6 Weeks Training Report

8/13/2019 6 Weeks Training Report

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AcknowledgementA well-known company like G.S. AUTO INTERNATIONAL LTD. with a

work force of over thousand employees and having huge margin of profits

highlights the most efficient and smooth working of the organization. This

thereby creates an eagerness for its known and law.

I take this opportunity to express my deep sense of gratitude and whole

hearted thanks to G.S. AUTO INTERNATIONAL LTD.for enabling me to

undergo the first phase of the industrial trainingof B. Tech(4th sem.)

for six weeks.

I would like to mention my indebtedness towards Mr. Jasbir Singh Ryait,

Chairman & Mr. Surinder Singh Ryait, MD for this act of kindness.

I am also thankful to Mr. Vijay Pal Sharma (HR Manager) who helped

me and guided me to carry out my duties for their much needed guidance

and advices.

However my most sincere special thanks also goes to HOD Mechanical

Engineering Dr. Sehijpal Singh, Prof. Harwinder Singh, training head

Mechanical Engineering Department and also Prof. K.S. Mann, our

dean Training & Placement, and the Director of our GURU NANK DEV

ENGINEERING COLLEGE, Dr. M.S. Saini.

Lastly I would like to thank all of them who actively helped me during this

course.

LAKSH JAIN


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AbstractThis report is the result of work carried out at G. S. AUTO

INTERNATIONAL LTD., Ludhiana during the six weeks industrial training

of the author for the fulfilment of B. Tech. (MECHANICAL) from Guru

Nanak Dev Engg. College, Ludhiana.

In this report the company profile along with various operations in industry

are explained. Namely:

A REPORT ON INDUSTRIALTRAINING

This report consists of the study of the products being manufactured at

different plants of the company.

Then it includes the study of operations being carried out in various shops

of the company. The material and process flow comprises of various

activities. Metallurgical aspects of various materials are also discussed.


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ContentsSr no. Topic Page No.

1 I n t r o d u c t i o n 5

2 I n d u s t r y P r o f i l e 6

3 P l a n t s 8

4 R a w M a t e r i a l P r o c u r e m e n t 9

5 U - B o l t 11

6 C e n t r e B o l t 13

7 S p r i n g P i v o t P i n 15

8 S p r i n g B o l t 19

9 H u b B o l t 21

10 N u t 23

11 K i n g P i n 2512 P l a n t - 1 27

13 P l a n t - 2 34

14 P l a n t - 3 36

15 P l a n t - 4 38

16 F o u n d a r y S h o p 41

17 M e t a l l u r g ic a l A s p e c t s 44

18 C o n c l u s i o n 48


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Introduction

Practice makes a man perfect. Training is a good investment. It provides onewith the knowledge about the application of what one studies. In case of anengineering student it becomes inevitable. Being the students of mechanicalengineering branch it was really necessary for us to have training in anindustry of repute. So I had done six weeks training at G.S. AutoInternational Ltd. Ludhiana one of the most reputed industry of the town.


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Industry ProfileG.S. Auto International Ltd. is an establishment of S. Gurmukh Singh Ryaitwith

whose efforts the company came into existence in 1938. G.S. Auto International is

located inside G.S. Estate along with G.S. Automotives Ltd., G.S. Sales

Corporation, Ryait Exports & G.S. Radiators Ltd., spread over an area of 1 million

square feet.

Products Infrastructure: The Companys core strength has beendiversification which has helped the constant growth. The company is engaged in

the manufacture of auto parts, which are divided into two categories:

a) Cast Components: To cope with the varying requirements of thecustomers in the automobile industry;

casting unit was set up with complete facilities for die casting, trimming, machining, shot blasting, core making, pattern making, painting & other relevant operations, all under one roof.

b) Machined Components: On the strength of its expertise in thedevelopment & manufacturing of components, the industry has explored

new horizons to provide a diverse range of machined components. These

include:

U- bolt, centre bolt, hub bolt, spring pin, king pin, axle stud, shackle bolt & different types of nuts.


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Customers:The company makes these parts as original equipments as well asfor replacement market. The company's customers include:

TATA MotorsMaruti Udyog Ltd.Mahindra & MahindraHindustan Motors Ltd.Ashoka Leyland Ltd. (Iveco)Delphi Automotive Systems Ltd.Swaraj Mazda Ltd.Volvo India Ltd.Eicher Motors Ltd.

