Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
ON
AT
Prepared by:
PRARIT CHAUHAN
1
PREFACE
The Knowledge of Frame Body and Part is very useful in our day to day
life and one needs to know at least the basics of the same. The content
of this report include an overview about the whole manufacturing
processes to be followed in this category in order to obtain the final
product.
The report contains the description of various processes to be followed
and their analysis for their better understanding. The various processes
included in this report are welding process, functional line, etc. The
operation study, machine study and material information are clearly
mentioned out there.
At the end of this report I would like to thanks the people who help me
to get the things and share their knowledge about the things and the
processes are actually going on there.
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Acknowledgement
And I would also like to thank the crew of Metalman. The management
of the company and workers really cooperative. They gave us each and
every information that was needed and taught us the useful
fundamentals.
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1.Introduction
Metalman Auto (P) Ltd. is engaged into manufacturing of Sheet Metal
and Tubular Fabricated Assemblies and Sub Assemblies with In House
Surface Treatment facilities such as Ni-Cr Plating , Cataphoresis
Electrolysis Deposition (CED Painting) , Epoxy Powder Coating &
Phosphating. We act as a one stop shop for all your fabrication needs
and are currently catering to Global Automotive OEM’s, Heavy
Fabrication & Construction Equipment Industry, Off Road Vehicles &
White Goods Industry. All our plants are ISO-TS 16949:2009 Certified
which means supplying Defect Free Parts at a Competitive Price and at
Right Time, Every Time.
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Dharuhera Unit
This the Unit-II of Metalman Micro Turners which is being established
over an area of 4 acres. This plant has facility of frame and assessories
manufacturing along with press shop, CED paint shop. The exclusivity of
this plant this that it’s a very highly automated plant with over 50+
welding robots. This plant come in operation in august 2017.
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2.Functional line flow chart
AAGE
Forward Inspection
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REAR ASSEMBLY CELL
Manual clip
welding
Rework
Spatter
Removal
Retapping
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Add on Gauge
Boring Machine
Final Gauging
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AAGG
Forward Inspection
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REAR ASSEMBLY CELL
Manual Clip
Welding
Rework
Spatter
Remval
Retapping
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Add On Gauge
Boring Machine
Final Gauging
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AANP
Forward Inspection
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REAR ASSEMBLY CELL
Manual Clip
Welding
Rework
Spatter
Removal
Retapping
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Add on Gauge
Boring Machine
Final Gauging
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3.Parts Clamped on Functional Line
AAGE
Stage-10&20
Head Pipe
Down Tube
Pipe Central Joint
Stage-30
Body Comp. R&L
Stay Plate Lower
Stage-40
Pipe Centre Joinery
Stay Relay L
Centre Tube Joinery
Stage-50
Stay Side Lower L
Collar Fuel Tank
Stage-60
Main Stand R&L
Engine Mounting
Stay Plate
Stay ING Coil
Stay Canister
Stage-70
Patch Rear Upper
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Stage-80
Patch Plate
Stay Relay L
Stay Centre Pipe
Collar Tube Down
Stage-90
Tube R&L
Plate Tail Cross
Plate Tank RR Cross
Upper Tube R&L
Stage-100
Cushion R&L
Patch R&L
Stage-110
Stay CDI
Stage-120
FR & RR Frame Welding
Hook Spring
Plate Cushion Cross
Stay RR Fender L&R
Stage-130
Stay Air Cleaner
Bkt RP Step
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AAGG
Stage-100&110
Steering Head
Body R&L
Stage-140
Button Plate
Centre Pipe R&L
Stage-120
Down Tube R&L
Pipe Down Tube Bridge
Pipe Lower Cross FR&RR
Bkt Comp. L Step
Collar Down Tube
Stage-130
Plate Engine Lower Cross
Hook Spring Cross
Plate Lower Pipe
Horn Comp.
