INDUSTRIALTRAINING REPORT

ON
Aluminium Castings, Clutches and Bra es
Su!mitted in the "artial #ul#ilment #$r the a%ard $# Bachel$r $# Techn$l$g& in 'echanical Engineering

Su!mitted T$( Pr$#) R)*) Tri"athi +) O) D)

Su!mitted B& An it Garg R$ll N$) ,-./ 'echanical Engineering 0rd 1ear 'ech) Engg

De"artment $# 'echanical Engineering +INDU COLLEGE O2 ENGINEERING 3A##iliated t$ ') D) Uni4ersit&, R$hta 5

PRE2ACE

The im"$rtance $# industrial training needs n$ em"hasis) One $# the characteristics $# m$dern scenari$ is the increasing ra"idit& $# change) This intensi#ies the need #$r stud&, ada"tati$n and training) 2$r an engineering student the "ractical training is as im"$rtant as the the$retical n$%ledge and s$metimes m$re than the the$r& "art) The "ractical training n$t $nl& ma es a student #amiliar %ith the atm$s"here a n d c $ n d i t i $ n s $ # i n d u s t r & ! u t s u # # i c i e n t l & i n c r e a s e s h i s 6 h e r n $ % l e d g e ! & "r $ 4 i d i n g a s e n s e $ # c$n#idence and m$ti4ati$n) The main $!7ect $# all industrial trainings is t$ "re"are an indi4idual s$ that he6she can acc$m"lish his6her tas e##icientl& and e##ecti4el& and can ta e u" and handle 7$!s $# higher res"$nsi!ilit&) Training is an act $# increasing the n$%ledge and s ills $# an em"l$&ee #$r d$ing a "articular 7$!) The ma7$r $ut c$me $# training is learning) A trainee learns ne% ha!its, re#ined s ills and use#ul n$%ledge during the training that hel"s him6her as im"r$4ed "er#$rmance) Training ena!les an indi4idual t$ d$ his6her "resent 7$! m$re e##icientl& and !e "re"ared #$r higher le4el 7$!) Training is a " l a n n e d " r $ g r a m m e d e s i g n e d t $ i m " r $ 4 e "er#$rmances and !ring a!$ut measura!le changes in n$%ledge, s ill, attitude and s$cial !eha4i$ur $# an indi4idual) I "ers$nall& #eel "r$ud and ha""& in %riting this training re"$rt that I ha4e c$m"leted m& training in such a g$$d $rganisati$n %hich taught me s$ man& use#ul things)

AC*NO8LEDGE'ENT

I #eel immense "leasure in c$m"leting this training and su!mitting this #inal re"$rt) The %h$le internshi" "eri$d %ith AS* Aut$m$ti4e P4t) Ltd) +as !een #ull $# learning and a sense $# c$ntri!uti$n t$%ards increasing the "ractical n$%ledge) I %$uld li e t$ than 'r) R)*) ARORA 3C+AIR'AN5 #$r gi4ing me the $""$rtunit& t$ c$m"lete m& training in such a g$$d $rganisati$n) A success#ul training can ne4er !e c$m"leted !& the e##$rts $# a single "ers$n, !ut it als$ demands the hel" and guardianshi" $# s$me c$n4ersant "ers$n %h$ hel"ed the undersigned acti4el& $r "assi4el& inc$m"leti$n $# success#ul training) During the actual training

'r) De4ender Sharma 3+ead Training De"artment5

has !een a s$urce $# ins"irati$n thr$ugh his c$nstant g u i d a n c e , " e r s $ n a l i n t e r e s t , enc$uragement and hel") I %$uld li e t$ c$n4e& m& sincere than t$ him) I als$ ta e this $""$rtunit& t$ than

'r) G$4ind *aushi 3Su"er4is$r5

and all th$se "e$"le %h$ made this e9"erience a mem$ra!le $ne) An it Garg

CONTENTS
:)PRE2ACE

;)AC*NO8LEDGE'ENT 0)CERTI2ICATE <)INTRODUCTION /)ORGANISATION ,)8OR* CULTURE -)PLANT LA1OUT =)PRODUCTS >)SECTIONS :.)?UALIT1 ASSURANCE ::)ALU'INIU' CASTINGS :;)CLUTC+ES :0)BRA*E ASSE'BL1 :<)BIBILIOGRAP+1

