NEEL AUTO PVT LTD(JBM GROUP)

FROM
10
TH
JUNE13 to 26
st
JULY13
SUBMITTED BY: -
VIVEK
AMBARDAR
B.E. II
ND

YEAR
MEHANIAL
ENGINEERING
M.B.M
ENGINEERING OLLEGE
JODHPUR

Incorporation : 1979
Commercial Production : 1981
Initial Public Offer : 1995
Traded at : Mumbai Stock
Ec!an"e

Product : Cold #or"ed $i% Ten&ile #a&tener&


'ork : ()# Indu&trial *rea+ #aridabad
Total
number of
Emplo,ee& -*pr./80 : 15/

Total number of
Mac!ine&- *pr./80 : 19/
Ma2or Manufacturin"
Proce&&e& : Cold #or"in"
3ollin"
$eat Treatment
P!o&p!atin"
Platin"

Domestic
Customers
ACKNOWLEDGEMENT
IN MODERN TECHNICAL FIELD MORE INTEREST AND MORE
IMPORTANCE IS BEING GIVEN TO PRACTICAL KNOWLEDGE OF A
PARTICULAR STUDENT. FOR THIS REASON THESE DAYS
WORKSHOPS AND TRAINING SESSIONS ARE BEING CONDUCTED
TO KEEP THE STUDENTS TECHNICALLY SOUND. AFTER MY SIXTH
SEMESTER I HAVE UNDERGONE IMPLANT TRAINING AT !TERLING
TOOL! LTD. "ARIDABAD.
I AM EXTREMELY GRATEFUL TO Mr. Pradee So!o"a#
$PRODUCTION A.M.%& FOR THEIR EXPERT GUIDANCE AND
VALUABLE SUPPORT DURING MY TRAINING PERIOD.
NAME' VIVEK AMBARDAR
B.E. IIND YEAR
MECHANICAL ENGINEERING
M.B.M ENGINEERING COLLEGE& (ODHPUR
PREFACE
WITH IMMENSE SINCERITY AND PLEASURE I HAVE COMPLETED MY
TRAINING AT WELL)DEVELOPED PLANT WITH LATEST TECHNOLOGY
OF !TERLING TOOL! LTD. THE PURPOSE OF TRAINING IS TO
TAKE ONE TECHNICALLY SOUND AND WORK EFFICIENTLY AND
EFFECTIVELY. IT HELPS ONE TO GET THE RE*UIRED KNOWLEDGE
OF MANPOWER& ACTUAL WORK RE*UIREMENT& INDUSTRIAL AND
HUMAN RELATIONSHIPS. THE EXPERIENCE AT THE INDUSTRY
DEALING WITH SUPERVISORS AND ACTUAL WORK ENVIRONMENT
GAVE ME SOME PRACTICAL KNOWLEDGE WITH RESPECT TO WHAT
WE HAVE STUDIED THEORETICALLY FROM THE CURRICULUM
BOOKS.
THIS SIX WEEKS TRAINING GAVE ME SOME KNOWLEDGE OF THE
THINGS STATED ABOVE OF THE INDUSTRIAL TRAINING AND WE
HAVE UTILI+ED THE SAME TO THE BEST OF MY EFFORTS.
BOLT MAKING PROCESS
( FORGING MACHINE ) CUTTING
CONE MAKING
HEAD FORMING
TRIMMING

