SATYUG DARSHAN INSTITUTE

OF
ENGINEERING AND TECHNOLOGY

SUMMER TRANING REPORT

AT
VICTORA AUTO AND ENGINEERING INDUSTRIES
PVT. LTD.

SUBMITTED BY

SHUBHAM SHARMA
ME/15/057
B.Tech Mechanical

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 ACKNOWLEDGEMENT

First, I thank The HR Head, MR.SUNIL for considering my potential in doing this
summer internship and providing this wonderful opportunity.

I would like to express my gratitude to Mr. Sudeep Singh for his invaluable suggestions,
motivation,guidance and support through out the training. His methodology to start from simple
ant then deepen through made me to bring out this project report without anxiety.

Thanks to all other VICTORA AUTO officials, operators and all other members of
VICTORA , yet uncounted for their help in completing the project and see the light of
success.

I am very thankful to friends, colleagues and all It is indeed a great pleasure and
privilege to present this report on training at VICTORA AUTO AND ENGINEERING
INDUSTRIES PVT. LTD.

I am extremely grateful to my training and placement officer for issuing a Training letter, which
made my training possible at VICTORA AUTO AND ENGINEERING INDUSTRIES PVT.
LTD
other persons who rendered their assistance directly or indirectly to complete this project
work successfully.
SHUBHAM SHARMA

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ABOUT COMPANY
VICTORA AUTO began its journey and became an organization commenced operations as a
manufacturer of press metal and other automotive parts for the Delhi-NCR region of India. Moving
strength to strength, assisted with experience and knowledge, VICTORA AUTO entered into the other
industries.

VICTORA auto signed a joint venture with scott India Ltd for the manufacturing of sheet metal
components and assemblies. The journey began with a vision to expand the business in the
automotive sector by keeping abreast with market trends and global technology.

Headquartered at Delhi-NCR, is a diversified conglomerate with presence in automotive, engineering &

design services, renewable energy and education sectors. The organization ’s commitment towards all
stakeholders and community has made it a leading manufacturing and engineering player.

The milestones and achievements of VICTORA auto gave the energy for diversification and
establishment of multiple business units in order to meet the needs of customers. The organization ’s
management follow a unique business model to create empowered companies that enjoy the best of
entrepreneurial independence, assisted with leverage of group-wide synergies.

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“Expanding leadership in our business through people, keeping pace with market trends and
technology.”

Core Values
We believe in ...

Simplicity,by keeping a low profile externally and having clear, open and effective
communication within the organization.

Teamwork, with well-defined responsibilities and accountability.

Relationships of trust amongst people, through well-defined job responsibility and authority.

According top priority to customer focus,through prompt and appropriate response.

Respect and care for all those dedicated to meeting commitments.

TECHNOLOGY
Technology, Innovation and People serve as the 3 key pillars of the VICTORA AUTO. Core to
this philosophy is a constant quest for excellence by enhancing technology, enabling innovation
and empowering people, thereby, creating consistent value for all stakeholders.

VICTORA AUTO has always kept a close watch on the dynamic needs of its customers and
continues the journey of efficiency by enhancing the technology at every stage. The
organization has collaborated with best global technology partners; possess state-of-the-art
manufacturing facilities and highly automated processes. These advantages have established
new benchmarks that have aided in providing superior quality and flawless technical perfection
to the organization's deliverables.

The continuous commitment towards excellence and consistent efforts to innovate have brought
excellent growth results for the Group. Apart from incorporating sophisticated technology, JBM
Group aims to not only exceed expectations, but to create value through innovation. The long
standing commitment to nurture research and development has brought the organization a long
way since its commencement 3 decades ago.

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Environment, Health & Safety
At VICTORA AUTO, sustainability is the way of doing business. The Group aligned its
goals for environment, health and safety, making an impact across its value chain worldwide.
Together with the suppliers, customers and stakeholders, VICTORA 4strives to maintain
highest standards to preserve and protect the environment, as well as enhance the health and
safety of the Group’s employees and communities.

