ABOUT COMPANY

Talbros Automotive Components Ltd., the flagship manufacturing company of

the Group was established in the year 1956 to manufacture Automotive &
Industrial Gaskets in collaboration with Coopers Payen of UK.

Today, after 58 successful years, Talbros stands proud and tall as a mother
brand of Gaskets & Heat Shields, Forgings, Suspension Systems & Modules,
Anti Vibration components and Hoses.

Talbros Group has strong partnerships formed with global giants. Notable
among the joint venture partners are Nippon Leakless Corporation- Japan,
Magneti Marelli- Italy, Marugo Rubber- Japan and technology partners are
Sanwa Packaging Japan and Interface Solutions USA.

While our symbiotic relationship with our Global partners have kept us
abreast with innovations within the field, our long and fruitful association
with them bears witness to the trust and solidarity that Talbros name is
synonymous with.

Our Research & Development Centres showcase our design capabilities

including endurance, static and simulated environment testing. Today, our
manufacturing prowess spans over 5 business and 8 facilities.

The largest OEMs like Ashok Leyland, Bajaj Auto, Cummins Group, Eicher
India, Escorts Group, Force Motors, General Motors, Hero Honda, Honda,
Hyundai, John Deere, Mahindra & Mahindra, Maruti Suzuki, Suzuki, TAFE, Tata
Motors, Tata Cummins, Simpsons and international corporates like Carraro,
DANA, KMP Brand, Maxi Force, GKN Driveline are our proud customers.

The Group companies are TS 16949, ISO 14001 and OHSAS 18001 certified.
Our team takes the quest for quality very seriously. For every piece that is
manufactured, quality standards are strictly adhered to and industry
benchmarks often set.
Our unrelenting quest for perfection extends to the supply chain and to every
person responsible for extending quality service to the customer.
Talbros is where it is today due to the excellence of its product offerings, its
commitment to quality, attention to detail and, primarily, due to its incredible
workforce. Our people-friendly and professional approach towards human
resource development is responsible for our remarkably low attrition rate.
Constant upgradation of skills at training programmes in India and abroad
and an exemplary work culture has made every member of our team geared
for new challenges. Both employee and customer satisfaction are of extreme
importance to us.
Talbros Group portfolio also includes Mercedes Benz dealership for passenger
cars.
Talbros, where it is today is due to the excellence of its product offerings,
commitment to quality, attention to detail and professional approach.

GLOBAL PARTNERSHIPS
The Indian automobile industry is growing leaps and bounds. With new
players from across the globe venturing into the Indian market to tap its
immense and future potential, the demand for cutting-edge automotive
components is skyrocketing.
To further consolidate its leadership position in such a scenario, and provide
its customers with world-class components, Talbros Group has entered into
partnerships with global giants. Each of these partnerships brings along new
know-how, technology and vast experience, and empowers the Group to
further enhance its product offerings for its esteemed customers.

1. Nippon Leakless (JV partner in Nippon Leakless Talbros Pvt. Ltd.)

Established in 1955 Nippon Leakless is one of the largest global

manufacturers of Gaskets for Automotive, Motorcycle, Power Equipment,
Industrial and a major Honda supplier.
Head quarter in SAITAMA Japan With facilities spread over 10 countries; it has
annual sales of US$ 156 million. Its range of in-house developed products like
Mats and Rubber Coating.

2. Magneti Marelli (JV partner in Magneti Marelli Talbros Chassis Systems

Pvt. Ltd.)
With 8 business lines, 85 manufacturing units, 26 application centre and 12
R&D facilities in Italy, Germany, France, Brazil and India, Magneti Marelli is a
name to reckon with in the automotive industry the world over. Employing
over 38,000 people globaly and having an annual sale of 6 Billion. Its
technological and design prowess, added to its vast experience in
manufacturing is simply unmatched.

