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CHAPTER 1 INTRODUCTION
1.1 Objective of Industrial Training:
The main objective of the Industrial Training is to experience and understand real life situations in industrial organizations and their related environments and accelerating the learning process of how students knowledge could be used in a realistic way. In addition to that, industrial training also makes one understand the formal and informal relationships in an industrial organization so as to promote favorable human relations and teamwork.Industrial training also provides a systematic introduction to the ways of industry and developing talent and attitudes, so that one can understand how Human Resource Development works. Moreover, students can gain hands-on experience that is related to the students majoring so that the student can relate to and widen the skills that have been learnt while being in university. Industrial training also exposes the students to the real career world and accustoms them to an organizational structure, business operation and administrative functions. In conclusion, there is strong evidence that industrial training is highly beneficial to students development, and it is highly valued. The students are well equipped to manage the period of industrial training successfully and undoubtedly gain useful experience of applying their specialist and technical skills, as well as developing their personal and communications skills. This internship also help student to prepare for the work environment and also teach the ergonomics of organizations in the real world. In brief:
To understand the organization structure of an industry. To understand Management skills. To understand the functions and responsibilities of different departments.
Apart from that, I also used observation method to gather information for my project. I observed how the operations are carried out, how the employees interact among themselves, how the working culture is practiced, how the relationship between the manager and the sub ordinates is and the how the working environment is.
To train at real working situation at industries before applied the real job. T o e xpose to a new technology and applications in engineering. T o respect and follow the companys rules. To involve in the real working environment. To i mprove students confidence and develop responsibility. To know how to solve a problem that occurs in a real work. To increase the creativity and innovative during the work. To improve working skill.
Fig. 2.1 Rane (Madras) Ltd., Front View RANE (MADRAS) LIMITED PLANT II 79/84, HOOTAGALLI INDUSTRIAL AREA, MYSORE 570018.
Rane (Madras) Ltd is one of the top auto ancillary company and is a part of the Rs. 2709 crore Rane group, engaged in the manufacture and distribution of steering and suspension systems.
Provide superior products and services to their customers and to maintain market leadership. Evolve as an institution that serves the best interests of all stakeholders. Pursue excellence through total quality management. Ensure the highest standards of ethics and integrity in all their actions.
Founded as Rane Private Limited in 1929, started as a trading house, trading in automobiles and parts. Represented General Motors, Renault, American Motors etc
As first diversification from trading, in 1959 Engine Valves Limited was established for manufacturing IC engine valves.
In 1960 Rane (Madras) limited commenced manufacture of Steering Linkages (Tie rod ends). Rane Brake Linings Limited was established in 1964 for manufacturing friction materials. In 1965 Rane Madras Limited discontinued with its trading activities. In 1975 Rane (Madras) Limited started manufacturing of Steering Gears. RML Mysore division was started in the year 1985.
Inception of manufacturing facilities in the year 1960 Manufacturer of steering and suspension systems for every segment of automobile industry, viz Passenger cars, Multi utility vehicles, Light commercial vehicles, Heavy commercial vehicles and Farm tractors
Branched in Hydraulic products in anticipation of shift in customer requirements Strategic Technical partnerships with M/s TRW Inc, USA for Steering Gear Products and TRW Ehrenreich GmbH and Co., Germany for Steering Linkage Products
Holds 39% market share in Steering Gear Products (SGP) and 72% market share in Suspension and Steering Linkage Products (SSLP) in India.
The 5 manufacturing facilities location and the product range following locations Location Mysore plant Puducherry plant Uttarakhand (Pantnagar) plant Velachery (Chennai) plant Varanavasi (Chennai) plant Product SSLP, SGP, Hydraulic products SSLP,SGP SSLP,SGP Costumer Segment Tractor and Commercial vehicle segments, and Hydraulic products Passenger Car segment Tractors and small commercial vehicles catering to customers in North India Passenger Car, utility vehicle mainly caters to exports market Light Commercial vehicle, Heavy SSLP,SGP Commercial vehicle and Utility vehicles segments Table 2.1 Manufacturing facilities location and the product range
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SSLP
7 8 9 10
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12 13 14 15 16 17 18
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AMW
Expanding Rack and Pinion business through new customer acquisition. Establishing stronger position in suspension ball joints. Expanding export business through current and new customers in different geographies. Enhancing the Companys position significantly in hydraulic products. Expanding scope and reach in after market segment Company plans Capex of Rs. 160 crore, achieve CAGR of 21% in Sales and ROCE of 30% by 2015-16
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The purpose is to sustain and enhance availability of plant and machinery to it's maximum level and to improve quality and maintainability of equipments.
