SIX MONTH INDUSTRIAL TRAINING REPORTON
Studied everything in brief about production of various products
in cold forging shop
COMPLETED AT
MICROTURNERS-6 BADDISUBMITTED IN PARTIAL FULFILLMENT FOR AWARD
OF DEGREE OF
BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
BY
RAVINDER SINGH2011UGME093
DEPARTMENT OF MECHANICAL ENGINEERING OF BAHRA UNIVERSITY SHIMLA
HILLS (Waknaghat distt. Solan).
DECLARATION
I hereby declare that the Industrial Training Report entitled
("Study everything in brief about production of various Products in
Cold Forging Shop") is an authentic record of my own work as
requirements of 6-months Industrial Training during the period from
16 july 2014 to 16 jan 2015for the award of degree of B.Tech.
(Mechanical Engineering), BAHRA UNIVERSITY SHIMLA HILLS
(WaknaghatDistt. Solan) under the guidance of
Ravinder Singh 2011UGME093Date: 10 December 2014Certified that
the above statement made by the student is correct to the best of
our knowledge and belief.
SignaturesExamined by:HOD/DEAN(Signature and
Seal)AcknowledgementI have taken efforts in this project. However,
it would not have been possible without the kind support and help
of many individuals and organisations. I would like to extend my
sincere thanks to all of them
Iam highly indebted to Sanjeev doogle for their guidance and
constant supervision as well as for providing necessary information
regarding the project & also for their support in completing
the project.
I would like to express my gratitude towards my parents &
member of Micro Turners Company for their kind co-operation and
encouragement which help in completion of the project.
I would like to express my special gratitude and thanks to
industry persons for giving me such intentions and time.
My thanks and appreciations in completing the project also go to
the people who have willingly helped me out with their
abilities.PROFILE
The core strength of our organization is the latest machining
facility and the dedicated man power of approx. 300 numbers which
comprises of qualified engineers , skilled machinist and competent
administrative work force.
We have designed S.P.M s for doing the critical operations which
are otherwise difficult to do in conventional machining. For
effective measurement we have design gauges for every operation
even if the operation is small.
With such an infrastructure strength, we have been identified as
single source supplier for many components of TVS motor company,
Honda and many other company.
ABOUT COMPANY
Microturners group , founded in 1969 (started with name A.K
Automatics) is one of the largest integrated component manufactures
in INDIA .It has 12 world class manufacture facility mainly located
in the north and west INDIA.With the infrastructure and technology
platform development over 25 years , the group is well positioned
in INDIA auto and non- auto component markets.
With over 1400 component , microturner is mainly into the
manufacturing of kick start mechanism , transmission gear train
assembly , gear shifting towers and forks , chain/timing sprocket ,
ratchets , pinion , special engines fastener , clutch shafts ,
armature shafts , bearing races and rings , 2-WHD chassis , frames
, silencers and special turned component.
Microturners mainly aims at expanding their business across the
globes through technological excellence.We significantly
features-HIGH QUALITY-HIGH VOLIME-LOW COST.
VISION
To be a leader amongst the original equipment manufactures by
constantly evolving, continuously absorbing and implementing latest
techniques.
MISSION
To work efficiently and meeting total satisfaction of our valued
customer and for the prosperity and growth of our associates and
people with us.
QUALITY POLICY
We will endeavour to be world class organisation and satisfy our
customerneeds towards reliable performance in all our products .We
shall be committedto continuous improvement through. Quality
Management System in order to meet customer needs and expectation
with increased morale of our personnel .For this we shall create an
environment to encourage all our employee and suppliers to prevent
defects and strive for excellence.
QUALITY AWARDS
Quality award 2005(Hero Honda
Quality award-Bronze 2009(Bajaj Auto
Quality award-Gold 2011(Bajaj Auto
Best Machining Award 2010(Honda
Quality Award 2011(Mahindra
DOL Award 2007(Hero Honda
TPM Award 2011(Bajaj Auto
Delivery Award 2003(Honda
Quality Award 2002(YamahaMICROTURNERS PLANTSHIMACHAL
PRADESH:(MICROTURNERS-II BAROTIWALA
MICROTURNERS-IV NALAGARH
MICROTURNERS-PARVANU
HARYANA:(A.K AUTOMATICS-I ROHTAK
A.K AUTOMATICS-III ROHTAK
KHM Drive SYSTEM PVT MANESAR GURGAON
MICROTURNERS-III BINOLA GURGAON
MICROTURNERS-I ROHTAK
MAHARASHTRA:(MICROTURNERS-IV CHAKAN
UTRAKHAND:(MICROTURNERS-VII HARIDWAR
MICROTURNERS-V PANTNAGAR
MICROTURNERS METAL MAN PANTNAGARFACT SHEETYear of
establishment-1969
Nature of business-supplier manufacture
India mart member since-2010
Aim / Vision / Mission
Cost effective solutions
World class quality
Value added products to customers
Team work
Continual improvement
Zero defects
TPM
To provide best price at competitive price
Memberships / affiliations
AnTS- 16949:2009 AND TS-16949:2002 certified company.