The company also has a good reputation in export market exporting to more than

15 countries.

Accreditations: The company works on the 5-S concept & is managed by ateam of professionals with focus on customer satisfaction, continuous

improvement, defect prevention & reducing wastage. This has lead to the

conferring of various certifications. These certifications include:

ISQ-9002 certification in 1997

QS-9000 certification in 1999

TS-16949 certification in 2005


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PLANTSG.S. Auto International Ltd. comprises of following plants:

Plant- 1 (Machine Shop- 1)

It is subdivided in the following sections according to the type of product they

manufacture.

(a)Raw material stock(b)Material cold drawing section(c)U-bolt section(d)King pin section(e)Spring pin section(f) Machine nut section(g)Shackle bolt section(h)Grinding section & tool room(i) Zinc plating department(j) Laboratory(k)Induction hardening section(l) Cold forging(m)Maintenance unit

Plant- 2

It consists of the following sections;

(a)Hot forging section(b)Heat treatment section(c) Civil maintenance section(d)Auto-black section

Plant- 3 (Machine Shop- 2)

It comprises of following sections:

a) Hub bolt sectionb) Centre bolt sectionc) Non- ferrous bush section (casting)


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Plant- 4 (G.S. Automotives Ltd.)

It consists of following sections:

(a)Foundry shop(b)Fettling shop(c)Machine shop- 3

Raw Material ProcurementThe raw material is in form of long cylindrical rods. The raw material is different for different

types of nuts & bolts. The color codification for different materials is as follows:

Material Color CodeMild Steel/ C-30 No color

6T/EN-8K White

EN- 8D Black

CK-45 Brown

SAE-1541 Yellow

SAE-4140 Sky blue

SAE- 8620 Pink

EN-353 Green41 Cr 4 Navy blue

H.D.S. 9% W White, red

H.C.H. Cr Yellow, red

O.H.N.S. Yellow, navy-blue

H.S.S. 16:4:1 (TCV) White, yellow

H.S.S. 6:5:2 White, navy-blue

EN-24 Yellow, green

EN-31 Sky-blue, navy-blueEN-36 Yellow, black

H.D.S. 5% Cr Sky blue, red

EN-45 White, green

42 Cr Mo2 Smoke grey

SAE 15B41 Orange


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U-BoltMaterial- SAE 4140)

Facing:The cut round bars are sent to machine shop for facing. Facing is done

on both the sides of the bar by using an SPM lathe machine.

Turning:The rods are then sent for cylindrical turning. The machine is semi-

automatic lathe machine. The machine operates on cam & follower mechanism.

The work-piece is sent into the machine through a collet which holds it tightly.

Two tools work on the work-piece one after the other. One tool reduces the

diameter down to 22.37 mm on a 78 mm length & the other one gives a radius of

19 mm at the end. This operation is done on both the ends of the work-piece.

Threading:The turned rods are sent to the threading machine. The machine is

a profile making machine. The threading is done as a forming operation. The

rollers are made of high carbon steel. The threaded portion is of 76 mm length.

The size of thread is 22 2.5 P.

U-bolt bending: The rod with both ends threaded is sent to the induction

heating machine which heats the bar at the centre till red hot. The current that

passes through the rod is 100 ampere. The time for heating is 13 seconds.


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Threading:The next operation is done to make the thread on the limb of the

centre bolt. The machine is a hydraulic thread rolling machine which is also called

a profile making machine. The threading is done as a forming operation. The

rollers are made of high carbon steel. The size of the thread is 24.

Washing (removal of oil & grease):The pieces from machine shop are

sent to the auto-black section. First of all the U-bolt pieces coming out of machine

shop are checked for any kind of difference in the axis of both the limbs. If so then

the limbs are made co-axial. The work-pieces are then loaded on to a stand. Then

these pieces are dipped in a solution of salt acid (500 ltr.) & water (500 ltr.). This

process is called acidification. There after the pieces are washed with water. Then

the activation is done. The U-bolts are dipped into solution of Actisol (200 ltr.) &

water (400 ltr.). This process activates the auto-black process. This is done at

normal temperature.

Auto-black:After activation the pieces are dipped into another tank filled with

0C- 100oil (1000 ltr.). All the pieces are colored black. The oil used is No. 222

made by Blakfast industries limited. The temperature for the process is 30C.


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mm. Another hole is drilled along the same centre line, which is of 9 mm diameter

& the length of this hole is 8 mm.

