KIRAN UDYOG PVT. LTD.MANESAR(GURGAON)HARYANA

A TRAINING REPORT

SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE AWARD OFTHE DEGREE OF

BACHELOR OF TECHNOLOGY(Mechanical Engineering)

SUBMITTED TOLOVELY PROFESSIONAL UNIVERSITY, JALANDHAR

SUBMITTED BYName of Student Registration No.

Ashish 11106216

08-06-14 to 20-07-14

Lovely Professional University, JalandharPUNJAB

KIRAN UDYOG PVT. LTD.MANESAR(GURGAON)HARYANA

A TRAINING REPORT

SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE AWARD OFTHE DEGREE OF

BACHELOR OF TECHNOLOGY(Mechanical Engineering)

SUBMITTED TOLOVELY PROFESSIONAL UNIVERSITY, JALANDHAR

SUBMITTED BYName of Student Registration No.

Ashish 11106216

08-06-14 to 20-07-14

Lovely Professional University, JalandharPUNJAB

CANDIDATE DECLARATIONI hereby certify that the work, which is being presented in the project entitled The manufacturing of stator and rotor by various manufacturing processes in partial fulfilment of the requirement for the award of the degree of bachelor of technology submitted to the institution is an authentic record of my own work carried out during the period June-2014 to july-2014 under the supervision of supervisor Rajesh sir.

Date: - Signature of the Candidate:-

ii.OBJECTIVE OF TRAINING

The main purpose of this project is:- To manufacture rack and pinion gears by various manufacturing processes such as: Die casting Drilling Buffing Broaching

To design motor frame with the help of auto-cad software and unigraphics software To manufacture cylinder block by various method To manufacture hub and sprocket

iii.

ACKNOWLEDGEMENTIt was not easy to prepare this project report without the assistance and encouragement of other people.

On the very outset of this report, I would like to extend my sincere and heartfelt obligation towards all the personages who have helped me in this endeavour. Without their active guidance, help, cooperation and encouragement, I would not have made headway in the project. First and foremost, I would like to express my sincere gratitude to my faculties.I also thank to Rajesh Sir who helped me a lot during training.I am grateful to Sharma sir for their valuable guidance and encouragement to me.

Thanking youAshish

(To be signed by the student)Reg. No.:-11106216

iv.LIST OF FIGURES

NAMEPAGE NO.Fig.1Melting Of Raw Material Machine 7Fig.2 Aluminium Melting Furnace 7Fig.3Bolt Wheel Pressing M/C 10Fig.4Bolt Wheel 11Fig.5 Trimming Machine 13Fig.6Fettling machine 14Fig.7Forging Machine 14Fig.8 SPM 16Fig.9 Drilling 17Fig.10Pressure Die Casting Machine 17Fig.11Buffing Machine 19Fig.12Broaching Machine 19Fig.13Products 20-30

v.

PREFACEPractical knowledge means the visualization of the knowledge, which we read in our books. For this, we perform experiments and get observations. Practical knowledge is very important in every field. One must be familiar with the problems related to that field so that he may solve them and become a successful person.

After achieving the proper goal in life, an engineer has to enter in professional life. According to this life, he has to serve an industry, may be public or private sector or self own. For the efficient work in the field, he must be well aware of the practical knowledge as well as theoretical knowledge.

To be a good engineer, one must be aware of the industrial environment and must know about management, working in such a industry, labor problems etc., so that he can tackle them successfully.

Due to all the above reasons and to bridge the gap between theory and practical, our engineering curriculum provides a practical training of 45 days. During this period, a student works in the industry and gets all type of experience and knowledge about the working and maintenance of various types of machinery.I have undergone my 45 days training at KIRAN UDYOG PVT LTD. This report is based on the knowledge, which I acquired during my 45 days training period at the plant.

vi.

TABLE OF CONTENTS

TitlePage no.