DEPARTMENT IN THE VICTORA AUTO

1) Press shop

2) Paint shop

3) Quality department

4) Engineering department

5) Packaging department

6) Weld shop

7) Finance department

8) Purchase department

9) Maintenance department

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PROJECT TITLE

TO INCREASE THE PRODUCTION OF PRESS SHOP WITH THE HELP OF

GANGING OF DIES.

ABSTRACT

Now a days we see industry works on 6 factors. These factors are very much responsible for the
growth of a industry. These are

1) Safety
2) Productivity
3) Quality
4) Cost
5) Delivery
6) Moral

But here in this project we are concentrating on only on factor i.e. increase in productivity. Here
we are using a method of ganging of dies in which two similar dies are mounted on a press
machine. This help us reduction of productivity time. Which will enhance the productivity. So
this method is very much effective in increase the productivity of the material. This is cost and
time saving method which will help in the betterment of the industry.

PART NAME : GUSSET HEAD

THEORY:-

Here the work is done on 250T press machine. In the production of gusset head there are mainly
4 steps are involved. These processes are also shown in table according to there steps. Suitable
dies are used with respect to the process followed. Gusset head is generally a BAJAJ part which
are used in platina bikes. These parts gives the support to the engine.

The pictorial view of gusset head is shown in the figure which is given below

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 SHEET METAL

METHODOLOGY:-

1. First step all the sheets of metal is procured from the vendor.
2. The grade of the material is checked by the inspection department. In inspection these
three things are checked. Wrong size of the metal sheet, grade of the metal sheet and the
visual defects of the metal sheet.
3. Now the first operation is to be performed i.e. Blanking. It is done to extract the profile
sheet from the metal sheets. In this the operation the profile sheet should be according
to our need . it should be dent, scratch and burr free.
4. Second operation which to be performed is Forming. In this draw is done on the
blanked profile sheet. In this operation complete bend should be done, scratch should be
taken care of through oiling, crack/ thinning should be regularly checked.
5. After this Piercing is to be performed. It a type of operation which is totally opposite
of blanking. In this pierced profile sheet is avoided rest is considered. Dimension of
us/os has to be maintained,& location of hole should not be displaced.
6. Last step is Bending and Trimming. In this side part of gusset is bend and extra part of
the sheet is trimmed.

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TABLE:-

Process Incoming source Product Expected/actual

Description of variation characterstics strokes (per
hour)
Receiving Wrong size 1.5+/-0.1
Inspection
Wrong grade 260*1250 +/-2mm

Visual defects

Blanking Improper profile Free from

Dent/scratch Burr

Dent 250/150

Crack

Forming Incomplete bend Free from

Scratch Burr

Crack Crack 250/160

Dislocation Scratches

Piercing Dim us/os Free from

Hole/slot size Burr 250/170

Location Crack

Visual defects

Bending-trimming No thinning Free from

Incomplete profile Burr

Scratch Crack 250/180

burr Thinning

Visual defects

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Blanking-

FORMING

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Piercing

Bending-

NOW IF APPLY 2 DIES IN SAME PRESS THEN THE OPERATION CAN BE

PERFORMED AT FASTER RATE

TO USE GANGING OF DIES THE FOLLOWING THINGS SHOULD BE TAKEN INTO

CONSENDERATION

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 1. Power of the press.
2. Size of the bluster bed.
3. Size of the dies.
4. Shut height of the die.
5. Shut height of the press.
6. Tonnage required for the die.

Now let’s assume that the die is having the same shut height and is between in given range of
shut height of the press.

Condition for dies are :-

Length – 910mm

Shut height -650mm

Width – 500mm

Now consider we are having a press which is having the bluster bed which can
accommodate approximately 2 dies. We are having such presses in our industry.

CALCULATION :- (Cost Estimation)

Procurement for the metal sheet- 45 rupees per kg

Dimensions of sheet -1230x260mm

Weight of on sheet- 1.020 kg

Thickness of the sheets- 1.5mm

Scraps cost -25 rupees per kg

Generally cost is estimated with the help of 5 M. These are

1. Man
2. Machine
3. Material
4. Management
5. Method

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but as per general idea we are calculating as cost 2 rupees per strokes ignoring all the all
other hidden cost.

