PRESENTATION ON INDUSTRIAL TRAINING REPORT

SUBMITTED TO : SUBMITTED BY:

ASST PROF. GAURAV SAINI NAME: ANKIT TYAGI

ROLL NO: SG-12904

MECHANICAL (5 SEM)

"MAKINO is committed to consistently provide the Original Equipment Manufacturer and vehicle owner quality products. Our dedicated people, coupled with Technological Excellence gives us the competitive edge to do so.“

For over two decades, Makino Auto Industries Pvt. Ltd. has been the trusted name in the automotive industry. The company's product range of Automotive clutch assemblies, brake assemblies and components are amongst the category leaders in India and discerning markets of the world.

•Established in 1990 Makino has 4 plants in India. Started as a Friction Disc manufacturer and now a complete clutch & Brake Solution Provider.•Experts of Automotive Clutches & Brakes (2W, 3W and 4W applications)•Working with major OEM in India for 2 W and 3 W applications•Vision is to provide technologically advanced clutches & brakes for existing and future vehicles.

Technology Alliances & Partnerships :-

CUSTOMERS :-

Pressure Die Casting

Die casting is a metal casting process that is characterized by forcing molten metal under high pressure into a mold cavity. The mold cavity is created using two hardened tool steel dies which have been machined into shape and work similarly to an injection mold during the process.

There are two types of Pressure Die Casting :-

1. Hot-chamber die casting

Hot-chamber die casting, also known as gooseneck machines, rely upon a pool of molten metal to feed the die.

2. Cold-chamber die casting :-

These are used when the casting alloy cannot be used in hot-chamber machines; these include aluminium, zinc alloys with a large composition of aluminium, magnesium and copper. The process for these machines start with melting the metal in a separate furnace.Then a precise amount of molten metal is transported to the cold-chamber machine where it is fed into an unheated shot chamber (or injection cylinder). This shot is then driven into the die by a hydraulic or mechanical piston.

Advantages and disadvantages

Advantages of die casting:

•Smooth cast surfaces •Thinner walls can be cast as compared to sand and permanent mold casting •Inserts can be cast-in •Reduces or eliminates secondary machining operations .•Rapid production rates.•Casting of low fluidity metals.

Disvantages of die casting:

The main disadvantage to die casting is the very high capital cost. Both the casting equipment required and the dies and related components are very costly, as compared to most other casting processes. Therefore to make die casting an economic process a large production volume is needed. Other disadvantages are that the process is limited to high-fluidity metals, and casting weights must be between 30 grams (1 oz) and 10 kg (20 lb). In the standard die casting process the final casting will have a small amount of porosity. This prevents any heat treating or welding, because the heat causes the gas in the pores to expand, which causes micro-cracks inside the part and exfoliation of the surface.

MAKERS :-

Technocrats

ZITAI

PROCESS

In Furnace metal is heated which reaches the metal to its melting temperature . In makino aluminium is used as the metal. Then the operator pour the molten aluminium in the cavity provided in the PDC machine after the stroke the desired product is obtained other operator removes the fillet and ingates from the cast product. From here the cast product is send to the trimming shop.

Trimming machine is basically power press. It removes the bulges from the cast product. Then the product is send to the surface cleaning shop .

In surface cleaning shop Vibro machine is employed . Vibro finishing machine is a bowl type centrifugal finishing machine. The machine bowl is loaded with suitable ceramic/ plastic or steel media and the components to be processed. The mutual rubbing action takes place inside the chamber due to the gyratory vibrations, Compared to other simpler processes this method completes the deburring process faster.

Then the product is send to the CNC shop, The programs produce a computer file that is interpreted to extract the commands needed to operate a particular machine via a post processor, and then loaded into the CNC machines for production. Since any particular component might require the use of a number of different tools – drills, saws, etc., modern machines often combine multiple tools into a single "cell". In other installations, a number of different machines are used with an external controller and human or robotic operators that move the component from machine to machine.

MOULDING

• Molding or moulding  is the process of manufacturing by shaping liquid or pliable raw material using a rigid frame called a mold or matrix. This itself may have been made using a pattern or model of the final object.

• In manufacturing of clutch plates moulding is done between core plates and friction plates. One core plate is placed in between two friction plate and then placed in standard moulding machine which operate at temperature 150 ±10 celcius and 6 ±.5 bar pressure. Standard molding machine consist of three platform each consisting of 9 moulding die thus in one cycle each moulding machine produces 27 moulded clutch plates.

• In moulding section there are about 10 moulding machine, 3 grinders, 1 ADC, and an additional friction rings manufacturing section which have 1 mixer, 1 roller, and 2 klinger press.

