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08A620 INDUSTRIAL VISIT CUM LECTURE

A REPORT

C. SIDDHARTH NARAYANAN (10A249)

Dissertation submitted in partial fulfilment of the requirements for the degree of 

Bachelor of engineering

Branch: Automobile Engineering

March 2013

DEPARTMENT OF AUTOMOBILE ENGINEERING

PSG COLLEGE OF TECHNOLOGY

(Autonomous institution)

COIMBATORE-641004

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ACKNOWLEDGEMENT

We express our gratitude to Dr. R.RUDRAMOORTHY, Principal, PSG College of Technology,Coimbatore, for his never ending support and words of encouragement and for providing excellentenvironment to undergo training as Industrial Visits.

We sincerely thank Dr. S. NEELAKRISHNAN, Head, Department of Automobile Engineering, for  providing the necessary facilities for completing this report.

Our deep and profound thanks to Mr. M. P. Bharathimohan, Assistant Professor, Department of Automobile Engineering, who have been our mentor and constant source of encouragement andmotivation and for having helped us to complete this series of Industrial Visits with aplomb.

Our efforts could never be complete without thanking the DEPARTMENT OF AUTOMOBILE

ENGINEEERING for providing us the requisite permissions to use facilities available in their state-of-the-art laboratories.

For the souls that helped us, how better could we express our gratitude than extend our sincere and

humble thanks.

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CONTENTS

An Introduction to Fuel Cells.

Observation of Submersible Pump and Motor 

 Assembly

Product Lifecycle Management

Ambal Autos  – An Industrial Visit

CNC Turning and Machining Centres

Industrial visit to GT Tuners Limited

Guest Lecture by Head of GT Tuners

Introduction to Rapid Prototyping

Industrial Visit to ROOPA Engineering industry

Guest Lecture on by faculty from Ashok Leyland

Wire EDM and CMM

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1. Fuel Cells.

INTRODUCTION:

A fuel cell is a device that converts the chemical energy from a fuel into electricity through a

chemical reaction with oxygen or another oxidizing agent. Hydrogen is the most common

fuel, but hydrocarbons such as natural gas and alcohols like methanol are sometimes used.

Fuel cells are different from batteries in that they require a constant source of fuel and oxygen

to run, but they can produce electricity continually for as long as these inputs are supplied.

The most important design features in a fuel cell are:

  The electrolyte substance. The electrolyte substance usually defines the type of fuel

cell.

  The fuel that is used. The most common fuel is hydrogen.

  The anode catalyst, which breaks down the fuel into electrons and ions. The anode

catalyst is usually made up of very fine platinum powder.

  The cathode catalyst, which turns the ions into the waste chemicals like water or 

carbon dioxide. The cathode catalyst is often made up of  nickel  but it can also be a

nanomaterial-based catalyst. 

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Types of Fuel Cells

Fuel cells are classified primarily by the kind of electrolyte they employ. This classification

determines the kind of chemical reactions that take place in the cell, the kind of catalysts

required, the temperature range in which the cell operates, the fuel required, and other factors.

These characteristics, in turn, affect the applications for which these cells are most suitable.

There are several types of fuel cells currently under development, each with its own

advantages, limitations, and potential applications. Learn more about:

  Polymer Electrolyte Membrane (PEM) Fuel Cells

  Direct Methanol Fuel Cells

  Alkaline Fuel Cells

  Phosphoric Acid Fuel Cells

  Molten Carbonate Fuel Cells

  Solid Oxide Fuel Cells

  Regenerative Fuel Cells

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POLYMER ELECTROLYTE MEMBRANE (PEM) FUEL CELLS: 

Polymer electrolyte membrane (PEM) fuel cells — also called proton exchange membrane fuel

cells — deliver high-power density and offer the advantages of low weight and volume,

compared with other fuel cells. PEM fuel cells use a solid polymer as an electrolyte and

 porous carbon electrodes containing a platinum catalyst. They need only hydrogen, oxygen

from the air, and water to operate and do not require corrosive fluids like some fuel cells.

They are typically fueled with pure hydrogen supplied from storage tanks or on-board

reformers.

Polymer electrolyte membrane fuel cells operate at relatively low temperatures, around 80°C

(176°F). Low-temperature operation allows them to start quickly (less warm-up time) and

results in less wear on system components, resulting in better durability. However, it requires

that a noble-metal catalyst (typically platinum) be used to separate the hydrogen's electrons

and protons, adding to system cost. The platinum catalyst is also extremely sensitive to CO

 poisoning, making it necessary to employ an additional reactor to reduce CO in the fuel gas if 

the hydrogen is derived from an alcohol or hydrocarbon fuel. This also adds cost. Developers

are currently exploring platinum/ruthenium catalysts that are more resistant to CO.

