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TRAINING REPORT

EMKAY AUTOMOBILES

SAMPREET SINGH GORAYA400807025

Department of Mechanical EngineeringTHAPAR UNIVERSITY, PATIALA

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Emkay Group was founded in the year 1978 with the vision of bringing a new

dimension to the two business sectors; automotive, & distillery. Headquartered in New

Delhi. In Ludhiana (2 units), Nashik (2 units), Haridwar, Pant Nagar, Indore, Gurgaon

and Latur (Sakole).

Springs

Deep drawn & precision pressed components

Deep drawn and heavily pressed components

Tubular parts

Forged components

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MY ROLE

trained in the research and development of emkay automobiles. My work was to construct and understand the sheet metal components. My work was to model the tools in 3D- software.

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DESIGN APPROACH/CONSTRAINTS

CONCEPT DEVELOPMENTConcept development is the basic force behind the particular design and development. It is based on various factors-

Customer requirements- These are specifications demanded by the customer which are most necessary for us.

Technology requirements- Sometimes there are technology constraints in the way of designing of a component , so we have to go some other way by making some changes in the design process.

Economic considerations- Economic considerations are related to cost constraints .we have to complete a project under some allotted resources.

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ADVANCED PRODUCT QUALITY PLANNING

INITIATIATION

PHASE IPLAN AND

DEFINE

PHASE IIDESIGN INPUT

DESIGN OUTPUT, VERIFICATION

& RELEASE

PHASE IIIPROCESS DESIGN

& DEVELOPMENT

PHASE IVINSPECTION

PHASE VFEEDBACK

ASSESSMENT &

CORRECTIVE ACTION

DIFFERENT PHASES IN THE

DEVELOPMENT OF A COMPONENT

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PROJECTS

ASHOK LEYLAND CAB MTG BRKT

18 PARTS OF D09 FRAME

OUTER TUBE SUB ASSEMBLY

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Parts of d091-Rear brkt

2-Fixing plate relay

3-lower brkt fix radiator

4-enginr fix external brkt LH-RH

5-Footrest brkt LH-RH

6-Middle brkt RH-LH

7-Front engine brkt

RH-LH

8-Brkt head pipe RH-LH

9-Support brkt battery RH-LH

10-Radiaator mtg brkt

11-upper pad cover

12-control unit

Parts of assembly of cab mtg bracket

1- Cup2- Cab mtg bracket

Parts of outer tube assembly

1-Spring seat

2-Knuckle brkt

3-Outer tube

4-Lower cup

5-stabilizer brkt

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2D & 3D MODELING OF PARTS AND REQUIRED SOFTWARE

Modeling give us an idea and outlook of the features of componentsDesigner forms an opinion about the set of operation that are required for the development of the part Formation of different toolsSOFTWARES- Solid works, NX6, Autocad, Dwg editor

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PROTOTYPING PROTOTYPING here refers to the

manufacturing of parts with the help

of manufacturing machines like

Computer numerical control, direct

numerical control, wire cut etc.

Drilling machines for the holes from

2mm to 50 mm dia.

VMC and CNC Wire cut for profile

cutting

Grinding machines

75 Ton press

Milling and turning machine

Spring seat

Blanks with wire cut

Bending by bending tool

Trimming by cnc

Forming tool

Holes by cnc

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STRUCTURE AND TYPES OF TOOLS

TOP AND BOTTOM PLATE

DIE PLATE PUNCH GUIDE PLATE GUIDE BACK PLATE STRIPPER PLATE

SIMPLE TOOL COMPOUND TOOL PROGRESSIVE

TOOL

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EXAMPLE OF PROGRESSIVE TOOLSTRIP LAYOUT

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BLANKING

The success of other operation is

totally depends on the accuracy of the

size of blank. Blank size is

determined by a software called

BLANK WORKS but that does not

give the exact size of blank so HIT

and TRAIL method is used to get

down to the actual size.

Blanking of do9 parts

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Blank of spring seat

Blanking tool

Pillar set guide plate

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2D DRAWING FOR WIRE CUT

Wire cut is machine which can only read 2d data. The problem is overlapping of

multiple lines due to such geometry of component. Overlapping force the

designer to remake the whole geometry again.

Blank of brkt. battery

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FINALISATION OF LAYOUT W. R. T RAW MATERIAL YIELD

This ensures the optimized use of material. As the standard length of sheet is 1250mm so we have to convert that sheet into max. no. of blanks. As this will reduce the cost of manufacturing.SRTIP LAYOUT AND BLANKS OF DIFFERENT PARTS

STRIP LAYOUT AND BLANKS OF DIFFERENT PARTS

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Strip layout of spring seat

2d drawing of spring seat

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BENDINGBENDING is performed to get desired

curves on the component and also

making out of plane geometries. .

Bending deform the component

making it weaker at some sections and

also decreasing the size of blank

1. Cracking due to drawing

2. Deformation of holes

3. Displacement of internal geometry

4. Wrinkling

3D model of spring seat for bending

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2d drawing of bending & trimming of Spring seat

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TRIMMING

2d drawing of spring seat trimming tool

Die plate

Guide plate

Punch block

Component

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BENDING & TRIMMING

FOR DIFFRENTIATING

TWO PARTS

TRIMMING TOOL OF BRKT BATTERY

Punch back plate

Trimming punch block

Bending punch block

component

Guide plate

Bracket battery

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PUNCHING

3d view of punching tool

Blank of brkt main frame

punch to be created

we all know use to make holes or any kind of shapes through the body. Punching demands high level of accuracies because any deviation in hole can lead to the failure of component and leads to scrap

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Blank movement

pillar set

punch 1

punch 2 top plate

die plate

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punching tool of rear brkt main frame

REAR BKT(MAIN FRAME)

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FORMING

The feature formed is abruptly out from the plane of component.

2d drawing of forming tool of spring seat

die

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WELDING FIXTURES

- A fixture is a work-holding or

support device used in the

manufacturing industry. What makes

a fixture unique is that each one is

built to fit a particular part or shape.

The main purpose of a fixture is to

locate and in some cases hold a

workpiece during either a welding

operation

welding fixtures of i10 outer tube assembly

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RELATION GAUGES

Rec. gauges are tools which are used for the fast inspection of component. this make sure that defected goods should not passes to next stage

Click icon to add picture

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Materials

MS(C- .90-1.60)

EN-31(C-.90-1.20, Mn-.30-.75, Si- .10-.35, S-.040, P- .040, Cr- 1.00-1.60)

HCHCR(C=1.55%, Mn=0.3%, Si=0.3%, Cr=12%, Mo=1%)

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HEAT TREATMENT & ITS EFFECTS

SOFT ANNEALING (850-650)C STRESS-RELIEVING (650-500)C HARDENING Preheating temperature:

1110–1290°F (650–750°C). Austenitizing temperature: 1810–1920°F (990–

1050°C) but usually 1830–1905°F (1000–1040°C).

QUENCHING MEDIA Oil ,Vacuum (high speed gas, Forced air/gas, Martempering bath

-EFFECTS ON length , breadth, height

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THANK YOU