3. Marugo Rubber (JV partner in Talbros Marugo Rubber Pvt. Ltd.)

Marugo Rubber is a US $ 300 million company headquartered in Kurashiki,
Japan. It is a leading supplier of anti-vibration products and hoses to OEMs
globally. Through subsidiaries or joint ventures, it has manufacturing facilities
in 9 countries outside Japan, which include US, China, Germany, UK,
Thailand, Indonesia, Malaysia, India and Taiwan.
4. Sanwa Packing (Technology Partner in Talbros Automotive Components
Limited.)
Sanwa Packing came into existence in 1945 to manufacture automobile
gaskets. Since then it has come a long way and created a diverse set of
gaskets products based on metal-forming and coating technologies. Today,
its gasket and heat shield products especially the Nimbus Heat shield
developed in 1975, is widely used in the automotive industry. With
manufacturing base in China and Thailand, has a diverse customer base
including Daihatsu; Toyota; Honda, Suzuki and Nissan.

Awards and milestones

1. BAJAJ AUTO (Award received from Bajaj Auto)

2. EICHER MOTORS (Best Vendor Award)

3. WELFARE AWARDS
4. HONDA (Performance Award For Achieving Quality And Delivery Targets
(2010-11))

5. MAHINDRA & MAHINDRA AWARDS (Superior Performance(2011)

COMPANY MANUFACTURED

STEERING & SUSPENSION COMPONENTS-> TRACK CONTROL ARMS

-> SUSPENSION BALL JOINTS
-> INNER AND OUTER BALL JOINT

WISHBONES

SHEET METAL
FORGED AND ALUMINIUM FORGED
TIE ROD
DRAG ROD
STABLIZER LINK
STEERING LINK
TOURQUE ROD

 V FRAME
PITMAN ARMS

TIE RODS
Aluminium casting/forging is used to produce aluminium tie-rod ends for the
steering systems of automobiles. First, casting experiments were carried out
to attain a satisfactory preform for forging of tie-rod ends. In the casting
experiment, the effects of additives, Ti+B, Zr, Sr, and Mg, on the mechanical
properties and the microstructure of a preform cast were investigated. A
finite element analysis was performed to determine an optimal configuration
of the cast preform. Lastly, a forging experiment was carried out to make the
final product of an aluminium tie-rod end by using the cast preform.
In the casting experiments, when 0.2% Ti+B and 0.25% Zr were
simultaneously added into a molten AlSi alloy, the highest values of tensile
strength and elongation of the cast perform were obtained. When 0.04% Sr
was added into the molten aluminium ally, the finest silicon structure was
observed in the cast perform. The highest hardness was obtained when 0.2%
Mg was added. In the forging experiment, it was confirmed that the optimal
configuration of the perform cast could be predicted by FE analysis. The
hardness of a cast/forged product using the designed perform was superior
to that of required specifications.

DRAG LINK
A drag link converts rotary motion from a crank arm, to a second bellcrank,
usually in an automotive steering system.
The term is commonly used in automotive technology for the link in steering
linkage that converts rotation of a pitman arm to a steering arm and
eventually to tie rod links which pivot the wheels to be steered. The drag link
converts the sweeping arc of the steering arm to linear motion in the plane
of the other steering links.

FIG:- DRAG LINK

BALL JOINTS
A ball joint is used for allowing free movement in two planes at the same
time, including rotating in those planes. Combining two such joints with
control arms enables motion in all three planes, allowing the front end of an
automobile to be steered and a spring and shock (damper) suspension to
make the ride comfortable.
In an automobile, ball joints are spherical bearings that connect the control
arms to the steering knuckles. They are used on virtually every automobile
made and work similarly to the ball-and-socket design of the human hip joint.
A ball joint consists of a bearing stud and socket enclosed in a casing; all
these parts are made of steel. The bearing stud is tapered and threaded, and
fits into a tapered hole in the steering knuckle. A protective encasing
prevents dirt from getting into the joint assembly. Usually, this is a rubberlike boot that allows movement and expansion of lubricant. Motion-control