PEM fuel cells are used primarily for transportation applications and some stationaryapplications. Due to their fast startup time, low sensitivity to orientation, and favorable

 power-to-weight ratio, PEM fuel cells are particularly suitable for use in passenger vehicles,

such as cars and buses.

A significant barrier to using these fuel cells in vehicles is hydrogen storage. Most fuel cell

vehicles (FCVs) powered by pure hydrogen must store the hydrogen on-board as a

compressed gas in pressurized tanks. Due to the low-energy density of hydrogen, it is

difficult to store enough hydrogen on-board to allow vehicles to travel the same distance as

gasoline-powered vehicles before refuelling, typically 300 – 400 miles. Higher-density liquid

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fuels, such as methanol, ethanol, natural gas, liquefied petroleum gas, and gasoline, can be

used for fuel, but the vehicles must have an on-board fuel processor to reform the methanol to

hydrogen. This requirement increases costs and maintenance. The reformer also releases

carbon dioxide (a greenhouse gas), though less than that emitted from current gasoline-

 powered engines.

DIRECT METHANOL FUEL CELLS:

Most fuel cells are powered by hydrogen, which can be fed to the fuel cell system directly or 

can be generated within the fuel cell system by reforming hydrogen-rich fuels such as

methanol, ethanol, and hydrocarbon fuels. Direct methanol fuel cells (DMFCs), however, are

 powered by pure methanol, which is mixed with steam and fed directly to the fuel cell anode.

Direct methanol fuel cells do not have many of the fuel storage problems typical of some fuel

cells because methanol has a higher energy density than hydrogen — though less than gasolineor diesel fuel. Methanol is also easier to transport and supply to the public using our current

infrastructure because it is a liquid, like gasoline.

Direct methanol fuel cell technology is relatively new compared with that of fuel cells

 powered by pure hydrogen, and DMFC research and development is roughly 3 – 4 years

 behind that for other fuel cell types.

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ALKALINE FUEL CELLS: 

Alkaline fuel cells (AFCs) were one of the first fuel cell technologies developed, and they

were the first type widely used in the U.S. space program to produce electrical energy and

water on-board spacecrafts. These fuel cells use a solution of potassium hydroxide in water as

the electrolyte and can use a variety of non-precious metals as a catalyst at the anode and

cathode. High-temperature AFCs operate at temperatures between 100°C and 250°C (212°F

and 482°F). However, newer AFC designs operate at lower temperatures of roughly 23°C to

70°C (74°F to 158°F)

AFCs' high performance is due to the rate at which chemical reactions take place in the cell.

They have also demonstrated efficiencies near 60% in space applications.

The disadvantage of this fuel cell type is that it is easily poisoned by carbon dioxide (CO2). In

fact, even the small amount of CO2 in the air can affect this cell's operation, making it

necessary to purify both the hydrogen and oxygen used in the cell. This purification process

is costly. Susceptibility to poisoning also affects the cell's lifetime (the amount of time before

it must be replaced), further adding to cost.

Cost is less of a factor for remote locations, such as space or under the sea. However, to

effectively compete in most mainstream commercial markets, these fuel cells will have to

 become more cost-effective. AFC stacks have been shown to maintain sufficiently stable

operation for more than 8,000 operating hours. To be economically viable in large-scale

utility applications, these fuel cells need to reach operating times exceeding 40,000 hours,

something that has not yet been achieved due to material durability issues. This obstacle is

 possibly the most significant in commercializing this fuel cell technology.

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PHOSPHORIC ACID FUEL CELLS:

Phosphoric acid fuel cells use liquid phosphoric acid as an

electrolyte — the acid is contained in a Teflon-bonded silicon

carbide matrix — and porous carbon electrodes containing a platinum catalyst. The chemical reactions that take place in

the cell are shown in the diagram to the right.

The phosphoric acid fuel cell (PAFC) is considered the "first

generation" of modern fuel cells. It is one of the most

mature cell types and the first to be used commercially. This

type of fuel cell is typically used for stationary power 

generation, but some PAFCs have been used to power large

vehicles such as city buses.

PAFCs are more tolerant of impurities in fossil fuels that

have been reformed into hydrogen than PEM cells, which are easily "poisoned" by carbon

monoxide because carbon monoxide binds to the platinum catalyst at the anode, decreasing

the fuel cell's efficiency. They are 85% efficient when used for the co-generation of 

electricity and heat but less efficient at generating electricity alone (37% – 42%). This is only

slightly more efficient than combustion-based power plants, which typically operate at 33% – 

35% efficiency. PAFCs are also less powerful than other fuel cells, given the same weight

and volume. As a result, these fuel cells are typically large and heavy. PAFCs are also

expensive. Like PEM fuel cells, PAFCs require an expensive platinum catalyst, which raisesthe cost of the fuel cell.

