
thyristor
primary and secondary windings
electrode
arms
DISADVANTAGES
1. Gun weight is very heavy.
2. Carbon deposition is there which creates insulation. It is removed
by filing and cooling.
3. Machine breakdown due to movable arms.
4. Production is slow.
5. Requirement is of 27 deg Celsius is there but the temperature is 45
deg Celsius in the plant.
1728 m2
72 no.
110
128/shift
2
PRESS SHOP
Press is a machine which undergoes various processes by applying tonnage on the
raw material.
There are various types of presses1. hydraulic presses
2. mechanical presses
3. pneumatic presses
In CML there are 4 mechanical presses (800T, 400T, 400T, 400T) and 1
hydraulic press.
The raw material used in press shop is cold rolled forged steel sheet (because
CRS has high tensile strength, elongation is good) as per requirement.
The companies which supply raw material are TATA, BHUSHAN, and
POSCO STEELS.
The following operations which are held in the press shop are 1. Blanking It is the process in which the punch removes a portion of material from
a stock which is a strip of sheet metal of the necessary thickness and width. The
removed portion is called a blank.
2. Drawing It is the process of making cups, shells, and similar articles from metal
blanks.
3. Trimming - It is the process of removing extra material.
4. Piercing-
5. Reforming and piercing - It is the process of providing holes, punches to the part.
6. Side bending- It is a operation of deforming of a flat sheet around a straight axis
FIG.13
.
FIG. 14
FIG. 15
HYDRAULIC PRESS
FIG. 16
PROCESS CHART-
FIG.17
Specifications
Area
1648 m2
Number of presses 4
Press capacity
800T -1 press
Manpower
Operational shift
2 types of lines
400T 3 presses
32/shift
3
tandem lines
Transverse lines
SPECIFICATIONS OF DIES
Number of dies 114 dies
Weight of die - 20 ton
Die raw material F/C 25
Cushion pressure -0.9-1.2kg/cm2
QUALITY IMPROVEMENT
Definition of Quality:
2. ManufacturingBased
3. Product-Based
4. Value-Based
DEFINITIONS
Customer Satisfaction
Quality Tools
Metrics
Flow Charting
Benchmarking
Adding Value
QUALITY DEFECTS:
1. PRESS SHOP.
A. Cracks.
B. Neck.
C. Wrinkles.
D. Dents.
E. Burs.
2. WELD SHOP.
A. Failure of spot by spot welding.
B. Nugget test failure.
QUALITY DEFECT ANALYSIS1 TOOLS: There are 7 QC tools are as given below:
1). Fish-bone analyses.
2). Pareto diagram.
3). Histogram.
4). Check sheets.
5). Control chart.
6). Flow chart.
7). Scatter diagram.
Strategy to Change
3 PREVENTIVE MEASUREMENT :
a) FMEA (Failure mode & effective analysis)
b) MSA (Measurement system analysis)
c) Control plans
d) 7 QC tools
DEMING APPROACH
LEARNING
Blanking
Drawing
Trimming & piercing
Side bending
THANK YOU!!!