SUBMITTED BY:- PANKAJ and SUNITA RANI

MECHANICAL ENGG. ROLL NO:-12305 &12326

SEM:- 5th DRONACHARYA COLLEGE OF ENGG; GURGAON

CERTIFICATE

This is to certify that the project entitled “Brake & Fuel Line” submitted by Mr. Pankaj & Miss. Sunita Rani is a bonifide record of work carried out by her under my supervision from 15th June 2011 to 31st July 2011.the contents of this thesis, in full or in parts have not been submitted to any other institute or university for the award of any degree.

Mr. Mohan Singh.Sr.Executive(HR)

INDEX

PROJECT TITTLEACKNOELEDGEMENT

COMPANY INTRODUCTION About TI Automotives World

Organization StructureProduct Overview

Environment & quality INDUSTRY OVERVIEW

PROJECT INTRODUCTION Objective Of Training Objective Of Project

Introduction To Project ANALYSIS AND FINDINGS

CONCLUSION AND RECOMMENDATIONS ANNEXURE

ACKNOLEDGEMENT

I am very grateful to all under whom I completed my summer training .I would like to give my heartiest thanks to Mr. Mohan

Singh who give me opportunities (letter to join as trainee) to do training at Bundy India Limited.

I would like to express my deep gratitude to Mr. Ravi Verma (project guide) at Bundy India Limited for their keen interest, valuable guidance and constant encouragement during the

course of my accomplishment of this project. I am very grateful to them for introducing me to the technicalities and explaining

the subtleties of the project and process flow of the plant.

COMPANY INTRODUCTION

TI Automotive has maintained the position of a premier supplier to an ever-changing global market since 1922, with advances in small

diameter steel tube manufacture, design and fabricationTechnology and innovation have always been our driving force,

offering far more than just tubing expertise to the automotive industry.Bundy double wall tubing is manufactured from a low carbon, tight tolerance continuous strip of copper plated cold rolled steel, double

wrapped (through 720 degrees) and brazed in a controlled atmosphere to form a double-walled tube.

COMPANY BACKGROUND INFORMATION TI Automotive is the world's leading supplier of fluid storage, transfer and delivery systems including brake, fuel and air conditioning applications.

FOUNDED TI Automotive Ltd was formed as an independent company in 2001 in England. Following the merger of TI Group with Smiths Industries in December 2000, TI Group Automotive Systems became a division within Smiths Group plc. In July 2001, the automotive division demerged from Smiths Group.

EMPLOYEES TI Automotive has more than 16,000 employees in more than 100 facilities worldwide.

BUSINESS DIVISIONS TI Automotive is divided into two major divisions. The Fuel Systems group has approximately 40% of company sales and the Fluid Carrying Systems group has 60%.

GROWTH CHORONOLGY TI Automotive's roots are in the remarkable transformation of TI Group plc from a declining British company in 1986 to a thriving global business by 2000.TI Group, which originated as Tube Investments Ltd in Birmingham, England in 1919, grew its automotive business with these major acquisitions:

PRODUCT OVERVIEW Our core product offerings

focus on the design, development and manufacture of multi-layer blow molded plastic fuel tanks with integrated fuel delivery module assemblies, including turbine or gerotor pumps, electronic control modules, sensor units and fill

and vapor control valves. Complimenting these leading edge complex fuel

tank systems are TI Automotive's rigid and flexible fuel and brake lines, each available with a

comprehensive range of coating applications and unique connector technology.

Our total systems solutions provide the world's automotive manufacturers with a filler neck fuel rail package that is designed to optimize cost, space, weight and fitment parameters whilst

surpassing safety and emissions requirements. Additionally, TI Automotive offers world class air

conditioning module assemblies. Steel and aluminum accumulators and unitized receiver

dryers are integrated with rigid and flexible hose assemblies to provide efficient and optimum

performance in this high temperature environment.

Fluid Carrying Systems

Our routing expertise comes into its own in the crowded vehicle underbody. Brake and fuel line bundles, designed to optimize space and maximize fitment speed, save valuable assembly time. Supplied on a “just-in-time” or sequence-delivery basis, we provide simple inventory. Control and reduced assembly-line congestion.

