An

INDUSTRIAL TRAINING REPORT

On
PRODUCTION IN PRESS SHOP
At
INDO AUTOTECH LTD
Final Semester Training
Submitted for the partial fulfilment for the award of
degree of
BACHELOR OF TECHNOLOGY
In
MECHANICAL ENGINEERING
MAHARSHI DAYANAND UNIVERSITY, ROHTAK
(2015-2019)

Submitted By:
PARAS PANDEY
9138504

Under the Guidance of: Training & Placement Head: Submitted to:
MR. AJAY KUMAR MRS. ANITA BHALLA MR. GAURAV KANSAL

(Company’s Executive) (Head of Department)

B.S. ANANGPURIA INSTITUTE OF TECHNOLOGY AND

MANAGEMENT,
ALAMPUR, FARIDABAD

1
 Acknowledgement

I would like to express my deepest appreciation to all those who provided me the
possibility to complete my industrial training. I would like to give a special gratitude
to our training incharge, Mr RAKESH (incharge, press shop, IAL), who’s contribution
in stimulating suggestions and encouragement helped me to coordinate in my
training period.

Furthermore I would also like to acknowledge with much appreciation the crucial
role of the employee of the other sections who gave me the permission to use all
the required equipment’s and necessary materials to complete the task. A special
thanks to my team mate, who helped me to assemble the parts and gave
suggestions about the task. I have to appreciate the guidance given by the other
supervisors as well as the panels especially in our training period that has improved
our presentation skills and knowledge

A special thanks to Mr AJAY KUMAR (HR Head, IAL) for his guidance and care in
IAL.

Last but not least, many thanks to IAL who give me the opportunity to complete
my industrial training in such wonderful working environment in achieving my goal.

Paras Pandey

2
B.S.ANANGPURIA INSTITUTE OF TECHNOLOGY & MANAGEMENT,
ALAMPUR, FARIDABAD

Certificate

This is to certify that Mr Paras Pandey of Bachelor of Technology (M.E.) has

PRESS SHOP
successfully completed Industrial Training on the topic................................................
from Organization INDO AUTOTECK LTD., Plot No. 332-338, Sector-24, Faridabad, for
partial fulfilment for the award of degree of Bachelor of Technology in MECHANICAL.
The Industrial Training report being submitted by him / her is genuine work done by
him / her and the same is being submitted for evaluation.

Signature
Company Executive with seal

3
 PREFACE

Industrial training is a part and parcel of every technical course and gives
a face or form to all the theoretical knowledge we gain in our classroom.
We get to have a virtual experience of the processes, methods, objects and
phenomenon which used to be just an imaginary picture in our minds. We
have the theoretical as well as virtual knowledge of many different types
of processes, methods and other machines and certain phenomenon. It is
equally important that we may also have exposure of the things that
happens in the industry. It also gives an exposure to the environment of
the industries and workshops which are virtual components of our
professional life. We too were provided with the opportunity to gain some
knowledge about the technical environment of the industry. We too were
also provided with the opportunity to do the internship training in the
final year that is final semester of the technical course.

We are thankful to our college administration that handed this invaluable

chance to us and at the same time we pay our regards to the
administration of INDO AUTOTECH LTD, sector 24, Faridabad that
proved to be a great supporting force for the fulfilment of the purpose.
The officials and the workers of the firm provided us with the best of
their attention and share ample of knowledge of their concerned field
with us.

4
Table of Contents
ABOUT THE COMPANY....................................................................................................................viii
DIFFERENT MANUFACTURING PLANTS OF THE COMPANY...............................................................ix
CUSTOMERS OF THE COMPANY.........................................................................................................x
PRODUCTS MANUFACTURED BY THE COMPANY..............................................................................xi
LIST OF FIGURES...............................................................................................................................xii
LIST OF TABLES................................................................................................................................xiv
STRENGHTS OF THE PLANT -I...........................................................................................................xv
PRESS SHOP.......................................................................................................................................1
PNEUMATIC PRESS MACHINE........................................................................................................3
Operator Involvement...............................................................................................................4
MECHANICAL PRESS MACHINE......................................................................................................5
How Does Machine Press Work?...............................................................................................6
HYDRAULIC POWER PRESS............................................................................................................7
Principle of Operation...............................................................................................................7
Application................................................................................................................................8
Presses on the basis of operation..................................................................................................9
MAIN PARTS OF A DIE..................................................................................................................10
1. Holder SS400, S50C.............................................................................................................10
2. Backing plate SK3, SK5.........................................................................................................10
3. Punch plate SS400, S50C.....................................................................................................10
4. Stripper plate S50C..............................................................................................................11
5. Die plate SK materials, SKS3, SKD11....................................................................................11
6. Nested plates.......................................................................................................................11
7. Punch...................................................................................................................................11
Operations Performed On a Press...............................................................................................12
Types of press operations are as follows:........................................................................................13
1. Blanking...............................................................................................................................13
2. Coining.................................................................................................................................13
3. Crimping..............................................................................................................................13
4. Curling.................................................................................................................................13
5. Drawing...............................................................................................................................13
6. Embossing...........................................................................................................................13
7. Extrusion..............................................................................................................................13

5
 8. Ironing.................................................................................................................................13
9. Lancing................................................................................................................................14
10. Necking............................................................................................................................14
11. Piercing............................................................................................................................14
12. Redrawing........................................................................................................................14
13. Staking.............................................................................................................................14
14. Swaging...........................................................................................................................14
15. Trimming..........................................................................................................................14
TYPES OF TOOLS..............................................................................................................................15
1. Simple Tool..........................................................................................................................15
2. Compound Tool...................................................................................................................15
3. Progressive Die....................................................................................................................15
PROGRESSIVE TOOL.....................................................................................................................16
Defects in Sheet Metal Components during Different Operations..................................................17
STUDY OF ALL FACTORS CAUSING BURR......................................................................................19
1) MAN................................................................................................................................19
2) METHOD..........................................................................................................................19
3) MATERIAL........................................................................................................................20
4) MACHINE.........................................................................................................................20
a) Press Machine Alignment:...........................................................................................20
b) Press Tool: Clearance between die & punch..................................................................21
TOOL RAW MATERIAL..............................................................................................................21
PROCESS FOR MANUFACTURING FR-FENDER..............................................................................22
SPOT WELDING............................................................................................................................23
APPLICATIONS OF SPOT WELDING...........................................................................................24
MATERIALS SUITABLE FOR SPOT WELDING..............................................................................24
PROCESSING AND EQUIPMENT...............................................................................................25
MIG WELDING.................................................................................................................................26
TIG WELDING..................................................................................................................................27
ROBOTIC WELDING..........................................................................................................................28
CNC BENDING MACHINE.................................................................................................................29
GRINDING MACHINE.......................................................................................................................30
CYLINDRICAL GRNDER.....................................................................................................................31
DRILL MACHINE...............................................................................................................................32