Sidewise drilling:The pieces are then sent for sidewise drilling. The hole is

to be made in the grease slot. The operation is performed on a vertical drillingmachine. The centre of the hole is at 61.5 mm from the smaller diameter end. The

diameter of the hole is 5 mm.

Tapping: The next operation is tapping. In the hole of diameter 9 mm

threading is to be done. The machine is vertical tapping machine, which is an

SPM. The size of thread is 27 NPTF.

Counter sinking: The tapped hole is then counter sunk. The operation is

performed on a vertical drilling machine. The size of chamfer provided is 1.5 45.

Stamping: The machine used is fly- press. The operation is to emboss a stamp

of G.S. International logo on the head of the spring pivot bolt. The die strikes the

head of the bolt with a large force & stamp is marked on the bolt.

Induction hardening:To make the pieces suitable for working under high

stresses they are case hardened by induction hardening process. There is an

induction-hardening machine. There is a coil of diameter 3 mm more than the sizeof the king pin diameter. A total of 8 pieces can be put in the holder on the

machine, which is of circular shape. The holder rotates anti-clockwise. The pieces

come under the heating coil one by one & the coil starts moving down. When the

coil reaches the bottom of the piece the heating process starts. The coil then

starts moving upwards to the top of the piece consequently heating the pieces.

After heating, water falls on the piece immediately thereby hardening it. The

temperature maintained is 950- 1000. The total heating time is 8 seconds. Then

to refine the grain structure the pieces are annealed. The case depth is kept 2

mm. The hardness of the pin is 57-61 HRC.


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Spring PinMaterial- CK 45)

Raw grinding:This operation is done in order to remove a very small amount

of material from the work-piece. The machine is a centre-less grinder. In the first

cut the diameter made is 35.27 mm & in the second cut the diameter made is

35.23 mm.

Facing:The cut round bars are sent for facing operation. The machine is an SPM

lathe machine. Both the sides of the round bar are faced with the cutting tool.

The work is held in a collet & tool is advanced to make a cut. The length of thepiece is made 139 mm by the facing operation.

Chamfering: The next operation is chamfering. The chamfer is provided at

both the ends of the work-piece. The machine is hydraulically operated lathe

machine. The chamfer size is 2.515.

Stamping:The stamp of the logo G.S. International is marked on one end of

the work-piece. The machine is hydraulic press.

Drill & tap-hole:The next operation is drilling. The diameter of the drilled

hole is 14.50 mm & the length of this hole is 21 mm. the machine is semi-

automatic. After the drilling of hole the tapping operation is performed. The size

of the internal thread is 161.5 P.


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Hub Bolt Head type)Material- EN 19/SAE 4140)

Cold forging:The cut & straightened pieces are sent to cold forging section.

Here the pieces are reduced in diameter from one side. Also the head of the bolt

is formed. The stamp is also marked on the head side. The machine used for

reducing is the power press. The machine used for head formation is cold forging

machine, also called header machine.

Head turning:The next operation is head turning. This is done in the hub bolt

machining section. The machine used is SPM lathe machine. The diameter of the

head is made 29.00 mm.

Step turning:The next operation is step turning. Different steps or diameters

are made in this operation. The thickness of the head is made

8 mm, the smaller diameter is made 21.05 mm. The larger diameter is 22.45 mm.

The total length of the piece is 75 mm. the chamfer of 230 is also provided at

the smaller end pf the work- piece. The length of the smaller end is 51 mm.

Grinding:The smaller end is ground to make the diameter 20.90-20.95 mm.

The machine is an SPM centre-less grinder. The chamfering of 230 is provided

on the smaller end.


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Head milling: The head of the hub bolt is made flat on one to avoid its

slipping during use. The machine used is a milling machine. At one time eight

pieces can be mounted on the jig. The flattened end is 13.70 mm away from thecentre line.

Knurling: It is provided on the larger diameter side. This is done leaving a 2

mm distance from the head of the bolt. The number of flutes is 30. The length

over which knurling is provided is 21 mm.

Threading:The next operation is threading. It is provided on the smaller end.

The machine is hydraulic thread rolling machine, which is also called profile

making machine. The threading is done as a forming operation. The rollers are

made of high carbon steel. The size of the thread is 22 1.5 mm.

