PROJECT REPORT

ON

PRESSING & WELDING

TECHNOLOGY

AT

CAPARO MARUTI LTD.

GURGAON

(15thJune to 30thJuly,2014)

SUBMITTED BY :----

MRINAL RATHORE
B.E. 3rd year, MECHANICAL
IMS ENGINEERING COLLEGE
 ACKNOWLEDGEMENT

Industrial training is an indispensable part of our engineering curriculum. It

provides the students an opportunity to gain experience on the pragmatic
applications of their knowledge. My training at Caparo Maruti Ltd, Gurgaon has
been very fruitful. I am sure that the experience I gained here will help me
towards making me a competent and proficient engineer.

I would like to convey my sincere gratitude to MR.VIRENDER SINGH ,who

entrusted me with the responsible project work and provided me with timely and
proper guidance whenever required. This enabled me to gain experience in not
only the technical and practical aspects of industry but also in human relations,
teamwork and also provided great insights into the actual working of an
industry. Without his efforts this training would not have been as great learning
experience as it been.

I would also like to thank MR. RATAN YADAV (AGM, HR), who ensured
a proper work environment.

I take this opportunity to thank my training incharge MR.UMESH KUMAR

and my H.O.D MR.KULDEEP SINGH for their constant advice.

I hereby also declare that the contents in this report are true to the best of my
knowledge.
TABLE OF CONTENTS

S.NO. TOPIC
1.

Introduction

2. Compan

y profile

Welding shop

3. Resistance welding

3.1 Spot welding

3.2 Projection welding

3.3 Seam welding

4. Arc welding

4.1 Stud welding

5 Metal inert gas welding

5.1 CO2 MIG welding

6. Equipments for welding

6.1 IT GUN

7. Welding shop specifications

Press shop
 8 Operations in press shop

9. Project assigned

10. Learning

INTRODUCTION
Caparo Maruti Limited is a joint venture of Maruti Udyog Limited.
Caparo group belongs to Lord Swaraj Paul. It is a U.K based company.
It has 19 plants all over India , amongst them 3 are the joint ventures
with Maruti Udyog Limited.

Caparo maruti is a medium scale industry. It consists of 400 employees

in Gurgaon plant. It makes 21sub components out of which 7 are made
only at press shop and remaining by the help of welding process.

There are 2 shops in this plant -

a. PRESS SHOP
b. WELD SHOP

In press shop there are 4 mechanical presses (800T, 400T, 400T,400T)

and one hydraulic press.

The processes involved in this shop are -

a. Drawing
b. Trimming
c. Piercing
d. Side bending

In weld shop there are 4 welding processes involved –

a. Spot welding (using IT Gun)

b. Projection welding
c. Stud welding
d. MIG welding
COMPANY PROFILE
 A. WELDING
It is a fabrication technique and is used to join the metals by heating
and then pressing together.

Welding is the process of joining metals

FILLER MATERIAL

MELTING
JOINING
HEAT OF METAL
OF METAL

1. CURRENT
2 GAS NO FILLER MATERIAL
3 CHEMICAL
REACTION

FIG . 1

Welding is of various types:-

1. Resistance welding

a. Spot welding
b. Seam welding

2. Electric arc welding

3. Gas welding

In Caparo Maruti Limited (CML) there are different types of welding techniques used
for processing of sub assemblies of the automobiles like-

1. Spot welding
2. Projection welding
3. Stud welding
4. MIG (metal inert gas welding) welding

FIG. 2
1. RESISTANCE WELDING
It is the process of joining metal pieces together by raising the temperature of
the pieces to fusion point and applying a mechanical pressure to join them. In
this, the pieces to be joined are held together and a strong electric current of
high amperage and low voltage is passed through them. This current comes
across a certain resistance in passing from one piece to other and it is this
resistance offered to the flow of current which results in raising the
temperature of the two pieces to fusion or melting point at their junction. The
mechanical pressure applied at this moment completes the weld.

FIG. 3

Resistance welding process depends upon correct application and proper

control of the following factors:-

1. Welding current – Enough current is needed to bring the metal to its

plastic state for welding.