DECLARATION.......................................................................................................iiOBJECTIVE..............................................................................................................iiiACKNOWLEDGEMENT.........................................................................................ivLIST OF FIGURE.....................................................................................................vPREFACE.................................................................................................................vi

INTRODUCTION....................................................................................................1COMPANY PROFILE..............................................................................................2COMPANY OVERVIEW.........................................................................................3COMPANY INFRASTRUCTURE...........................................................................5PROCESS..................................................................................................................6PRODUCTS..............................................................................................................21PROBLEMS AND SOLUTIONS............................................................................29IMPLEMENTATION & RESULT...........................................................................30REFERENCES.........................................................................................................31

INTRODUCTION

Kapsons Industries Ltd. founded in 1982 at Jalandhar by an entrepreneur duo, S. K. Sehgal and N. K. Sehgal.Rapid industrialisation in India from 1980 onward propelled the growth in motor manufacturing. S. K. Sehgal, a techno wizard, correctly sensed the need for laminations required by the motor industry and the entrepreneur in him anticipated the huge potential. At the same time, he was fully aware that only quality products could establish Kapsons reliably and make it grow.And the wheels were set in motion. Modern machines were installed one-by-one. Skilled technicians got down to work. Product lines were expanded. Manufacturing capacity increased manifold year-after-year. Global technology was assimilated and implemented. New quality assurance methods and testing procedures were adopted.Today, our range also comprises rotor, stators, aluminium die-castings and enamelled copper wire and strips for various applications. All manufactured with the same care for highest possible quality and precision.

COMPANY PROFILEKapsons Industries Limited is an IS/ISO 9001:2000 and ISO/TS 16949:2002 (Die Casting Division) certified company, with a driving forceto the crest in the sector of electrical stamping & Rotor-die castings. A prosperous empire since 1981, Kapsons is an outstanding pioneer in manufacturing & supplying die-cast automobile & electrical components, all over India.

Diversifying with the pressure diecasting plant in 1997, Kapsons has grown all the taller with competitive edge in the domestic as well as in the internationalmarket. A firm with a strong endurance, Kapsons Industries operates from Jalandhar with two eco friendly gargantum units. Each ofthe unit is fully equipped with the upgraded technology & sufficient manpower to carry out the detailed & precision production.

Progressing to the foreseen pinnacle, Kapsons merchandise is put to use by the big manufacturers of large Industrial motors, pumps, windmills, traction motors, generators, alternators, fans & transformers. Apart from this, at the pressure die cast plant, components of electric motor bodies, motor terminal boxes, automobiles, table fans, ceiling fan covers are also die casted. Kapsons Industries is driven by the forceful magic ethos of quality consciousness, customer satisfaction & assured trust. This is the reason why the company outstands as a well known recipient in the province offering the best quality products at competitive rates. Hence with holding the distinction of touching various lives through different electrical & automobile range, Kapsons has a presence felt everyday & everywhere.

2COMPANY OVERVIEW

Introduction:Kapsons is accredited with ISO 9001:2000 and ISO 14000 certification and our Aluminium Pressure Die Cast division is accredited with TS 16949:2002 certification.Our range also comprises rotor, stators, aluminium die-castings and enamelled copper wire and strips for various application.Kapsons Industries Limited was registered on 13 February, 1987. Kapsons Industries Limited's Corporate Identification Number (CIN) is U31909PB1987PLC007303, Registration Number is 007303.Their registered address on file is G T Road Suranussi Jalandhar, Punjab - 144027, Punjab, India. Kapsons Industries Limited currently have 6 Active Directors / Partners: Nishant Sehgal, Narinder Kumar Sehgal, Surinder Kumar Sehgal, Prashant Sehgal, Anita Sehgal, Sunita Sikka, and there are no other Active Directors / Partners in the company except these 6 officials.