Stage-150
Bkt Engine Guard
Patch Front
Stage-160
Collar Fuel Tank
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Stage-170
Stay Utility Box
Bkt M Stand L&R with Collar
Plate Centre Pipe Cross
Stopper
Stay ING Coil
Stay Canister
Bkt U Box
Stage-180
Stay L Side Lower
Stage-190
Upper Pipe R&L
Down Tube R&L
Plate Tank RR Cross
Plate Tail Cross
Stage-200
Cushion R&L
Patch RR Upper R&L
Stage-210
Stay Air Cup
Stay L CDI
Plate Air/C Duet
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Stage-220
Hook Spring
Plate Cushion Cross
Side Stand Mounting
Stay Guard
Stage-230
Bkt Pillion Step R&L
Stay Side Cover R
Stay Air Cleaner
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AANP
Stage-100&110
Steering Head
Body R&L
Stage-140
Centre Pipe L&R
Button Plate
Cross Plate
Stage-120
Down Tube Pipe L&R
Pipe Lower Cross FR
Collar Down Tube
Bkt Comp. L Step
Stage-130
Plate Engine Lower
Plate Lower Pipe
Hook Spring
Horn Comp.
Stage-150
Centre Tube
Down Tube
Patch Plate
Bkt Engine Guard
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Stage-160
Stay Front Fuel Tank
Collar Fuel Tank
Stage-170
Stay Utility Box
Bkt M Stand L&R Collar
Plate Centre Pipe Cross
Stopper RR
Stay IGN Coil
Bkt U Box
Stage-180
Side Cover L&R
Stage-190
Upper Pipe L&R
Sub Tube L&R
Fuel Tank Plate
Plate Tank Cross
Stage-200
Cushion L&R
Patch L&R
Stage-210
Plate Tail Cross Bkt
Helmet Holder
Dash Cover
Stage-220
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Side Stand Mounting
Plate Cushion Cross
Stage-230
Bkt R Pillion Step
Stay Air/C UP
Bkt L Pillion Step
Stay Air Cleaner
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4.Sub Assembly
Stage-10 A&B
Collar
Pipe Body Steering Head
Plate
Stopper
Stage-20 A&B
Plate
Hook Spring
Plate Side Stand Bkt
Patch Side Stand Bkt
Stage-40 A&B
Bkt Cushion
Cushion Bolt
Nut
Stage-50 A&B
Plate
Guide Drain Tube
Stage-60 A&B
Bkt M Step
Pipe
Plate Bottom R&L
Pivot
Gusset Pivot
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5.Welding
Welding is a fabrication or sculptural process that joins materials,
usually metals or thermoplastics, by causing fusion, which is distinct
from lower temperature metal-joining techniques such as brazing and
soldering, which do not melt the base metal. In addition to melting the
base metal, a filler material is typically added to the joint to form a pool
of molten material (the weld pool) that cools to form a joint that, based
on weld configuration (butt, full penetration, fillet, etc.), can be
stronger than the base material (parent metal). Pressure may also be
used in conjunction with heat, or by itself, to produce a weld. Welding
also requires a form of shield to protect the filler metals or melted
metals from being contaminated or oxidized.
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6.Types of Welding
Resistance
Resistance welding involves the generation of heat by passing current
through the resistance caused by the contact between two or more
metal surfaces. Small pools of molten metal are formed at the weld
area as high current (1000–100,000 A) is passed through the metal. In
general, resistance welding methods are efficient and cause little
pollution, but their applications are somewhat limited and the
equipment cost can be high.
Spot Welding
Spot welding is a popular resistance welding method used to join
overlapping metal sheets of up to 3 mm thick. Two electrodes are
simultaneously used to clamp the metal sheets together and to
pass current through the sheets. The advantages of the method
include efficient energy use, limited work piece deformation, high
production rates, easy automation, and no required filler
materials. Weld strength is significantly lower than with other
welding methods, making the process suitable for only certain
applications. It is used extensively in the automotive industry—
ordinary cars can have several thousand spot welds made by
industrial robots. A specialized process, called shot welding, can
be used to spot weld stainless steel.