Now according to table

Cost estimated for blanking- 2x150=Rs300

Cost estimated for forming- 2x160=Rs320

Cost estimated for percing-2x170=Rs340

Cost estimated for bending-trimming- 2x180=Rs360

Total cost-Rs1320

This is a rough calculated cost in this hidden cost are not involved like maintainace,
worker availability etc. are not included.

Now if re plan our process and mount 2 dies in one press

For example

Blanking and forming at a time in a single press having different dies. This will save time as well
as machine cost.

And similarly at the same time piercing and bending trimming operation can be

done. Now the calculation of cost

Cost for blanking and forming-2x150=Rs300

Cost for piercing and bending-2x170=Rs340

Total cost=Rs640

This is a rough calculated cost in this hidden cost are not involved like maintainace,
worker availability etc. are not included.

Advantages of ganging of dies

1. Cost saving
2. Time saving
3. Man power saving
4. Less press machine required
5. Utility of press machine increases

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 6. Pace of work is fast
7. Production is high

Disadvantages of ganging of dies

1. Require bigger bluster bed

2. May require a dummy cushion when one die require cushion and other’s didn’t so
dummy cushion is given to the second die in order to balance it.
3. Tonnage of press should be greater or equal to the die required.
4. Shut height of both the dies should be same and should be in press shut height range.

Conclusion of Project

This method is very much effective in increasing the production rate. This works quite
efficiently. By using this method we can cover some parameter which is very much important for
every industry.

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Dies and its Types:

Die:
The die may be defined as the female part of a complete tool for producing work in a press. It is also
referred to a complete tool consists of a pair of mating members for producing work in a press.

Types of dies:
The dies may be classified according to the type of press operation and according to the method
of operation.

(A): According to type of press operation:

According to this criterion , the dies may be classified as cutting dies and forming dies.

1: Cutting Dies:
These dies are used to cut the metal. They utilize the cutting or shearing action. The common
cutting dies are : blanking dies , perforating dies , notching dies , trimming , shaving and
nibbling dies.

2: Forming Dies:
These dies change the appearance of the blank without removing any stock. Theses dies include
bending, drawing and squeezing dies etc.

(B) According to the method of operation:

According to this criterion, the dies may be classified as : single operation or simple dies ,
compound dies , combination dies , progressive dies , transfer dies and multiple dies.

1: Simple Dies:
Simple dies or single action dies perform single operation for each stroke of the press slide. The
operation may be one of the operation listed under cutting or forming dies.

2: Compound Dies:
In these dies, two or more operations may be performed at one station. Such dies are considered
as cutting tools since, only cutting operations are carried out. Figure shows a simple compound
die in which a washer is made by one stroke of the press. The washer is produced by simulation
blanking and piercing operations. Compound dies are more accurate and economical in
production as compared to single operation dies

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3: Combination Dies:
In this die also , more than one operation may be performed at one station. It is difficult from
compound die in that in this die, a cutting operation is combined with a bending or drawing
operation, due to that it is called combination die.

4: Progressive Dies:
A progressive or follow on die has a series of operations. At each station , an operation is
performed on a work piece during a stroke of the press. Between stroke the piece in the metal
strip is transferred to the next station. A finished work piece is made at each stroke of the press.
While the piercing punch cuts a hole in the stroke , the blanking punch blanks out a portion of
the metal in which a hole had been pierced at a previous station. Thus after the first stroke , when
only a hole will be punched , each stroke of the press produces a finished washer.

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 Progressive die

6: Transfer Dies:
Unlike the progressive dies where the stroke is fed progressively from one station to another. In
transfer dies the already cut blanks are fed mechanically from one station to other station.

7: Multiple Dies:
Multiple or gang dies produce two or more work piece at each stroke of the press. A gang or
number of simple dies and punches are ganged together to produced two or more parts at each
stoke of the press.