MOLTEN CARBONATE FUEL CELLS:

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Molten carbonate fuel cells (MCFCs) are currently being developed for natural gas and coal-

 based power plants for electrical utility, industrial, and military applications. MCFCs arehigh-temperature fuel cells that use an electrolyte composed of a molten carbonate salt

mixture suspended in a porous, chemically inert ceramic lithium aluminum oxide (LiAlO2)

matrix. Because they operate at extremely high temperatures of 650°C (roughly 1,200°F) and

above, non-precious metals can be used as catalysts at the anode and cathode, reducing costs.

Improved efficiency is another reason MCFCs offer significant cost reductions over 

 phosphoric acid fuel cells (PAFCs). Molten carbonate fuel cells, when coupled with a turbine,

can reach efficiencies approaching 65%, considerably higher than the 37% – 42% efficiencies

of a phosphoric acid fuel cell plant. When the waste heat is captured and used, overall fuelefficiencies can be as high as 85%.

Unlike alkaline, phosphoric acid, and polymer electrolyte membrane fuel cells, MCFCs do

not require an external reformer to convert more energy-dense fuels to hydrogen. Due to the

high temperatures at which MCFCs operate, these fuels are converted to hydrogen within the

fuel cell itself by a process called internal reforming, which also reduces cost.

Molten carbonate fuel cells are not prone to carbon monoxide or carbon dioxide "poisoning"

 — they can even use carbon oxides as fuel — making them more attractive for fueling with

gases made from coal. Because they are more resistant to impurities than other fuel cell types,scientists believe that they could even be capable of internal reforming of coal, assuming they

can be made resistant to impurities such as sulfur and particulates that result from converting

coal, a dirtier fossil fuel source than many others, into hydrogen.

The primary disadvantage of current MCFC technology is durability. The high temperatures

at which these cells operate and the corrosive electrolyte used accelerate component

 breakdown and corrosion, decreasing cell life. Scientists are currently exploring corrosion-

resistant materials for components as well as fuel cell designs that increase cell life without

decreasing performance.

REGENERATIVE FUEL CELLS 

Regenerative fuel cells produce electricity from hydrogen and oxygen and generate heat and

water as byproducts, just like other fuel cells. However, regenerative fuel cell systems can

also use electricity from solar power or some other source to divide the excess water into

oxygen and hydrogen fuel — this process is called "electrolysis." This is a comparatively

young fuel cell technology being developed by NASA and others.

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 COMPARISON OF FUEL CELL TYPES:

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2.SUBMERSIBLE PUMP AND MOTOR ASSEMBLY:

submersible pump (or electric submersible pump (ESP)) is a device which has a hermetically

sealed motor close-coupled to the pump body. The whole assembly is submerged in the fluid

to be pumped. The main advantage of this type of pump is that it prevents pump cavitation, a problem associated with a high elevation difference between pump and the fluid surface.

Submersible pumps push fluid to the surface as opposed to jet pumps having to pull fluids.

Submersibles are more efficient than jet pumps. 

WORKING PRINCIPLE:

Produced liquids, after being subjected to great centrifugal forces caused by the high

rotational speed of the impeller, lose their kinetic energy in the diffuser where a conversion of 

kinetic to pressure energy takes place. This is the main operational mechanism of radial and

mixed flow pumps.

The pump shaft is connected to the gas separator or the protector by a mechanical coupling at

the bottom of the pump. Well fluids enter the pump through an intake screen and are lifted by

the pump stages. Other parts include the radial bearings (bushings) distributed along the

length of the shaft providing radial support to the pump shaft turning at high rotational

speeds. An optional thrust bearing takes up part of the axial forces arising in the pump but

most of those forces are absorbed by the protector‘s thrust bearing. 

PSG PUMPS AND MOTORS:

SUBMERSIBLES (3")

Application : Household, apartments, Industrial and rural water 

supply, Irrigation ( Flood, Sprinkler, Drip),

Farm houses water supply, cooling water circuiting systems.

Features :

  water filled design for longer life

  Pump casing is designed to ensure the best

hydraulic efficiency.  Dynamically balanced rotors and impellers for vibration free

 performance

  Wide voltage range motor design and hardwearing water 

lubricated bushes

  Easy dismantling and repairing

  Highly durable water cooled rewind able motor 

SUBMERSIBLES (4") 

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Application :

Household, apartments, Industrial and rural water 

supply, Irrigation (Flood, Sprinkler, Drip),Farm houses water sup

 ply, cooling water circuiting systems.

Features :

  Water filled design for longer life

  Pump casing is designed to ensure the best

hydraulic efficiency.