Achievements
1969
Start of AK Automatics, Rohtak:equipped with single spindle
automats (traubs) for manufacture of precision turned
components
1981
Establishment of micro turners, Rohatk: equipped with hot / warm
forging presses coupled with induction heaters, resistance heating
and metal gathering machines.
1983
1983 establishment of micro turners, parwanoo (HP):a dedicated
unit to Maruti Udyog limited for manufactures and supplies of gear
shifting rods.
1984
1983approval received from hero Honda as a vendor to start
supply of engine / chasis components of motor cycles.
1993
Approval received from Bajaj auto ltd to start supplies for cold
forged axles / cylinder heads bolts and other fasteners and
precision machined components followed by supply of kick shaft
assembly in subsequent years.
1994
Addition of better heat treatment facilities including gas
carburising and LCN treatment facilities.
1996
Addition of gear shapers and gar hobbing machines to finish
complete gears.
1998
Addition of facilities for bearing races manufacturing including
track grinding
2002
Establishment of micro turners, BROTIVALA (HP)-equipped with 4
die 5 station part formers, k knuckle joint presses, hydraulic
presses, long stroke headers, CNC machine, CNC grinders, gear
hobbing of manufacturing of kick shafts , transmission
gears,bearing races, cam chain sprockets, ratchets and gear/pinion
kick starter
2005
Establishment of microturners, Gurgaon (HR)- A unit equipped
with knuckle joints presses, hydraulic presses, CNC machine,
grinding machine e, gear hobbing machines for manufacturing of
transmission shafts and gears, cam chain sprocket chain, gear kick
starter etc.sealed quench furnaces.
2006In process to establish micro turners, PANTNAGAR (UK)-A
dedicated unit for BAL PANTNAGAR (UTTRANCHAL)
2009
Establishment of microturner, HARIDWAR (UK)-A dedicated unit for
HERO HONDA motor LTD. HARIDWAR (UK) for suppliers of precision
machine and forged components.
2010
In process-a new unit of microturners is in process at Nalagarh
(HP) Micro turners, Gurgaon gets TS-16949:2002 certification
MICROTURNERS CUSTOMERS
Yamaha
TVS Tata
SuzukiSona
Piaggio
NissanMaruti Suzuki
Mahindra Two Wheeler
Mahindra
Kirloskr
Honda
Hero Bajaj
Ashok Leyland
TABLE OF CONTENTS
1. Introduction to organisation 12 No. of departments and shops
22.1 Production shop 2
2.1.1 Cold forging shop 2 2.1.2 Machine shop 4 2.1.3 Heat
treatment shop 8 2.1.4 Plating shop 11 2.1.5 Material testing lab
14 2.2 Product services 15 2.2.1 Tool room 15
2.2.2 Tool control cell 15
2.2.3 Production planning & control 15 2.2.4 Material
Management & control 15 2.2.5 Quality Engineering 15
2.2.6 Maintenance 15
3. Project details 15 3.1 Introduction 15 3.1.1 Background 16
3.1.2 Cold forging process 17
3.1.3 Cold Extrusion 19
3.1.4 Design Consideration for Cold Forging 20
3.1.5 Thread rolling 243.2 Raw Material selection 30 3.2.1
Introduction 30 3.2.2 Material used 31
3.3 Selection of Die Material 33
3.3.1 Introduction 33
3.3.2 Die Blocks 34
3.3.3 Die Analysis 35
3.4 Lubricants 36
3.4.1 Introduction to Lubrication 36
3.4.2 Classification of Lubrication Mechanism 36
3.4.3 Characterstics of Ideal Lubricants 37
3.4.4 Selection Criteria for Industrial Lubricants 39
3.4.5 Lubrication used in Microturner 393.3 Study of Machine
(NBM) 41 3.3.1 Specification & features 41 3.3.2 Product formed
42 3.3.3 Die & punches used 43 3.3.4 Instruments & Gauges
46 3.3.5 Tools used 463.4 Results 503.5 Conclusion 51LIST OF
TABLES
Table No. Table Caption Page Number
Table 2.1.4 Chemicals showing resistance against corrosion
14Table 3.2.2 Chemical composition of typical cold forging grades
31Table 3.3.1 Recommended Die Block Material for Forging Various
34
Material
Table 3.5.3 Specification of Cam Brake 45Table 3.5.5
Specification of Front Axle 49LIST OF FIGURE
Fig No. Fig Caption Page Number
Fig 2.1.1 Layout of Cold Forging Shop 2Fig 2.1.2 CNC Products
7Fig 3.1.2(a) Cold Heading 18Fig 3.1.2(b) Trimming 18Fig 3.1.2(c)
Piercing 18Fig 3.1.2(d) Extrusion 19Fig 3.1.4(a) Machine Drawing of
the Component 21Fig 3.1.4(b) Single Blow Header 23Fig 3.1.4(c)
Double Blow Header 23Fig 3.1.4(d) Multiple Die Machine 24Fig
3.1.5(a) Thread Rolling 24Fig 3.1.5(b) Rolling of External Threads
by Flat Die 26Fig 3.1.5(c) Principle of Thread Rolling by Flat Dies
27Fig 3.5.2 Cam Front Brake 42Fig 3.5.3 Types of Dies used in Bolt
Maker Machine 44III