ROLLING SECTION

• This section is used for manufacturing of friction rings

that is used in clutch plates in order to provide friction.

• Friction ring are made from the mixture of

various materials such as rubber etc. mixed in

a desired portion with the help of a mixer and then rolled into sheet by

the help of a roller of thickness of about

1mm and temperature of about 50ºC.

SMM(Standard moulding machine)

• Moulding is done in order to attain predetermined shape

on a particular object. In this mouling unit ,core plates and

friction rings are kept together so as to mould a shape on

the friction which are placed on both side of core plate made

of aluminium as ii is easy to mould a synthetic ring then to

mould a aluminium plate

• The working condition of a SMM

Temperature - 150±10º c

Pressure - 6±.5 bar

CORE PLATES

• Core plate are mainly made of aluminium. The boiling point of

aluminium is about 600-650ºC. These are manufactured by mainly

two process :

• Die Casting process .

• Power press method.

Adhesive been applied :

The adhesive which bond the core plate and friction

rings can be applied in two ways :

• Manually : the adhesive manully applied is done by

the workers which keep the core plate

•By machine : The adhesive is applied by machine

through the machine known as ADS.

MOULDING PROCESS

DEFLESHINGThe process of removing extra friction rings from the clutch plates is termed as defleshing. It is done manually with the help of a rasp.

Before Defleshing After Defleshing    

 

ID CLEANING, BRUSHING, INSPECTION AND PACKING:

• ID cleaning refers to internal diameter cleaning as in deflesing only external part of the friction ring is cleaned so in order to remove the extra part of the friction ring.

• When the clutch plates manufacturing is all done then the plates are inspected to see whether they are able to fulfil all the specification as given by their buyer or not.

• The different test of inspection are :

Ring test in which the clutch plate are passed through it to see whether its diameter is off desired value or not.

VBOX fitted Test VehiclesVBOX fitted Test Vehicles

  SAE 2 Based DynamometersSAE 2 Based Dynamometers

• Packing is done by passing the rings placed in polythene bags and passesing it through the Packing is done by passing the rings placed in polythene bags and passesing it through the machine machine

ALODINISATION:• Chromate conversion coating or alodinisation  is a type of  conversion coating  use to

 passivate aluminium, zinc, cadmium, copper, silver,magnesium, and tin alloys. It is primarily used as a corrosion inhibitor, primer, decorative finish, or to retain electrical conductivity.

• The alodinisation machine here is a automatic machine whose

programming work on a counter base system. As alodinisation

process is a multistep process as each tank have different

compostion of mixture present and the amount time

spend by the machine in each tank. The alodinisation

machine has a box type outlet in which the rings to be

alodinised are put. Then the machine is turned on and

then according to programming it will stop at the tank

which contain mixtures such as dm water, nitric acid ,

aalodine in different composition according to the need

Of the core plate.

GRINDING

• Grinding is an abrasive machining process that uses a grinding wheel as the cutting tool. Grinding practice is a large and diverse area of manufacturing and tool making. It can produce very fine finishes and very accurate dimensions; yet in mass production contexts it can also rough out large volumes of metal quite rapidly

DUST COLLECTOR

• After the grinding is done the dust which is produced due to grinding of clutch plates in grinding machine is collected through the dust collector which have fan situded at the botton of the tunnel which create a pressure difference which allow to suck up the dust and collect it ina a drum situated outside the moulding section.

CNC MACHINE• Numerical control (NC) is the automation of machine tools that are operated

by precisely programmed commands encoded on a storage medium, as opposed to controlled manually via hand wheels or levers, or mechanically automated via cams alone. Most NC today is computer numerical control (CNC), in which computers play an integral part of the control.

• Mainly lathe operation are done on it.

DRILLING• Drilling is a cutting process that uses a drill bit to cut or enlarge a

hole of circular cross-section in solid materials. The drill bit is a rotarycutting tool, often multipoint. The bit is pressed against the workpiece and rotated at rates from hundreds to thousands of revolutions per minute. This forces the cutting edge against the workpiece, cutting off chips (swarf) from the hole as it is drilled.

• Multiple spindle drilling press is generally used with different dia of drill according to the necessity of the hole to be drilled. Generally 4-5 drill are placed in the spindle of the drilling machine as the hole to be corrected on housing is generally four

BROACHING• Broaching is a machining process that uses a toothed tool, called a broach,

to remove material

ASSEMBLY OF CLUTCH

ASSEMBLY SHOP

THANK YOU