6
COORDINATE MEASURING MACHINE..............................................................................................33
INSTRUMENTS USED IN THE COMPANY..........................................................................................35
1. VERNIER CALIPER.................................................................................................................35
2. HEIGHT GAUGE....................................................................................................................35
3. MICROMETER......................................................................................................................36
4. RADIUS GAUGE....................................................................................................................36
5. SURFACE PLATE....................................................................................................................37
6. DIAL GAUGE.........................................................................................................................37
7. V BLOCK...............................................................................................................................38
8. BEVEL PROTECTOR...............................................................................................................38
9. SINE BAR..............................................................................................................................39
10. SHEET METAL THICKNESS MEASURING GAUGE...............................................................40
11. FEELER GAUGE.................................................................................................................41
12. DIAL BORE GAUGE...........................................................................................................41
PRODUCTS MANUFACTURES IN ASSEMBLY SHOP...........................................................................42
RESULTS AND DISCUSSION..............................................................................................................43
RESULTS.......................................................................................................................................43
Successful Development of The Part:......................................................................................43
DISCUSSION.................................................................................................................................44
 Defects Produced In the Sheet........................................................................................44
 Problem Produced In the Presses....................................................................................44
CONCLUSION...................................................................................................................................45
REFERENCES....................................................................................................................................46

7
 ABOUT THE COMPANY

 IAL was originally set up as a partnership concern, Indo Industrial Engineers, by Mr S K

Jain in 1974. This firm was reconstituted a public limited company with the current name
in 2006, with Mr S K Jain as the chairman and his nephew, Mr Anand Kumar Jain, as the
managing director.

 IAL has six plants, three of which are at Faridabad in Haryana, and one each at Manesar in
Haryana, Bengaluru, and Tapukara in Rajasthan.

 Commitment to quality and sense of innovation is deep rooted in the company.

 The company has the most impressive track record in meeting stringent quality
requirements and is committed to make available products of the best quality standards at
the most competitive prices.

 Our Engineering, Production and Quality Assurance departments coordinate to guarantee

and maintain the highest quality levels. Process controls assure quality from prototype
through production.

 The company is certified ISO/TS 16949:2009, ISO 14001:2004 & OHSAS 18001:2007 by
DNV.

 By exceeding our customer requirements Indo has

become a valued supplier of major Sheet Metal
Components,Tubular components and assemblies
and sub assemblies to leading OEM’s in the
Indian as well as global automotive industry.

 IAL has a strength of over 4200 employees and 850000 square feet of production facility
spread across six production units in India

 Top quality skills in Sheet Metal Press, CNC Pipe Bending, Pipe End forming, Squeezing,
Robotic Welding, Mig Welding and lot more industrial processes.

 IAL has been recognised as best manufacturer by Maruti, JCB, Honda, Suzuki, Yamaha
and many other customers.

DIFFERENT MANUFACTURING PLANTS OF THE COMPANY

This company has 6 different manufacturing plants which are located all over the country.

8
Indo Autotech Limited – I
Plot No. 332-338, Sector-24,
Faridabad, Haryana 121005
India
Phone
01294020837

Indo Autotech Limited – II

Plot No. 261, Sector-24,
Faridabad, Haryana. 121005
India

Indo Autotech Limited – III

Plot No. 132-133, Sector-8, IMT
Manesar, Haryana. 122050
India

Indo Autotech Limited – IV

Plot No. 61, Sector-25,
Faridabad, Haryana. 121005
India

Indo Autotech Limited – V

Plot No. 176-181, Narsapura I.A.,
Narsapura, Distt Kolar,
Bangalore. Karnataka 560001 Figure 1 MAP
India

Indo Autotech Limited – VI

SPL-5, Tapukara, Alwar Bypass,
RIICO Industrial Area,
Tapukara Bhiwadi, Tapukara Rajasthan. 301707
India

9
 CUSTOMERS OF THE COMPANY

Figure 2 CUSTOMERS

10
 PRODUCTS MANUFACTURED BY THE COMPANY

Sheet Metal Components

Tubular Components

Welded Assembly Components

Figure 3 COMPONENTS

11
 LIST OF FIGURES

Figure 1 MAP...................................................................................................................................ix
Figure 2 CUSTOMERS........................................................................................................................x
Figure 3 COMPONENTS....................................................................................................................xi
Figure 4 COMPANY..........................................................................................................................xv
Figure 5 PRESS SHOP........................................................................................................................1
Figure 6 DIE AND PUNCH..................................................................................................................2
Figure 7 PNEUMATIC PRESS..............................................................................................................3
Figure 8 PNEUMATIC PRESSES..........................................................................................................4
Figure 9 MECHANICAL PRESS............................................................................................................5
Figure 10 MECHANICAL PRESSES......................................................................................................6
Figure 11 HYDRAULIC PRESS.............................................................................................................7
Figure 12 PASCAL'S LAW...................................................................................................................7
Figure 13 PREESS TYPES....................................................................................................................9
Figure 14 PARTS OF DIE..................................................................................................................10
Figure 15 NESTED PLATES...............................................................................................................11
Figure 16 BLANKING TOOL..............................................................................................................13
Figure 17 DRAW TOOL....................................................................................................................13
Figure 18 PIERCING.........................................................................................................................14
Figure 19 TRIMMING TOOL............................................................................................................14
Figure 20 PROGRESSIVE TOOL........................................................................................................16
Figure 21 PARETO DIAGRAM..........................................................................................................18
Figure 22 CAUSE & EFFECT DIAGRAM............................................................................................18
Figure 23 ALIGNMENT....................................................................................................................20
Figure 24 STRESSES.........................................................................................................................21
Figure 25 TOOL LIFE........................................................................................................................21
Figure 26 FORMING'........................................................................................................................22
Figure 27 BLANKING........................................................................................................................22
Figure 28 BENDING..........................................................................................................................22
Figure 29 RESTRIKING......................................................................................................................22
Figure 30 PUNCHING.......................................................................................................................22
Figure 31 SPOT WELDING................................................................................................................22
Figure 32 SPOT WELDING................................................................................................................23
Figure 33SPOT WELDING TIPS.........................................................................................................24
Figure 34 PROCESS..........................................................................................................................25
Figure 35 WELDED JOINT.................................................................................................................25
Figure 36 MIG WELDING.................................................................................................................26
Figure 37 MIG WELDING.................................................................................................................26
Figure 38 TIG WELDING...................................................................................................................27
Figure 39TIG WELDING....................................................................................................................27
Figure 40 ROBOTIC WELDING..........................................................................................................28