Hardening & Annealing:Then all the pieces are hardened. The pieces are

put in the furnace containing a salt made by Lopan Industries, which helps in

heating the pieces to a temperature of 850- 860 C. Then the pieces are put in

quenching oil for hardening. Due to various operations the material of the work-

piece is unevenly stressed. To remove these stresses & to refine the grain

structure the pieces are again heated to a temperature of 400 C for about 30

minutes. The final hardness of pieces is 55-61 HRC.

Phosphating: Due to various operations the material of the work-piece is

unevenly stressed. To remove these stresses & to refine the grain structure the

pieces are heated to a temperature of 150 C. Then the pieces are sent for

phosphate process. These are put in a bath of caustic soda solution for degreasing

which is at 70 C. Thereafter these are washed with free flowing water. Scales are

removed by hydrochloric acid treatment. Then the pieces are treated with

phosphodine 20solution. The whole process takes 40 minutes. Sometimes the

threading on bolts becomes tight after this process. So rethreading is done after

phosphating.


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Nut Wheel Inner)Material- S48C/CK 45)

Hot forging:The cold drawn pieces are sent to the hot forging section. Here

the rods are heated to a high temperature & are forged by the dies in the screw-

press. The basic shape of the inner wheel nut is thus formed with hot forging.

Flash trimming:After forging a collar of circular shape is formed around the

nut head. This is called flash. This flash has to be removed. So the forged piecesare sent to another power- press where the pieces are held in a fixture. The press

is actuated & the circular flash is removed.

Facing:The trimmed pieces are then sent for machining. Here the first

operation is facing. The machine used is SPM lathe machine. The head is faced

first & then the other side of the nut is also faced. This is done in order to remove

any kind of irregularity on the both ends. The length of the work-piece is 56.35-

56.60 mm.

Turning:The next operation is cylindrical turning. The middle part of the work-

piece is turned on an SPM lathe machine. The job is held in a collet & operation is

started. The diameter in the middle part of the nut is made 27.10-26.97 mm.


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King PinMaterial- EN 353)

Facing:The first operation after bar drawing is facing. This operation is done in

order to make the length of the work-piece according to specifications. The

machine used is SPM lathe machine. The length of the piece is made 180.50 mm.

A chamfer is also provided at both the ends. The size of chamfer is 3.5 15.

Grinding: The next operation is grinding. In this operation the previously

turned diameter of the work-piece is ground on a centre-less grinder. The

diameter of the work-piece after grinding is 31.27 mm.

Grooving:The next operation is grooving. Two oil grooves are made both the

sides of the king pin. The machine used is SPM lathe machine. The groove is of 6

mm width. The depth of the groove is .6-.7 mm. The distance between the edge

of the groove & end of the pin is 20.5 mm.

Drilling & countersinking: The next operation is drilling holes on both

the ends of the pin. The machine used is horizontal drilling machine. The diameter

of the drilled hole is 6 mm. the length till which the hole is drilled is 25.26 mm.

Then the chamfer is provided on the end of the hole by countersinking operation.

The size of the chamfer is 1.545.


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Tapping: The next operation is vertical tapping. This is done to make internal

threads on the previously drilled hole of 6 mm. The job is held in a fixture on a

vertical drilling machine. Then the operation is started. The size of the thread is

6 1.5 P.

Slot cutting:The next operation is slot cutting. In this operation a slot is cut in

the middle portion of the pin. The distance between the centre of the slot & the

end of pin is 85.5 mm. The size of the slot is made with the milling cutter. The gap

between the milled end & the opposite end diameter is 29.90 mm. Thus the

depth of the slot is 1.35 mm.

Stamping:The next operation is stamping. In this operation letter T on the

work-piece to locate the top of the pin. On the other side of the pin oil hole ismade which is of 3 mm diameter. A process hole is also drilled on this end whose

diameter is 2 mm & it is 2 mm deep. In the end the stamp of manufacturers

name (G.S. International) is marked on the bottom end of the king pin.

Induction hardening:To make the pieces suitable for working under high

stresses they are case hardened by induction hardening process. There is an

induction-hardening machine. There is a coil of diameter 3 mm more than the size

of the king pin diameter. A total of 8 pieces can be put in the holder on themachine, which is of circular shape. The holder rotates anti-clockwise. The pieces

come under the heating coil one by one & the coil starts moving down. When the

coil reaches the bottom of the piece the heating process starts. The coil then

starts moving upwards to the top of the piece consequently heating the pieces.

After heating, water falls on the piece immediately thereby hardening it. The

temperature maintained is 950- 1000. The total heating time is 17 seconds.