3.3.2 Role:
3.3.3 Functions: Plant consists of around 320 production machines, H.T furnaces, utilities and facilities including buildings. Caters to the technical service requirement of manufacturing and calibration requirement of testing and measuring instruments. It takes care of company statutory and legal requirements.
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The purpose is to support the manufacturing function through optimizing the process through modern and innovative tooling, Reduction in cycle time and setup time, Establish manufacturing process for New Product, to meet market demand and quality
3.4.2 Role:
Improve manufacturing Processes Productivity Improvement Projects Special initiative on Tool Cost Saving Projects
3.4.3 Functions:
Manufacturing cost competitiveness. Manufacturing system inability to meet fluctuating demand Lead time of New product productionization Process Quality improvement Inadequate use of Statistical tools
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3.5.2 Role:
Improve incoming material quality Improve in-process quality Improve out going product quality
3.5.2 Functions:
Customer Quality Assurance (CQA) - To improve out going product quality. In process Quality Assurance (IQA) - To support in-process material quality to meet internal customer requirements.
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rod links which pivot the wheels to be steered. A drag link is used when the steering arm operates in a plane above the other links. The drag link converts the sweeping arc of the steering arm to linear motion in the plane of the other steering links. Typically, one end of the drag link is connected via the Pitman arm and steering gearbox to the steering wheel (providing the connection between the driver and the steering system); the other end is attached to the vehicle frame by the idler arm.
Fig 4.2 Drag link assembly Ishikawa product module(Integrated cell) is as shown in the figure
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Process Flow in Integrated cell: 1. 2. 3. I. Raw materials from supplier to stores Raw materials (Forged part) to the Integrated cell Machining Process Machining of Ball pin a. Turning b. Pin hole drilling c. Pin hole chamfering d. Turning and Burnishing e. Thread rolling II. Machining of Socket a. Piercing b. Bore machining c. Garter grooving d. Stem centering e. Stem turning f. Thread rolling 4. 5. 6. Heat Treatment Inspection magnetic inspection for crack detection and other faults Assembly Line a. Pre assembly b. Roller peening c. Boot greasing d. Boot assembly e. Boot clip assembly f. 90 deg correction and Packing
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Fig 4.4 Ball pin turning Mount the ball pin between the tail stock center and the face drive and clamp the component. Switch on the machine, after completion check visually and if found ok proceed to first off inspection check with appropriate gauges and continue. Machine Used: C.N.C. TURNING MACHINE Process parameters: PARAMETER Speed Feed Tail stock pr. Cutting medium SPECIFICATIONS 3150-2000 rpm 0.28-0.22 mm/rev 16-20 Kg/cm2 Soluble oil CHECK METHOD Visual Visual Visual pressure gage Visual
Tooling details: TOOL NO DESCRIPTION TOOL LIFE Per Edge No of Edges Total MTJNL 2020 TNMG 150608 Holder Insert 200 6 1200
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Fig 4.5 Ball pin hole drilling Mount the ball pin in the guide bush and lock the Pneumatic cylinder. Switch on the cycle. After completion visually check and if found ok proceed to first off inspection and check with appropriate gauges and continue. Machine Used: DRILLING MACHINE (AURAM) Process parameters: PARAMETER Speed Feed Cutting medium Tooling details: TOOL NO DESCRIPTION Per Edge RJF 0314 MJF 0151 Fixture Drill jig 3.2 s.s drill 100 10 1000 TOOL LIFE No of Edges Total SPECIFICATIONS 1000-1750 rpm Auto Soluble oil CHECK METHOD Visual Visual Visual
Fig 4.6 Ball pin hole chamfering Hold the component in the vice and switch on the cycle. After completion check & if found ok continue. Machine Used: DRILLING MACHINE (AURAM)
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Process parameters: PARAMETER Speed Feed Cutting medium SPECIFICATIONS 475-750 rpm Manual Dry CHECK METHOD Visual Visual Visual
Fig 4.7 Ball pin head turning & burnishing Mount the ball pin in the spindle, and switch on the cycle .After completion of the process visually check and if found ok proceed to first off inspection check with appropriate gauges and continue. Machine Used: BALL PIN TURNING & BURNISHING MACHINE Process parameters: PARAMETER Speed Feed Cutting medium Hydraulic Pr. SPECIFICATIONS Fixed Hydraulic Dry 30-40 Kg/cm2 CHECK METHOD Visual Visual Visual Visual
Tooling details:
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TOOL NO
ZZ 473 ZZ 363
5 Thread rolling:
Fig 4.8 Ball pin thread rolling Place the ball pin on the ball head rest (Nylon), and stem on the rolling blade, switch on the cycle. After completion visually check and if found ok proceed to first off inspection and also check for any flat threads and also any over ride of the thread. Machine Used: THREAD ROLLING MACHINE (PRAGA) Process parameters: PARAMETER Hydraulic pressure Dwell Time Cutting Medium Tooling details: TOOL NO DESCRIPTION Per Edge M12x1.25 RH Thread Rolls 1 TOOL LIFE No of Edges 10000 Total 10000 SPECIFICATIONS 8-12 Kg/cm2 2.0-4.0 sec Servo cut 945 Oil CHECK METHOD Visual Timer Visual
1 Piercing:
Fig 4.9 Piercing blank Load the socket in between the Fixture jaws & Tighten the jaws, Switch on the cycle. After completion of the cycle, Check visually and if found ok move on to first off inspection. Check with appropriate gauges for the critical dimensions as in check list and continue the operation. Machine Used: COLUMN DRILLING MACHINE Process parameters: PARAMETER Speed Feed Cutting medium SPECIFICATIONS 315 rpm 0.315-0.5 mm/rev Soluble oil CHECK METHOD Rotary switch Needle Visual
Tooling details: TOOL NO DESCRIPTION Per Edge RJF2002 MJF 141 Pneumatic Vice 26.50mm T S 2F drill within house made step 500 TOOL LIFE No of Edges Total
2 Bore machining:
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Fig 4.10 Bore machining of socket Clamp the socket in the Spindle and switch on the cycle. After completion, check visually and if found ok move on to first off inspection. Check with appropriate gauges. If found ok continue the process. Machine Used: MURATA CNC CENTER Process parameters: PARAMETER Speed Feed Cutting medium Chuck pressure SPECIFICATIONS 2500 rpm 0.22-0.28 mm/rev Soluble oil 16-20 kg/cm2 CHECK METHOD Visual visual Visual Pr. gage
Tooling details: TOOL NO DESCRIPTION Per Edge PCLNR 2020 CNMG 120408 S16SCLCR CCMT09T308 Dia 165 mm Tool Holder Insert Boring Bar Special boring bar 500 cutting Insert 3 Jaw Chuck 2+2 2000 4months 800 04 3200 TOOL LIFE No of Edges Total
3 Garter grooving:
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Fig 4.11 Garter grooving of socket Clamp the socket in the grooving collet and tight the collet with the help of handle. Switch on the cycle, after completion of the cycle visually check for any damage and if found ok move on to first off inspection. Check with appropriate gauges and also check manually for any burr fold and after inspection continue the process. Machine Used: COLUMN DRILL MACHINE Process parameters: PARAMETER Speed Feed Cutting medium SPECIFICATIONS 315 rpm 0.125 mm/rev Soluble oil CHECK METHOD Rotary switch Needle Visual
Tooling details: TOOL NO DESCRIPTION Per Edge RJF 0216 MT 0023 Fixture In house made garter grooving tool 8mm x 8mm HSS Sq.bar of constant length 47.5 mm to be used 600 2 1200 TOOL LIFE No of Edges Total
4 Stem centering:
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Fig 4.12 Stem centering of socket handle Locate the socket in the bunk and clamp pneumatically. Switch on the cycle, after completion of the cycle visually check and if found ok move on to first off inspection. Machine Used: DRILLING MACHINE (AURAM ) Process parameters: PARAMETER Speed Feed Cutting medium SPECIFICATIONS 450-1750 rpm Auto feed Dry CHECK METHOD Visual Timer Visual
Tooling details: TOOL NO DESCRIPTION Per Edge RJF 0148 Centering fixture 3/16 x7/16 Center Drill MT2 Taper shank adapter . 1200 2 2400 TOOL LIFE No of Edges Total
5 Stem turning:
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Fig 4.13 Stem turning of socket handle Locate the groove I.D of socket in the plate provided in headstock fixture. Clamp the socket in between the Spindle & Tail stock center. Switch on the cycle, after completion of the cycle check visually and move on to first off inspection and check with appropriate gauges and continue. Machine Used: TAKISAWA Process parameters: PARAMETER Speed Feed Cutting medium SPECIFICATIONS 2000-2500 rpm 0.2-0.3 mm/rev Coolant CHECK METHOD Visual Timer Visual
Tooling details: TOOL NO DESCRIPTION Per Edge PDJNN DNMH12 TOOL HOLDER INSERT 200 4 800 TOOL LIFE No of Edges Total
6 Thread rolling:
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Fig 4.14 Thread rolling on the socket handle Load the dummy component on the work rest blade, Switch on the cycle. After completion check visually and if found ok move for first off inspection and continue the process with socket. Machine Used: THREAD ROLLING MACHINE (PRAGA) Process parameters: PARAMETER Hydraulic pressure Dwell Time Cutting Medium SPECIFICATIONS 25-40 kg/cm2 25-60 sec Servo cut 945 oil CHECK METHOD Pr. gage Timer Visual