INTRODUCTION
AS* Aut$m$ti4e 3P5 Ltd) %as #$unded in :>=> !& 'r) *) S) Rathee %ith a 4isi$n t$ achie4e e9cellence in the #ield $# manu#acturing Aut$m$ti4e C$m"$nents) The c$m"an& has technical c$lla!$rati$n %ith the %$rld leader in #ricti$n material '6S) AS* Technical C$r"$rati$n, @a"an) 8ith its m$tt$

$# ACust$mer 2irstB the c$m"an& gr$%n $4er the &ears and "resentl& it has three "lants at di##erent l$cati$ns in Gurga$n, +ar&ana) Thr$ugh its c$mmitment t$ inn$4ati$n, "r$cess im"r$4ements, Cualit& c$ntr$l and cust$mer ser4ice the c$m"an& has !een a!le t$ "$siti$n itsel# as a e& res$urce #$r leading OE's) The AS*Bs "r$ducts are in line %ith the m$st demanding Cualit& standards) All $# AS*Bs $"erati$n ha4e secured a""r$"riate ?ualit& Certi#icati$ns and the C$m"an& has recei4ed a n$ $# Cualit& and "er#$rmance a%ards #r$m cust$mers)

The e& aut$m$ti4e OE' d$mestic cust$mers include

The c$m"an&Bs sale gra"h is increasing &ear !& &ear) The #$ll$%ing chart sh$%s that Latest Sales Gra"h

INR in 'ILLIONS

The #$ll$%ing #e% lines sh$% the success st$r& $# the c$m"an& :>=>Setting u" $# c$m"an& :>><DBest Eend$r A%ardF #r$m *inetic '$t$r :>>=ISO(>..; Certi#icati$n

:>>>?S(>... Certi#icati$nDBest Eender A%ardF #r$m *inetic '$t$r ;..:Signed TCA %ith AS* Technica C$r" $# @a"anSetting u" $# unit IISetting u" $# Die Casting #acilit& ;..0DChallenge India Su""$rt A%ardF #r$m +'SI ;..<Setting u" $# unit IIISetting u" $# Paint Sh$"TS( :,><> Certi#icati$n ;../DBest and 2astest De4el$"ment A%ardF #r$m +'SISetting u" $# 8heel Assem!l& #acilit&FC$mmendati$n Certi#icati$n #$r ?ualit& and Deli4er&F #r$m +'SI ;..,Setting u" $# InGh$use T$$l R$$m ;..- Setting u" $# Design Centre ;..>Plan t$ set unit IE

PLANT LA1OUT

ORGANISATION

O r g a n i s a t i $ n ma & ! e d e # i n e d a s t h e "r $ c e s s $ # i d e n t i # & i n g a n d g r $ u " i n g t h e % $ r t $ ! e " e r # $ r me d , de#ining and delegating the auth$rit& and res"$nsi!ilit& and esta!lishing relati$nshi" #$r the "ur"$se $# ena!ling "e$"le t$ %$r m$st e##ecti4el& t$gether in acc$m"lishing $!7ecti4e) The AS* Aut$m$ti4e 3P5 Ltd) has a 4er& g$$d #uncti$nal $rganisati$n) An $rganisati$n chart $# the c$m"an& is sh$%n !el$%

Under each head there is $ne seni$r engineer and $ne engineer) Under engineer there are su"er4is$rs and under su"er4is$rs there are %$r ers)

8OR* CULTURE

Eari$us acti4ities $# AS* gr$u" stands t$%ards maintaining /GS and T?' are !eing underta en in the c$m"an& #$r achie4ing $4erall e9cellence) S$me $# these are listed !el$%( H The "lant has !een di4ided int$ 4ari$us I$nes %ith each I$ne ha4ing a I$nal leader H The I$nal leader is res"$nsi!le #$r /GS acti4ities in his I$ne H Peri$dic /GS audits are !eing c$nducted !& the c$re gr$u" H C$nce"t $# TEI has !een intr$duced H SGIA 3Small Gr$u" In4$l4ement Acti4ities5 teams #$rmed #$r di##erent acti4ities

PRODUCTS

AS* Aut$m$ti4e 3P5 Ltd) manu#acture "r$ducts $# man& t&"es and s"eci#icati$ns acc$rding t$ the need $# OE' cust$mers, !ut still these can !e di4ided int$ t%$ t&"es
:)

2ricti$n 'aterial Pr$ducts

These are the "r$ducts %hich reCuire #ricti$n linings $n their sur#ace) 'ain #ricti$n material "r$ducts are( H Bra e Sh$e H Bra e Assem!l& H Bra e Lining H Clutch Plate