  Dynamically balanced rotors and impellers for vibration free

 performance

SUBMERSIBLES (6")

Application :

Industrial and rural water supply, Irrigation (

Flood, Sprinkler, Drip), Farm houses water supply,

cooling water circuiting systems.

Features :

  water filled design for longer life

  Pump casing is designed to ensure the best

hydraulic efficiency.

  Dynamically balanced rotors and impellers for 

vibration free performance

  Wide voltage range motor design and hardwearing

water lubricated bushes

  Easy dismantling and repairing

  Highly durable water cooled rewind able motor 

SUBMERSIBLES (8")

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Application :

Industrial and rural water supply, Irrigation (

Flood, Sprinkler, Drip), Farm houses water supply,

cooling water circuiting systems.

Features :

  water filled design for longer life

  Pump casing is designed to ensure the best

hydraulic efficiency.

  Dynamically balanced rotors and impellers for 

vibration free performance

  Wide voltage range motor design and hardwearing

water lubricated bushes

  Easy dismantling and repairing

  Highly durable water cooled rewind able motor 

PARTS:

PRESSURE DIE CASTING:

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Die casting is a metal casting  process that is characterized by forcing molten metal under high pressure into a mould cavity. The mould cavity is created using two hardened tool steel

dies which have been machined into shape and work similarly to an injection mould during

the process. Most die castings are made from non-ferrous metals, specifically zinc,  copper, 

aluminium, magnesium, lead,  pewter  and tin  based alloys. Depending on the type of metal

 being cast, a hot- or cold-chamber machine is used.

ADVANTAGES:

  Excellent dimensional accuracy (dependent on casting material, but typically 0.1 mm

for the first 2.5 cm (0.005 inch for the first inch) and 0.02 mm for each additional

centimetre (0.002 inch for each additional inch).

  Smooth cast surfaces (Ra 1 – 2.5 micrometres or 0.04 – 0.10 thou rms).

  Thinner walls can be cast as compared to sand and permanent mould casting

(approximately 0.75 mm or 0.030 in).

  Inserts can be cast-in (such as threaded inserts, heating elements, and high strength

 bearing surfaces).

  Reduces or eliminates secondary machining operations.

  Rapid production rates.

  Casting tensile strength as high as 415 mega Pascal (60 ksi).

  Casting of low fluidity metals.

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3. PLM:

•  product lifecycle management is the process of managing the entire lifecycle of a

 product from its conception, through design and manufacture, to service and disposal.

•  PLM systems help organizations in coping with the increasing complexity and

engineering challenges of developing new products for the global competitive

markets.

•  PLM describes the engineering aspect of a product, from managing descriptions and

 properties of a product through its development and useful life.

Phase 1: Conceive:

Imagine, specify, plan, innovate

Phase 2: Design

Describe, define, develop, test, analyse and validate

Phase 3: Realize

Manufacture, make, build, procure, produce, sell and deliver 

Phase 4: Service

Use, operate, maintain, support, sustain, phase-out, retire, recycle and disposal.

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FIVE PRIMARY AREAS OF PLM:

•  Systems engineering (SE)

•  Product and portfolio management (PPM)

•  Product design (CAx)

•  Manufacturing process management (MPM)

•  Product Data Management (PDM)

Benefits of PLM:

•  Reduced time to market

•  Improved product quality

•  Reduced prototyping costs

•  More accurate and timely request for quote generation

•  Ability to quickly identify potential sales opportunities and revenue contributions

•

  Savings through the re-use of original data

•  A framework for product optimization

•  Reduced waste Savings through the complete integration of engineering workflows

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4. AMBAL AUTOS:

Workshop facilities:

1.  WORKSHOP

2.  SERVICE

3.  EXPRESS SERVICE BAY

4.  BUFFING

5.  WATER WASH

6.  BODY SHOP

7.  DENTING

8.  TINKERING

9.  PAINT BOOTH

10. WHEEL ALIGNMENT

11. WATER WAHSH

WHAT THEY DO:

Workshop: Where the entire automobile are serviced by the technicians and electricians.

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Service: Every vehicle that comes for periodic servicing like oil change, battery check, and

other major components functional testing are carried. If there is any fault found that part is

replaced by a new one.

Express service bay: Here the vehicle which is to serviced quickly is handled and the

charges is costly. Express service bay for people who are always busy. 

Buffing: here they do the finishing process like buffing and polishing. Polishing and

 buffing are finishing processes for smoothing a work piece‘s surface using an abrasive and a

work wheel. Technically polishing refers to processes that use an abrasive that is glued to the

work wheel, while buffing uses a loose abrasive applied to the work wheel. Polishing is amore aggressive process while buffing is less harsh, which leads to a smoother, brighter 

finish. A common misconception is that a polished surface has a mirror bright finish,

however most mirror bright finishes are actually buffed.