Tooling details: TOOL NO DESCRIPTION Per Edge RZZ 2111 M12x1.25 6g RH Thread Rolls for(M12) M14x1.25x90 LH/ RH thread Rolls for (M14) 50000 TOOL LIFE No of Edges 50000 Total
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Fig 4.15 Pre assembly of Drag link Press the bottom cup into the socket, apply a thin layer of AP2 INDROL grease on the ball pin head, then Insert ball pin & top cup on the ball pin head .Press the grease smeared ball pin ,top cup into the socket by operating the switch. After completion of the operation check visually and if found ok continue. Machine Used: PNEUMATIC PRESS Process parameters: PARAMETER Pneumatic pr. 2 Roller peening: SPECIFICATIONS 4-6 kg/cm2 CHECK METHOD Visual
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Fig 4.16 Roller peening machine Assemble spring, spring seat & end plug into the socket, place them in the fixture & Peen it. After completion of the cycle check visually& if found ok move to first off inspection & continue. Machine Used: ROLL PEENING MACHINE Process parameters: PARAMETER Roller gap Pneumatic pr. Dwell time SPECIFICATIONS 1.250.1 mm 4-6 kg/cm2 110-130 sec CHECK METHOD plate gage indicator indicator
Fig 4.17 Boot greasing Set for approximately 5gms AP2 (Yellow colour) & fill uniformly on inside groove of
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the boot by operating the switch. After completion check visually for proper filling of grease inside the groove portion & if found ok continue. Machine Used: GREASE DISPENSING UNIT (CENLUB) Process parameters: PARAMETER Pneumatic pr. SPECIFICATIONS 4-6 kg/cm2 CHECK METHOD Visual
4 Boot assembly:
Fig 4.18 Boot assembly Manually fit the larger dia of the grease filled boot on the back opening of the peeened end through ballpin after completion check visually & if found ok continue. Boot after assembly should be in free condition & not to be in squeezed condition. 5 Boot clip assembly:
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Insert the boot assembled end on the taper cone through the ball pin end. Place the clip on the clip seat & position the taper cone, operate the air valve. After completion of the cycle check visually 100%. Machine Used: BOOT CLIPPING MACHINE Process parameters: PARAMETER Pneumatic pr. SPECIFICATIONS 4-6 kg/cm2 CHECK METHOD Visual
Fig 4.20 90deg correction and packing of drag link assembly Insert 3mm pin into the ball pin hole & turn such a way that the ball pin hole axis is approximately90deg (15deg ) to the axis of the socket stem center. 1. Apply rust off oil. 2. Fix the protective cap to the ball pin. 3. Place the assembly into the cartoon box (16 Nos. in each box). 4. Check for the presence of batch code.
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CHAPTER 5 CONCLUSION
As a postgraduate student I would like to say that a training program like an industrial training is an excellent opportunity for me to get to the ground level and experience the things that we would have never gained through going straight into a job. I am grateful to my college PESCE and Dept of Mechanical Engineering, for including training like this in the curriculum. The industrial exposure and learning is the best way to get the knowledge about the manufacturing world. It gives clear picture of the organization. The main objective of the industrial training is to provide an opportunity to postgraduates to identify, observe and practice how engineering is applicable in the real industry. It is not only to get experience on technical practices but also to observe management practices and to interact with fellow workers. During my stay at RML, I got hat experience and the feeling of responsibility. It was a great experience. Engineering personnel of the RML are people that have a lot of experience. All of them were willing to help in my training. They have a vast knowledge about the fields they are work with. So it was easy to learn from them. The 2 months training that I received at Rane (Madras) Ltd., was great experience for me not only on technical terms but also in terms of interaction with other workers. I learnt a great deal on applying the knowledge I have gained at the college. Learning something from books and lectures is nothing like having firsthand experience. At Rane I got to apply my knowledge. The company gives the full freedom for the trainee. The trainees are allowed to ask and do anything relevant to the training. Engineers are always very enthusiastic on giving us the best training experience.
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CHAPTER 6 BIBLIOGRAPHY
Bibliography:
Information from departments. RML library. Company Literature. Annual reports. Internet
www.rane.co.in http://en.wikipedia.org/wiki/Rane_(Madras)_Ltd
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