(CNC LATHES) SIMPLE TURNING
TAPER TURNING



(ROLLING MACHINE) ROLLING
KNURLING
(HEAT TREATMENT) HARDENING
*UENCHING $OIL%
TEMPERING
*UENCHING $OIL%
(PLATING) +INC PLATING
PHOSPHATING
COLOR PASSIVATION
(INSPECTION)
ROCKWELL HARDNESS MACHINE FOR HARDNESS
MANUAL INSPECTION FOR FORGING , ROLLING DEFECTS
EDDY CURRENT TESTING FOR PROPER DIMENSIONS
"ORGING
For-.!- ./ t0e ro1e// o2 de2or3.!-
t0e 3eta# 4et"ee! d.e/ , 5!10e/ to
o4ta.! a art o2 redeter3.!ed /.6e ,
/0ae
METHOD! O" "ORGING
1) HAND (!MITH) "ORGING
2) DROP "ORGING
3) UP!ET (MAHINE ) "ORGING
Ma10.!e 2or-.!- ./ 5/ed .!
3a!52a1t5r.!- 2a/te!er/.
2or-.!- ./ o2 t"o t7e/'
HOT FORGING
COLD FORGING
cold forging is used in
manufacturing fasteners.
HOT "ORGING
Hot 2or-.!- ./ t0e #a/t.1 de2or3at.o!
o2 3eta# at a te3erat5re a!d /tra.!
rate /510 t0at re1r7/ta##.6at.o! o115r/
/.35#ta!eo5/#7 ".t0 de2or3at.o!& t05/
a8o.d.!- /tra.! 0arde!.!-. For t0./ to
o115r& 0.-0 "or9 .e1e te3erat5re
$3at10.!- t0e 3eta#:/ re1r7/ta##.6at.o!
te3erat5re% 35/t 4e atta.!ed
t0ro5-0o5t t0e ro1e//. A 2or3 o2 0ot
2or-.!- ./ #s$t%&'()* +$',#-,& "0ere
3ater.a#/ a!d d.e/ are 0eated to t0e
/a3e te3erat5re. I! !ear#7 a## 1a/e/&
./ot0er3a# 2or-.!- ./ 1o!d51ted o!
/5era##o7/ .! a 8a1553 or 0.-0#7
1o!tro##ed at3o/0ere to re8e!t
COLD FORGING
Co#d 2or-.!- .!8o#8e/ e.t0er .3re//.o!
d.e 2or-.!- or tr5e 1#o/ed d.e 2or-.!-
".t0 #54r.1a!t a!d 1.r15#ar d.e/ at or
!ear roo3 te3erat5re. Car4o! a!d
/ta!dard a##o7 /tee#/ are 3o/t
1o33o!#7 1o#d)2or-ed. Part/ are
-e!era##7 /733etr.1a# a!d rare#7
e;1eed <= #4. T0e r.3ar7 ad8a!ta-e
./ t0e 3ater.a# /a8.!-/ a10.e8ed
t0ro5-0 re1./.o! /0ae/ t0at re>5.re
#.tt#e ?!./0.!-. Co3#ete#7 1o!ta.!ed
.3re//.o!/ a!d e;tr5/.o!)t7e 3eta#
@o" 7.e#d dra2t #e//& 1#o/e)to#era!1e
1o3o!e!t/. Prod51t.o! rate/ are 8er7
0.-0 ".t0 e;1et.o!a# d.e #.2e. W0.#e
1o#d 2or-.!- 5/5a##7 .3ro8e/
3e10a!.1a# roert.e/& t0e
.3ro8e3e!t ./ !ot 5/e25# .! 3a!7
1o33o! a#.1at.o!/ a!d e1o!o3.1
ad8a!ta-e/ re3a.! t0e r.3ar7
.!tere/t. Too# de/.-! a!d 3a!52a1t5re
are 1r.t.1a#.
A STATION BOLT MAKING
RAW -MATERIAL
For Bolts
S!r"#s
R$# M$t"r%$l
S&"!%'!$t%o(
a% B.B Grade $ <<)C<
HRC%
DE B <D ) 5 to M DE
/.6e
D= B <= F Fro3 MD< to M
DG /.6e
4% DE.H -rade $C<)
CHHRC%
D=AD Fro3 M = to M D<
D=BAD,ADAE F MDA ,
a4o8e
1% D<.H -rade $ CBF
A< HRC %
ADAE
For N5t/ DEDE& DED= a!d DE B <D
I3orta!t Ra" 3ater.a# /e#e1t.o!
./ 4a/ed o! rod51t
-rade OR C5/to3er
/e1.?1 re>5.re3e!t