12
Figure 41 ROBOTIC WELDING..........................................................................................................28
Figure 42 CNC BENDING MACHINE..................................................................................................29
Figure 43 CNC BENDING MACHINE..................................................................................................29
Figure 44 GRINDING MACHINE........................................................................................................30
Figure 45 SURFACE GRINDER...........................................................................................................30
Figure 46 CYLINDRICAL GRINDER....................................................................................................31
Figure 47 CYLINDRICAL GRINDER....................................................................................................31
Figure 48 DRILL MACHINE...............................................................................................................32
Figure 49 CMM................................................................................................................................33
Figure 50 CMM MACHINE...............................................................................................................33
Figure 51 CMM MACHINE...............................................................................................................34
Figure 52 VERNIER CALLIPER...........................................................................................................35
Figure 53 HEIGHT GAUGE................................................................................................................35
Figure 54 INSIDE MICROMETER.......................................................................................................36
Figure 55 MICROMETER..................................................................................................................36
Figure 56 RADIUS GAUGE................................................................................................................36
Figure 57 SURFACE PLATE................................................................................................................37
Figure 58 DIAL GAUGE.....................................................................................................................37
Figure 59 V-BLOCK...........................................................................................................................38
Figure 60 BEVEL PROTECTOR...........................................................................................................38
Figure 61 SINE BAR..........................................................................................................................39
Figure 62 SINE BAR..........................................................................................................................39
Figure 63 DIGITAL THICKNESS GAUGE.............................................................................................40
Figure 64 SHHET THICKNESS GAUGE...............................................................................................40
Figure 65 FEELER GAUGE.................................................................................................................41
Figure 66 DIAL BORE GAUGE...........................................................................................................41
Figure 67 SIDE STAND......................................................................................................................42
Figure 68 CHASSIS OF BIKE..............................................................................................................42
Figure 69 SIDE FOOT REST...............................................................................................................42
Figure 70 DOUBLE STAND FOR ACTIVA............................................................................................42
Figure 71 FRAME FOR ACTIVA.........................................................................................................42

13
 LIST OF TABLES

Table 1 OPERATIONS.......................................................................................................................12
Table 2 DEFECTS.............................................................................................................................17
Table 3 PROBLEMS DUE TO MAN....................................................................................................19
Table 4 PROBLEM DUE TO METHOD...............................................................................................19
Table 5 PROBLEM DUE TO MATERIAL.............................................................................................20
Table 6 MATERIAL OF DIE & PUNCH................................................................................................21
Table 7 HARDNESS OF MATERIAL....................................................................................................21

14
 STRENGHTS OF THE PLANT -I

Figure 4 COMPANY

The main strengths of the company

Some of the main facilities that are available in the company are as follows and
these include

15
 Press Shop  Tool Room

 CNC Pipe Bending  Pipe End Forming

 Pipe Squeezing  Robotic Welding

 MIG Welding  TIG Welding

 Projection Welding  Furnace Brazing For SS Parts

 Furnace Brazing For MS Parts  Powder Coating

 Assembly Facility  Laser Cutting

 Plasma Cutting  CNC Press Brake

16
 PRESS SHOP

Figure 5 PRESS SHOP

 A forming press, commonly shortened to press, is a machine tool that changes the
shape of a work piece by the application of pressure. The operator of a forming press is
known as a press-tool setter, often shortened to tool setter.
 Machine presses can be hazardous, so safety measures must always be taken. Bi-
manual controls (controls the use of which requires both hands to be on the buttons to
operate) are a very good way to prevent accidents, as are light sensors that keep the
machine from working if the operator is in range of the die.
 Presses can be classified according to
 their mechanism: hydraulic, mechanical, pneumatic;
 their controllability: conventional vs. servo-presses
 There are 30 mechanical presses, 28 pneumatic presses and a hydraulic press.
 There is a facility of spot welding.
 There are 6 spot welding machines.
 In the press shop more than 100 people work that includes operators, helpers,
supervisors, engineers.

1
Figure 6 DIE AND PUNCH

2
 PNEUMATIC PRESS MACHINE

 A pneumatic press derives its primary mechanical action (such as shearing, punching,
bending, forming, drawing, extruding, assembly, or other action) from a pressure source by
means of compressed air.
 Such presses are used in mechanized binderies for a variety of purposes, and, although they
cannot supply the extreme pressures available with the hydraulic press, they do offer the
advantages of speed of operation and cleanliness.

 A fully pneumatic power press differs from a mechanical or hydraulic press, which may
use pneumatic systems to only activate a brake/clutch, slide counterbalance or other
systems but that uses mechanical means or hydraulic fluid to power the ram.

Figure 7 PNEUMATIC PRESS

3
 Operator Involvement

The operator is responsible for feeding or placing the stock on the bottom die, seeing that it
is properly positioned, activating the press cycle with a pressure control switch, and
removing the completed part.

Figure 8 PNEUMATIC PRESSES

4
 MECHANICAL PRESS MACHINE

 A mechanical power press is a machine used to supply force to a die that is used to
blank, form, or shape metal or non-metallic material.
 Thus, a press is a component of a manufacturing system that combines the press, a
die, material and feeding method to produce a part.
 The designer of the manufacturing system must also provide proper point of
operation guards to safeguard pressroom personnel.
 Each of the components of this manufacturing system is important and will be
discussed in turn later in this work.
 A foundation for understanding the system is acquiring a working knowledge of
the press.

Figure 9 MECHANICAL PRESS

How Does Machine Press Work?

5
 Punch press, machine that changes the size or shape of a piece of material, usually
sheet metal, by applying pressure to a die in which the workpiece is held. The form
and construction of the die determine the shape produced on the workpiece.
 A punch press has two co-acting components: the punch, which is attached to
the reciprocating ram of the machine, and the die, which is clamped onto a bed or
anvil whose flat surface is perpendicular to the path of the ram. In operation, the
punch pushes against the workpiece, which is held in the die. A blanking die shears
out a slug of sheet metal to make it into a blank that will fit dies for subsequent
punch-press operations. These include forming or bending and drawing, in which
cup-shaped articles are produced by a process that entails some plastic flow of the
metal.
 Punch presses are usually driven by electric motors, and conversion from the rotary
motion of the drive shaft to reciprocation of the ram is effected by a crank, a toggle,
or a cam mechanism. Because the power demands are intermittent, a flywheel is
attached to the drive shaft to store energy during the idling period between strokes
of the ram and to deliver energy to the shaft during a punching operation, thus
reducing the required capacity of the driving motor.

Figure 10 MECHANICAL PRESSES

6
 HYDRAULIC POWER PRESS

A hydraulic press is a machine press using a

hydraulic cylinder to generate a compressive
force. It uses the hydraulic equivalent of a
mechanical lever, and was also known as a
Bramah press after the inventor, Joseph
Bramah, of England. He invented and was
issued a patent on this press in 1795. As Bramah
(who is also Hydraulic press - 400T known for
his development of the flush toilet) installed
toilets, he studied the existing literature on the
motion of fluids and put this knowledge into the
development of the press.