2. Welding pressure- In this welding mechanical pressure is required to be

applied at two stages- first to hold the metal pieces tightly between the
electrodes, while the current flows through them, and secondly when the
metal has been heated to its plastic state, to forge or squeeze the metal
pieces together to form the weld. The former is known as WELD
PRESSURE and the latter FORGE PRESSURE

3. Heat is directly proportional to the square of current and time.

H=I2xRxT.
H = Heat
 I2 = Current in amperes,
R = Resistance of the work in 0hms,
T = Time the current flow in cycles
( 50 CYCLES IN ONE SECOND)

4. Time of application - It can also be described as cycle time and is the sum
total of the following time periods-

a. Weld time – It is the time period during which the current flows
through the metal pieces to raise their temperature.

b. Squeeze time or forging time- It is the time period during which the
forge pressure is applied to the metal pieces to squeeze them together
to form the weld.

c. Hold time- It is the time period during which the metal pieces are
held together under forge pressure for a short while to enable the
weld to solidify. It can therefore, be called cooling time also.

d. Off-time- After cooling of weld the electrode pressure is released and

the metal pieces removed for the next operation cycle. The time
period between this release of electrodes and the start of next welding
cycle is called off-time.

5. Contact area of electrodes - The weld size depends on the contact area of
the face of the electrodes. It can be varied by selecting suitable set of
electrodes to provide the desired area of contact at their tips.
CURRENT

OFF
WELD

HOLD
UP SLOPE

DN SLOPE
EEZE
Q
U
S

TIME

FIG.4 WELD TIME CONTROL FOR SPOT

WELDING
NUGGET TEST (RELATION BETWEEN CURRENT
AND PRESSURE) -

No Nugget
Larg
Splash
e
Pr

su
re
es

Nugget Dia B - will have

(Strength) eld Good Weld
W Less Spatters
d
Small oo Explosion Optimum Nugget Dia
G

Current
A:High Current and High Pressure -
SPLASH
B:Medium current and medium Pressure -
GOOD WELD
C: Small Current and High Pressure
NO NUGGET

FIG. 5
 1 (a). RESISTANCE SPOT WELDING

The principle of spot welding- in which a transformer core is having primary and
secondary winding. One end of the secondary winding is connected to the upper
electrode carried in the movable copper or bronze arm A and the other end to the
lower electrode mounted on the fixed arm B. In operation the metal sheets S1
and S2 are held and pressed between the electrodes and a strong current at low
voltage is switched on. Due to the resistance offered by the sheet metal to the flow
of this current the temperature at the contact surfaces rises to fusion point and
the weld is completed under the contact pressure of the electrodes.

WELD SPOTS

CHIESEL
NUGGET DIA

NUGGET CHECKING METHOD

IF METAL SOUND ----- OK

UTM
SPOT SHOULD NOT FAIL

TENSILE STRENGTH CHECKING METHOD

 FIG.6 SPOT CHECKING METHOD

SPOT WELDING ELECTRODES & ELECTRODE HOLDER

The electrode holders should possess the following characteristics-

1. They should be good conductors of electricity.
2. They should be good conductors of heat.
3. They should possess high mechanical strength and hardness.

Most of these holders are water cooled and so are the electrode tips which are
made hollow for this purpose.

1(b). RESISTANCE PROJECTION WELDING

This process is similar to spot welding but differs from the latter in that the spots
at which the welding takes place are previously located by providing projections
at the desired locations on the surface of one of the work pieces. Thus the
surfaces of the work pieces are in contact with each other only at the projections.
As the current is switched on the projections are melted and the work piece
pressed together to complete the weld, by pressing the upper electrodes
downwards
NG OK
UPPER ELECTRODE

PIN

SPRING
LOWER ELECTRODE
PIN

NUGGET

FIG. 7 PROJECTION NUT WELDING

1(c). STUD WELDING
It is an arc welding process adopted specifically for welding of studs to structures
and other surfaces for fastening other components to them .it is done with the
help of a specially designed gun called stud welding gun. As soon as the gun
trigger is pressed the current is switched on and a solenoid inside pulls the stud
away from work piece by a predetermined distance. This creates an arc between
the stud and the work and the stud end and base metal melts. It has a controller,
3 phase transformer, and automatic trigger.

DRAWBACK-

If get unbalanced very difficult to balance.