;) Aluminium Castings
Aluminium castings include man& "r$ducts li e(

H Panels H +u!s H N$nGAut$m$ti4e H Cran Case H Gri" H Engine Parts

Gri"s All the "r$ducts manu#actured !& AS* are n$t $# $ne s"eci#icati$n !ut !ased u"$n the 4ari$us di##erent s"eci#icati$n gi4en !& the di##erent cust$mers)

SECTIONS
The di##erent secti$ns $# unit III are( Ra% 'aterial St$re 'achining Secti$n Drilling Secti$n 2inishing Secti$n Paint Sh$" Assem!l& Secti$n T$$l R$$m 2inished G$$ds St$re

RA8 'ATERIAL STORE

The ra% material reCuired in Unit III c$mes #r$m Unit II) 2$r !ra es the ra% material is all c$m"$nents $# sh$e !ra e such as !ra e sh$e, !ra e lining, !ac "late, retract$r s"ring etc) 2$r clutches ra% material is clutch "lates and #$r aluminium castings the ra% material is unmachined and un#inished castings %hich are #inished and "ainted there)

'AC+INING SECTION

In machining secti$n all the machines reCuired t$ d$ !asic machining $# an& c$m"$nent are a4aila!le)The machines a4aila!le in machining secti$n are( Lathe 'achine Sha"er Sl$tter Drill 'achine Reaming 'achine B$ring 'achine 'illing 'achine Grinding 'achine Br$aching 'achine P$%er +ac sa%

DRILLING SECTION
The drilling secti$n $# the industr& is $ne $# the m$st im"$rtant secti$ns #$r Cualit& as"ects) The di##erent "arts manu#actured !& c$m"an& reCuire man& "recise drilling $"erati$ns) T$ meet the Cualit& stand ards the drilling secti$n is eCui""ed %ith CNC machine t$$ls) The entire drill machines a4aila!le in drilling secti$n are CNCs) There are :/ CNC drill machines $ut $# %hich ten machines are $# #i9ed aut$mati$n t&"e and the rest #i4e are used #$e #le9i!le "r$gramming) The !asic idea !ehind using CNC machines is the reCuired accurac&) Als$ the c$m"uter readil& and easil& "r$grammed, there#$re, the s&stem is 4er& #le9i!le) The machine can manu#acture a "art #$ll$%ed !& $ther "arts $# di##erent design)

2INIS+ING SECTION
The #inishing secti$n is #ull& eCui""ed %ith the machines and techn$l$g& reCuired t$ c$ntr$l the sur#ace #inish $# the c$m"$nents) The sur#ace #inishing s"eciall& reCuired #$r the castings is d$ne in this secti$n) 8 h a t e 4 e r ma & ! e t h e ma n u # a c t u r i n g "r $ c e s s , a n a ! s $ l u t e l & s m$ $ t h a n d # l a t s u r # a c e c a n n $ t ! e $!tained) There are s$ man& irregularities "resent $n the sur#ace $# the c$m"$nent %hich n$t $nl& gi4e a !ad l$$ t$ the c$m"$nent !ut "r$4ide a !ase #$r c$rr$si$n and scale etc t$ $ccur) T$ sa4e metal #r$m these "r$!lems sur#ace #inishing is reCuired) All the sur#ace #inishing "r$cesses can !e "er#$rmed in the #inishing secti$n such as

Grinding La""ing +$ning Bu##ing Barrel Tum!ling Barrel R$lling Su"er 2inishing Burnishing P$%der C$ating P$lishing

PAINT S+OP
AS* has a "$siti4e "ressurised "aint sh$" %ith #$ll$%ing #acilities( ECui""ed %ith humidit& c$ntr$ller Using h&dr$static guns #$r highest Cualit& $# "ainting Ba ing $# "aint is d$ne in tem"erature c$ntr$lled $4en t$ ensure c$nsistenc& in Cualit& $# "r$duct Se4en !ath "reGtreatment "lant #$r chr$m$tising

ASSE'BL1 SECTION
The assem!l& secti$n is the last stage #$r c$m"leti$n $# a c$m"$nent) The assem!l& secti$n at AS* is a manual $ne) Th$ugh s$me $# the "r$cesses #$r assem!l& are carried $ut aut$maticall& !ut m$st $# the %$r is d$ne manuall&)