ball joints tend to be retained with an internal spring, which helps to prevent
vibration problems in the linkage.
On modern vehicles, ball joints are the pivot between the wheels and the
suspension of an automobile. They are today almost universally used in the
front suspension, having replaced the kingpin/ linkpin or kingpin/trunnion
arrangement, but can also be found in the rear suspension of a few higherperformance autos. Ball joints play a critical role in the safe operation of an
automobile's steering and suspension.
Many currently manufactured automobiles worldwide use MacPherson strut
suspension, which utilises one ball joint per side, between the lower end of
the strut and the control arm, with the necessary small amount of
articulation at the top of the strut being usually provided by an elastomeric
bearing, within which is a ball bearing to allow free rotation about the
steering axis. So, there are commonly only two ball joints in the suspension,
however there will be at least four (track rod ends and rack ends) in the
steering linkage.
In non-MacPherson strut automobile suspension, the two ball joints are called
the "upper ball joint" and "lower ball joint". Lower ball joints are sometimes
larger and may wear out faster, because the fore and aft loads, primarily due
to braking, are higher at the bottom ball joint. (Torque reaction and drag add
at the bottom joint, and partly cancel at the top joint.) Also, lateral cornering
loads are higher at the bottom joint. Depending on the suspension design,
the vertical load from the suspension spring may be handled entirely by the
top ball joint, or entirely by the bottom ball joint. The damper load, (which is
low in normal conditions, zero when stationary, but in peak bump or rebound
rate may be almost as large as the spring load) is usually, but not always,
taken on the same ball joint as the spring load. The anti-roll bar loading is
often, but not always, taken on the bottom ball joint. It may be taken by the
top ball joint, or directly from the steering knuckle by ball-jointed drop links.

FIG:- BALL PINS

PURPOSES
If one of the ball joints does not carry spring load, it may be fitted with an
internal anti-rattle spring to keep the ball preferentially in contact with one
seat. This was the case in the BMC Mini of 1959 and its many derivatives,
where the lower control arm carried no vertical loading, so the joint needed
and anti-rattle spring, while the top joint, comprising identical parts, was
always in compression due to spring (rubber cone) and damper loads, and so
was not fitted with a spring.
Other vehicles of the 1960s era, including some Vauxhalls, had lower ball
joints with considerable end float, because the joint was always in tension as
the spring and damper loads were applied via the lower control arm and
were always non-zero.
Another example is the Ford Focus, which uses MacPherson struts, and the
anti-roll bar is connected directly to the strut, so the lower ball joint is only
carrying fore and aft traction/braking and lateral cornering loads.

FAILURES:While there is no exact lifespan that can be put on sealed ball joints, they
can fail as early as 80,000 miles (130,000 km) in modern vehicles, and much
sooner in older vehicles. Signs of a failing ball joint may start with a sudden
burst sound as a result of ball joint dismantling. Then it keeps on with
clicking, popping or snapping sound when the wheel is turned and eventually
turn into a squeaking sound at the end of a stop, when the gas pedal is used
and/or also when hitting bumps. Another symptom could be 'thud' noises
coming from front suspension when going over bumps. Dry ball joints have
dramatically increased friction and can cause the steering to stick or be more
difficult.
If a ball joint fails, the results can be dangerous as the wheel's angle
becomes unconstrained, causing loss of control. Because the tire will be at
an unintended angle, the vehicle will come to an abrupt halt, damaging the
tires. Also, during failure, debris can damage other parts of the vehicle.

FIG:- BALL PINS

MAINTAINENCE

Sealed ball joints do not require lubrication as they are "lubed for life".
Formerly most ball joints had grease fitting (sometimes called a grease zerk)
and were designed for periodic addition of a lubricant, however almost all
modern cars use sealed ball joints to minimise maintenance requirements.
The lubricant was usually a very high-viscosity lubricant. It is commonly
believed that standard ball joints will outlive sealed ones because eventually
the seal will break, causing the joint to dry out and rust.

CONTROL ARMS:In automotive suspension, a control arm, also known as an A-arm, is a hinged
suspension link between the chassis and the suspension upright or hub that
carries the wheel.
The inboard (chassis) end of a control arm is attached by a single pivot,
usually a rubber bushing. It can thus control the position of the outboard end
in only a single degree of freedom, maintaining the radial distance from the
inboard mount. Although not deliberately free to move, the single bushing
does not control the arm from moving back and forth; this motion is
constrained by a separate link or radius rod.
This is in contrast to the wishbone. Wishbones are triangular and have two
widely spaced inboard bearings. These constrain the outboard end of the
wishbone from moving back and forth, controlling two degrees of freedom,
and without requiring additional links.
Control arms are most commonly encountered as part of the MacPherson
strut independent front suspension. The control arms are perpendicular to
the axis of the vehicle and are termed track control arms. A diagonal radius
rod constrains the strut from moving forward and back.