Projection
It is a modification of spot welding. In this process, the weld is
localized by means of raised sections, or projections, on one or
both of the work pieces to be joined. Heat is concentrated at the
projections, which permits the welding of heavier sections or the
closer spacing of welds. The projections can also serve as a means
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of positioning the work pieces. Projection welding is often used to
weld studs, nuts, and other threaded machine parts to metal
plate. It is also frequently used to join crossed wires and bars. This
is another high-production process, and multiple projection welds
can be arranged by suitable designing and jigging.
Seam
seam welding relies on two electrodes to apply pressure and
current to join metal sheets. However, instead of pointed
electrodes, wheel-shaped electrodes roll along and often feed the
work piece, making it possible to make long continuous welds. In
the past, this process was used in the manufacture of beverage
cans, but now its uses are more limited.
Arc Welding
These processes use a welding power supply to create and maintain an
electric arc between an electrode and the base material to melt metals
at the welding point. They can use either direct current (DC) or
alternating current (AC), and consumable or non-consumable
electrodes. The welding region is sometimes protected by some type of
inert or semi-inert gas, known as a shielding gas, and filler material is
sometimes used as well.
TIG
Gas tungsten arc welding (GTAW), also known as tungsten inert
gas (TIG) welding, is an arc welding process that uses a non-
consumable tungsten electrode to produce the weld. The weld
area and electrode is protected from oxidation or other
atmospheric contamination by an inert shielding gas (argon or
helium), and a filler metal is normally used, though some welds,
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known as autogenous welds, do not require it. A constant-current
welding power supply produces electrical energy, which is
conducted across the arc through a column of highly ionized gas
and metal vapors known as a plasma.
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7.Welding Station
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6. Fixtures and Tooling - Mechanisms that hold a part as it's welded,
may be designed to be operated automatically through the controller
with programming or manually by the worker running the cell.
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9. Welding Power Supply - Supplies power to the welding torch to
produce an arc. Supplies will vary in size, performance, and cost
depending on customer need and are matched to the processes and
metals being welded in the cell.
10. Stack Light - Used to offer an easy to visual guide to what the cell is
doing. Red indicates an E-Stop or emergency that has stopped cell
movement, orange means the robot is in teach mode, and green means
a cell is running in auto.
11. Operation Box - Controls to start and stop a cell, and reset it after
any issues preventing normal operations have been corrected.
12. Safety Features - This cell is equipped with fencing and arc shielding
to prevent workers from being directly exposed to arc flash. Full fence
enclosures, access doors, and light curtains are all commonly used to
limit workers' exposure to hazardous light, fumes, and motion while a
cell works.
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Work Station issues
Clamped part length problem in fixtures.
Problem in part clamping.
Welding gap in processes.
Welding gun nozzle get weld itself.
Burr problem sometime on parts stop the station or cause
improper welding.
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8.Quality
Receiving Area
To properly oversee beverage product deliveries the beverage
manager, or those who are responsible for product receiving, must
know the specifics of each order. This becomes easier when written
purchase orders, not verbal phone orders, are in use. Written purchase
orders can then be checked to ensure that the products being received
meet the specifics of the purchase order.
A copy of the purchase order or purchase record that was agreed on at
the time of purchasing should be available in the receiving area.
Personnel with receiving responsibilities will then know what to expect,
including the following:
• What products are coming in?
• In what volume or quantity will they arrive?
• What is the size of the purchase unit?
• What quality is expected?
By checking the quantity and quality of products delivered against
purchase orders, receiving personnel can ensure that they do not
accept items that were not ordered or are in damaged condition.
Finally, they must accept only items of proper quantity and quality.
Inspection
Activity of measuring, examine, testing one or more parameters of the
product and compare the result with specified requirements in order
whether conformity is achieved for each characteristic.
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Then the record is prepared by the inspector they received material.
Sample are randomly taken from it and then compare it with the
specify parameters with the help of gauges.
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Gauge
A gauge or gage, in science and engineering, is a device used to make
measurements or in order to display certain dimensional information. A
wide variety of tools exist which serve such functions, ranging from
simple pieces of material against which sizes can be measured to
complex pieces of machinery.