TOOL ROO'
The t$$l r$$m is $ne $# m$st im"$rtant secti$n $# an& industr&) At AS* the t$$l r$$m is eCui""ed %ith a l l t h e t $ $ l i n g s $ l u t i $ n s r e C u i r e d ) T h e t $ $ l r $ $ m i s 4 e r & c a " a ! l e t $ s u " " $ r t t h e c $ m" a n & g $ a l # $ r achie4ing de4el$"ment c$mmitments gi4en t$ its cust$mers !& "r$4iding related t$$ling s$luti$ns %ell %ithin sti"ulated time #rame) The t$$l r$$m %$r s t$ eliminate t$$l related ?ualit& Pr$!lems, Pr$ducti$n Pr$!lems, Brea d$%n Pr$!lems In e9isting and du"licated t$$ling !& ad4ancement thr$ugh design

?UALIT1 ASSURANCE
The Cualit& assurance de"artment "la&s an im"$rtant r$le in an& c$m"an& as in case $# AS*) The main #uncti$n $# Cualit& assurance de"artment is t$

4eri#& the Cualit& $# an& "r$cess $r "r$duct as "er AS* standards) The ne9t #uncti$n is the de4el$"ment that include H T$ de4el$" the 4end$r H G$$d c$mmunicati$n %ith the 4end$r H I# necessar& sh$t $ut the "r$!lem in a "articular c$m"$nent at a 4end$rBs end AS* is the IndiaBs #irst c$m"an& t$ !e a%arded the ?S >... certi#icate $# a""r$4al in its categ$r&, #$ll$%ed !& an$ther landmar $# achie4ing certi#icati$n TS :,><>(;..; this ensures that the Cualit& standard $# AS* can match u" %ith the !est in %$rld) S$me $# the ma7$r achie4ements $# Cualit& de"artment are( H :>>< ABest Eend$r A%ardB #r$m *inetic '$t$rs H :>>= ISO(>..; Certi#icati$n H :>>> ?S(>... Certi#icati$n H ;..< TS(:,><> Certi#icati$n H ;../ AC$mmendati$n Certi#icate 2$r ?ualit& and Deli4er&B #r$m +'SI

ACTIEITIES PER2OR'ED B1 ?UALIT1 DEPART'ENT

H Recei"t Ins"ecti$n H In "r$cess Ins"ecti$n H 2inal Ins"ecti$n H Eend$r De4el$"ment H Cust$mer C$m"laint H 'aintain and Im"lementati$n $# ?ualit& S&stem H Internal Audit

DIE CASTINGS
The die castings manu#actured !& AS* ha4e e9cellent sur#ace #inishes that are c$nsistent dimensi$nall& %ith the "recisi$n #eatures and minimum dra#t) AS*

Aut$m$ti4e P4t) Ltd) "r$duces e##icientl& engineered and high "ressure aluminium castings) Die casting all$&s are generall& n$n #err$us and there are a large n$ a4aila!le %ith a %ide range $# "h&sical and mechanical "r$"erties t$ c$4er alm$st e4er& a""licati$n a designee might need) The #le9i!le aut$mati$n techn$l$gies a4aila!le at AS* include( H ?uic change t$$ling #$r standard machines H '$dular #i9tures and 7igs H +igh s"eed ca"a!ilit&, multi #uncti$nal, e9cellent Cualit& and %ell "r$cessed design H Internet s&stems transmitting in#$rmati$n !et%een engineering and management H In "r$cess gauging and em!edded ins"ecti$n de4ices #$r Cualit& c$ntr$l H Rec&cle s&stems #$r achie4ing green "r$ducts and a health& %$r en4ir$nment

*e& die casting s"eci#icati$ns include(

H 'aterials G Aluminium and Aluminium All$&s H Al G - g ma9) %eight and >/. sC cm ma9) siIe H 2inishes G S"ra& Painting H C$m"lete range $# sec$ndar& $"erati$ns J CNC machining, drilling, assem!l& ser4ices H All #act$ries ?S( >... and TS :,><> certi#ied H In h$use m$uld6t$$l design and #a!ricati$n ca"a!ilities H Central melting #urnace $# ca"acit& #r$m =. t$ ,,. t$nnes The casting $# these "r$ducts is "re"ared in Unit II and these are !r$ught here #$r #inishing) +ere at Unit III the castings #r$m ;.g t$ ;)/. g $# %eight are dul& machined, #inished and "ainted) 'achining $# casting in4$l4es !asic $"erati$ns li e turning, milling, sl$t cutting, drilling etc and the $"erati$ns are "er#$rmed $n the machines a4aila!le in di##erent secti$ns $# unit) A#ter c$m"leti$n $# machining %$r t h e c a s t i n g s a r e s e n t t $ t h e # i n i s h i n g s e c t i $ n ) I n t h e # i n i s h i n g s e c t i $ n # i r s t $ # a l l t h e c $ m" $ n e n t s ar e cleaned #$r all t&"es $# chi"s and !urrs rem$4al) Then it is c$m"letel& cleaned #$r all t&"es $# #$reign materia ls li e dust, dirt, greases, $il etc) a#ter cleaning the c$m"$ nent is "ainted in "aint sh$") Cleaning and "ainting $# casting is a l$ng "r$cess and c$m"leted in #$ll$%ing stages