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HYDRAULIC AND MECHANICAL PRESSES

The press represents a specific type of machine tool, essential in the performance of industrial
manufacturing processes. Presses deliver energy through a force that acts over a distance or
stroke. One important application is in metal forging manufacture. The energy of the press is
used to close the die, forging the part within. Press machine tools apply force/energy to the work
differently than drop hammers, (that deliver energy to the work through a collision), hammers
are the other class of machine tools used to forge metal parts. Drop hammers are covered on the
previous page. This page will cover different types of press machines, their function, and
capabilities, although it is located in the metal forging section, forging is only one class of
manufacturing processes that employ presses.

Press machines are also the primary machine tool used in metal extrusion and sheet metal
fabrication processes. Hydraulic and mechanical presses are employed during sheet metal
forming to the extent that sheet metal processes, in general, are often referred to as press
working. Presses may be used in the manufacture of plastic parts. Machining operations, such as
broaching, may also require presses.

Press machine tools vary in size and in the amount of force they can output. The energy from a
press is often used to do work requiring a tremendous amount of force, such as a large amount
of plastic deformation of a sizable piece of metal. The method and nature by which a press
machine will deliver its energy will vary, dependent on its type.

Machine presses shown here are vertical, meaning that the force vector is up and down relative
to gravity. In many cases these same machine types are utilized horizontally, meaning the force
is delivered in a path perpendicular to the direction of the force of gravity. If the force be exerted

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vertically, horizontally, or at some intermediate angle, the working principles of each type of
machine tool are the same.

Press machine tools are of two main types, hydraulic presses and mechanical presses. Selection
of a type of machine press depends on the factors of the manufacturing process. The first
consideration would be the basic type of process the press tool will be employed to perform. For
example, a press for metal forging, a press for extrusion, a press for impact extrusion, or a press
for sheet metal working will all have different general requirements. The next very important
factor in machine press selection for a manufacturing operation is the press capacity required.
Required press capacity is likely related to the size of the work stock, and type of process.
Length of stroke over which the press delivers force is another primary factor when choosing a
press machine tool, this also will be related to the basic type of process being employed. These
initial considerations should give an immediate idea of the general type of press required. After
this, all the specific factors of the manufacturing process should be weighed, to determine the
best choice for a press machine tool.

Hydraulic Presses

Hydraulic presses are a powerful class of machine tools, they derive the energy they deliver
through hydraulic pressure. Fluid pressure, in a particular chamber, can be increased or
decreased by the use of pumps, and valves. Sometimes devices and systems may be used to
increase the capacity of the pumps in more powerful presses. These presses can operate over a
long distance and at a constant speed. Hydraulic presses are generally slower relative to other
press machine types. This involves longer contact with the work, therefore the cooling of the
work can be an issue when hot forming a part with hydraulic force. Hydraulic presses are
capable of being the most powerful class of presses. Some may be as large as buildings, and
can deliver awesome pressure. The largest hydraulic presses are capable of applying 75,000
tons, (150,000,000 lbs), of force. The hydraulic press shown is being used to manufacture a
metal forging. Extrusion is also a very common use for such a press, although extrusion is often
performed horizontally.

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The basic working principles of the hydraulic press are simple, and rely on differences in fluid
pressure. Fluid is pumped into the cylinder below the piston, this causes the fluid pressure
under the piston to increase. Simultaneously, fluid is pumped out of the top channel, causing the
fluid pressure above the piston to decrease. A higher pressure of the fluid below the piston than
the fluid above it causes the piston to rise. In the next step, fluid is pumped out from below the
piston, causing the pressure under the piston to decrease. Simultaneously, fluid is pumped into
the cylinder from the top, this increases the fluid pressure above the piston. A higher pressure of
the fluid above the piston, than the fluid below it, moves the piston downward.

Mechanical Presses

Mechanical presses belong to a class of machine tools that encompass a wide range of different
machine types. Primarily, the mechanical press transforms the rotational force of a motor into a
translational force vector that performs the pressing action. Therefore, the energy in a
mechanical press comes from the motor. These types of presses are generally faster than
hydraulic or screw presses, (actually the screw press may also be classified as a mechanical
press). Unlike some presses, in a mechanical press, the application of force varies in both
speed and magnitude throughout the distance of the stroke. When performing a manufacturing
operation using a mechanical press, the correct range of the stroke is essential.