Then to refine the grain structure the pieces are annealed. The case depth is kept

2 mm. The hardness of the pin is 57-63 HRC.

Grinder packing: The pieces are sent to the grinder packing section. Here

these pieces are ground to remove very small quantity of material. The final

diameter of the pieces is kept 30.800- 30.805 mm.


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Plant-11) PPC Department:Production, planning & control (PPC) department:

I. Procedure for production, planning & control.Purpose:To ensure timely delivery of products as per requirements.

Scope:This procedure is applicable to all the manufacturing activities in the

organization.

Responsibility: HOD, PPC is responsible for effective implementation of

this procedure. Stores head is responsible for ensuring delivery ofconsumables.

II. Procedure for control of jigs, dies & fixtures.Purpose: To ensure timely delivery of jigs, dies & fixtures used in the

factory.

Scope: It covers all the activities related to developments & control of

dies, jigs, fixtures & their proper storage & working.

Responsibility: HOD (PPC) & HOD (production) are responsible for

development & section heads are responsible for proper storage,

identification & maintenance of their respective sections.

III. Procedure for management of raw material, carton box & bought outparts stores.

Purpose: To ensure timely delivery of all the input required for production.

Scope: This procedure covers all the activities involved in estimation,

demand increase, storage & receipt of raw material.


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Responsibility: HOD (PPC) is responsible for implementing this procedure.

Following sections are covered under this procedure:

1. Raw material store2.

Consumable material store(a)Tools store

(b)Oil & chemicals store(c)Foundry store

3. Carton box store2) Engineering Department: The function of engineering department

is mainly related to the designing of items. It consists of computers

provided with CAD facility. The software used are Auto CAD 2005 & Pro-E

(wildfire).

3)Work Department:a) Spring pin section:This section deals with manufacture of spring

pins. The various types of machines used are:

S. No. Name of Machine

1. Facing machine (SPM)

2. Horizontal drilling machine

3. Vertical drilling machine (double spindle)

4. Horizontal milling machine (double spindle)

5. Vertical drilling machine (single spindle)

6. Horizontal milling machine (single spindle)

7. Tapping machine (horizontal)

8. Tapping machine (vertical)9. Grooving machine (SPM)

10. Pneumatic press


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b) King pin section: This section deals with the manufacture ofkingpins. The machines in this section are:

c) Grinder Section: This section deals with the grinding of variouscomponents like spring pins & kingpins etc. The machines in this section

are:

d) Nut Section: There are two sections in nut section. Both of themdeal with manufacture of machined & hot forged nuts. The machines

used are:


1. SPM lathe2. Drilling machine (double spindle)

3. Drilling machine (single spindle)

4. Horizontal milling machine

5. Hydraulic press


1. Centre-less grinder

2. Cylindrical grinder

3. Internal grinding machine

4. Drilling machine

5. Tool grinding machine

6. Magnaflux crack detector


1. SPM lathe machine

2. Vertical tapping machine3. Vertical drilling machine

4. Hydraulic press

5. Air compressor

6. Pedestal grinder

7. SPM press (for washer fitting)


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e) Maintenance section:As the name reveals, this section deals withthe maintenance of machines. It plays an important role in smooth

running of the works department. The machines used here include:

f) U-bolt section:This section deals with the manufacture of U-bolts.It consists of following machines:

g) Shackle bolt section: This section deals with the manufacture ofshackle bolts, spindle dampers & pin front shock absorber. The

machines used are:


1. Facing machine

2. Turning machine

3. Milling machine


1. Lathe machine

2. Radial drilling machine

3. Vertical drilling machine


5. Pedestal grinder

6. Shaping machine

7. Slotting machine

8. Milling machine


1. SPM facing

2. SPM turning

3. Hydraulic press

4. Profile thread machine

5. Hot bending machine

6. Cold bending machine

7. Air compressor

8. Baking furnace (for paint)


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4. Hand stamping machine

5. Tapping machine

6. Threading machine


8. Vertical drilling machine9. Horizontal drilling machine

10. Copy turning machine

h) Bar drawing section: The raw material comes in this section in form oflong bars & coils of different cross sections. Here it is pulled through dies

of different required diameters. The section consists of these machines:


1. Drawing machine

2. Power press

3. Automatic cutting machine

4. Bar straightening machine

5. Facing machine

6. SPM turning machine

i) Acid pickling section: This section is involved in the pickling of the rawmaterial rods. It consists of following equipment:

S. No. Name of Equipment

1. Pickling tank

2. Turning machine

j) Induction hardening section: In this section case hardening of differentproducts is done. These include spring pin, king pin, shackle bolt etc. The

machines used are:


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S. No. Name of machine

1. Induction hardening machine

2. Rockwell hardness tester

k) Tool room: There are two tool rooms in this section, which arecomplimentary to each other. These play very vital role in the company.