FIG:- CONTROL ARM

WISHBONES
In automobiles, a double wishbone (or upper and lower A-arm) suspension is
an independent suspension design using two (occasionally parallel)
wishbone-shaped arms to locate the wheel. Each wishbone or arm has two
mounting points to the chassis and one joint at the knuckle. The shock
absorber and coil spring mount to the wishbones to control vertical
movement. Double wishbone designs allow the engineer to carefully control
the motion of the wheel throughout suspension travel, controlling such
parameters as camber angle, caster angle, toe pattern, roll center height,
scrub radius, scuff and more.

ADVANTAGES AND DISADVANTAGES:-

Double wishbone suspension provides the engineer more free parameters

than some other types do. It is fairly easy to work out the effect of moving
each joint, so the kinematics of the suspension can be tuned easily and
wheel motion can be optimized. It is also easy to work out the loads that
different parts will be subjected to which allows more optimised lightweight
parts to be designed. They also provide increasing negative camber gain all
the way to full jounce travel, unlike the MacPherson strut, which provides
negative camber gain only at the beginning of jounce travel and then
reverses into positive camber gain at high jounce amounts.
Conversely, it may take more space and is slightly more complex than other
systems like a MacPherson strut. Due to the increased number of
components within the suspension set up it takes much longer to service and
is heavier than an equivalent MacPherson design. At the other end of the
scale, it offers less design choice than the more costly and complex multi-link
suspension system.

PITMAN ARM
The Pitman arm is a steering component in an automobile or truck. As a
linkage the steering box (see recirculating ball) sector shaft, it converts the
angular motion of the sector shaft into the linear motion needed to steer the
wheels. The arm is supported by the sector shaft and supports the drag link
or center link with a ball joint. It transmits the motion it receives from the
steering box into the drag (or center) link, causing it to move left or right to
turn the wheels in the appropriate direction. The idler arm is attached
between the opposite side of the center link from the Pitman arm and the
vehicle's frame to hold the center or drag link at the proper height. A worn
ball joint can cause play in the steering, and may get worse over time.

FIG:- PITMAN ARM

MANUFACTURING PROCESS

MAIN WORKSHOP
THE WORKSHOP FLOOR IS DIVIDED INTO 2 PARTS
1. Machine shop and,
2. Assembly line.

Machine shop
The machine shop is divides in 3 bays

Bay 1
Bay 2
Bay 3

Bay 1 includes magnaflux and drilling machines.

Magnaflux is used to check for internal cracks, which may rise due to
several casting and cooling defects,present in component. The component is
exposed to UV rays and the region where cracks are present appears red.
The machine takes 30 minutes to become functIon after switching on the
power supply and once the machine started, the life of the UV bulbs is
reduced by 4 hrs.
Bay 2 includes special purpose machine (SPM) and CNCs. SPMs carry out
burnishing process.
Bay 3 includes a mixture, i.e., CNCs, Drilling and Boring Machine.

ASSEMBLY LINE
The assembly line is classified in:

Assembly
Assembly
Assembly
Assembly
Assembly
Assembly

line
line
line
line
line
line

1
2
3
4 (inner ball joints)
5(outer ball joints)
YR-9

Assembly line YR-9 houses a sealing machine, which seals the ball pin to the
control arm with specific amount of lubricants with the help of cap, by
applying pressure. The machine has 3 rollers, which after the component is
kept in place for sealing, come down and apply uniform pressure, thus
sealing the joints. The machine is known as orbital machine.
After the ball pins has fitted , the control arm is then sent in to a furnace,
where the mobility of all pin is increased with the application of heat.

A no. of tests , rubber and metal bush is fixed on to control arm structure .As
the components are fitted, a marketing is provided simultaneously, to
indicate that ,that particlepart had been fitted at the time of assembly. This
technique is helpful to elude the situation in which blame is put on the
company for providing incomplete assemblies.
After these many processes, the control arm is then kept in lost boxes and
loaded for delivery.

ORDER OF MACHINING OF FEMALE PARTS (HOUSING)

1. Forging
2. Pre Drilling
3. Incoming inspection
4. Ppc department
5. Machine shop
6. Body machining
7. OD Turning and Grooving
8. Shank Turning
9. Burnishing
10.
Induction Harding
11.
Paint shop
12.
Phosphating
13.
Thread Rolling
14.
Component Inspection
15.
Assembly
MALE PART (BALL PIN)
1.
2.
3.
4.
5.
6.
7.
8.
9.