Figure 11 HYDRAULIC PRESS

Principle of Operation

The hydraulic press depends on Pascal's principle-the pressure throughout a closed system is
constant. One part of the system is a piston acting as a
pump, with modest mechanical force acting on a small
cross-sectional area; the other part is a piston with a
larger area which generates a correspondingly large
Main principle mechanical force. Only small-diameter
tubing (which more easily resists pressure) is needed if
the pump is separated from the press cylinder. Pascal's
law: Pressure on a confined fluid is transmitted
undiminished and acts with equal force on equal areas
Figure 12 PASCAL'S LAW
and at 90 degrees to the container wall. A small effort
force acts on a small piston. This creates a pressure which is transferred through the hydraulic fluid
to a large piston.

7
 Application

Hydraulic presses are commonly used for forging, clinching, moulding, blanking, punching, deep
drawing, and metal forming operations. With the on-going surge towards lightweight parts for
aerospace, automotive appliances and many other industries, Servo Hydraulic and Hydraulic
presses have become a key tool for the Thermoplastic Industries. Otherwise known as compression
moulding presses, control of speed, pressures, position, heating and cooling mould temperatures
can be managed with the I-PRESS HYDRO controller for press and automation functions.

8
 Presses on the basis of operation

Types Of Presses On
The Basis Of Operation

Hand Operated

Foot Operated

Single Hand Operated

Both Hand Operated

Figure 13 PREESS TYPES

9
 MAIN PARTS OF A DIE

Figure 14 PARTS OF DIE

1. Holder SS400, S50C
The punch and die holder are not only for fixing the die to the press machine but also
for supporting the rigidity of the die. They also have the role of adjusting the die height
and providing the space for springs, etc. Usually, the materials used are SS400 or
S50C.

2. Backing plate SK3, SK5

Backing plates are used at three locations in a die. They are used for the purpose of
backing up so as to prevent components such as small diameter punches, etc., from
getting too deep inside the holder due to the force of press operation. Apart from that,
backing plates are used for preventing the parts from getting detached (stripper backing
plate) and for adjusting the height of the die. For backing up, an SK material is used
after heat treatment (to 56 HRC).

3. Punch plate SS400, S50C

A punch plate is used for the purpose of holding a small punch. Usually, SS400, S50C,
etc. are used without heat treatment.

4. Stripper plate S50C

10
 While the main function of a stripper is to remove scrap, very frequently it is made to
have important secondary functions of pressing the material or guiding the tip of the
punch. When removing scrap in small volume production is important, materials such
as S50C hardened steel are used which do not require heat treatment.

5. Die plate SK materials, SKS3, SKD11

SK materials or SKS3 is used in dies for small volume production. The standard
material used is SKD11. This trend has become established because preparation of dies
using electric discharge wire cutting machines has become widespread.

6. Nested plates

Figure 15 NESTED PLATES

The descriptions given above assume single type plates. In dies, nested type (insert
type) plates are used very often. Such plates are used for stripper plates or die plates. In
the case of small volume production, materials such as S50C without heat treatment
are sometimes used for the main plate. For medium or higher volume production,
materials such as SKS3 or SKD11 are used after heat treatment. The materials SKD11,
SKH51, pre-hardened steel, and cemented carbide, etc. are used as the materials for
nested plates. The selection of the material is based on ease of maintenance, accuracy,
and operating life.

7. Punch
The materials used for punches are SKS3, SKD11, SKH51, powdered high speed tool
steel, cemented carbide, etc. The standard material used is SKD11. SKS3 is sometimes
used in the case of small volume production. SKH51 is used when the size is small, or
when toughness is required. Powdered high speed tool steel or cemented carbide are
used when wear resistance is required or for large volume production.

11
 Operations Performed On a Press

Table 1 OPERATIONS

12
 Types of press operations are as follows:

1. Blanking – Cutting or shearing of

outside contours or shapes from
Sheet or strip stock. The piece cut
out is the useful part.

2. Coining – A squeezing operation, Figure 16 BLANKING TOOL

usually performed in a closed die in which the metal is forced to flow and fill the shape and
profile of the die. There is a definite change in metal thickness.

3. Crimping – An operation in which the open end of a can or shell is forced tight over or
around a mating part. This type of work is limited largely to assembly operations.

4. Curling – The forming of an edge having a circular cross section along a sheet or around
the end of a shell or tube. This operation is sometimes called false wiring.

5. Drawing- A process in which a shell

of any shape, is produced from flat
sheet metal. Holding pressure is applied
to the blank edge to prevent wrinkles in
the flange as the punch forces the metal
down into the die.

6. Embossing – A process for Figure 17 DRAW TOOL

producing raised or sunken designs in sheet metal by means of a male and female die.

7. Extrusion – A process in which pressure is applied to a slug of metal causing the metal
to flow either up around the punch (toothpaste tubes) or down in the direction of pressure .
8. Ironing – A process in which the wall thickness of the shell is reduced without changing
the O.D. of the shell.

13
9. Lancing – Slitting and forming a pocket shaped opening in sheet metal, without
removing metal.

10. Necking – Reducing the diameter of a portion of the length of a cylindrical shell or tube.

11. Piercing – Practically the same

operation as blanking except it is limited
to holes or slots in sheet metal. The piece
cut out is the scrap.

Figure 18 PIERCING

12. Redrawing – The second operation following deep-drawing operations, in which cups
are deepened and reduced in cross section.

13. Staking – An operation in which two or more parts are assembled permanently by
upsetting a small portion of metal over the mating part, causing the compression on the
assembled parts.

14. Swaging – Forming a metal by the rapid striking of a large number of successive blows.
In the case of aircraft cable fittings, the fitting is rotated while the press blows are being
struck.

15. Trimming – A secondary operation on

drawn or formed parts to remove excess
metal on the flange or axial length.

Figure 19 TRIMMING TOOL

14
 TYPES OF TOOLS

1. Simple Tool
 The tool which is manufactured to perform only one operation at a particular workstation
from all the operations which are to be done on a particular component.

2. Compound Tool
 The compound tool differs from progressive and stage tools by the arrangement of the
punch and die.
 It is an inverted tool where blanking and piercing takes place in a single stage. Compound
dies perform multiple operations on the part. The compound operation is the act of
implementing more than one operation during the press cycle.
 A compound die differs from a progressive die in that it performs two or more cutting
operations during one stroke of the press at one station only.
 Compound dies are slower in operation than progressive dies.
 A compound die allows the cutting of internal and external part features on a single press
stroke.