 LIFT PLUNGE
STUD

BASE METAL LIFTED CONDITION

EXCITATION
LIFTING OF COIL
ACTION PLUNGE
WELDING
PULSE POINT
PILOT ARC
VOLTAGE PILOT ARC
WELDING
CURRENT

MELT CONDITION

HEATING
TEMPERATURE

FIG. 8

STUD WELDING (FLASH WELDING)

FIG. 9
 Reference condition for Stud welding

SPRING FORCE

SET STICK OUT TO 2 ~ 2.5 MM IN ALL CASE

SET LIFT 1 ~ 1.5 MM

SET CURRENTAND TIME FOR PILOT ARC MOST SUITED

A 15 30 50
M.S. 100 200 400

1(d). MULTI SPOT WELDING (MSW) -

It is similar to spot welding but as the name suggests it is used for doing multiple
spots at the same time. There are number of cylinders having magnetic slips in
them which creates magnetic field.
FIG. 10
 1(e). PORTABLE SPOT WELDING (PSW)-
It is a non integral type welding. It consists of a kick less and a coaxial cable. The
nugget produced is of very high diameter. The cost production is less because it
uses only 1 IT gun in place of 2.

PSW WELDING
SYSTEM Controller E
Welding gun Transformer B

FIG. 11

2. GUN WELDING
The specific use of this method is in welding of irregular surfaces, such as
fabrication of automobile bodies. The electrodes are actuated either
hydraulically or pneumatically. The equipment consists of a transformer,
flexible leads connecting the transformer to the welding gun, the welding gun
unit comprises of two electrodes and a trigger switch.
2(a). IT GUN (inbuilt transformer gun)

There are 4 cables in this gun-

1. Power cable (red)

2. Air cable (green)
3. Water cooling cables (black)

FIG.12
The water is coming from cooling towers with a flow rate of 6 to 8 liters/ minute.
The force produced by trigger is 200kg.

The major components of gun are-

1. firing card
2. control card
3. trigger switch
4. transformer
5. thyristor
6. primary and secondary windings
7. electrode
8. arms

DISADVANTAGES
1. Gun weight is very heavy.
2. Carbon deposition is there which creates insulation. It is removed
by filing and cooling.
3. Machine breakdown due to movable arms.
4. Production is slow.
5. Requirement is of 27 deg Celsius is there but the temperature is 45
deg Celsius in the plant.

3. METAL INERT GAS WELDING (MIG)

MIG stands for metal inert gas welding. It involves welding of metals using
consumable metal electrode in an inert gas atmosphere. The arc is struck
between the electrodes and the work piece. The electrode is in the form of
continuous wire which is fed into the arc, by an adjustable speed electric
motor, at the same speed at which it is melted and deposited in the weld. The
electrode holder also incorporates passage for supply of inert gas for shielding
the electrode, molten weld metal, arc from atmospheric contamination.
Usually D.C. with reverse polarity is used in MIG welding. Use of this enables
a deeper penetration.
 3(a). CO2 MIG WELDING
In this process the electrode used is either flux cored or magnetized flux
coated. Co2 is used as a shielding gas. In either case the filler wire or electrode
is fed the arc in the same way as in MIG welding.

In Caparo Maruti Limited (CML) there are different types of welding

techniques used for processing of sub assemblies of the automobiles like-

1.Spot welding
2.Projection welding
3.Stud welding
4. MIG (metal inert gas welding) welding

WELDING SHOP SPECIFICATIONS-

Area 1728 m2
Welding jigs 72 no.
Number of Guns 110
Manpower 128/shift
Operation shift 2
 PRESS SHOP
Press is a machine which undergoes various processes by applying tonnage on the
raw material.

There are various types of presses-

1. hydraulic presses
2. mechanical presses
3. pneumatic presses

In CML there are 4 mechanical presses (800T, 400T, 400T, 400T) and 1
hydraulic press.

The raw material used in press shop is cold rolled forged steel sheet (because
CRS has high tensile strength, elongation is good) as per requirement.

The companies which supply raw material are TATA, BHUSHAN, and
POSCO STEELS.

The following operations which are held in the press shop are -

1. Blanking – It is the process in which the punch removes a portion of material from
a stock which is a strip of sheet metal of the necessary thickness and width. The
removed portion is called a blank.