FORGING
Semi finish
Store
Incoming inspection
PPC Department
Machine Shop
Profile Turning
Split hole drill
Ball Burnishing

10.
11.
12.
13.
14.
15.

Induction hardening
Oil Grooving
Ball Grinding
Thread rolling
Component Inspection
Assembly

QUALITY CONTROL
QUALITY CONTROL DEPARTMENT
Quality control, or QC for short, is a process by which entities review the
quality of all factors involved in production. ISO 9000 defines quality control
as "A part of quality management focused on fulfilling quality requirements".
Elements such as controls, job management, defined and well managed
processes, performance and integrity criteria, and identification of records
Competence, such as knowledge, skills, experience, and qualifications
Soft elements, such as personnel, integrity, confidence, organizational
culture, motivation, team spirit, and quality relationships.
Controls include product inspection, where every product is examined
visually, and often using a stereo microscope for fine detail before the
product is sold into the external market. Inspectors will be provided with lists
and descriptions of unacceptable product defects such as cracks or surface
blemishes for example.
The quality of the outputs is at risk if any of these three aspects is deficient
in any way.
Quality control emphasizes testing of products to uncover defects and
reporting to management who make the decision to allow or deny product
release, whereas quality assurance attempts to improve and stabilize
production (and associated processes) to avoid, or at least minimize, issues
which led to the defect(s) in the first place.[citation needed] For contract
work, particularly work awarded by government agencies, quality control
issues are among the top reasons for not renewing a contract.

QUALITY POLICY

The company commits itself to manufacture and deliver products that

consistenly meet customer specifications at each stage and operations of
manufacturing thus producing reliable and enduring products.
Quality at each stage by all is the company motto and guiding principle, this
shall be attached by Continual improvements in systems, technology,& process.
Employee development, involvement and empowerment thereby
improving competence.
Reducing cost and improving performance by eliminating variation and
wastes.

QUALITY OBJECTIVES: Improving in design for product reliability.

Reducing non conformities.
Continual up graduation of system and operations.
Improvements In technology to enhance operational
performance and meet over changing of all global
environment.
SUB-DEPATMENTS: Centralised Sample evaluation Cell
Supplier Quality Control
Receipt Inspection
Standard Room
PROCESS: Receipt inspection- Inspection at the time of receiving the stock from
vendor.
Process Inspection- Inspection done time to time at various stages of
machining,
painting, assembling for conformation.
Final Inspection- Inspection of the finished products before the dispatch
of order to ensure quality.
Supplier Quality Assurance- Confidence in a suppliers ability to deliver
a good or service that will satisfy the customers needs.

QUALITY CONTROL TOOLS

1. Check Sheet- A Sample from used to enable data to be collected and

interpreted by making check marks.
2. Pareto Diagram- Diagram which defines VITAL FEW- TRIVAL MANY
problems.
3. Histograms- A graphic summary of variation is a set of data which is
known as frequency distribution diagram.
4. Cause & Effect Diagram- A useful method for identifying potential root
causes of a problem.
5. Graphs & Controls Charts
Graph- A graph for plotting data and showing temporal changes to
easily
understand the overall situation.
Control chart- A line graph used to access and maintain the
stability of a process for reducing process variability.
6. Scatter Diagram- A diagram which represents relation between two
sets of data.
7. Stratification- A method of regrouping data by common points to
understand similarities and characteristics of data.

IN-PROCESS INSPECTION
Inspection done time to time during the process of machining for
conformation is in process inspection.
It includes the following checking parameters: Parts per million calculation=(qty rejected)/(qty produced)*1000000
Process parameter Audit.
Functionality of machine:Tailstock Pressure
Feed
Speed

PRODUCT AUDIT- Drawing verification/ parts checking with visual of with

gauges or instrument like: Articulation Torque Gauge
Rotational Torque Rig

CSE CELL

Centeralised Sample Evalution (CSE) - This department works for sample

evalution which is coming from varios vendors for manufacturingcomponent
in the existing point.
Through every lot no. of pieces are selected and verified. This can be done
through 2 verified methods:1. Physical Verification:- critical dimensions, color, appearance
2. Chemical verification:-Metallurgical verification