3. Progressive Die
 A series of two or more dies arranged in line for performing two or more operations on
apart - one operation (single or compound) performed in each die, at each station.
 Work in the form of a strip is usually fed to progressive dies automatically by a roll feed. In
a progressive tool the final component is obtained by progressing the sheet metal or strip in
more than one stage. At each stage the tool will progressively shape the component
towards its final shape, with the final stage normally being cutting-off.
 The sheet metal is fed through as a coil strip, and a different operation (such as punching,
blanking and notching) is performed at the same station of the machine with each stroke of
a series of punches.
 The dies which performed two or more operations at different stages every time the ram
descends are known as Progressive die.
 The principle advantage of Progressive die is in the number of operations that can be
achieved with one handling of the stock strip. The main disadvantage is that work pieces
may become “dished” as they pushed through the die as they generally have very little
support.

15
 PROGRESSIVE TOOL

12 operations can be performed

simultaneously on different
workstations

MADE IN TAIWAN

Scrap

Finished
Product

Figure 20 PROGRESSIVE TOOL

Feeder
16
Defects in Sheet Metal Components during Different Operations

 There are certain type of defects that generally occur while manufacturing a particular
component by the means of forming I.e., Sheet metal operations and some of them are as
shown in the table below:

Table 2 DEFECTS

 As it is clear from the above table that there are 2 kinds of processes
 One is cutting process and
 other is non-cutting processes
 It is also clear that in the cutting processes the defect that occurs is mainly BURR which
can be reworked.
 While in the non-cutting processes the defects that occur are wrinkles, thinning, and crack
and we also know that these defects cannot be reworked and only get included in rejection
and finally in production loss.
 We all know that the defects help in decreasing the quality standard of the respective
company.

17
 Following data was observed in a sheet metal industry with the help of Pareto Diagram
which shows how important is to control the burr, a defect, which has a major contribution
to increase the defect graph of any organization.

Figure 21 PARETO DIAGRAM

 From the above Pareto diagram it is clear that the main defect that comes while
manufacturing any component is burr.
 BURR is a thin edge or ridge.
 When we are able to get the problem then we have to find the causes to this effect
by the means of CAUSE AND EFFECT DIAGRAM (Fishbone diagram).

18
Cause
Figure 22&CAUSE
Effect&Diagram
EFFECT DIAGRAM

19
 STUDY OF ALL FACTORS CAUSING BURR
1) MAN
Table 3 PROBLEMS DUE TO MAN

2) METHOD
Table 4 PROBLEM DUE TO METHOD

20
3) MATERIAL
Table 5 PROBLEM DUE TO MATERIAL

4) MACHINE
There are several reasons responsible for burr formation during machining phase. Broadly
they can be classified into two groups.

a) Press Machine Alignment:

 As far as burr is concern, press machine alignment is an important factor
which is responsible for the burr formation and is clear from figure

Figure 23 ALIGNMENT

21
 b) Press Tool: Clearance between die & punch
 The cutting of sheet metal in press work is a shearing process. The punch is of the
same as of the die opening except that it is smaller on each side by an amount
known as clearance. As the punch touches the material and travels downwards, it
pushes the material into the die opening; the material is subjected to both tensile
and compressive stresses.

 For brass and

Figure 24 STRESSES soft steels c =
5% of t
 For medium steel, c= 6% of t
 For hard steel, c= 7% of t
 For aluminium, c= 10% of t

TOOL RAW MATERIAL

 Raw material selection influences

three following areas.
1. Tool Life
2. Part Quality
3. Tool sharpening frequency
Figure 25 TOOL LIFE

Table 7 MATERIAL OF DIE & PUNCH Table 6 HARDNESS OF MATERIAL

If we choose a lower grade tool material then tool Name of material

life will be less. Die & punch edge will bunt earlier
which leads to the burr formation.
22
 PROCESS FOR MANUFACTURING FR-FENDER
Fr-fender is called the bracket for the rear seat of MARUTI SUZUKI.

Figure 27 BLANKING Figure 26 FORMING'

BENDING
Figure 28 BENDING RESTRIKING
Figure 29 RESTRIKING

SPOT
FigureWELDING
30 SPOT
PUNCHING
Figure 31 PUNCHING WELDING

23
 SPOT WELDING
 Spot welding is one of the oldest welding processes.
 Resistance spot welding (RSW) is a process in which contacting metal surface points are
joined by the heat obtained from resistance to electric current.
 Work-pieces are held together under pressure exerted by electrodes.
 Typically the sheets are in the 0.5 to 3 mm
thickness range.
 The process a spot welding robot uses two
shaped copper alloy electrodes to concentrate
welding current into a small "spot" and to
simultaneously clamp the sheets together.
 Forcing a large current through the spot will
melt the metal and form the weld. The
attractive feature of spot welding is that a lot
of energy can be delivered to the spot in a
very short time that permits the welding to
occur without excessive heating of the
remainder of the sheet.
 Thicker stock is more difficult to spot weld
because the heat flows into the surrounding
metal more easily. Figure 32 SPOT WELDING

 The amount of heat delivered to the spot is determined by the resistance between the
electrodes and the magnitude and duration of the current.
 The amount of energy is chosen to match the sheet's material properties, its thickness, and
type of electrodes.
 Applying too little energy will not melt the metal or will make a poor weld. Applying too
much energy will melt too much metal, eject molten material, and make a hole rather than
a weld. Another feature of spot welding is that the energy delivered to the spot can be
controlled to produce reliable welds.
 It is used in a wide range of industries but notably for the assembly of sheet steel vehicle
bodies. This is a type of resistance welding where the spot welds are made at regular
intervals on overlapping sheets of metal.
 Spot-weld diameters range from 3 mm to 12.5 mm.

24
 APPLICATIONS OF SPOT WELDING

 Spot welding is typically used when welding particular types of sheet metal, welded wire
mesh or wire mesh.
 Spot welding can be easily identified on many sheet metal goods, such as metal buckets.
 The most common application of spot welding is in the automobile manufacturing industry,
where it is used almost universally to weld the sheet metal to form a car.
 Spot welders can also be completely automated, and many of the industrial robots found on
assembly lines are spot welders.
 Spot welding is also used in the orthodontist's clinic.

MATERIALS SUITABLE FOR SPOT WELDING

 Steel has a higher electrical resistivity and lower thermal conductivity than the copper
electrodes, making welding relatively easy. Low carbon steel is most suitable for spot
welding. Higher carbon content or alloys steel tend to form hard welds that are brittle and
could crack.
 Aluminium has an electrical resistivity and
thermal conductivity that is closer to that of
copper. However, aluminium's melting point is
much lower than that of copper, making welding
possible.
 Higher levels of current must be used for welding
aluminium because of its low resistivity.
 Galvanized steel requires a different welding
approach than uncoated steel. Zinc coating must
first be melted off before the steel is joined.
Figure 33SPOT WELDING TIPS
 Zinc has a low melting point, so a pulse of current
before welding will accomplish this. During the
weld, the zinc can combine with the steel and
lower its resistivity. Therefore, higher levels of
current are required to weld galvanized steel.

