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