)* FUNDAMENTALS OF
FORGING OPERATION
T0e ra" 3ater.a# ./ 5/0ed .!to >5.##
, 15tter 47 t0e 2eed ro##/.
T0e re>5.red a3o5!t o2 3ater.a# ./
15t do"! 47 t0e 15tter ".t0 t0e 0e#
o2 >5.##.
T0e tra!/2er ?!-er/ 5/0e/ t0e .e1e
.!to t0e ?r/t /tat.o! "0ere 1o!e ./
2or3ed.
I! t0e /a3e "a7 t0e .e1e ./ 5/0ed
.!to /e1o!d , t0.rd /tat.o! "0ere
ro1eed.!-/ o2 0ead 2or3at.o!&
o.!t.!-& 3o!o-ra3 1arr.e/ o! a!d
a2ter t0at t0e .e1e ./ eIe1ted o5t 47
9!o19)o5t .!.
O!1e a-a.! t0e .e1e ./ .! t0e
tra!/2er ?!-er "0.10 a//e/ .t .!to
t0e A
t0
/tat.o! "0.10 ./ t0e tr.33.!-
/tat.o!.
No" t0e 4o#t .d/ read7 2or 25rt0er
ro1e//e/
THE TRANSFER FINGER MECHANISM
+* CNC MACHINING
CNC 3a10.!.!- ./ !ot a !e1e//ar7
ro1ed5re o2 4o#t 3a9.!-.
Pro1e//e/ at CNC deart3e!t are'
S.3#e t5r!.!-
Taer t5r!.!-
I! t0./ ro1ed5re t0e 4o#t .e1e ./
treated ".t0 /.3#e o.!t too# .! 1!1
#at0e to -.8e t0e re>5.red ?!./0.!- o2
t0e /5r2a1e o2 4o#t a/ re>5.red 47 t0e
15/to3er
A /e1.?ed de/.-!ed ro-ra3 ./
r5!!.!- 2or art.15#ar t7e o2 4o#t
Ea10 , e8er7 .e1e ./ 3a!5a##7
10e19ed 47 t0e 1!1 oerator at t0e
t.3e o2 1!1 3a10.!.!-. A!d 10a!-e/
are ta9e! to -et 1orre1t d.3e!/.o!/.

,* FUNDAMENTALS OF
THREAD ROLLING
OPERATION
T0e C
rd
, e//e!t.a# ro1e// o2 4o#t
3a9.!- ./ t0e ROLLING oerat.o!.
Here t0e 4#a!9 4o#t ./ ro##ed 4et"ee!
a 3o8.!- , a !o!) 3o8.!- D.e/. T0e
ro##.!- 3a10.!e ./ dr.8e! 47 t0e 1ra!9 F
/#.der 3e10a!./3
T0e /#.der 1o!/./t/ o2 a 3o8a4#e , a
!o! F3o8a4#e d.e a!d t0e 4o#t .e1e ./
ro##ed do"! 4J" t0e/e d.e/ , -ot t0e
re>5.red t0read.!-.