25
 PROCESSING AND EQUIPMENT

 Spot welding involves three stages

 First of which involves the electrodes
being brought to the surface of the
metal and applying a slight amount of
pressure.
 The current from the electrodes is then
applied briefly after which the current
is removed but the electrodes remain in
place for the Processing and Equipment
material to cool.
 Weld times range from 0.01 sec to 0.63
sec depending on the thickness of the
metal, the electrode force and the
diameter of the electrodes themselves.
 The equipment used in the spot
welding process consists of tool holders and electrodes.
 The tool holders function as a mechanism to hold the electrodes firmly in place and also
support optional water hoses that cool the electrodes during welding.
Figure 34 PROCESS
 Tool holding methods include a paddle-type, light duty, universal, and regular offset.
 The electrodes generally are made of a low resistance alloy, usually copper, and are
designed in many different shapes and sizes depending on the application needed.
 The two materials being welded together are known as the workpieces and must conduct
electricity.
 The width of the workpieces is limited by the
throat length of the welding apparatus and
ranges typically from 5 to 50 inches (13 to Figure 35 WELDED JOINT 130
cm). Workpieces thickness can range from
0.008 to 1.25 inches (0.20 to 32 mm).
 After the current is removed from the workpieces, it is cooled via the coolant holes in the
centre of the electrodes. Both water and a brine solution may be used as coolants in spot
welding mechanisms.

MIG WELDING

 FULL FORM is metal inert gas welding

26
 Metal inert gas (MIG) welding or metal active gas (MAG) welding is a welding process in
which an electric arc forms between a consumable MIG wire electrode and the workpieces
metal(s), which heats the workpiece metal(s), causing them to melt and join.

 Along with the wire electrode, a shielding gas feeds through the welding gun, which
shields the process from contaminants in the air.
Figure 36 MIG WELDING

 The process can be semi-automatic or automatic. A constant voltage, direct current power
source is most commonly used with GMAW, but constant current systems, as well as
alternating current, can be used.

 There are four primary methods of metal transfer in GMAW, called globular, short-
circuiting, spray, and pulsed-spray,
Figure 37 MIG WELDING
each of which has distinct
properties and corresponding advantages and limitations.

27
 TIG WELDING

 Gas tungsten arc welding

(GTAW)
 Also known as tungsten inert gas
(TIG) welding is an arc welding
process that uses a non-consumable
tungsten electrode to produce the
weld.
 The weld area and electrode is
protected from oxidation or other
atmospheric contamination by an
inert shielding gas (argon or
helium), and a filler metal is
normally used, though some welds, known as autogenous
Figurewelds,
38 TIGdo not require it.
WELDING

 A constant-current welding
power supply produces
electrical energy, which is
conducted across the arc
through a column of highly
ionized gas and metal
vapours known as plasma.
 GTAW is most commonly
used to weld thin sections
of stainless steel and
Figure 39TIG WELDING
nonferrous metals such as
aluminium, magnesium, and copper alloys.

 The process grants the operator greater control over the weld than competing processes
such as shielded metal arc welding and gas metal arc welding, allowing for stronger, higher
quality welds.
 However, GTAW is comparatively more complex and difficult to master, and furthermore,
it is significantly slower than most other welding techniques.

28
 ROBOTIC WELDING

 Robot welding
is the use of
mechanized
programmable
tools (robots),
which
completely
automate a
welding process
by both
performing the
weld and
handling the part.
Figure 40 ROBOTIC WELDING
 Processes such as gas metal arc welding, while often automated, are not necessarily
equivalent to robot welding, since a human operator sometimes prepares the materials to be
welded. Robot welding is commonly used for resistance spot welding and arc welding in
high production applications,
such as the automotive industry.

 The major components of arc

welding robots are the
manipulator or the mechanical
unit and the controller, which
acts as the robot's "brain".
 The manipulator is what makes
the robot move, and the design of
these systems can be Figure 41 ROBOTIC WELDING
categorized into several common types, such as SCARA and Cartesian coordinate robot,
which use different coordinate systems to direct the arms of the machine.

29
 CNC BENDING MACHINE

 CNC bending machines

are developed for high
flexibility and low
setup times.

 Those machines are

able to bend single
pieces as well as small
batches with the same
precision and
efficiency as series
produced parts in an
economical way.
Figure 42 CNC BENDING MACHINE

 The basic machine consists of a CNC operated side stop, a work bench, and software for
programming and operating.
 Its modular construction offers an affordable entry into the bending technology, because
after an initial investment the machine can be customized and extended later without any
conversion.

Figure 43 CNC BENDING MACHINE

30
 GRINDING MACHINE
 Surface grinding is used to produce a smooth
finish on flat surfaces.

 It is a widely used abrasive machining process in

which a spinning wheel covered in rough particles
(grinding wheel) cuts chips of metallic or non-
metallic substance from a workpiece, making a
face of it flat or smooth.

 The surface grinder is composed of an abrasive

wheel, a work holding device known as a chuck,
Figure 44 GRINDING MACHINE
and a reciprocating or rotary table.
 The chuck holds the material in place while it is being worked on.
 It can do this one of two ways: ferromagnetic pieces are held in place by a magnetic chuck,
while non-ferromagnetic and non-metallic pieces are held in place by vacuum or
mechanical means.
 A machine vise (made from ferromagnetic steel or cast iron) placed on the magnetic chuck
can be used to hold non-ferromagnetic workpieces if only a magnetic chuck is available.
 Factors to consider in surface grinding are the material of the grinding wheel and the
material of the piece being worked on.
 Typical workpiece materials include cast iron and mild steel.

 These two materials don't tend to clog the

grinding wheel while being processed.
Other materials are aluminium, stainless
steel, brass and some plastics. When
grinding at high temperatures, the material
tends to become weakened and is more
inclined to corrode.

 This can also result in a loss of magnetism

Figure 45 SURFACE GRINDER
in materials where this is applicable.
 The grinding wheel is not limited to a
cylindrical shape and can have a myriad of options that are useful in transferring different
geometries to the object being worked on.

CYLINDRICAL GRNDER

31
 The cylindrical grinder is a type of grinding machine used to shape the outside of an
object.

 The cylindrical grinder can work on a variety of shapes; however the object must have
a central axis of rotation.

 This includes but is not

limited to such shapes as a
cylinder, an ellipse, a cam, or a
crankshaft.
Figure 46 CYLINDRICAL GRINDER
 Cylindrical grinding is defined
as having four essential
actions:
1. The work (object) must be
constantly rotating
2. The grinding wheel must be
constantly rotating
3. The grinding wheel is fed towards and away from the work
4. Either the work or the grinding wheel is traversed with respect to the other.

