INDUSTRIAL TRAINING REPORT

On,

“TO STUDY MANUFACTURING PROCESS OF

AUTOMOTIVE GEARS AND SHAFTS”

Submitted to
SHIVAJI UNIVERSITY KOLHAPUR

In the partial fulfillment of the requirement of

BACHELOR OF ENGINEERING

Under the guidance of

Prof. MALAGE Sir

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 INTERNSHIP PROJECT REPORT

ON,
“TO STUDY MANUFACTURING PROCESS OF
BRAKING PISTON AND GEAR SHIFTING FORK
PLANT”

Mr. Sachin Patil (Deputy General Manager)

ACKNOWLEDGEMENTS

The internship opportunity I had with Snehadeep Enterprices Pvt. Ltd was a great
chance for learning and professional development. Therefore, I consider myself as a very
lucky individual as I was provided with an opportunity to be a part of it. I am also grateful for
having a chance to meet so many wonderful people and professionals who led me though this
internship period.

Bearing in mind previous I am using this opportunity to express my deepest gratitude

and special thanks to the MD of Snehadeep Enterprices Pvt. Ltd who in spite of being
extraordinarily busy with her/his duties, took time out to hear, guide and keep me on the
correct path and allowing me to carry out my project at their esteemed organization and
extending during the training.

I express my deepest thanks to Patil Sir, General Manager for taking part in useful
decision & giving necessary advices and guidance and arranged all facilities to make life
easier. I choose this moment to acknowledge his contribution gratefully.

I perceive as this opportunity as a big milestone in my career development. I will

strive to use gained skills and knowledge in the best possible way, and I will continue to
work on their improvement, in order to attain desired career objectives. Hope to continue
cooperation with all of you in the future,
Sincerely,

Shirkande Shubham Dilip

Place:Shiroli

Date:

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 Snehadeep pvt. Ltd

INDEX
Sr No. Title Page No.
1 Introduction 05
2 History 06

3 Manufacturing 09-16
Process
4 Layout of manufacturing plant 17
5 Quality Control 18
6 Costumers 21
7 Conclusion 22

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 INTRODUCTION
SNEHADEEP ENTERPRICES PRIVATE LIMITED, popularly known
as SNEHADEEP,established in year 2001 with a conventional machining setup. Within a
very short span of time, SNEHADEEP has converted into an ultra modern facility with CNC
Turning Centers, Vertical Machining Centers, Double Disc Grinding Machines, Single Pass
Vertical Honing Machines, Centerless Grinding Machines and many more.

SNEHADEEP has not only established the machining setup but has also established
its own Foundry, sophisticated Tool Room and Machine Tools Division as well which
enables the Customer to get a complete solution for his requirements.

SNEHADEEP is established as a reliable source for the major 2 wheeler

manufacturers in India. Precision components used in Engine & Transmission system are the
strengths. SNEHADEEP also has expertise in Aluminium Extrusion components and Special
Surface Treatments like Hard Anodizing, Zinc Plating (Cr+3) etc.

The promoters of the company are in engineering industry since 18 years and have
pioneered jig / fixture designing & manufacturing in Shiroli area.Incorporated in August
2001, mainly started for jig/fixture manufacture,further, automotive component machining
was added to the mainstream activities and is the major activity today.

The company has created good will amongst its customers by supplying machined
components right on time, coupled with firm control on the quality requirements stated by
them.The company has successfully handled high volume components to the peak
production levels of around 100000 components per month.For example Guile Gear Shift,
Rotor Oil Filter.

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Snehadeep pvt. Ltd

HISTORY

COMPANY PROFILE
It has been a trailblazing journey of quality, excellence, innovation and commitment.
Since 1995, Snehadeep Engineering Pvt. Ltd. has evolved as a leader in material handling
solutions catering to diverse industries. The company is renowned for high quality vertical
integration from design to commissioning of material handling products and assembly line
equipment.

With state-of-the-art establishment and focus on Research & Development, the

company is scaling heights of success. The wide Tecnovision portfolio consists large varity
of Material Handling Equipments, Pipe and Joint products and Pellets and Trollyes.

Snehadeep is one of the Leading Manufacturer of Material Handling Equipments. The

core focus of the company lies in superior quality and excellent customer service. The
company is one of the front runners in Lean Manufacturing Solutions in India with an ISO
9001-2015 certification. The company owns Five Manufacturing set-ups and total area of
52000 sq. ft. with all manufacturing and design equipment.