-* HEAT TREATMENT
PROCESS
H&)t t'&)t(&-t #s t%&
.'$/&ss $+ %&)t#-, 0 t%&-
/$$*#-, t%& s.&/#(&- t$
)/%#&1& t%& '&23#'&4 %)'4-&ss
$+ t%& .)'t#/3*)'.
Heat treat3e!t ./ re>5.red 2or t0e
2o##o".!- rea/o!/'
To re#.e8e /tre//e/ d5e to 1o#d
"or9.!-.
To .3ro8e 0ard!e// o2 /e1.3e!.
For 0o3o-e!eo5/ /tr51t5re.
For 4etter 3a10.!a4.#.t7.
T0e 0eat treat3e!t ro1e//e/ 5/ed .!
t0e 1o3a!7 '
D. Harde!.!- $ o.# >5e!10ed%
<. Te3er.!- $o.# >5e!10ed%
H"$t tr"$t."(t Pro!"ss $t STL
H)'4&-#-, T&(.. 5 660 t$
66074&,
H)'4&-#-, At($s.%&'& 5
M&t%)-&8LPG
93&-/% #- $#* )t '$$(
t&(.&')t3'&
H)'4&-&4 .'$43/ts 5 P$st
:)s%&4
T&(.&'#-, t&(.&')t3'& 5 ;00
t$ <<0
T&(.&'#-, )t($s.%&'& 5 A#'
93&-/% #- =)t&' )t '$$(
t&(.&')t3'&
HARDENING FURNANCE
HEAT TREATMENT OF FASTENERS IN STL
T0e 4o#t/ a!d /1re"/ are 0eat
treated .! t0e 25r!a1e to -et t0e
te!/.#e /tre!-t0
A% H)'4&-#-, > Mater.a# 0eated
a4o8e BGE ) BBE de- 1 a!d t0e!
>5e!10ed .! o.#
B% T&(.&'#-, F T0e 0arde!ed
2a/te!er/ are 0eated 4et"ee!
AEE to=EE 1 a!d 0ot a.r 1.r15#ated to
re3o8e t0e /tre//e/ de8e#oed d5e
to 0arde!.!-
/* PLATING -PROCESS
P#at.!- o2 2a/te!er/ ./ re>5.red 2or 9ee
t0e3 /a2e 2ro3 1orro/.o! , a#/o 2or
4r.-0t!e// o.!t o2 8.e".
Fo##o".!- t7e o2 #at.!- ./ do!e .! STL'
+INC PLATING
PHOSPHATING
!TEP! O" ?IN PLATING O"
"A!TENER! IN !TL
LAODING
SOAK DEGREASING
DENSITY)G)DE
E
C
TEMP)G=)K= EC
TIME)B)DE MIN.
DRAG OUT
CASCADE PHLMH
WATER RINSING
PICKLING
CASCADE PHNMA
WATER RINSING
ANODIC CLEANING $te3 G=)K=
E
C%
CURRENT)<EE)AEE AMP
TIME)G)DE MIN
DRAG OUT
CASCADE $PHLMH%
ACID ACTIVATION
WATER RINSING
+INC PLATING $TEMP)<=)C=
E
C%
TIME)GE)K= MIN
WATER RINSING
BRIGHT DIP $ (UST DIP%
PASSIVATION $ TRIVALENT SILVER
WHITE%
TEMP)=E)GE
E
C
TIME )GE SEC.
PH)D.G)<.E
CASCADEC
RE*UIRED COLORING
$USING DYING WATER%
CENTRIFUGAL DRIER
$RPM)<EE)AEE%
$TIME F =)DE MIN%
UNLOADING
6. IN!PETION
S.!1e .!/e1t.o! ./ do!e a2ter e8er7
ro1e// to 10e19 t0e d.Oere!1e
4et"ee! t0e re>5.red , a10.e8ed
tar-et.
E8e! t0e! t0e ?!a# .!/e1t.o! ./ a#/o
do!e& "0.10 ./ DEEP 10e19.!- o2 a##
t0e 2a/te!er/ 3ade , read7 to
d./at10.
T0e ?!a# .!/e1t.o! ./ o2 t"o t7e/'
MANUAL INSPECTION
EDDY CURRENT TESTER
I! 3a!5a# te/t.!- "or9er/ are
10e19.!- ea10 , e8er7 .e1e
3a!5a##7 2or t0e ro##.!- de2e1t/ a!d
2or-.!- de2e1t/. T0ere ./ a #./t o2
2or-.!- , ro##.!- de2e1t/ ".t0 ?-5re/
a!d .! edd7 15rre!t te/ter e8er7
.e1e ./ te/ted a5to3at.1a##7
THREAD ROLLING DEFECTS
T0e/e are /o3e ro##.!- de2e1t/
3a!5a##7 .!/e1ted'
DENT
THRED DAMAGE
INCLINED THREAD
CHIPS
BODY ROLLED
MACHINING OUT
THREAD GAP
FLAT THREAD
WITHOUT ROLL
DIE MARK ON FLANGE
SETTING PIECE
FORGING DEFECTS
T0e/e are /o3e o2 2or-.!- de2e1t/
.!/e1ted 3a!5a##7'
CHIP MARK
BURR
SHORT FEED
SCORING MARK
BEND
EXTRA MATERIAL ON FLANGE
HEX PIN CRANK MARK
FINGER OUT
CRACK
WITHOT TRIMMING
DIE CRACK
STUDD PIN BROKEN
STL PRODUCTS
GROUNDE , KNURLED BOLTS
DIFFERENT TYPES OF BOLTS
CYLINDER HEAD , ENGINE BOLTS
FASTENERS OF CRITICAL APPLICATIONS
FASTENERS WITH WASHER& STUDDS , RIVETS
I!O D&s#,-)t#$- s@st&( $+
")st&-&'s
I!O s.&/#A&s ) s@st&( +$'
t%& 4&s#,-)t#$- $+
+)st&-&'s #- .'$43/t
st)-4)'4s
)* N$."
+* R"l"0$(t ISO St1
,* T2r"$1 1%$ OR (o.%($l
D%$
-* F3rt2"r 1%$
4"$t3r"s( %4 ("!"ss$r5 )
/* No.%($l L"(6t2
7* T2r"$1 l"(6t2 or
S2$(8 L"(6t2
9* T5&" o4 &ro13!t ( %4
("!"ss$r5 )
:* Pro13!t Gr$1"( %4
("!"ss$r5)
;* T5&" o4 1r%0" ( %4
("!"ss$r5
)<* S3r4$!" Prot"!t%o(