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Water Wash: A car wash (also written as "carwash") or auto wash is a facility used to clean

the exterior and, in some cases, the interior of motor vehicles. 

Wheel Alignment: Wheel alignment, sometimes referred to as breaking or tracking, is

 part of standard automobile maintenance that consists of adjusting the angles of the wheels so

that they are set to the car maker's specification. The purpose of these adjustments is to

reduce tire wear, and to ensure that vehicle travel is straight and true (without "pulling" to

one side). Alignment angles can also be altered beyond the maker's specifications to obtain a

specific handling characteristic. Motorsport and off-road applications may call for angles to

 be adjusted well beyond "normal" for a variety of reasons.

Painting:  Spray painting is a  painting technique where a device sprays a coating (paint, ink,

varnish, etc.) through the air onto a surface. The most common types employ compressed gas — 

usually air  — to atomize and direct the paint particles. Spray guns evolved from airbrushes, and the

two are usually distinguished by their size and the size of the spray pattern they produce. Airbrushes

are hand-held and used instead of a brush for detailed work such as photo retouching, painting nails or 

fine art. Air gun spraying uses equipment that is generally larger. It is typically used for covering

large surfaces with an even coating of liquid. Spray guns can be either automated or hand-held and

have interchangeable heads to allow for different spray patterns. Single color  aerosol paint cans are

 portable and easy to store.

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Tinkering: The process of tinkering is that to service the vehicles which are undergone to

accidents.

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5. CNC Turning and Machining Centres

CNC machines:

•  CNC are computer controlled

automatic machines which will

machine the give component to

required dimension.

•  Types

LATHE

Milling machine

Combined lathe and milling

•  The VICE: This holds the material

to be cut or shaped. Material must be held securely otherwise it may 'fly' out of the

vice when the CNC begins to machine. Normally the vice will be like a clamp that

holds the material in the correct position.

•  The GUARD: The guard protects the person using the CNC. When the CNC is

machining the material small pieces can be 'shoot' off the material at high speed. This

could be dangerous if a piece hit the person operating the machine. The guard

completely encloses the the dangerous areas of the CNC.

•  The CHUCK: This holds the material that is to be shaped. The material must be

 placed in it very carefully so that when the CNC is working the material is not thrown

out at high speed.

•  The MOTOR: The motor is enclosed inside the machine. This is the part that rotatesthe chuck at high speed. Servo motor is used.

•  The LATHE BED: The base of the machine. Usually a CNC is bolted down so that it

cannot move through the vibration of the machine when it is working.

•  The CUTTING TOOL: This is usually made from high quality steel and it is the part

that actually cuts the material to be shaped.

Lathe operations:

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•  Turning

•  Facing

•  Threading

•  Parting off 

•  Chamfering

•  drilling

Some Milling operations:

•  Profiling

•  Plain milling

•  Drilling

•  Slotting

G codes and m codes:

•  G codes are preparatory functions

•

  m-codes are miscellaneous functions.

SOME G-CODES:

•  G00-Rapid positioning

•  G01-linear interpolation

•  G02-circular interpolation clockwise

•  G03 -circular interpolation counter 

clockwise

•  G04-Dwell

•  G17- xy plane

•  G18- zx plane

•  G19- yz plane

•  G20- in inches

•  G21- in mm

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M-codes:

  M00- compulsory stop

  M02- End of program

  M03- Spindle on (clockwise rotation)

  M04- Spindle on (counterclockwise rotation)

  M05- Spindle stop

  M06-Automatic tool change (ATC)

  M08-Coolant on (flood)

  M09-Coolant off 

  M30-End of program, with return to program top.

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6. Industrial visit to GT Tuners.

Motorized Work:

We offer a full line of auto repair services in our state-of-art facility. our services include

engine repair, transmission reapir, electrical repair, fluid ex-change, air-conditioning repair,

 battery service, brake repair , tyre service and alignment and balancing services. We also

have a full service auto parts department that can obtain most parts in minutes.

Body Collision Repairs:

From fender benders to severe body damage, our repair shop repairs them all. Our staff hasyears of touch-of-class car repair and body shop experience in all aspects of auto body and

frane damage repair. All work is done in-house and utmost care is given to make your car 

look like a new one after we are done. We are approved by major insurance companies.

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 Auto Painting:

We offer custom paiting and custom mixed paints with original manufacturer paint match-up. At our

state-of-the-art paint booth we ahve computerized paint mixing with Glasruit Paint. We offer you

factory baked finish. Restoration of Bumpers / Fenders / Doors / Hooks / Dent Reapir / ScratchRepairs and any banged up part of your car. We are approved by global car manufacturers.

Car Valeting:

We use the best possible products available to the trade. For this reason we don't just use one

 brand, but the best product for any particular job. These inlcude Auto Glym,3M,Meguirs.