New machines, jigs, fixtures are manufactured in this section as per the

requirement. The machines in this section include:


1. Lathe machine

2. Horizontal milling machine3. Universal milling machine


5. Surface grinder

6. Pedestal grinder

7. Slotting machine

8. Shaping machine

9. Tool & cutter grinder

10. Planning machine

11. Thread grinder

l) Zinc plating section: This section comes into play when the product is atits final stage. The products reach here after all the machining

operations done on them. Here they are coated with zinc, which gives

them a sparkling look & finish. The products, which are zinc plated

include- shackle bolt, hub bolt, nuts, studs etc. The zinc plating bath

consists of:

ZnO 20-25 gm/l

NaOH 40-50 gm/l

NaCN 50-60 gm/l

NaCN/Zn ratio 2.5


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m)Cold forging section: In this section, the material is cold forged by theuse of header machines. The products manufactured here include- axle

stud, hub bolt & centre bolt. The machines used are:


1. Header machine

2. Power press

3. SPM lathe

4. Pedestal grinder

5. Lathe machine

6. Profile threading machine

7. SPM chamfering machine

8. Air compressor

n) O.E. packing section: This section is called original equipment packingsection. Here the products, which are to be used as original ones, are

packed. These include studs, shackle bolts, U-bolts etc.


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Plant- 21. Hot forging section: In this section material is hot forged. By hot

forging we mean working on the metal at a temperature above its re-

crystallization temperature, but below the melting point. This section hasgot the following machines:

2.

3. Heat treatment section:Heat treatment of various items is done inthis section. Heat treatment is an important operation in the manufacturing

process of the components. It may be defined as an operation of heating &

cooling of metals in the solid state to induce certain desired characteristics

by changing the size & shape of grains of which these are composed. Heat

treatment serves following purposes:

(a)To change or refine the grain size.(b)To relieve the stresses induced in the material during hot or cold working.(c)To increase the resistance to wear, heat & corrosion.(d)To produce a hard surface on a ductile interior.4. Civil maintenance section: This section deals with the regular

maintenance of the equipment to keep it operating smoothly. The

machines used include the following:


1. Friction screw press

2. Power press

3. SPM lathe

4. Induction heater

5. Heating furnace


1. Power hacksaw

2. Arc welding machine

3. Gas welding equipment

4. Sheet metal shearing machine

5. Lathe machine


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5.Auto-black section:This section is involved in the surface treatment ofthe products. The parts manufactured are degreased by treatment with

caustic soda solution. Then they are washed with water & thereafter

activated by treatment with Actisol. The solution of Actisol activates the

auto-black process. Then the pieces are dipped in oil LT-222, which gives

them surface treatment of auto black. The parts, which are auto-blacked

include- centre bolt, U-bolt, axle stud, nuts etc.


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Plant- 31. Hub bolt section:This section deals with the manufacture of hub

bolt. The machines used in this section include:

2. Centre bolt section:This section deals with the manufacturing ofcentre bolts. This section consists of the following machines:

3. Non-ferrous bush section: This section deals with the casting of non-ferrous bush. This section consists of the following equipment:


1. SPM turning machine

2. Vertical drilling machine

3. Vertical tapping machine

4. Hydraulic tapping machine


6. Profile threading machine7. SPM milling machine

8. SPM facing

9. Hydraulic stamping machine

10. CNC turning machine

S. No. Name of Machine1. SPM lathe

2. SPM turning

3. Thread cutting machine

4. Pedestal grinder


1. Furnace

2. Power press

3. Core making equipment


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4. Pattern Shop: Patterns of different shapes & sizes according torequirement are made in this shop. First of all a master pattern is made

by taking into account various casting allowances e.g. shrinkage

allowance, machining allowance, grinding allowance etc.

This shop consists of the following machines:

The procedure of making a pattern is as follows:

1.

As & when drawing of a component is received from the engineeringdepartment for development of pattern, the drawing is thoroughly

studied by pattern shop in-charge.