Salient Features:We have production capacity of 20,000 MT/year. A wide range of laminations, castings, rotors and stators are manufactured and supplied to a number of reputed manufacturers of motors, pumps, alternators, generators, turbines, windmills, compressors, automobiles, etc.The company has been operating from the premises of nearly 25000 sq. m. at Jalandhar, near Delhi where our corporate office and three manufacturing units are situated. A new plant of 5, 574 sq. m. area at Pune, near Mumbai is about to start operations.We have been achieving growth of nearly 35-40 % in recent years with a major thrust on exports. During 2007-2008, we crossed the annual turnover of around 62 million USD.We have consolidated our position in the Indian markets through well equipped manufacturing set up, efficient service and a wide range of high-quality products and acquired the top position in the Indian market for laminations.

Vision:

Cost competitive global company. Costumer delight. Enhancing stake holders value.Mission:To install and maintain efficient quality management system as per International Standards, Continuously improve quality through up gradation of products, process, design and quality system. These objects are achieved through dedicated team workand continuous training of each member of Kiran family.Quality PolicyAn IS/ISO 9001:2000 and TS16949:2000 & ISO 14001 (Die Casting Division) certified company. At Kiran every individual is committed to ensure complete customer satisfaction by supplying best quality products at competitive.

4.COMPANY INFRASTRUCTURE

COVERED AREAUNIT II 6740 Sq. meterTOOL ROOM CAPABILITIESWe are having, in addition to our production activities, a well-established Tool Room Infrastructure including Heat Treatment Facility. We are making Stampings and Aluminium components Dies upto the accuracy of 0.02mm in-house. The manufacturing cost of Dies & Tools because of in-house tool room is very economical and development is also completed at a very fast pace. In addition to the in-house facilities available with us, we have also to CAD/CAM & CMM facilities and all complex tools and electrodes are being manufactured on VMC/Turning Centre using the above facilities.PRESSURE DIE CAST ACTIVITIESAt present we are die casting a wide range of automobile components for leading manufacturers in India. These include Motor Frame, Rack Housing ,Pinion Housing, Hub, Sprocket, Cylinder Block, Crank Case , Automobile Components .

5.

PROCESS

MELTING FURNACE Melting Of Raw MaterialSquare regenerative aluminium melting furnace, adopting regenerative burner, can rapidly melt solid materials (e.g., aluminium ingot, deformative aluminium alloy flotsam) that can be charged by special charging tools (such as forklifts, special charging cart). After melting, liquid aluminium will be effective, full mixed so that it can be more uniform in temperature and composition. The furnace is mainly used for the melting of re-melting aluminium ingots, and deformative aluminium alloy flotsam. It also has the function of heating, refining & slagging-off, insulating and draining of liquid aluminium for casting. This series of furnace is mainly applied in the aluminium casting plant of aluminium profile and aluminium board. Technical ParametersFurnace typesquare; tilting

Control accuracy of molten aluminum temperature/5(After mixing & refining)

Maximum working temperature1150

FuelNatural gas, LPG, heavy oil, diesel

Temperature control methodPLC automatic control

Ways of molten aluminum drain offManually or tilting draining off

Burner modeRegenerative

Burner amount2-4pcs

Furnace pressureSlight positive pressure control

Energy consumption (kcal/T.Al)62*104Kcal/T.Al(For pure aluminum ingots, temperature of molten aluminum 720)

Testing standards of energy consumptionAccording to "JB T50168-1999 Aluminum Melting Fuel Furnace Energy Consumption Classification Standard"

6.

Fig.1 MELTING OF RAW MATERIAL

Fig.2 ALUMINIUM MELTING FURNACE

7.