The combination results in an outstanding overall finish which we are confident of. Hence,

you would be proud of as much as we are.

Power Performance Tuning:

Performance Tuning Accesories, Air-Intake system, Body and Exterior Styling, Interior 

Styling, Roll-Cage, Brake System, Bushing, Chasis / Body Strengthing, Cooling Systems,Drive Train, ECU, Electronics, Fuel Systems, Super Charger, Suspension and Turbo.

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8. Rapid Prototyping: 

Rapid prototyping is a group of techniques used to quickly fabricate a scale model of a

 physical part or assembly using three-dimensional computer aided design (CAD) data.

The Basic Process:

Although several rapid prototyping techniques exist, all employ the same basic five-step

 process. The steps are:

1.  Create a CAD model of the design

2.  Convert the CAD model to STL format

3.  Slice the STL file into thin cross-sectional layers

4.  Construct the model one layer atop another 

5.  Clean and finish the model

Selective Laser Sintering:

uses a laser beam to selectively fuse powdered materials, such as nylon, elastomer, and

metal, into a solid object. 

Parts are built upon a platform which sits just below the surface in a bin of the heat-

fusable powder. A laser traces the pattern of the first layer, sintering it together. The

 platform is lowered by the height of the next layer and powder is reapplied. This process

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continues until the part is complete. Excess powder in each layer helps to support the part

during the build. SLS machines are produced by DTM of Austin, TX.

Fused Deposition Modelling:

In this technique, filaments of heated thermoplastic are extruded from a tip that moves in the

x-y plane. Like a baker decorating a cake, the controlled extrusion head deposits very thin

 beads of material onto the build platform to form the first layer. The platform is maintained ata lower temperature, so that the thermoplastic quickly hardens. After the platform lowers, the

extrusion head deposits a second layer upon the first. Supports are built along the way,

fastened to the part either with a second, weaker material or with a perforated junction.

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9. ROOPA Engineering industry:

They produce components that are used for spinning mills. Example for such componentsspinning dies, nut and bolts, washers.

The machines used are:

1.  Centre lathe

2.  Turret lathe

3.  Drilling machine

4.  CNC milling machine

5.  CNC lathe machine

6.  Thread forming

7.  Gear hobbing

8.  Gear milling

Centre lathe:  The Centre Lathe is used to manufacture cylindrical shapes from a range of 

materials including; steels and plastics. Many of the components that go together to make anengine work have been manufactured using lathes. These may be lathes operated directly by

 people (manual lathes) or computer controlled lathes (CNC machines) that have been

 programmed to carry out a particular task. A basic manual centre lathe is shown below. This

type of lathe is controlled by a person turning the various handles on the top slide and cross

slide in order to make a product / part. 

Turret lathe:  The turret lathe is a form of  metalworking lathe that is used for repetitive

 production of duplicate parts, which by the nature of their cutting process are usually

interchangeable. It evolved from earlier lathes with the addition of the turret, which is anindexable tool holder that allows multiple cutting operations to be performed, each with a

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different cutting tool, in easy, rapid succession, with no need for the operator to perform

setup tasks in between, such as installing or uninstalling tools, nor to control the tool path.

The latter is due to the toolpath's being controlled by the machine, either in jig-like fashion,

via the mechanical limits placed on it by the turret's slide and stops, or via electronically-

directed servomechanisms for computer numerical control lathes.

Drilling machine:

When it comes to mechanical machining, radial drilling machine is used for all functions

such as drilling, counter boring, spot facing, lapping, screwing reaming, tapping and boring.

Radial drilling machines work well with a variety of material such as cast iron, steel, plastic

etc. Drilling machines hold a certain diameter of drill (called a chuck) rotates at a specified

rpm (revolutions per minute) allowing the drill to start a hole.

Radial drills are of three types. With the plain radial drill, the drill spindle is always vertical,

and may not swing over any point of the work. The spindle in the half-universal drill may be

swung over any point of the work and it may swing in one plane at any angle to the vertical

up to complete reversal of the direction of the drill. And the spindle in the full-universal drill

can be swung in any plane at any angle to the vertical.

Gear hobbing machine:

Hobbing is a machining  process for making gears,  splines, and sprockets on a hobbing

machine, which is a special type of  milling machine. The teeth or splines are progressivelycut into the work piece by a series of cuts made by a cutting tool called a hob. Compared to

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other gear forming processes it is relatively inexpensive but still quite accurate, thus it is used

for a broad range of parts and quantities.

Gear milling:

Milling is a form-cutting process limited to making single gears for prototype or very small

 batches of gears as it is a very slow and uneconomical method of production. A involute

form-milling cutter, which has the profile of the space between the gears, is used to remove

the material between the teeth from the gear blank on a horizontal milling machine. The

depth of cut into the gear blank depends on the cutter strength, set-up rigidity and

machinability of the gear blank material.