STAGE I G 2INIS+ING

Stage $ne includes sur#ace #inishing "r$cesses)

SUR2ACE 2INIS+ING
All t&"es $# sur#ace #inishing "r$cesses are a4aila!le in #inishing secti$n and can !e used acc$rding t$ reCuirement) These are( H Grinding H La""ing H +$ning H Bu##ing H Barrel Tum!ling H Barrel R$lling H Burnishing H P$%der C$ating H P$lishing 2$r aluminium castings the m$st used "r$cess is !urnishing)

BURNIS+ING
Burnishing $"erati$n is the "r$cess $# getting a sm$$th and shining sur#ace !& c$ntact and ru!!ing $# the sur#ace against the %alls $# a hard t$$l) It is a #inishing and strengthening "r$cess) Burnishing is !asicall& a c$ld sur#ace "lastic de#$rmati$n "r$cess %hich im"r$4es the sur#ace #inish and induces the sur#ace c $ m " r e s s i 4 e r e s i d u a l s t r e s s e s , t h u s i m" r $ 4 i n g t h e # a t i g u e l i # e $ # t h e c $ m " $ n e n t ) I n t h e " r $ c e s s $ # ! u r n i s h i n g a c& l i n d r i c a l r $ l l e r $ # h ar d e n e d s t e e l $ r c e m e n t e d c a r ! i d e i s m a d e t $ r $ l l a g a i n s t t h e c$m"$nent sur#ace) +$le !urnishing is "re#erred %ith multi r$ller t$$ls $n drill "resses, turret lathes, h$riI$ntal !$res, unit !uilt machines and aut$matic lathes) Burnishing raises the hardness $# the sur#ace !& ;. t$ /.K and its %ear resistance !& :)/ t$ ; times)

STAGE II G CLEANING
Stage II includes sur#ace cleaning "r$cesses)

SUR2ACE CLEANING

Sur#ace cleaning is necessar& !e#$re "ainting) It "r$4ides a !ase #$r "aint $r an& $ther c$ating material t$stic %ith sur#ace #irml&) 2irst $# all the c$m"$nent is cleaned !& %ire !rush and c$tt$n %aste and thensur#ace cleaning $# castings is d$ne !& #$ll$%ing "r$cesses(

AL*ALINE CLEANING
In this meth$d the "arts are cleaned !& di""ing them in aCue$us s$luti$n $# al aline silicates, caustic s$da $r similar cleaning agents) S$me t&"e $# s$a" is added t$ aid in emulsi#icati$n) This meth$d satis#act$ril& rem$4es greases and $il) The cleaning acti$n is !& emulsi#icati$n $# $ils and greases) S"ecial %ashing machines are em"l$&ed in l$t and mass "r$ducti$n) 8ashing machines ma& !e $# single, d$u!le $r multicham!er t&"e)

C+E'ICAL POLIS+ING
Chemical "$lishing is $ne $# m$st im"$rtant sur#ace #inishing "r$cess #$r aluminium and its all$&s) In this "r$cess the metallic $!7ects are immersed in !aths $# selected acids) During the "r$cess, certain am$unt $# metal, mainl& #r$m "ea s is diss$l4ed, "r$ducing a !right sur#ace, %ith$ut the #$rmati$n $# etched "attern) 2$r chemical "$lishing $# aluminium all$&s the m$st success#ul $# the s$luti$ns used c$ntain "h$s"h$ric, nitric and sul"huric acids) The "r$ducti$n c&cle c$nsists $# #$ll$%ing ste"s Immerse #$r : t$ 0 minutes at :..LCRem$4e and rinse in h$t %ater 3-.LC5 t$ rem$4e 4isc$us #ilm #$rmati$n Rinse in a mi9ture c$ntaining eCual am$unts $# %ater and :)<; s") gr) nitric acid at r$$m tem" I# an$dising reCuired, rinse in c$ld %ater I# lacCuering reCuired, rinse in h$t %ater The resultant sur#ace #inish %ill !e $# the $rder $# .)</ t$ .)/. %ith a high re#lecti$n #act$r $# ==K)