BOLT WHEEL PRESSING

ABolt Wheel Pressingis a type ofmachine pressin which the ram is driven up and down by a screw. The screw shaft can be driven by a handle or a wheel. It works by using a coarsescrewto convert the rotation of the handle or drive-wheel into a small downward movement of greater force. The overhead handle usually incorporates balls as flyweights. The weights helps to maintain the momentum and thrust of the tool to make it easier to operate.The screw press was first invented and used by the Romans in the first century C.E. It was used primarily in wine and olive oil production. The screwpress was also used in Gutenberg's printing press in the mid-15th century.[1]A press is ametalworkingmachine toolused to shape or cut metal by deforming it with a die. It is frequently used to punch holes insheet metalin one operation, rather than by cutting the hole or drilling.If used as a punch, the tool itself consists of apunch and a matching die, into which it very closely fits. Both are usually precision machined and then hardened. The material is introduced between the punch and die, and the machine operated. The punch will cut through the material in one movement byshearingit. The punch and die may be of any desired shape, so odd shaped holes and cutouts may be created.If used as a forging tool the dies can be many different shapes varying from flat to various shapes that will mold the metal to the desired configuration.

9.

Fig.3 BOLT WHEEL PRESSING M/C

10

Fig.4 BOLT WHEEL

11. FORGING PROCESSForgingis amanufacturing processinvolving the shaping of metal using localized compressive forces. Forging is often classified according to the temperature at which it is performed: "cold", "warm", or "hot" forging. Forged parts can range in weight from less than a kilogram to 580 metric tons.Forged parts usually require further processing to achieve a finished part. Today, forging is a major world-wide industry that has significantly contributed to the development of the manufacturing cycles.

TRIMMING PROCESSTrimming is a manufacturing process that is used as a finishing operation for forged parts, in order to remove flash. Flash is a characteristic common in most metal forgings. For that reason trimming, while not technically a forging or even a forming operation in general, is discussed in this section. Trimming basically presses a part through a cutting die that runs the periphery of the work. The cutting die are precisely designed to remove the flash from a particular part. Most often it is desirable to perform this operation while the work is still hot for maximum efficiency, therefore it is usually incorporated into the larger production process. For more delicate forgings, flash can be ground or cut off using different methods. For certain metal forgings, this is an extremely quick and easy method for the removal of the extra material.

FETTLING PROCESS Fettling is a word that is used in several different senses. Most of the uses of the word relate to cleaning, polishing, and maintaining systems so that they will be functional or will remain functional. The word itself is derived from a root word referring to condition, as seen in the phrase in fine fettle, which is meant to convey that the person or object being described is in good condition, shape, or health.In the railroad industry, this term is used to describe routine maintenance performed on tracks. It includes confirming that the rails are aligned properly, checking drainage systems, replacing ties if necessary, and conducting other tasks which will keep the tracks in good condition. It is important for this maintenance to be performed on a regular basis since a wide variety of situations can cause damage to the tracks, and this can result in damage to trains passing over the tracks, most spectacularly in the case of a derailment.Track fettling is usually accomplished with the assistance of a small handcar or truck specially fitted to roll on the tracks, which allows track workers to carry tools and replacement parts as they traverse the track to inspect it. This is done in constant rotation to make sure that all of the track is seen at some point or another.

12.

Fig.5 TRIMMING

13.

Fig.6 FETTLING

Fig.7 FORGING14. DRILLING PROCESS Drillingis acuttingprocess that uses adrill bitto cut or enlarge a hole of circularcross-sectionin solid materials. The drill bit is a rotary cutting tool, often multipoint. The bit ispressedagainst the workpiece and rotated at rates from hundreds to thousands ofrevolutions per minute. This forces the cutting edge against the workpiece, cutting offchips (swarf)from the hole as it is drilled.Exceptionally, specially-shaped bits can cut holes of non-circular cross-section; asquarecross-section is possibleDrilled holes are characterized by their sharp edge on the entrance side and the presence ofburrson the exit side (unless they have been removed). Also, the inside of the hole usually has helical feed marks.Drilling may affect the mechanical properties of the workpiece by creating lowresidual stressesaround the hole opening and a very thin layer of highlystressedand disturbed material on the newly formed surface. This causes the workpiece to become more susceptible tocorrosionat the stressed surface. A finish operation may be done to avoid the corrosion. Zinc plating or any other standard finish operation of 14 to 20m can be done which helps to avoid any sort of corrosion.Forfluteddrill bits, any chips are removed via the flutes. Chips may be long spirals or small flakes, depending on the material, and process parameters.[3]The type of chips formed can be an indicator of themachinabilityof the material, with long gummy chips reducing machinability.When possible drilled holes should be located perpendicular to the workpiece surface. This minimizes the drill bit's tendency to "walk", that is, to bedeflected, which causes the hole to be misplaced. The higher the length-to-diameter ratio of the drill bit, the higher the tendency to walk. The tendency to walk is also preempted in various other ways.