 While the majority of

cylindrical grinders employ
all four movements, there are Figure 47 CYLINDRICAL GRINDER
grinders that only employ
three of the four actions...

32
 DRILL MACHINE

 A drill is a tool primarily used for making round holes or driving fasteners.
 It is fitted with a bit, either a drill or driver, depending on application, secured by a chuck.
 Some powered drills also include a hammer function.
 Drills vary widely in speed, power, and size.
 They are characteristically corded electrically driven devices, with hand operated types

dramatically decreasing in popularity and cordless battery powered ones proliferating.

 Drills are commonly used in woodworking, metalworking, machine tool fabrication, and

construction and utility projects.

 Specially designed versions are made for medicine, Space, and miniature applications.

COORDINATE MEASURING
Figure 48 DRILL MACHINE
MACHINE

33
 A coordinate measuring machine (CMM) is a device that measures the geometry of
physical objects by sensing discrete points on the surface of the object with a probe.

 Various types of probes are used in

CMMs, including mechanical,
optical, laser, and white light.
Depending on the machine, the
probe position may be manually
controlled by an operator or it may
be computer controlled.

 CMMs typically specify a probe's

position in terms of its
displacement from a reference
Figure 49 CMM
position in a three-dimensional
Cartesian coordinate system (i.e.,
with XYZ axes). In addition to
moving the probe along the X, Y,
and Z axes, many machines also allow the probe angle to be controlled to allow
measurement of surfaces that would otherwise be unreachable.

 The typical 3D "bridge" CMM allows probe movement along three axes, X, Y and Z,
which are orthogonal to each other in a
three-dimensional Cartesian
coordinate system.

 Each axis has a sensor that monitors

the position of the probe on that axis,
typically with micrometer precision.
 When the probe contacts (or otherwise
detects) a particular location on the
Figure 50 CMM MACHINE
object, the machine samples the three
position sensors, thus measuring the
location of one point on the object's
surface.
 This process is repeated as necessary,
moving the probe each time, to produce a "point cloud" which describes the surface areas
of interest.
 A common use of CMMs is in manufacturing and assembly processes to test a part or
assembly against the design intent.

34
 In such applications, point clouds are generated which are analysed via regression
algorithms for the construction of features.
 These points are collected by using a probe that is positioned manually by an operator or
automatically via Direct Computer Control (DCC). DCC CMMs can be programmed to
repeatedly measure identical parts.
 Thus an automated CMM is a specialized form of industrial robot.

Figure 51 CMM MACHINE

INSTRUMENTS USED IN THE COMPANY

1. VERNIER CALIPER
 It is a measuring device that consists of a main scale with a fixed jaw and sliding jaw with
an attached vernier scale.

35
 The principle of Vernier Calliper is the difference
between two scales.
 Through Vernier we can measure internal dimensions,
outside dimensions and depth.
 Least Count=1-Divison on vernier scale/Division on
main scale
 Least count=1-49/50=1÷50=0.02mm

Figure 52 VERNIER CALLIPER

2. HEIGHT GAUGE
 A height gauge is a measuring device used for determining the height of objects, and for
marking of items to be worked on.
 These measuring tools are used in metalworking or metrology to either set or measure
vertical distances; the pointer is sharpened to allow it to
act as a scriber and assist in marking out work pieces.
 Height gauges may also be used to measure the height of
an object by using the underside of the scriber as the
datum.

3. MICROMETER
 Another useful device for magnifying small measurements
is the micrometer. Figure 53 HEIGHT GAUGE
 The principle of micrometer is nut and bolt.
 These instruments are often made in various ranges like 0-
25mm, 25-50mm, 50-75mm to reduce wear and maintain
accuracy of the thread.
 Pitch ÷ number of circular division Figure 54 INSIDE MICROMETER
 Least Count=0.5÷50=0.01mm

36
 For measuring dimensions of outside
and inside of the component different
Figure 55
types of micrometer are used
MICROMETER

4. RADIUS GAUGE
 A radius gauge, also known as a fillet
gauge, is a tool used to measure the
radius of an object.
 A good set of gauges will offer both
convex and concave sections, and allow for
their application in awkward locations.
 Every leaf has a different radius.
 The material of the leaves is stainless steel.
 It is of two types: 1. Internal 2. External. It is used to check the radius of inner and outer
surfaces.

Figure 56 RADIUS GAUGE

5.
SURFACE
PLATE
 It is a
solid
flat
plate
used as
the main
horizontal reference plane for precision inspection, marking out and tooling setup.

37
 Figure 57 SURFACE PLATE

6. DIAL GAUGE
 A gauge consisting of a circular
graduated dial and a pointer actuated
by a member that contact with the part
being calibrated.
 A dial bore gauge is a convenient term
for the measuring or transfer tool that
is used in the process of accurately
measuring holes.
 Least Count=1÷100=0.01mm

Figure 58 DIAL GAUGE

7. V BLOCK

 V-Blocks are precision metalworking jigs typically used to hold round metal rods or pipes
for performing drilling or milling operations.

38

Figure 59 V-BLOCK
  They consist of a rectangular steel or cast iron block with a 90-degree channel rotated 45-
degrees from the sides, forming a V-shaped channel in the top.
 A small groove is cut in the bottom of the "V".
 They often come with screw clamps to hold the work. There are also versions with internal

magnets for magnetic work holding .

8. BEVEL PROTECTOR
 A bevel protractor is a graduated circular protractor with one pivoted arm; used for
measuring or marking off angles.
 Sometimes Vernier scales are attached to give more precise readings. It has wide
application in architectural and mechanical drawing,
 Although its use is decreasing with the availability of modern drawing software or CAD.

9. SINE BAR

Figure 60 BEVEL PROTECTOR

 Sine bar is an indirect measuring
instrument used for measuring
small angles which are made in the
product made.
 It consists of a bar to which two
cylinders are of equal diameter are
attached at a précised distance
apart.
 The distance between both the
cylinders is known to us.

SinѲ= H/L (FOR FIGURE 1)

39
Figure 61 SINE BAR

SinѲ= (H2-H1)/L (FOR FIGURE 2)

Figure 62 SINE BAR

10. SHEET METAL THICKNESS MEASURING GAUGE

40
 Many different types of metal can be made into sheet metal, including aluminium, brass,
copper, steel, titanium, tin and stainless steel.

 Sheet metal is available in a variety of different metal types and thicknesses.

 Choosing the right sheet metal

gauge and thickness is essential to
any metal fabrication project

 . Similar to wire, sheet metal

thickness is measured in gauges.

 The higher the number, the thinner

the sheet metal. A gauge is a Figure 63 DIGITAL THICKNESS GAUGE
traditional, non-linear
measurement.

 The most commonly used sheet

metal sizes range from 30 gauges
(thinner) to 7 gauges (thicker).