STAGE III G PAINTING

The IIIrd stage is c$nsists $# "ainting "r$cess) A#ter cleaning the sur#ace a c$at $# "aint is a""lied $n the sur#ace $# c$m"$nent as e9"lained !el$%( 'etal "arts are "ainted t$ "r$tect their sur#aces against the c$rr$si4e acti$n

$# surr$unding medium and als$ t$ im"r$4e their a""earance) The "r$cess $# c$ating %ith "aints and 4arnishes is carried $ut in three stages( "re"arati$n $# the sur#ace t$ !e c$ated, "ainting and Dr&ing %ith #inishing)

SUR2ACE PREPARATION
The castings %ith clean sur#aces are #irst "re"ared !& a""l&ing "rimers li e $il 4arnish, Ole$G !itumin$us, %ater s$lu!le and nitr$ s$lu!le "rimers) The "rimed sur#ace is then treated %ith #iller, %h$se la&er sh$uld !e as thin as "$ssi!le) Oil 4arnish #illers and Cuic dr&ing "&r$9&lin #illers are c$mm$nl& used)

PAINTING
Painting is d$ne !& a""l&ing $ne $r se4eral la&ers $# "aint) Oil and enamel "aints and 4arnishes are used #$r this "ur"$se) Nitr$ enamels dr& in 0. t$ <. minutesM a#ter dr&ing these #$rm a hard gl$ss& la&er) Oil and s"irit enamels dr& #$r ;< t$ <= h$urs

'eth$ds $# Painting
The 4ari$us meth$ds $# industrial "ainting are H Brush Painting H S"ra& Painting H Di" C$ating H 2l$% C$ating H Painting in Drums At AS* s"ra& "ainting is used as "ainting meth$d

S"ra& Painting
The meth$d c$nsists in a""l&ing #luid "aint in at$mised #$rm) This meth$d is m$st c$mm$n and "r$ducti4e, !ut reCuires "remises eCui""ed %ith e9haust de4ices and s"ra&ing eCui"ment) This meth$d can !e used in the #$ll$%ing #$ur %a&s(

'echanical S"ra&ing
In this meth$d the "aint is deli4ered t$ a s"ra& gun !& a "um")

Air S"ra&ing
In this meth$d the "aint is s"ra&ed !& a 7et $# c$m"ressed air %hich carries the "aint mist t$the sur#ace t$ !e "ainted) The meth$d is ca"a!le $# c$ating 0. t$ =. $# sur#ace "er h$ur, !utl$sses are high 3<. t$ /. K5)

Air Less S"ra&ing

In this meth$d, "aint heated t$ -. t$ >.LC is #$rced thr$ugh a n$IIle at a "ressure $# ; t$ < N6mmN and s$ s"ra&ed) The meth$d all$%s the use $# highl& 4isc$us "aints, %hich cuts the s$l4ent reCuirements dr&ing time) The "r$ducti$n rate can !e /. J ;.. mN $# sur#ace "er h$ur and "aint l$sses am$unt t$ ;/ J /.K)

Electr$static S"ra&ing
In this meth$d, a negati4el& charged s"ra&er deli4ers "aint %hich gets int$ the sur#ace $# a "$siti4el& charged metal "art !eing "ainted) The charging is !eing "r$4ided !& a high 4$ltage c$nstant current s$urce) The "aint l$sses are less than /K) The meth$d ma es it "$ssi!le t$ im"r$4e %$r ing c$nditi$ns, t$ "r$4ide #$r #airl& high "r$ducti4it& 3/. mN $# sur#ace "er h$ur5 and #$r the "$ssi!ilit& $# de4el$"ing a #ull& aut$mated "ainting "r$cess

DR1ING
A#ter !eing "ainted, the "arts underg$ dr&ing) The Cualit& $# " a i n t c $ a t i n g s d e " e n d $ n t h e meth$d $# dr&ing) Dr&ing is a c$m"le9 chemical "r$cess in4$l4ing e4a"$rati$n $# the s$l4ent and $9idati$n $r "$l&meriIati$n $# the c$ating #ilm) Dr&ing can !e natural $r arti#icial) T h e n a t u r a l $ r a i r d r & i n g i s c a r r i e d $ u t a t a t e m" e r a t u r e $ # : = t $ ; / L C $ 4 er a l $ n g t i me ) T h e arti#icial dr&ing ma es it "$ssi!le t$ s"eed u" s$lidi#icati$n $# the c$at and als$ t$ greatl& im"r$4e its Cualit&) The m$st c$mm$n meth$d $# arti#icial dr&ing is !& c$n4ecti4e heating) The dr&ing is carried $ut in a cl$sed cham!er %hich is airGheated !& gas, electricit&, $r steam t$ tem"erature $# // t$ ;;.LC $r !& means $# a re#lect$r eCui""ed %ith !an s $# s"ecial electric lam"s) The latter meth$d ta es $nl& #r$m $ n e # $ u r t h t $ $ n e h a l # a s m u c h t i m e a s h $ t a i r