Presses are chosen based on the characteristics of the manufacturing process. Mechanical press
machine tools are commonly used in metal forging manufacture, and sheet metal working. The
desired application of force will dictate the type of machine required. Extrusion will often
necessitate a more consistent force over a longer distance. However, a mechanical press may often
be a good choice for impact extrusion, since a fast, quickly repeatable application of force

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over a limited distance is what is needed for that type of manufacturing process. The most
powerful mechanical presses in modern manufacturing industry will have a press capacity
of about 12,000 tons, (24,000,000 lbs).

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 SHEET METAL WORKING
1. Introduction

Sheet metal is simply metal formed into thin and flat pieces. It is one of the fundamental forms
used in metalworking, and can be cut and bent into a variety of different shapes. Countless
everyday objects are constructed of the material. Thicknesses can vary significantly, although
extremely thin thicknesses are considered foil or leaf, and pieces thicker than 6 mm (0.25 in) are
considered plate.

2. Sheet metal processing

The raw material for sheet metal manufacturing processes is the output of the rolling process.
Typically, sheets of metal are sold as flat, rectangular sheets of standard size. If the sheets are thin
and very long, they may be in the form of rolls. Therefore the first step in any sheet metal process is
to cut the correct shape and sized ‘blank’ from larger sheet.

3. Sheet metal forming processes

Sheet metal processes can be broken down into two major classifications and one minor classification

 Shearing processes -- processes which apply shearing forces to cut, fracture, or separate
the material.
 Forming processes -- processes which cause the metal to undergo desired shape changes
without failure, excessive thinning, or cracking. This includes bending and stretching.
 Finishing processes -- processes which are used to improve the final surface
characteristics.
4. Shearing Process

1. Punching: shearing process using a die and punch where the interior portion of the sheared
sheet is to be discarded.
2. Blanking: shearing process using a die and punch where the exterior portion of the shearing
operation is to be discarded.
3. Perforating: punching a number of holes in a sheet
4. Parting: shearing the sheet into two or more pieces
5. Notching: removing pieces from the edges

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 6. Lancing: leaving a tab without removing any material

Shearing Operations: Punching, Blanking and Perforating

5. Forming Processes

 Bending: forming process causes the sheet metal to undergo the desired shape change by
bending without failure.
 Stretching: forming process causes the sheet metal to undergo the desired shape change
by stretching without failure.
 Drawing: forming process causes the sheet metal to undergo the desired shape change by
drawing without failure.
 Roll forming: Roll forming is a process by which a metal strip is progressively bent as it
passes through a series of forming rolls.

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 Common Die-Bending Operations

Various Bending Operations

Schematic illustration of a stretch-forming process.

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Finishing processes

Material properties, geometry of the starting material, and the geometry of the desired final
product play important roles in determining the best process

Equipments

Basic sheet forming operations involve a press, punch, or ram and a set of dies.

5.1 Marking and measuring tools

 Steel Rule - It is used to set out dimensions.
 Try Square - Try square is used for making and testing angles of 90degree
 Scriber – It used to scribe or mark lines on metal work pieces.
 Divider - This is used for marking circles, arcs, laying out perpendicular lines, bisecting lines, etc.

Marking and measuring tools

Cutting Tools
 Straight snip - They have straight jaws and used for straight line cutting.
 Curved snip - They have curved blades for making circular cuts.

Striking Tools
 Mallet - It is wooden-headed hammer of round or rectangular cross section. The striking
face is made flat to the work. A mallet is used to give light blows to the Sheet metal in
bending and finishing. As shown in fig.

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 CONCLUSION

It’s always a great opportunity to experience the valuable exposure of an industry. There is lot of
difference between the Theories and Practices. This Training enables me to understand the
aspects of professional life. I like the working environment followed at VICTORA AUTO PVT.
LTD. and come to know how to deal with our colleagues. The company’s members are well
cultured & well mannered.

An effective process is followed at VICTORA AUTO PVT. LTD. but it would become more
valuable and impressive by implementing certain efficient measures. The company is constantly
focusing on providing better services, quality and reliability to customers, and running
successfully in this era of competition.

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