Thread forming: Thread forming is performed using a flute less tap, or roll tap,[17] which

closely resembles a cutting tap without the flutes. There are lobes periodically spaces around

the tap that actually do the thread forming as the tap is advanced into a properly sized hole.

Since the tap does not produce chips, there is no need to periodically back out the tap to clear 

away chips, which, in a cutting tap, can jam and break the tap. Thus thread forming is

 particularly suited to tapping blind holes, which are tougher to tap with a cutting tap due to

the chip build-up in the hole. Note that the tap drill size differs from that used for a cutting

tap and that an accurate hole size is required because a slightly undersized hole can break the

tap. Proper lubrication is essential because of the frictional forces involved, therefore

lubricating oil is used instead of cutting oil. 

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10. SMED and Guest Lecture by Ashok Leyland: 

Single-Minute Exchange of Die (SMED) is one of the many lean production methods for 

reducing waste in a manufacturing process. It provides a rapid and efficient way of 

converting a manufacturing process from running the current product to running the next product. This rapid changeover is key to reducing production lot sizes and thereby improving

flow (Mura).

Effects of implementation: 

However, the power of SMED is that it has a lot of other effects which come from

systematically looking at operations; these include:

  Stockless production which drives inventory turnover rates,

  Reduction in footprint of processes with reduced inventory freeing floor space

  Productivity increases or reduced production time

o  Increased machine work rates from reduced setup times even if number of 

changeovers increases

o  Elimination of setup errors and elimination of trial runs reduces defect rates

o  Improved quality from fully regulated operating conditions in advance

o  Increased safety from simpler setups

o  Simplified housekeeping from fewer tools and better organization

o  Lower expense of setupso  Operator preferred since easier to achieve

o  Lower skill requirements since changes are now designed into the process

rather than a matter of skilled judgment

  Elimination of unusable stock from model changeovers and demand estimate errors

  Goods are not lost through deterioration

  Ability to mix production gives flexibility and further inventory reductions as well as

opening the door to revolutionized production methods (large orders ≠ large

 production lot sizes)

   New attitudes on controllability of work process amongst staff.

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How Can SMED Help My Organization?

SMED and quick changeover programs have many benefits for manufacturers. From

reducing downtime associated with the changeover process to reducing the waste created

during startup. Additional benefits include:

  WIP and lot size reduction

  Finished goods inventory reduction

  Improved equipment utilization/yield

  Increased profitability without new capital equipment purchase

Effective SMED programs identify and separate the changeover process into key operations –  

External Setup involves operations that can be done while the machine is running and before

the changeover process begins, Internal Setup are those that must take place when the

equipment is stopped. Aside from that, there may also be non-essential operations. The

following is a brief example of how to attack the SMED process:

  Eliminate non-essential operations  –  Adjust only one side of guard rails instead of 

 both, replace only necessary parts and make all others as universal as possible.

  Perform External Set-up – Gather parts and tools, pre-heat dies, have the correct new

 product material at the line… there's nothing worse than completing a changeover 

only to find that a key product component is missing.

  Simplify Internal Set-up  –  Use pins, cams, and jigs to reduce adjustments, replace

nuts and bolts with hand knobs, levers and toggle clamps… remember that no matter 

how long the screw or bolt only the last turn tightens it.

  Measure, measure, measure  – The only way to know if changeover time and startup

waste is reduced is to measure it!

Always measure time lost to changeover and any waste created in the startup process so that

you can benchmark improvement programs. Ever see a racing pit crew? They have mastered

SMED and quick changeover! In less than 15 seconds they can perform literally dozens of 

operations from changing all tires and refueling the car to making suspension adjustments

and watering the driver. Watch closely next time  – you will always see one person with a

stopwatch benchmarking their progress.

Quick Definition

SMED is the term used to represent the Single Minute Exchange of Die or setup time that can

 be counted in a single digit of minutes. SMED is often used interchangeably with ―quick 

changeover‖. SMED and quick changeover are the practice of reducing the time it takes to

change a line or machine from running one product to the next. The need for SMED and

quick changeover programs is more popular now than ever due to increased demand for 

 product variability, reduced product life cycles and the need to significantly reduce

inventories.

Expanded Definition

The successful implementation of SMED and quick changeover is the key to a competitiveadvantage for any manufacturer that produces, prepares, processes or packages a variety of 

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 products on a single machine, line or cell. SMED and quick changeover allows manufacturers

to keep less inventory while supporting customer demand for products with even slight

variations. It also allows manufacturers to keep expensive equipment running because it can

 produce a variety of products. SMED has a lot of hidden benefits that range from reducing

WIP to faster ROI of capital equipment through better utilization.