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 Manufacturing Process
Machining Division :
 Gear Fork:-

A CAD system also can be useful during the initial phase of the work holder design as
numerous tooling options are developed. CAD is sometimes faster than sketching by hand,
especially when detailed cost estimates are required. Analytical Design and 3 D modeling of
a fork modal is as shown in figure.

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Snehadeep pvt. Ltd

Fixture assembly :

As the operations to be carried out are in 2 different planes, so we decided to make 2

different fixtures. The fixture design is categorized in 2 types for machining gear shifting
fork. The fixture is to be designed for Vertical Milling Machine (VMC) i.e
1) Base Plate Fixture
2) Angle Plate Fixture Base Plate Fixtures are constructed from plate with a variety of
support, clamps and locators. They are the most common type of fixture because their
versatility make them adaptable to a wide range of machine tools.the pads are made on the
base plate so that fork can be mounted on it. After the mounting of fork it will be clamped
with the toggle clamp as shown in figure 4, operations like drilling of 16.5 mm hole,
chamfering, boring of 16.5 mm hole to 16.60 mm, Slotting of end arms can be carried out.
The purpose of making angle plate fixture is to perform a drilling of 6 mm hole & reaming of
6.35 mm hole as shown in figure To reduce the number of fixture, a concept of turning table
fixture is introduced. Turning table can be useful to carry out operations at 2 different planes
and also there is reduction in material and machining time. The purpose of designing the
fixture at 0 deg. shown in figure 6 as to carry out the following operations:
1) Drilling of 16.5 mm hole
2) Boring of this hole by 16.660 mm
3) Slotting of end arms
4) Chamfering As shown in figure , the fork is assembled on the pad so that the operations
can be carried out very easily without any shocks or vibrations.

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  Breaking Piston Making:-

A design methodology is applied to manufacturing a disk-brake piston component.

A rigid plastic finite element method is applied to simulate the conventional four-stage
manufacturing process and the one-step process from a selected stock to the final product
shape for information on metal flows. Two-stage forming operations with different punch
corner and nose radii are also simulated to identify the best possible solutions. The best
manufacturing process is selected, which uses a hemispherical punch in the drawing
process. Experiments are conducted for comparison with the numerical results. The good
agreement between the experimental and numerical results validates the design
methodology using the finite element method.

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Snehadeep pvt. Ltd

The KUKA system software is the operating software and the heart of the entire
control. In it, all basic functions are stored which are needed for the deployment of the robot
system.
Robots come with a control panel that has a display and an integrated 6D mouse, with
which the manipulator is moved, positions are saved (Touch Up), or where modules,
functions, data lists, etc. are created and modified. To manually control the axes, the enabling
switch on the back of the control panel (the KCP, or KUKA Control Panel) must be activated
(today only with a panic function). The connection to the controller is a VGA interface and a
CAN-bus.A rugged computer located in the control cabinet communicates with the robot
system via an MFC card. Control signals between the manipulator and the controls are
transferred using the so-called DSE-RDW connection. The DSE card is in the control cabinet,
the RDW card in the robot socket.
Controls for the old KRC1 types used Windows 95 to run V x Works-based software.
Peripheral equipment includes a CD-ROM and a disk
drive; Ethernet, Profibus, Interbus, Devicenet and ASI sockets are also available.
Controls for the newer KRC2 type use the Windows XP operating system. Systems
contain a CD-ROM drive and USB ports, Ethernet connection and feature optional
connections for Profibus, Interbus, DeviceNet and Profinet.

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Heat Treatment Processes :-.

 Hardening

Hardening involves heating of steel, keeping it at an appropriate temperature until all

pearlite is transformed into austenite, and then quenching it rapidly in water or oil. The
temperature at which austentizing rapidly takes place depends upon the carbon content in the
steel used. The heating time should be increased ensuring that the core will also be fully
transformed into austenite. The microstructure of a hardened steel part is ferrite, martensite,
or cementite.