Fig.8 SPECIAL PURPOSE MACHINE

16.

Fig.9 DRILLING PROCESS

17 DIE CASTING

Die castingis ametal castingprocess that is characterized by forcingmolten metalunder high pressure into amold cavity. The mold cavity is created using two hardenedtool steeldies which have been machined into shape and work similarly to aninjection moldduring the process.Die castings are made from non-ferrous metal such as Aluminium in the above process.Die castings are characterized by a very goodsurface finish(by casting standards) and dimensional consistency.Two variants are pore-free die casting, which is used to eliminategas porositydefects; and direct injection die casting, which is used with zinc castings to reduce scrap and increaseyield. PROCESSThere are four steps in die-casting process:i. Die preparationThe dies are prepared by spraying the mold cavity withlubricant. The lubricant both helps control the temperature of the die and it also assists in the removal of the casting.ii. FillingThe dies are then closed and molten metal is injected into the dies under high pressure; between 10 and 175 megapascals (1,500 and 25,400psi). Once the mold cavity is filled, the pressure is maintained until the casting solidifies.iii. EjectionThe dies are then opened and the shot (shots are different from castings because there can be multiple cavities in a die, yielding multiple castings per shot) is ejected by the ejector pins.iv. ShakeoutFinally, the shakeout involves separating the scrap, which includes thegate,runners,spruesandflash, from the shot. This is often done using a special trim die in a power press or hydraulic press. Other methods of shaking out include sawing and grinding.

18. TYPES OF DIE CASTING MACHINES USED: PRESSURE DIE CASTING MACHINE

Fig.10 PRESSURE DIE CASTING MACHINE

BUFFINGDrilled holes are characterized by their sharp edge on the entrance side and the presence ofburrson the exit side (unless they have been removed). Also, the inside of the hole usually has helical feed marks.[3]Drilling may affect the mechanical properties of the workpiece by creating lowresidual stressesaround the hole opening and a very thin layer of highlystressedand disturbed material on the newly formed surface. This causes the workpiece to become more susceptible tocorrosionat the stressed surface. A finish operation may be done to avoid the corrosion. Zinc plating or any other standard finish operation of 14 to 20m can be done which helps to avoid any sort of corrosion.Forfluteddrill bits, any chips are removed via the flutes. Chips may be long spirals or small flakes, depending on the material, and process parameters.[3]The type of chips formed can be an indicator of themachinabilityof the material, with long gummy chips reducing machinability.When possible drilled holes should be located perpendicular to the workpiece surface. This minimizes the drill bit's tendency to "walk", that is, to bedeflected, which causes the hole to be misplaced. The higher the length-to-diameter ratio of the drill bit, the higher the tendency to walk. The tendency to walk is also preempted in various other ways, which include:

Fig11 Buffing Machine

BROACHINGBroachingis amachiningprocess that uses a toothed tool, called abroach, to remove material. There are two main types of broaching:linearandrotary. In linear broaching, which is the more common process, the broach is run linearly against a surface of the workpiece to effect the cut. Linear broaches are used in abroaching machine, which is also sometimes shortened tobroach. In rotary broaching, the broach is rotated and pressed into the workpiece to cut an axis symmetric shape. A rotary broach is used in alatheorscrew machine. In both processes the cut is performed in one pass of the broach, which makes it very efficient.Broaching is used when precision machining is required, especially for odd shapes. Commonly machined surfaces include circular and non-circular holes,splines,keyways, and flat surfaces. Typical workpieces include small to medium sizedcastings,forgings, screw machine parts, andstampings. Even though broaches can be expensive, broaching is usually favored over other processes when used for high-quantity production runs.[1]Broaches are shaped similar to a saw, except the height of the teeth increases over the length of the tool. Moreover, the broach contains three distinct sections: one for roughing, another for semi-finishing, and the final one for finishing. Broaching is an unusual machining process because it has thefeedbuilt into the tool. The profile of the machined surface is always the inverse of the profile of the broach. The rise per tooth (RPT), also known as thestepor feed per tooth, determines the amount of material removed and the size of the chip. The broach can be moved relative to the workpiece or vice-versa. Because all of the features are built into the broach no complex motion or skilled labor is required to use it.A broach is effectively a collection ofsingle-point cutting toolsarrayed in sequence, cutting one after the other; its cut is analogous to multiple passes of ashaper.

Fig12 Broaching Machine PRODUCTS1. Bracket Compressor

2. Alternator

3. Case Gear Shift Guide

21.4. Case DLI Sensor

5. Crank Case -R

6. cup

22.7. Cylinder Block

8. End Shield

9. Hub Comp Scooter

23.10. Mid Shield

11. Motor Frame

12. Pinion Housing D2-l

24.

13. Rack Housing For Houndai

14. Rear cover

15. Rear Half

25.16. Retainer Input

17. Sprocket RR

18. Wheel Assembly Motorcycle

26.

Fig.14 PRODUCTS

28. PROBLEMS & SOLUTIONSS. No.NATURE OF PROBLEMSUGGESTION

1.Unskilled and unexperienced workersRecruitment of workers on the basis of their past experience and their skills. It is not necessary to have recruitment in mass but only skilled labours.

2.Misalignment of DieAs we have already discussed it occurs due to carelessness of the labours.

3.Development of BurrBurr is developed due to misalignment of die. So workers should be careful during alignment of die.

4.Time Setting for Changing DieAs we have to make a workpiece of different diameter, so die needs to be changed which takes an hour or half an hour. Time setting for changing die occurred due to less number of machines. So this problem can be solved by increasing number of machines.

5.Target not fixed to the workerTarget should be assigned to the worker.

6.Inspection not done on Regular basis.During our training we observed that whenever we entered any of the shops the workers started doing their work properly on seeing us. This means if there is regular inspection, workers will work properly.

Table No.1

29. RESULT & DISCUSSION

I visited the Industry and visualized every machine in the unit II of the Kiran Udyog Pvt. Ltd. Gurgaon and perceived knowledge about the various processes being carried out. The details of every machine and tools used were given to me by my supervisor Mr. Rajesh Chokkar.Then me, as a part of the Kiran Udyog Pvt. Ltd., enrolled myself in the manufacturing of Die Casting of Aluminium & Zinc. I came to know practically about every process performed and problems related to every shop became known to me while the training. I also gave suggestions on my part to the industry so as to improve their production.I learnt about how such large machines like High Speed Press Machine can increase the production by a large difference. But it depends on the demand of the clients.

30.

REFERNCES1. www.fiecpowerpresses.co.in2. www.pearlengineeringco.com3. www.directindustry.com4. www.ahmedabadstrips.com5. www.tmaintl.com6. www.researchgate.net7. John L., Jorstad (September 2006), "Aluminum Future Technology in Die Casting", Die Casting Engineering: 1825, archived from the original on 11-12-2010.8. www.diecasting.com/general-die-casting9. www.kiranudyogindia.com

31.