To understand how SMED can help we have to look at the changeover process. Typically

when the last product of a run has been made the equipment is shut down and locked out, the

line is cleaned, tooling is removed or adjusted, new tooling may be installed to accommodate

the next scheduled product. Adjustments are made, critical values are met (die temperature,

accumulators filled, hoppers loaded, etc.) and eventually the startup process begins  – running

 product while performing adjustments and bringing the quality and speed up to standard. This

 process takes time, time that can be reduced through SMED.

Goals 

  Reduce inventory and improve cash flow

  Reduce lot sizes and improve lead time

  Reduce impact on equipment utilization and increase OEE

  Reduce scrap rates and improve quality

  Decrease changeover duration so that improve throughput and capacity

  Increase daily model change and improve flexibility

  Improve customer satisfaction and decrease costs so that become more competitive

  By all means, utilise labor and energy effectively

  Ensure standardization at each changeover and thus avoid individual solutions and

chaos.

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12. Wire EDM and CMM.

Electrical Discharge Machining

Electric discharge machining (EDM), sometimes colloquially also referred to as spark 

machining, spark eroding, burning, die sinking orwire erosion, is a manufacturing process

whereby a desired shape is obtained using electrical discharges (sparks). Material is removed

from the workpiece by a series of rapidly recurring current discharges between

two electrodes, separated by a dielectric liquid and subject to an electricvoltage. One of the

electrodes is called the tool-electrode, or simply the ‗tool‘ or ‗electrode‘, while the other is

called the workpiece-electrode, or ‗workpiece‘. 

When the distance between the two electrodes is reduced, the intensity of the electric field in

the volume between the electrodes becomes greater than the strength of the dielectric (at least

in some point(s)), which breaks, allowing current to flow between the two electrodes. This

 phenomenon is the same as the breakdown of a capacitor (condenser) (see also breakdown

voltage). As a result, material is removed from both the electrodes. Once the current flow

stops (or it is stopped – depending on the type of generator), new liquid dielectric is usually

conveyed into the inter-electrode volume enabling the solid particles (debris) to be carried

away and the insulating properties of the dielectric to be restored. Adding new liquid

dielectric in the inter-electrode volume is commonly referred to as flushing. Also, after a

current flow, a difference of potential between the two electrodes is restored to what it was

 before the breakdown, so that a new liquid dielectric breakdown can occur.

Electrical Discharge Machining

Wire-cut EDM

The wire-cut type of machine arose in the 1960s for the purpose of making tools (dies) from

hardened steel. The earliest numerical controlled (NC) machines were conversions of 

 punched-tape vertical milling machines. The first commercially available NC machine built

as a wire-cut EDM machine was manufactured in the USSR in 1967. Machines that could

optically follow lines on a master drawing were developed by David H. Dulebohn's group in

the 1960s at Andrew Engineering Company for milling and grinding machines. Master drawings were later produced by computer numerical controlled (CNC) plotters for greater 

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accuracy. A wire-cut EDM machine using the CNC drawing plotter and optical line follower 

techniques was produced in 1974. Dulebohn later used the same plotter CNC program to

directly control the EDM machine, and the first CNC EDM machine was produced in 1976.

Coordinate Measuring Machine

A coordinate measuring machine is a 3D device for measuring the physical geometrical

characteristics of an object. This machine may be manually controlled by an operator or it

may be computer controlled. Measurements are defined by a probe attached to the third

moving axis of this machine. Probes may be mechanical, optical, laser, or white light,

amongst others. A machine which takes readings in six degrees of freedom and displays these

readings in mathematical form is known as a CMM.

Coordinate Measuring Machine

Description

The typical 3 "bridge" CMM is composed of three axes, an X, Y and Z. These axes are

orthogonal to each other in a typical three dimensional coordinate system. Each axis has a

scale system that indicates the location of that axis. The machine will read the input from the

touch probe, as directed by the operator or programmer. The machine then uses the X,Y,Z

coordinates of each of these points to determine size and position with micrometre precision

typically.A coordinate measuring machine (CMM) is also a device used in manufacturing and

assembly processes to test a part or assembly against the design intent. By precisely recording

the X, Y, and Z coordinates of the target, points are generated which can then be analyzed

via regression algorithms for the construction of features. These points are collected by using

a probe that is positioned manually by an operator or automatically via Direct Computer 

Control (DCC). DCC CMMs can be programmed to repeatedly measure identical parts, thus

a CMM is a specialized form of industrial robot. 

PartsCoordinate-measuring machines include three main components:

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  The main structure which include three axes of motion

  Probing system

  Data collection and reduction system - typically includes a machine controller, desktop

computer and application software.

UsesThey are often used for:free-standing, handheld and portable.