d r & i n g me t h $ d ) O t h e r dr & i n g m e t h $ d s u t i l i I e h i g h #reCuenc& current 3inducti$n heating5 and in#rared ra&s)

CLUTC+ES
A clutch is the de4ice used in transmissi$n line !et%een the engine and gear !$9 %hich transmits the r$tar& m$ti$n $# engine sha#t t$ the gear !$9 sha#t at desire) It is the de4ice %hich ma es $r !rea s c$ntact !et%een the engine and gear !$9) Clutch Plates

2RICTION 'ATERIAL 2OR CLUTC+ES

'ainl& the #ricti$n materials #$r clutches are $# three t&"es( 'ill!$ard T&"e '$ulded T&"e 8$4en t&"e

'ILLBOARD T1PE
This is $nl& as!est$s sheet treated %ith certain im"regnants) 2r$m this sheet are then #acing discs cut acc$rding t$ di##erent siIe reCuirements) This is the chea"est a4aila!le t&"e and is Cuit satis#act$r&

'OULDED T1PE
This is made !& mi9ing as!est$s #i!res %ith a suita!le !inding material, heating t$ a certain %ell de#ined tem"erature and then m$ulding in dies under "ressure) 'etallic %ires are als$ s$metimes used t$ im"r$4e %earing Cualities) This t&"e $# #acing is m$re dense and ca"a!le $# ta ing hea4ier %$r ing l$ads) +$%e4er there is $ne disad4antage that each clutch #acing has t$ !e m$ulded se"aratel&

8OEEN T1PE
This t&"e c$nsists $# a cl$th im"regnated %ith certain !inders) The cl$th ma& either !e %$4en li e $rdinar& cl$th %ith %ra" and %e#t $r !& %inding the #i!res in circum#erential directi$n $nl&) In the s$lid %$4en 4ariet&, the cl$th is %$4en 7ust t$ the reCuired thic ness) In case $# laminated 4ariet&, the la&ers $# cl$th $ne u"$n the $ther are held t$gether !& a !inder) Stitches are "r$4ided in additi$n t$ the !inder)

CO''ON CLUTC+ 2ACING 'ATERIALS

Organic #ricti$n materials are the m$st c$mm$n t&"es $# clutch #acing materials) These are( H Leather ( Dr& leather $n ir$n has c$e##icient $# #ricti$n $# .);-) H C$r ( C$r $n dr& steel $r ir$n has c$e##icient $# #ricti$n $# .)0;) H 2a!ric ( G$$d Cualit& #a!ric materials ha4e c$e##icient $# #ricti$n $# a!$ut .)<) But the& can n$t !e used at high tem"eratures) H As!est$s ( As!est$s #acing has a c$e##icient $# #ricti$n $# a!$ut .);) +$%e4er it has g$t anti heat characteristics) H Re&!est$s and 2er$d$ ( These as!est$s !ased #acings ha4e a c$e##icient $# #ricti$n $# a!$ut $)0/ !ut $!s$lete due t$ health ris "$ssessed !& as!est$s) H N$n As!est$s Based Clutch 2acing These are made $# man made #i!re &arns such as glass #i!re, mi9ed %ith s"ecial ru!!er c$m"$und t$ im"r$4e #ricti$nal "er#$rmance, #irml& l$c ed %ith the elast$mer !ased n$4alac !inder and m$ulded %ith "ressure and heat) S$me materials ma& als$ !e %$4en and ma& c$ntain !rass %ires) E9am"les $# this t&"e are S80GA2, +8* ;.. etc)