PPAP (PRODUCTION PART APPROVAL PROCESS)

This documents include following: Part submission warrant- This is the warrant statement given by
material control department to CSE cell along with documentation for
verification.
Process control plan- this plan helps us to control the critical
dimensions during varios machining process.
Incoming material Control Plan- this plan includes all the parameters
which are necessary to determined at the preliminary stage.
Report-this report helps us in identifying potential causes of failure to
aware manufacture in future and to device its remedies in due time.
Dimensional Results-this is a verification sheet stating that all the
dimensions have been checked using specific gauges.
Metallurgical test results- this report tells us about the micro structure
of the component.
Process capability Evalution- it forecasts about the manufacturing
capability of a plant.
Checking aid list This list gives us a brief idea about the type of
instruments gauges used for measurement which is properly
caliberated in accordance with some standards.
Gauge repeatability and reproducibility Study- This study depicts the
precession and accuracy of gauges to measure different dimensions.
Attribution Gauge Study- this study shows the quality characteristics of
a gauges.
Raw material TC- this is a certification which includes composition at
the time when materials heat treated. It includes following important
parameters.
1. Heat treatment no.- it helps us to detect component profile at any stage.
2. Hardness test.
3. Inclusion

4. Oil Quenched.

MATERIAL RECEIPT REPORT

GATE ENTRY-

When the raw material is brought to company, the first stage is passes by
gate. Here, entry is made in the system giving the necessary details. A
unique serial no. is provided, through which the particle lot of raw material
can be traced in the store. This completes MRA or material receipt advice.

STOREAfter entering the company, the material is placed in the store according to
the place allotted to the material at the time of gate entry.

For the material leaving the company, following 4 bills are attached along:
1.
2.
3.
4.

Original MRR
Photocopy of MRR
Form Vat D3
Tax invoice

FINAL STEP

The materials received are tested dimensionally and visually. The no. of parts to be
inspected depends on the size of goods.

MARKETING DEPARTMENT
This department may be classified into following: Marketing
Sales
The marketing departments has following field to look after:
Export Segment
OE Segment
Department of after market

EXPORT SEGMENT- This segment looks after the selling of companys

products in the international market

OE SEGMENT-This segment caters to the need of original equipment

manufactured.

DEPARTMENT AFTER MARKET-This is the most important part of

marketing part of the marketing department. The company also has its
authorized retail outlets throughtout the country to cater for servicing needs.

SALES-This departments looks after the transportation needs of the

company. Arrangement for logistics is responsible of segment.

LABORATORYIn the lab., varios tests are performed to determine the metallurgical
structure of material received. This is also a part of component inspection. A
detailed report is prepared giving the details of internal structure of
component.
APPARATUS AVAILABLE: SALT SPRAY TEST
This test determines the corrosion resistance of a component. The red abd
white corrosion time for the component is determined. The component is
exposed to 5% NACL sol. For the time period. If any rust appears on the
comp. before the specified time, the entire lot is rejected.
ROCKWELL HARDNESS TESTING MACHINE

This test is used to determine the hardness of a material. The test is

conducted and the specimen with the specified strength is passed while the
oters are rejected.
MICROSCOPE

This is used for microstructure analysis. Materials with specified grain size
are passed whereas others are rejected.
SPECIFIC GRAVITY TESTING MACHINE

This machine is used to test the specific gravity of component. Materials are
ground and mixed for testing. The readings are taken and component is put
to use only when the component fulfills the set norms.
STROHLEN APPARATUS
This apparatus is used to test the C content of material.
ELECTRONIC BALANCE
Used for weighing purpose.

PHOSPHATING
Phosphate coatings are used on steel parts for corrosion resistance, lubricity,
or as a foundation for subsequent coatings or painting .It serves as a
conversion coating in which a dilute solution of phosphoric acid and
phosphate salts is applied via spraying or immersion and chemically reacts
with the surface of the part being coated to form a layer of insoluble,
crystalline phosphates. Phosphate conversion coatings can also be used on
aluminium , zinc, cadmium, silver and tin.
The main types of phosphate coatings are manganese, iron and zinc.
Manganese phosphates are used both for corrosion resistance and lubricity
and are applied only by immersion. Iron phosphates are typically used as a
base for further coatings or painting and are applied by immersion or by
spraying. Zinc phosphates are used for corrosion resistance (phosphate and
oil), a lubricant base layer, and as a paint/coating base and can also be
applied by immersion or spraying.