2. A layout of component is made as per drawing.3. Master pattern (wooden) with allowances e.g. shrinkage allowance,

machining allowance, grinding allowance etc. is made from layout.

4. The master pattern after machining is used for casting finish pattern.5. Finish patterns are then machined to dimensions & inspected;

mounted on the pattern plate with appropriate gating, part no. &

company stamp engraved on finish pattern.6. The pattern plate is then sent to foundry for sample casting. Samples

are sent to QAD for dimensional & metallurgical testing.

7. If the sample qualifies the inspection then it is taken in production asper PPC.

8. The pattern is worked on if any discrepancy is pointed out by QAD.The same cycle of processing is repeated till it gets all right.

9. All discrepancies are noted down in corrective action form.


1. Lathe machine

2. Drilling machine

3. Milling machine


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2. Machine Shop:

This section deals with the machining of cast components. The various cast

components machined in this section are:

S. No. Component Name Vehicle

1. Front spring bracket rear TATA

2. Front spring shackle -do-

3. Rear spring bracket front -do-

4. Rear spring bracket rear -do-

5. Rear spring shackle -do-

6. Helper bracket -do-

7. Centre bearing bracket -do-

8. Base plate (small hole) -do-

9. U-bolt bracket front -do-

10. U-bolt bracket rear -do-

11. Front spring bracket front -do-

12. Centre bearing bracket cut type -do-

13. Hub cup front -do-

14. Threaded ring -do-

15. Engine foundation bracket -do-

16. Hanger bracket -do-

17. Screw adjuster -do-

18. Hinge front (left hand) -do-

19. Hinge front (right hand) TATA20. Bracket alternator -do-

21. Mounting cup -do-

22. Slide support -do-

23. Rear spring rear hanger (left) Swaraj Mazda

24. Rear spring rear hanger (right) -do-

25. Rear spring rear shackle -do-

26. Centre bearing bracket -do-

27. Bracket TATA-407

28. Front U-bolt bracket -do-

29. Bracket engine front (right) -do-30. Gear box housing -do-

31. Threaded ring (Tail pinion) -do-

32. Guide plate -do-

33. Spring bracket front TATA-2416

34. Spring bracket rear -do-

35. ssy. support bracket TATA-1210


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3. Machine shop (Non-ferrous bush):

This section deals with the machining of the non-ferrous bush. The various

operations performed in the manufacture of this bush are as follows:

S. No. Process Machine

1. Rough bore SPM boring

2. Outer dia. turning SPM turning

3. Facing SPM facing

4. Final boring SPM boring

5. Final grinding Grinding machine


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Foundry ShopThe foundry shop is an important part of G.S. Automotives Ltd. It is engaged in

casting of various automotive parts. The processes involved in casting are

discussed in detail below:

Moulding sand:

The principal material used in the foundry shop for molding is the sand. The main

ingredients of the molding sand are:

(a)Silica(b)Clay(c)Moisture(d)Limestone(e)Magnesia, potash etc.

Mainly green sand is used for molding purpose. It is a mixture of sand with 18-

30% clay, water percentage according to the ambient conditions. If the humidity

in environment is high then moisture content is kept 3.0-3.5%. If humidity is less

then moisture content is kept 3.4-3.8%. The clay & water furnish the bond for

green sand. It is fine, soft, light & porous.

Cast dust is added in the molding sand, whish gives it black appearance. The

additional coal dust tends to make sand more porous & helps to cool the mouldafter it has been prepared.

Moulding Process:

Machine moulding is the common method of moulding employed here. The

dimensions of machine cast castings are more accurate than those of hand made

one & it is possible to produce castings of close tolerances. Consequently the

weight of the casting reduces & material is saved.

A molding machine packs the sand & draws the pattern. Jolt-squeeze machines

are used for moulding. A jolting section is used to consolidate the sand on the

face of the pattern & is followed by squeezing action to impart the desired density


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throughout the mass of sand. The jolt squeeze machine is so constructed that

both squeeze & jolt actions can beobtained.

Core Making:

Cores are separate shapes of sand that are generally required to form the hollow

interior of the casting or a hole through the casting.

Core sands:

The ingredients of core sands are sands & binders. Core sands are usually silica.