Micrometer
A micrometer sometimes known as a micrometer screw gauge, is a
device incorporating a calibrated screw widely used for precise
measurement of components[1] in mechanical engineering and
machining as well as most mechanical trades, along with other
metrological instruments such as dial, vernier, and digital calipers.
Micrometers are usually, but not always, in the form of calipers
(opposing ends joined by a frame). The spindle is a very accurately
machined screw and the object to be measured is placed between the
spindle and the anvil. The spindle is moved by turning the ratchet knob
or thimble until the object to be measured is lightly touched by both
the spindle and the anvil.
Radius gauge
Radius gauges require a bright light behind the object to be
measured. The gauge is placed against the edge to be checked
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and any light leakage between the blade and edge indicates a
mismatch that requires correction.
A good set of gauges will offer both convex and concave sections,
and allow for their application in awkward locations.
Vernier caliper
A popular refinement replaces the analog dial with an electronic
digital display that displays the reading as a numeric value. Rather
than a rack and pinion, these calipers use a linear encoder. Some
digital calipers can be switched between centimeters or
millimeters, and inches. All provide for zeroing the display at any
point along the slide, allowing the same sort of differential
measurements as with the dial caliper. Digital calipers may
contain a "reading hold" feature, allowing the reading of
dimensions after use in awkward locations where the display
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cannot be seen. Ordinary 6-in/150-mm digital calipers are made
of stainless steel, have a rated accuracy of 0.001 in (0.02mm) and
a resolution of 0.0005 in (0.01 mm).
Bevel protector
A bevel protractor is a graduated circular protractor with one
pivoted arm used for measuring or marking off angles. Sometimes
Vernier scales are attached to give more precise readings. It has
wide application in architectural and mechanical drawing,
although its use is decreasing with the availability of modern
drawing software or CAD.
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Height gauge
A height gauge is a measuring device used either for determining
the height of objects, or for marking of items to be worked on.
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Rejection area
This area consists the rejected parts which cannot be used in
process or having unspecified parameter according to the
planned. It is decided by the inspector whether the part is minor
faulted or major faulted. Minor faulted parts are sent for the
rework for the further use. Major faulted parts are returned to
the supplier. Rejected part may have following issues;
Burr
Rust
Dent
Crack
Failed in gauging test
Weak material
Shine/Sweep
3S – cleanliness point with cleaning tools and resources.
Shine is sweeping or cleaning and inspecting the workplace, tools and
machinery on a regular basis.
Goals:
Prevent deterioration.
Keep the workplace safe and easy to work in.
Keep the workplace clean and pleasing to work in.
Implementation:
Clean the workplace and equipment on a daily basis, or at another
appropriate (high frequency) cleaning interval.
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Standardize
It is to standardize the processes used to sort, order and clean the
workplace.
Goal:
Establish procedures and schedules to ensure the repetition of
the first three ‘S’ practices.
Implementation:
Develop a work structure that will support the new practices and make
it part of the daily routine.
Ensure everyone knows their responsibilities of performing the sorting,
organizing and cleaning.
Use photos and visual controls to help keep everything as it should be.
Sustain/Self-discipline
Sustain the developed processes by self-discipline of the workers. Also
translates as "do without being told".
Goal:
Ensure that the 5S approach is followed.
Implementation:
Organise training sessions.
Perform regular audits to ensure that all defined standards are being
implemented and followed.
Implement improvements whenever possible. Worker inputs can be
very valuable for identifying improvements.
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INDEX
4 Sub-Assembly 23
5 Welding 24
6 Type of welding 25
7 Welding station 28
8 Quality 32
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Name of figure
2.Functional line flow chart
AAGE
AAGG
AANP
3.Parts clamped on functional line
AAGE
AAGG
AANP
6.Types of welding
Resistance
Spot
Projection
Seam
Arc
TIG
MIG or MAG
8.Quality
Receiving area
Inspection
Gauge
Micrometer
Radius gauge
Vernier caliper
Bevel protector
Height gauge
Rejection area
Maintain 5’S for smooth flow of work
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