2. Drawing – It is the process of making cups, shells, and similar articles from metal
blanks.

3. Trimming - It is the process of removing extra material.

4. Piercing- The process of making holes in sheet.

5. Reforming and piercing - It is the process of providing holes, punches to the part.

6. Side bending- It is a operation of deforming of a flat sheet around a straight axis

where the neutral plane ( plane with no stresses) lies.
 FIG.13
.
FIG. 14
FIG. 15
HYDRAULIC PRESS

FIG. 16
PROCESS CHART-

FIG.17
Specifications
Area 1648 m2
Number of presses 4
Press capacity 800T -1 press

400T – 3 presses
Manpower 32/shift
Operational shift 3
2 types of lines tandem lines
Transverse lines
800 T press - motor of 96 kW
3.3- 3.2 bar atm. Pressure with die
2.8 bar atm. Pressure without die
400T press- motor of 64 kw
2.8 bar with die
2.5 bar without die
Hydraulic clutch is used

Components of dies-

1. Upper die
2. Lower die
3. Blank holder

SPECIFICATIONS OF DIES
Number of dies – 114 dies
Weight of die - 20 ton
Die raw material F/C 25
Cushion pressure -0.9-1.2kg/cm2
QUALITY IMPROVEMENT
What is Quality?: Definitions and Contrasts

The term quality means different things to different people. For example, a
quality automobile may be one which has no defects and works exactly as we
expect. "Quality is fitness for use." However, there are other definitions widely
discussed. Quality as "conformance to specifications" is a position that people in
the manufacturing industry often promote. Which include the expectation that a
product or service exceed the expectations of the customer? 1) Meet customer
standards, 2) meet and fulfill customer needs, 3) meet customer expectations, and
4) will meet unanticipated future needs and aspirations. Still others simply ignore
definitions and say "I'll know quality when I see it." It seems that we all 'know'
or 'feel' somehow what quality is. A product or service that exceeds our
preconceived idea about the quality of the product or service to be received is
likely to be designated as a quality product or service. It is equally clear that the
best of a group of bad products is not likely to be perceived as a quality product

Definition of Quality:

1. Customer-Based Fitness for use, meeting customer expectations.

2. Manufacturing- Conforming to design, specifications or requirements,

Based Having no defects.

The product has something that other similar products

3. Product-Based
Does not that add value?

The product is the best combination of price and

4. Value-Based
Features.
The Terminology of Quality

TERM DEFINITIONS
Customer Satisfaction 'Just what the term says...'
Tools used to measure and observe every aspect of the
Quality Tools
creation of a product.

Ways to measure: for example, time, cost, customer

Metrics
satisfaction, quality.
Flow Charting Creating a 'map' of the operations of a process.
Benchmarking Comparing your product to the best competitors.
Adding something that was not there before that the
Adding Value
customer wants.

Refers to what each individual in a meeting can

'Bring to the Table' contribute to a meeting, for example, a design or
brainstorming meetings.
 QUALITY DEFECTS:

1. PRESS SHOP.

A. Cracks.
B. Neck.
C. Wrinkles.
D. Dents.
E. Burs.

2. WELD SHOP.

A. Failure of spot by spot welding.

B. Nugget test failure.

QUALITY DEFECT ANALYSIS-

1 TOOLS: There are 7 QC tools are as given below:

1). Fish-bone analyses.

2). Pareto diagram.
3). Histogram.
4). Check sheets.
5). Control chart.
6). Flow chart.
7). Scatter diagram.
 Strategy to Change

3 PREVENTIVE MEASUREMENT :

a) FMEA (Failure mode & effective analysis)

b) MSA (Measurement system analysis)

c) Control plans

d) 7 QC tools
DEMING APPROACH
 LEARNING

The training at CAPARO MARUTI LIMITED provides me with great

knowledge in the fields of PRESS shop & WELD shop. I have seen the
manufacturing of different parts of automobiles like DASH ALTO, DASH
WAGONR etc. using mechanical presses of various tonnage where 4 operations
take place on a cold rolled forged steel sheet –

1. Blanking
2. Drawing
3. Trimming & piercing
4. Side bending

I have learnt welding concepts for different welding processes –

1. Spot welding
2. Stud welding
3. MIG welding
4. Projection welding

THANK YOU!!!