Sands that contain more than 5 % clay cannot be used for cores. Core sand has no

natural bond. Hence some other materials are added to sand before & after the

cores are baked. The binder used in the foundry is molasses. Core making consistsof following processes:

(a)Core molding: Cores are made manually. Normally a core box isrequired for the preparation of core. Green sand cores are made by

ramming the sand mixture into the boxes, the interiors of which have the

desired shapes & dimensions.

(b)Core baking:After the cores are prepared & placed on to metal platesor core carriers, they are baked to remove moisture & develop the strength

of binder in the core ovens at a temperature of 150- 400 C. Batten typeovens are used for this purpose.

(c)Core finishing:After the baking operation the cores are smoothened.All rough edges, unwanted fins are removed by filing. After this, the core

dressing is done via applying a thin layer of refractory coating to the

surface.

Melting:

For melting, electric induction furnaces have been employed in the shop. Theprinciple of induction is based on that of a transformer. It has a primary coil about

which an alternating current is set up. With the magnetic lines of forces of

definite density, when an alternating current is passed through the coil, the

magnetic field induces alternating current in the secondary circuit. This circuit


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comprises of a crucible containing a melt charge. The current melts the metal.

Thus induction furnace operates on an alternating current. one after the other.

Pouring:

Pouring equipment is used to carry the molten metal from the furnace to the

moulding box. The most commonly used ladle is shank ladle. The bigger ladle used

in the foundry shop can hold a weight of up to 1 ton of molten metal. The

temperature of the molten metal is 1387 C. From this ladle the molten metal is

poured into small shank ladles. The shank ladle resembles a bucket with long

removable handle called shank. The shank ladle is to be carried by two men.

While pouring the metal into the ladles ferro-silicon copper is added to it as

inoculants.

Shake Out:

After the molten metal has been poured into the mould, it is allowed to cool &

solidify & when the casting has solidified; it is removed from mould box. This

operation is called shake out.

Fettling:

The operation of removing unwanted parts, cleaning & finishing the casting isknown as fettling. In the fettling first cores are removed from the casting. After

this the gates, risers & runners are removed. The cleaning of casting is done

manually & mechanically, both ways. In manual method wire brush & files are

used. In mechanical method shot blasting machine is used.

Material:

The material used for casting is SG- Iron which consists of:

Carbon - 3-4% Sand - .02% (max.)

Manganese - 2-3% Phosphorous - .059%

Silicon - .5-.6% Magnesium - .036% (min.)


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Metallurgical AspectsMaterial Composition for S48C

% C .48-.51% Si .15-.35

% Mn .80-.90

% S .010-.030

% P .030 max.

% Cr .15-.20

Material Composition for EN 47

% C .45-.55

% Si .50 max.

% Mn .50-.80

% S .050 max.

% P .050 max.

% Cr .80-1.20

% V .15 max.

Material Composition for 6T/EN-8K

% C .35-.40

% Si .05-.35

% Mn .60-1.00

Material Composition for MS/EN-3

% C .25 max.

% Si .05-.35

% Mn 1.00 max.


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Material Composition for CK-45

Material Composition for EN-8D

% C .40-.45

% Mn .70-.90

% Si .05-.35

Material Composition for SAE 1541

% C .36-.44

% Mn 1.35-1.65

% Si .15-.35

% S .05 max.

% P .03 max.

Material Composition for EN-18

% C .35-.45

% Mn .60-.95

% Si .10-.35

% S .05 max.

% P .05 max.

% Cr .85-1.15

Material Composition for 41 Cr 4

% C .38-.44

% Mn .50-.80

% C .42-.50

% Mn .50-.80

% Si .15-.35


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Material Composition for EN-353

% C .20 max.

% Mn .50-1.00

% Si .35 max.% S .05 max.

% P .05 max.

% Cr .75-1.25

% Mo .08-.15

% Ni 1.00-1.50

Brinell Hardness No. (BHN) for Materials

Material BHN

Mild steel 160

CK-45 180-220

EN-353 170-220

SAE 1541 215-260

SAE 4140 270-320

41 Cr 4 215-260


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CONCLUSIONAs my internship comes to an end I realize

the importance of internship and practical

applications. These days of training gave me

a chance to get exposed to the industry

culture and environment.

I have learnt a lot about automobile

components, their effective role in vehicles,

their operations and different problem

solving techniques. I have also got familiar

to foundry and heat treatment operations.

These months at G. S. AUTO INTERNATIONALwere a great learning experience all the way.

I once again thank the whole G. S. group and

my worthy teachers.

LAKSH JAIN

Documents

6 Weeks Training Report