Brake & Fuel Products :-

TI Automotive provides a brake and fuel solution for each customer application. Our tubular products include rigid brake and fuel lines, flexible fuel lines, and high-pressure diesel products designed to meet a variety of customer needs. Corrugated monoand multi-layer tubes and assemblies complete the portfolio for fuel-vapor systems. A comprehensive range of coatings, which exceed corrosion and abrasion protection standards, enhances product quality and durability

Air Conditioning Tube & Hose Assemblies:- Ever-changing emission, fuel efficiency, and cost requirements demand enhancement of current air-conditioning systems as well as innovation in alternate refrigerant technology. As a driving force for cost-effective materials, design, and processes for the mobile air conditioning “loop,” TI Automotive continues to set standards within the industry. Our combination of coupling, bending, and connection technology enables us to meet our customers’ unique needs for quick connectors, in-line heat exchangers, and high-pressure couplings.

Heater & Radiator Hose Systems

We offer a wide range of hose constructions and diameters to match our customers’ needs, including high-temperature requirements. Manufacturing capabilities include formed, coupled hoses with tube or quick connectors and pre-positioned clamps (mechanical/adhesive).

Other Automotive Products

Our commitment to lean manufacturing has pushed our connector technology to the forefront of the automotive industry, and TI Automotive produces more quick connects than anyone else in the world. From high-pressure quick connects to spin-welding joints between a quick connector and flexible tube line, we provide solutions for every manufacturing need. In addition to meeting the automotive industry’s low-permeation standards, our connectors make for easy installation at the assembly line. TI Automotive also manufactures air bag tubes and other formed tubular products in a variety of intricate shapes to meet our customers’ specifications. These products are supplied to all tiers of the automotive supply cha

Product Quality:- Copper Plated Double Wall Steel Tubing specifications SAE J527, ASTM A254. Meets automotive brake tube specifications worldwide Available in coils, straight boom lengths, cut-to-length, or fabricated assemblies Available annealed Some common applications include brake lines, high-pressure fuel injection lines, hydraulic line and compressor lines

Product FeaturesProduct Features Product BenefitsProduct Benefits

Double wall constructionDouble wall construction Designed to withstand high internal pressures and combat vibration fatigueDesigned to withstand high internal pressures and combat vibration fatigue

Bead free no weld flash inside or outside the tubeBead free no weld flash inside or outside the tube Smooth, clean, precise I.D.Smooth, clean, precise I.D.

Copper finish on inside and outside of tubingCopper finish on inside and outside of tubing Facilitates brazing tubing to fittings, stampings and other partsFacilitates brazing tubing to fittings, stampings and other parts

Available in a wide variety of coatings.Available in a wide variety of coatings. Extended corrosion protectionExtended corrosion protection

Single Wall Low Carbon Steel Tubing Meets or exceeds specifications SAE J525, SAE J526, SAE J356A, ASTM A269, and ASTM A268. Meets all automotive industry standards. Some common applications include:

o fuel supply and return lines o vent and vacuum lines o fuel rails o power steering o engine/oil coolers o HVAC components o Fuel filler necks o refrigeration

Product FeaturesProduct Features Product BenefitsProduct Benefits

High grade single wall strip materials are utilized High grade single wall strip materials are utilized to ensure optimized physical propertiesto ensure optimized physical properties

Provides ease of fabrication and can be expanded, compressed, Provides ease of fabrication and can be expanded, compressed, flattened, cut formed or bent into almost any shapeflattened, cut formed or bent into almost any shape

Most sizes available as welded, cold drawn, or Most sizes available as welded, cold drawn, or annealedannealed

Enables low-cost material substitutionEnables low-cost material substitution

Available in a wide variety of coatings & stainless Available in a wide variety of coatings & stainless alloysalloys

Provides a variety of low cost corrosion protection options to Provides a variety of low cost corrosion protection options to meet every applicationmeet every application

Conductive Nylon O.D. coated tube, with or Conductive Nylon O.D. coated tube, with or without nickel I.D., availablewithout nickel I.D., available

Offers a replacement for many stainless steel and aluminum Offers a replacement for many stainless steel and aluminum tubing applicationstubing applications

Fluid and gas carrying capabilities at medium to Fluid and gas carrying capabilities at medium to high pressurehigh pressure

Provides a wide range of product capabilitiesProvides a wide range of product capabilities

Inner Sacrificial LayerInner Sacrificial LayerOuter Outer

Barrier Barrier LayerLayer

Other Info.Other Info.Meets OEM Meets OEM Customer Customer

SpecificationsSpecifications

Hot Dipped Alloy Layer consisting Hot Dipped Alloy Layer consisting of 95% Zinc and 5% Aluminumof 95% Zinc and 5% Aluminum

NoneNoneCoating may be soldered. Contact TI Coating may be soldered. Contact TI Automotive for method description.Automotive for method description.