 Tempering
Tempering involves heating steel that has been quenched and hardened for an
adequate period of time so that the metal can be equilibrated. The hardness and strength
obtained depend upon the temperature at which tempering is carried out. Higher temperatures
will result into high ductility, but low strength and hardness. Low tempering temperatures
will produce low ductility, but high strength and hardness. In practice, appropriate tempering
temperatures are selected that will produce the desired level of hardness and strength. This
operation is performed on all carbon steels that have been hardened, in order to reduce their
brittleness, so that they can be used effectively in desired applications.

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Snehadeep pvt. Ltd

 Annealing
Annealing involves treating steel up to a high temperature, and then cooling it very
slowly to room temperature, so that the resulting microstructure will possess high ductility
and toughness, but low hardness. Annealing is performed by heating a component to the
appropriate temperature, soaking it at that temperature, and then shutting off the furnace
while the piece is in it. Steel is annealed before being processed by cold forming, to reduce
the requirements of load and energy, and to enable the metal to undergo large strains without
failure.

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  Normalizing
Normalizing involves heating steel, and then keeping it at that temperature for a
period of time, and then cooling it in air. The resulting microstructure is a mixture of ferrite
and cementite which has a higher strength and hardness, but lower ductility. Normalizing is
performed on structures and structural components that will be subjected to machining,
because it improves the machinability of carbon steels.

 Carburization
It is a heat treatment process in which steel or iron is heated to a temperature, below

the meltingpoint, in the presence of a liquid, solid, or gaseous material which

decomposes so as to release carbon when heated to the temperature used. The outer case or
surface will have higher carbon content than the primary material. When the steel or iron is
rapidly cooled by quenching, the higher carbon content on the outer surface becomes hard,
while the core remains tough and soft.
Surface Hardening
In many engineering applications, it is necessary to have the surface of the component hard
enough to resist wear and erosion, while maintaining ductility and toughness, to withstand
impact and shock loading. This can be achieved by local austentitizing and quenching, and
diffusion of hardening elements like carbon or nitrogen into the surface. Processes involved
for this purpose are known as flame hardening, induction hardening, nitriding and
carbonitriding.

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Snehadeep pvt. Ltd

 Grinding Process:-
Center less grinding is a machining process that uses abrasive cutting to remove material
from a work piece. Center less grinding differs from centered grinding operations in that
no spindle or fixture is used to locate and secure the work piece; the work piece is secured
between two rotary grinding wheels, and the speed of their rotation relative to each other
determines the rate at which material is removed from the work piece.
Center less grinding is typically used in preference to other grinding processes for operations
where many parts must be processed in a short time.
 Process:-
In center less grinding, the work piece is held between two wheels, rotating in the same
direction at different speeds, and a work holding platform. One wheel, known as the grinding
wheel (stationary wheel in the diagram), is on a fixed axis and rotates such that the force
applied to the work piece is directed downward, against the work holding platform. This
wheel usually performs the grinding action by having a higher tangential speed than the work
piece at the point of contact. The other wheel, known as the regulating wheel (moving wheel
in the diagram), is movable. This wheel is positioned to apply lateral pressure to the work
piece, and usually has either a very rough or rubber-bonded abrasive to trap the work piece.

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The speed of the two wheels relative to each other provides the grinding action and
determines the rate at which material is removed from the work piece. During operation the
work piece turns with the regulating wheel, with the same linear velocity at the point of
contact and (ideally) no slipping. The grinding wheel turns faster, slipping past the surface of
the work piece at the point of contact and removing chips of material as it passes.

 Reaming process:-
Reamers are rotary cutting tools used in metalworking. Reaming is the process of
enlarging and sizing a hole by means of a multifluted cutting tool. Precision reamers are
designed to enlarge the size of a previously formed hole by a small amount but with a high
degree of accuracy to leave smooth sides. Non-precision reamers are used for more basic
enlargement of holes and light material removal to deburr.

Reaming uses a pre-existing hole in the workpiece and removes a small amount of
material called chips. The process involves relative axial and rotational motions between the
reamer and the workpiece. It is often done on a drill press, but it may also be done on lathes.
The workpiece is held firmly in place by a vise, chuck, or fixture as the reamer is advanced
into the workpiece.

A typical reamer consists of a set of parallel or helical cutting edges along the length
of a cylindrical body. Each cutting edge is ground at a slight angle with an undercut below
the cutting edge. Reamers should only be used to remove small amounts of material to ensure
a long life for the reamer and a superior finish to the hole.