FIG:- PHOSPHATING TREATMENT

PROCESS
The application of phosphate coatings makes use of phosphoric acid and
takes advantage of the low solubility of phosphates in medium or high pH
solutions. Iron, zinc or manganese phosphate salts are dissolved in a solution
of phosphoric acid. When steel or iron parts are placed in the phosphoric
acid, a classic acid and metal reaction takes place which locally depletes the
hydronium (H3O+) ions, raising the pH, and causing the dissolved salt to fall
out of solution and be precipitated on the surface. The acid and metal
reaction also creates iron phosphate locally which may also be deposited. In
the case of depositing zinc phosphate or manganese phosphate the
additional iron phosphate is frequently an undesirable addition to the
coating.

The acid and metal reaction also generates hydrogen gas in the form of tiny
bubbles that adhere to the surface of the metal. These prevent the acid from
reaching the metal surface and slows down the reaction. To overcome this
sodium nitrite is frequently added to act as an oxidizing agent that reacts
with the hydrogen to form water. This chemistry is known as a nitrate
accelerated solution. Hydrogen is prevented from forming a passivating layer
on the surface by the oxidant additive.

The following is a typical phosphating procedure :

1.
2.
3.
4.
5.
6.
7.

Cleaning the surface

Rinsing
Surface Activation
Phosphating
Rinsing
Neutralizing Rinse
Drying

1. Degreasing- In the industry of materials transformation, the

degreasing is necessary stage before any other treatment. It is realized
with the help of an aqueous sol. Containing the detergent, which is to
emulsify the oil recovering the degreased.
The bath containing the degrease becomes progressively charged with
the oil and degreased must be replaced frequently, otherwise it quickly
becomes inefficient.
Mixture used is ASTRA Clean 702
Tank temp. is 53-65 degrees
Density of mixture should be 45-53 points
The component is kept in the tank for about 8-16 min.

2.

Derusting-

3.

Mixture used ASTRA derusting 702

Temperature of tank 55-65 degrees
Density of mixture is 45-55 points
The components are placed in the tanks for duration of
about 10-15 min.

Activation-

Mix. Used is ASTRA active 702

Tank temp. is same as room temp.

4.

Density of the mix. Is 7-10 points

Component kept for 1 min.

Phosphating- Mix. Used is ASTRA phosphate 702 + Toner.

-

Tank temp. is 45-55 degree

Component kept for 1 min.
Density of mix. Is 14-20 points.

Then the comp. are dried in an electric heater at a temp. of 70-100 degrees.
After Phospahting is done, the component are to proceed to powder
coating or spray painting and is more effective too.
After these treatments, the comp. are then again passed through an electric
furnace and then kept outside in room temp. After this, the comp. are placed
in the finished lot and then are loaded for delivery to specific clients.
APPLICATIONS:

The performance of the phosphate coating is significantly dependent on the

crystal structure as well as the weight. For example, a microcrystalline
structure is usually optimal for corrosion resistance or subsequent painting. A
coarse grain structure impregnated with oil, however, may be the most
desirable for wear resistance. These factors are controlled by selecting the
appropriate phosphate solution, using various additives, and controlling bath
temperature, concentration, and phosphating time. A widely used additive is
to seed the metal surface with tiny particles of titanium salts by adding these
to the rinse bath preceding the phosphating.This is known as activation.

USES:-

Phosphate coatings are often used to provide corrosion resistance, however,

phosphate coatings on their own do not provide this because the coating is
porous. Therefore, oil or other sealers are used to achieve corrosion
resistance. Zinc and manganese coatings are used to help break in
components subject to wear and help prevent galling.
Most phosphate coatings serve as a surface preparation for further coating
and/or painting, a function it performs effectively with excellent adhesion
and electric isolation. The porosity allows the additional materials to seep
into the phosphate coating and become mechanically interlocked after
drying.

PAINTS

INDUCTION HARDENING
A widely used process for the surface hardening of steel. The components
are heated by means of an alternating magnetic field to a temperature within
or above the transformation range followed by immediate quenching
Induction hardening is a form of heat treatment in which a metal part is
heated by induction heating and then quenched. The quenched metal
undergoes a martensitic transformation, increasing the hardness and
brittleness of the part. Induction hardening is used to selectively harden
areas of a part or assembly without affecting the properties of the part as a
whole.