RE?UIRE'ENT O2 GOOD CLUTC+ 2ACING

H G$$d %earing "r$"erties) The %ear $# the clutch #acing de"ends u"$n the ru!!ing s"eed and intensit& $# "ressure) 2$r ma9imum li#e the ru!!ing s"eed at the time $# engagement sh$uld n$t e9ceed 0. m6s %hile "ressure intensit& sh$uld n$t e9ceed :.. Pa) H Presence $# g$$d !inder in it) H Chea" and eas& t$ manu#acture) H +igh c$e##icient $# #ricti$n) H +igh resistant t$ heat) A g$$d clutch #acing can %ithstand tem"erature $# a!$ut 00.LC)

BRA*E ASSE'BL1
Bra es are the de4ices used t$ c$ntr$l and reduce the s"eed $# 4ehicle and t$ st$" the 4ehicle %hen reCuired) AS* manu#actures sh$e !rea s and disc !ra es)

BRA*ING RE?UIRE'ENTS

:) The !ra e must !e str$ng en$ugh t$ st$" the 4ehicle %ithin a minimum distance in an emergenc&) But this sh$uld als$ !e c$nsistent %ith sa#et& and 4ehicle must n$t s id);)The !ra e must ha4e g$$d antiG#ade characteristics) This reCuirement demands that the c$$ling $# !ra e sh$uld !e 4er& e##icient)

CO'PONENTS O2 BRA*E
The !asic c$m"$nents $# a !ra e are( H Bra e Drum $r C$4er H Bra e Sh$e H Bra e Lining H Retract$r S"ring H Ad7uster and E9"ender etc This t&"e is m$ulded directl& #r$m the Ami9B, %hich c$ntains as!est$s #i!res, t$gether %ith resin "$%ders and #illers) The a4erage c$e##icient $# #ricti$n %ith this t&"e $# lining is .)< and tem"erature resistance 4aries #r$m <.. t$ </.LC) The& ha4e g$$d antiG #ade and antiG%ear characteristics) The di##erent m$ulded t&"e !ra e linings used are( H Ferodo 2629 F ( This is #$r use $n drum t&"e !ra es)

Recommended Operating Range

Unit Pressure Ru!!ing S"eed Tem"erature C$ntinu$us Tem"erature -.G,>. N6mN'a9) := m6s 'a9) <..LC 'a9) :-/LC

Bonding C$mm$n adhesi4es ma& !e used #$r !$nding, !ut #$r !etter results therm$setting adhesi4es sh$uld !e em"l$&ed) Recommended Mating Surface G$$d Cualit&, #ined grained cast ir$n) Technical Data Ultimate Tensile Strength :/):= 'N6mN Ultimate C$m"ressi4e Strength ,)= 'N6mN Ultimate Shear Strength ,)> 'N6mN Thermal C$nducti4it& .),- @6m s6LC Brinell +ardness :;

2ricti$n C$e##icient

.)<: 3#$r design "ur"$se5

H Rane 9011 DC This is #$r use $# c$mmercial 4ehicle drum !ra es) Technical Data Densit& :>. g6cc +ardness 3R$c %ell ALB Scale5 >. Gr$ss Bra ing Strength </ 'Pa Tensile Strength ;:), 'Pa Shear Strength :/)- 'Pa C$m"ressi4e Strength :.-)> 'Pa 'a9) C$ntinu$us O"erating Tem") ;/.LC Transient O"erating Tem"erature 0/.LC

DISC BRA*E PADS

2er$d$ ;<<> E rigid m$ulded #ricti$n material is used #$r disc !ra e "ads) It is light !r$%n in c$l$ur, ha4ing a rand$m #i!re as!est$s !ase and c$ntaining c$""er "articles) The material has g$$d resistance t$ #ade and %ear) Recommended Operating Range Unit Pressure .)0/G/); 'Pa'a9) Ru!!ing S"eed ;< m6s'a9) Tem"erature //.LC'a9) C$ntinu$us Tem"erature ;/.LC

Recommended Mating Surface G$$d Cualit&, #ine grained "earlitic cast ir$n)

Technical Data '$dulus in C$m"ressi$n =0. 'Pa Ultimate Shear Strength :: 'Pa Thermal C$nducti4it& :);0 @6m sLC Brinell +ardness :< 2ricti$n C$e##icient .)0- 3#$r design "ur"$se5

The as!est$s #ree disc "ad material is Rane ,-:- +)

BIBILIOGRAP+1
A Te9t B$$ $# Pr$ducti$n Techn$l$g& !& P) C) Sharma Aut$m$!ile Engineering !& Dr) *ir"al Singh Elements $# 8$r sh$" Techn$l$g& !& S) *) +a7ra Ch$udhar& Industrial Engineering and 'anagement !& Dr) O) P) *hanna

T+AN* 1OU