Daimler ChryslerDaimler ChryslerPS-8688 Code NZPS-8688 Code NZFord Motor Ford Motor CompanyCompanyESA-M1A270-AESA-M1A270-AGeneral Motors General Motors Corp.Corp.GM123M GM123M GM124M Code AGGM124M Code AG

Coatings

PVF COATING

Inner Sacrificial LayerInner Sacrificial Layer Outer Barrier LayerOuter Barrier Layer Other Info.Other Info. Meets OEM Customer SpecificationsMeets OEM Customer Specifications

Electroplated Zinc LayerElectroplated Zinc Layer PVF ( Polyvinyl Fluoride ) Paint LayerPVF ( Polyvinyl Fluoride ) Paint Layer

Daimler ChryslerDaimler ChryslerPS-8688 Code PEPS-8688 Code PE

Ford Motor CompanyFord Motor CompanyWSK-M2P139-AESA-M21P20-WSK-M2P139-AESA-M21P20-AA

Process Of Production:- 1. Material receipt2 .Tube Cutting3 .Deburring +Air blow4 .Swaging5 .1st End Forming6 .Sleeve Cutting7 .Nut/Sleeve Insertion8 .2nd End Forming9 .Marking/Sleeve Location10 .Sleeve Shrinkage11 .Inspection/Final Air Blow12 .CNC/Power Bending13 .Manual Bending14 .Leak Testing15 .Final Inspection16 .Packing/Storage17 .Dispatch

1 .Material Receipt

2 .Tube Cutting:- Cut the tube with the help of power cutter according their length

3 .Deburring+Air BlowDuring they cutting process the sharp edges are formed in the end so we remove the sharp edges .We use deburring process & air blow for remove dart particle in tube.

4 .Swaging :-

During the deburring process the diameter of tube increases so we want to actual size of the diameter of the tube we use swaging process.

5 .1st End Forming :-

After the swaging operation we form the first and of the tube using pressure punching machine .pressure which is use is 70kgf/cm2

6.Sleeve Cutting Some time we avoid the fuel pipe and break pipe from heat and corrosion we use sleeve pipe insert in the sleeve

7 .Nut/Sleeve Insertion:- After forming the 1st end insert the nut and sleeve. This operation is held manually

9 .Marking/Sleeve Location Marking the position of the sleeve in the pipe and inert the sleeve

10 .Sleeve Shrinkage After insertion of the sleeve .The pipe is passes over the temperature about 140 C. and then sleeve shrink

11 .Inspection/Final Air Blow Inspection for the cut and other fault like leakage

12 .CNC/Power BendingThe pipe is bend with the help of the CNC/Power bending according to their PLANE,FEED,BEND.Pressure is required for this is 6 bar

13 .Manual BendingThis operation is also done with the help of manual bending

14 .Leak TestingThis is for the test for leakage in the pipe. Fill the air in the pipe then pipe deepwater tank

15 .Final Inspection16 .Packing/Storage17 .Despatch

Environment & QualityEnvironmental Responsibility

In order to minimize its own impact on the environment, TI Automotive is seeking ISO 14001 certification on a global basis.

This international standard sets criteria to ensure that an effective environmental management system is in place at each facility. We monitor our environmental performance closely and

third party verification audits are conducted annually. With these aids we can assess our achievements and review our targets on

a regular basis. Our aim is ongoing improvement so further developments are constantly being implemented.

All eligible TI Automotive sites are ISO 14001 certified or working toward certification.

Many of TI Automotive's products have positive environmental impacts in terms of emissions and noise reduction. We

constantly monitor emissions legislation on a global basis. California's upcoming LEV II and PZEV standards are the current driver for evaporative emissions regulations, worldwide. These

stringent standards are likely to serve as the model, with modifications, for future standards throughout the world.

TI Automotive is committed to helping its customers meet LEV II, PZEV and other future standards with innovative, cost-effective,

fuel system products.

Global Customer Base

TI Automotive has a supplier partnership with every major Original Equipment Manufacturer

(OEM) in the world. TI Automotive is able to maintain these relationships by continually adapting as the automotive industry's

boundaries expand across the globe. Our global customer base includes the following companies:

BMW Honda Hyundai

Fiat

FordFord

General Motors

Isuzu Daewoo

PSA

Renault

Toyota

Ned carNed car

BIBLIOGRAPHY:-

www.Tiautomotive.com

Thanks….No questions plzzz….