PROCESS:Induction heating is a non contact heating process which utilises the principle of
electromagnetic induction to produce heat inside the surface layer of a work-piece.
By placing a conductive material into a strong alternating magnetic field, electric
current can be made to flow in the material thereby creating heat due to the I2R
losses in the material. In magnetic materials, further heat is generated below the
curie point due to hysteresis losses. The current generated flows predominantly in
the surface layer, the depth of this layer being dictated by the frequency of the
alternating field, the surface power density, the permeability of the material, the
heat time and the diameter of the bar or material thickness. By quenching this
heated layer in water, oil, or a polymer based quench, the surface layer is altered to
form a martensitic structure which is harder than the base metal.

EQUIPMENTS:-

1.

POWER

Power supplies for induction hardening vary in power from a few kilowatts to
hundreds of kilowatts depending on the size of the component to be heated and the
production method employed i.e. single shot hardening, traverse hardening or
submerged hardening.
In order to select the correct power supply it is first necessary to calculate the
surface area of the component to be heated. Once this has been established then a
variety of methods can be used to calculate the power density required, heat time
and generator operating frequency. Traditionally this was done using a series of
graphs, complex empirical calculations and experience. Modern techniques typically
utilise finite element analysis and Computer-aided manufacturing techniques,
however as with all such methods a thorough working knowledge of the induction
heating process is still required.

2.

FREQUENCY

Induction heating systems for hardening are available in a variety of different

operating frequencies typically from 1 kHz to 400 kHz. Higher and lower frequencies
are available but typically these will be used for specialist applications. The
relationship between operating frequency and current penetration depth and
therefore hardness depth is inversely proportional. i.e. the lower the frequency the
deeper the case.

3. COOLING TOWERS
Two cooling towers are situated near the induction hardening area. Reservoir for
these cooling towers is an IHB tank. The water used for induction hardening process
is cooled in these towers. Separate inlet and outlet are provided for incoming and
outgoing water. After induction hardening process, the water gains temp. after some
cycles, it becomes unsuitable for the hardening process. Therefore, cooling towers
are employed for maintaining the temp. of water at a certain suitable.
Chemicals are used for treating water:1. Chemical Thinner- 605

2. QD Enamel Deep Dark Grey

ADVANTAGES:1.

Fast process, no holding time is required, hence more production rate.

2.

No scaling or decarburizing.

3.

More case depth up to 8 mm.

4.

Selective hardening.

5.

High wear and fatigue resistance.

APPLICATIONS:1.
The process is applicable for electrically conductive materials such as steels
and cast iron.
2.

Long work pieces such as axles can be processed.

TOOL ROOM
Tool room is divided into 2 parts. One part houses:
1.
2.
3.
4.
5.

2
2
1
1
1

Lathe machine
Milling machine
bench drill
Power drill
power hacksaw

As the products manufactured by the company are in bulk, it becomes essential to

use jigs and fixtures for certain operations. Fixtures for testing the angle and
dimension of certain comp. are also manufactured within the company itself.

TESTING AREA
The second part of tool room houses is the testing equipments:
Rigidity Testing machine
Universal testing machine
Dustcover testing machine

Endurance testing machine

Ball joint test bed
Ozone chamber
Computerised Smoothness Tester
Leakage Testing machine
Fatigue Testing machine
Impact Test Rig

MAINTENCE DEPARTMENT
This department caters to maintenance needs of company. Fixing of the
defects in the machine is the responsibility of this department. The
department also has the responsibility of this department. The department
also has the responsibility of servicing the mac. In due time and keeping
them fit for efficient and accurate production.

CMM(COORDINATE MEASURING MACHINE)

This machine is used to exactly mark and locate the position where a
particular machining operation has to be perfomed. The machine can do the
following operations:

Location and Dimensions

True position Dimensions
Distance
Angle
Concentricity
Coaxiality
Cylindricity
Circularity
Straightness
Flatness Dimensions
Perpendicular Dimensions
Profile, arc, angularity and symmetricity.

A reference point is selected in the beginning and all the marking are then
made with reference to that reference point.