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INTERNSHIP REPORT
ON
MANUFACTURING
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ACKNOWLEDGEMENT
This report would not have been completed without the assistance, co-
operation and enthusiasm taken by Mr. Mohammad Ashfaq Ali for his
warm guidance throughout the training period.
I would like to thank the employees and the workers of the ACMI
Industry for showing me the way and the workings of the industry and
the engineering involved in the running of such a vast commercial and
impactful industry.
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Abstract
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CONTENTS
1. Introduction
2. Introduction to Manufacturing
3. Procedure
4. Results And Discussion
5. Conclusions
INTRODUCTION
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ACMI Industry is a manufacturing company which mainly manufactures
Aluminium Gravity Die Casted parts.
The main aim is to become a market leader with sustainable growth and
customer satisfaction by meeting the fast growing demands of
developing economies.
INTRODUCTION TO MANUFACTURING
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Manufacturing is the production of products for use or sale using labour
and machines, tools, chemical and biological processing, or formulation.
The term may refer to a range of human activity, from handicraft to high
tech, but is most commonly applied to industrial design.
1 Casting
3 Moulding
4 Forming
5 Machining
6 Joining etc.
PROCEDURE
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With the aim to supply ready to assemble Gravity casted parts, the
industry established all processes under one roof. These processes
include Casting Simulation, Designing, Foundry, Heat Treatment, Shot
Blasting, Machining-CNC, Lathe & Drilling and Leak testing (Pressure,
Pneumatic and Helium) which are added as forward integration.
The process starts with designing and simulation of the product after
which the raw material is inspected and melted in some calculated
proportions. The so formed alloy is then taken for inspection and if no
deviations are found then further melting is carried out and finally the
alloy is poured into the required die/mould. Once the alloy takes the
shape of the die, then the excess part is removed from the required cast
by cutting/fettling. This step is followed by Solution
treatment/Ageing. Once ageing has been done, it is necessary to verify
the Mechanical Properties of the alloy using a Universal Testing
Machine.
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DESIGNING & SIMULATION
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RAW MATERIAL INSPECTION
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Raw material consists of Aluminium Ingots, Magnesium blocks,
Manganese, Silicon Metal, and Iron.
AL INGOTS SI PIECES
IRON BLOCKS
MELTING
The flames heat up the tubes, which in turn heat the fluid inside in the
first part of the furnace known as the radiant section or firebox. In this
chamber where combustion takes place, the heat is transferred mainly by
radiation to tubes around the fire in the chamber.
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in which the ignition of the material is carried out by a conventional
method having a unit consisting of oil tank, blower and pump.
Aluminium Ingots are melted in these furnaces at high temperatures.
During the melting, Silicon is added first in the furnace whereas
Magnesium is added at the last. These materials increase the properties
of the alloy.
ALLOY TYPES
1) LM9 - AlSi10MgKT6(Brittle)
2) LM25 - AlSi7Mg0.3KT6(Ductile)
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The following table indicates the metal composition in these alloys:
ALLOY INSPECTION
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emission of radiation. The basic function of a spectrometer is to take in
light, break it into its spectral components, digitize the signal as a
function of wavelength, and read it out and display it through a
computer. The alloy is then passed for further production.
Each metal composition in the alloy plays a vital role in shaping up the
properties of the alloy. Iron composition should never exceed the given
range as more percentage of iron can cause an adverse impact on
ductility and it causes more chance of failure during testing. Magnesium
is responsible for giving the hardness property to an alloy, so low
percentage of Mg can cause low hardness in the alloy. The percentage of
Silicon should also be kept under control as Si is responsible for the
porosity of an alloy thus if an alloy exceeds its Silicon composition then
the alloy can go under porosity defects. Metals such as Strontium and
Titanium help in refining the grain structure of an alloy.
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SAMPLE REPORT
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POURING
The inspected alloy is then poured into different sized dies which are to
be produced. The pouring is carried out with the means of a crucible
made out of clay-graphite or silicon-carbide which has a higher melting
point than that of the material to be melted.
Cutting/Fettling
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Cutting has been at the core of manufacturing throughout history. For
metals many methods are used and can be grouped by the physical
phenomenon used. It is the process of producing a work piece by
removing unwanted material from a block of metal in the form of chips.
Fettling is the means by which a crude casting is turned into a cost
effective quality component that meets all the standards required by the
customer.
Solution Treatment/Ageing
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Solution treatment is the heating of an alloy to a suitable temperature,
holding it at that temperature long enough to cause one or more
constituents to enter into a solid solution and then cooling it rapidly
enough to hold these constituents in solution. Its purpose is to relieve
internal stresses that are developed during the casting process.
Mechanical Testing
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A universal testing machine, also known as a universal tester, is used to
test the tensile strength and compressive strength of materials.
Mechanical properties are checked on UTM with test bars poured
ensuring the tensile strength and compressive strength of sample alloy.
An earlier name for a tensile testing machine is a tensometer.
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Shot blasting is done using SS shots to give castings uniform matt finish.
Graphs are plotted online for the heat treatment process with memory
backup.
Machining
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Lathe machines, Drilling etc.
LEAK TESTING
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Mainly two types of testing are carried out:
INSPECTION
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Qualified and experienced team of quality engineers to ensure products
supplied meeting all quality requirements of customers.
After all the steps, the final step is packing the product and dispatching it
to the authorized customer.
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CONCLUSION
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