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Snehadeep pvt. Ltd

 Morse taper reamer

A morse taper reamer is used manually to finish morse taper sleeves. These sleeves are a tool
used to hold machine cutting tools or holders in the spindles of machines such as a drill or
milling machine. The reamer shown is a finishing reamer. A roughing reamer would have
serrations along the flutes to break up the thicker chips produced by the heavier cutting action
used for it.

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Layout Of Manufacturing Shop:-

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Snehadeep pvt. Ltd

Quality Control:-

Quality control is something that's a key part of almost every industry and every job.
You probably engage in your own form of quality control several times a day. If you
proofread your e-mail before you send it, that's a form of quality control. Even this article is
the result of a type of quality control system. The editor who publishes it onto the
HowStuffWorks.com Web site will check the published version for things like spacing issues,
image size and position and broken links.

It's a similar process in auto manufacturing. But you can't put something through
quality control until it's actually built. So, in automobile manufacturing, quality control starts
with the prototype of a car. From there, the prototype is put through its paces.

Engineers have designed several tests to determine how well a car will stand up to
real-world (and extreme) use. For instance, they drive the prototype car over specially
designed surfaces to test the smoothness of the ride and the durability of the suspension. They
also expose the cars to extreme heat and cold weather to test how the various mechanical
components will work in all types of weather. They even fill a car with smoke and then check
all the window and door seals to insure it's airtight.

One of the most well-known quality-control tests is the crash test. While most people
are familiar with government and insurance industry crash tests, car makers also run their
own tests to make sure its products and safety systems will work as they were designed to
and protect the vehicle's occupants.

Up next, learn about some of the advances made in automotive quality control.

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  Brinell hardness testing machine

The Brinell hardness test method as used to determine Brinell hardness, is defined in
ASTM E10. Most commonly it is used to test materials that have a structure that is too coarse
or that have a surface that is too rough to be tested using another test method, e.g., castings
and forgings. Brinell testing often use a very high test load (3000 kgf) and a 10mm diameter
indenter so that the resulting indentation averages out most surface and sub-surface
inconsistencies.

The Brinell method applies a predetermined test load (F) to a carbide ball of fixed
diameter (D) which is held for a predetermined time period and then removed. The resulting
impression is measured with a specially designed Brinell microscope or optical system across
at least two diameters – usually at right angles to each other and these results are averaged
(d). Although the calculation below can be used to generate the Brinell number, most often a
chart is then used to convert the averaged diameter measurement to a Brinell hardness
number.

Common test forces range from 500kgf often used for non-ferrous materials to
3000kgf usually used for steels and cast iron. There are other Brinell scales with load as low
as 1kgf and 1mm diameter indenters but these are infrequently used.

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Snehadeep pvt. Ltd

Typically the greatest source of error in Brinell testing is the measurement of the
indentation. Due to disparities in operators making the measurements, the results will vary
even under perfect conditions. Less than perfect conditions can cause the variation to increase
greatly. Frequently the test surface is prepared with a grinder to remove surface conditions.

The jagged edge makes interpretation of the indentation difficult. Furthermore, when
operators know the specifications limits for rejects, they may often be influenced to see the
measurements in a way that increases the percentage of “good” tests and less re-testing.

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Costumers

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Snehadeep pvt. Ltd

Conclusion
During the Industrial Training at Snehadeep Enterprices Pvt. Ltd.its technician
department have long been exposed to various activities and tasks in this company indirectly,
trainees also have to know every responsibility and role in the company. Exposure to real
working environment is good for student as trainers, especially to open the minds and brains
to be more creative and highly knowledgeable, students can also identify and address issues
that often arise in real work situations. It will further enhance the student's ability to think,
learn independently and solve problems effectively and more importantly can produce
creative work, Keratins and quality.
During training in technician department coach can identify some strengths and
weaknesses of the company. However, this drawback can be overcome and repaired.
Principles of organization and administrative functions play an important role in creating a
robust organizational planning, coordination and control is essential to coordinate all tasks.
An organization must be established and excellent efficient and effective decision-making
and planning, and this is the main principle in the management of an organization. Through
the Industrial Training, it is clear that the training objectives have been achieved during the
training conducted for11 Days Therefore, it can be concluded that all the exposure that has
been given to the trainees during training is very useful and should be exploited in the future.
Such training also can and will produce graduates who are knowledgeable and a great
personality.

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