Figure 64 SHHET THICKNESS GAUGE

11. FEELER
GAUGE

41
 A feeler gauge is a tool used to measure gap widths.
 Feeler gauges are mostly used in engineering to measure the clearance between two parts.
 They consist of a number of small lengths of steel of different thicknesses with
measurements marked on each piece.

 They are flexible enough that, even if they are all on the
same hinge, several can be stacked together to gauge
intermediate values.
 It is common to have two sets for imperial units (typically
measured in thousandths of an inch) and metric (typically Figure 65 FEELER GAUGE
measured in hundredths of a millimetre) measurements.

12. DIAL BORE GAUGE

 A bore gauge is a collective term for the tools that are unique to the process of accurately
measuring holes.

 The dial bore gauge must be set to the nominal value of the bore, and it will measure the
variation and direction of the bore from nominal.

 There are multiple ways to set this gauges to the nominal value. The most common method
is using an outside micrometer that is set
to the nominal value.

 This is the quickest and least expensive

way to set the dial bore gauge.
 This method is not the most accurate
because there can be high human error
and variation in the micrometer is passed
down into the dial bore gauge.

 A dial bore gauge has a contact needle

that is housed inside the head of the dial
bore gauge.

 The needle is moved when measuring the

bore and mechanically or electronically
transfers that data to the dial or readout.

 The head also includes an

interchangeable end that is used to set the Figure 66 DIAL BORE GAUGE
nominal size and reference contacts to aid
in alignment with the bore.

 The interchangeable ends come in varying lengths to accommodate a range of bore sizes.

42
 PRODUCTS MANUFACTURES IN ASSEMBLY SHOP

Figure 67 SIDE STAND

Figure 68 CHASSIS OF BIKE

Figure 69 SIDE FOOT REST

Figure 70 DOUBLE STAND FOR ACTIVA

Figure 71 FRAME FOR ACTIVA

RESULTS AND
DISCUSSION

RESULTS

Successful Development of
The Part: In the final we get
the result of the successful
development of the part. The
part can be developed

43
according to its profile which is provided by the company to the engineers. According to its
structure a die can be used for the manufacturing of the part. For the manufacturing of the
different parts different dies can be used which are according to the shape of the part. The die is
loaded on the M.B. and M.B. can be placed inside the press as the lower unit and an upper
portion of the die can be attached to the upper M.B. with the help of studs. When the die is
loaded then the complete automatic process of the press starts and the pressure starts creating in
the cylinders which are attached at the top portion of the press. When the pressure completes
then the upper die completes its stroke and the single- single operations can be completed on
different presses. The presses used for these different operations are of different pressures the
press used for the drawing operation is of 800 Tones and the presses used for the remaining
operations are of 400 Tones that means the upper die strikes on the lower one with that pressure.
The damps produced in the press by this strike are absorbed by the damping unit which is under
the cushion bed. The M.B. is placed on the cushion bed and the damps can be absorbed by the
damping unit. After the every operation complete the part sends to the welding shop where the
nut and bolts are attached to the part according to the constructional detail of the part with the
help of the spot welding and at last the part is checked by the quality checkers and ready for
delivery. So this is the successful development of the part.

Get The Chance To Gain The Knowledge: After watching the complete phenomenon of
manufacturing of part we are able to getting the knowledge about the different press operation
such as drawing, trimming, restriking and punching. The different part of the die works in a
different manner and these are automatically done so after watching these operations we are able
to get the knowledge of different press operations. After the different press phenomenon the
different welding operations are performed on it. The welding operation is used is the Spot
Welding operation in which spot welding can be done in two different ways:

1) Internal Transformer gun

2) Non Internal Transformer gun

These are the two welding operation which are used for spot welding so we get the knowledge
about the spot welding techniques and machines which are used for spot welding. By watching
this complete we are able to get the knowledge of different processes that can be used in the

44
factory for manufacturing of different parts. So after getting the complete training we get the
knowledge of different processes.

DISCUSSION

 Defects Produced In the Sheet

During discussion we discuss about the problem facing during the manufacturing process of
different parts. Basically the main problem can be faced is of different defects produced during the
manufacturing phenomenon. The different defects produced are:

1) Wrinkle
2) Overlapping
3) Crack
4) Burr
5) Dent
6) Deformation

These are the main problems that are faced during the manufacturing process of part. These
defects can be discussed during training.

 Problem Produced In the Presses

There are different problems that are produced during the working condition of press and these
defects can be studied or discussed during the training. The different defects produced in the
presses are:

1) Lubrication problem
2) Pressure problem

These are the problems that are faced during the working condition of the press. So these defects
can be discussed or solved out during training.

CONCLUSION

In conclusion we are discussed to solve the problem produced during the working condition of
press and manufacturing of the parts. To solve the defects produced on the surface of the sheet
during different press operations different processes can be used if the damage is small and it can

45
easily be repaired then it can be machined and repaired it but if the defect is not be able to
correct then the sheet can be thrown into scrap. If the problems are small and it can easily be
repaired then different operations such as hammering and machining can be used. After applying
these processes the defects can be removed from the surface of the sheet because without
removing these defects it can’t be possible to use these parts. A defective piece can’t be used in
the manufacturing of the final component so it is necessary to remove these defects. In conclusion
we discussed the process used for removal of the defects.

There are certain defects produced during the working of press. The different defects produced
during the press operation are lubrication problem, less pressure produced in the cylinders. It is
necessary to solve these problems because without solving these problems the press can’t work
automatically. If any operation of the press stops working then press stops working so it is
necessary to solve these problems. Sometimes the pump of lubrication stop working and the press
stops working. So this effect can be checked out and clear it so that the press should work
properly. Sometimes the cylinder cannot produce proper pressure for the stroke of the die so it is
necessary to solve this problem that the press should stroke properly. The pump stops working
and the pressure stops producing in the cylinders and due to this the press stops working so we
find out the problem and solve this so that press should work properly.

So these are the basic conclusions that are made to solve the problems produced during the
different operations.

REFERENCES

46
1. Pawan Kumar Rai, Dr. Aas Mohammad, Hasan Zakir Jafri / International

Journal of Engineering Research and Applications (IJERA) ISSN: 2248-9622

www.ijera.com

2. 1. Cyril Donaldson, George H LeCain, V C Goold, and Tool design 3rd edition,

Tata McGraw-Hill Education, New Delhi.

3. Wikipedia https://en.wikipedia.org/w/index.php?

title=Types_of_press_tools&oldid=890255012

4. https://en.wikipedia.org/w/index.php?

title=Die_(manufacturing)&oldid=887662315

5. Technical Resources (https://www.mate.com/technical-resources/)

6. "Coordinate Measuring Machine History – Fifty Years of CMM History leading

up to a Measuring Revolution", COORD3 Metrology. Accessed 23 August 2013

7. www.SutherlandPresses.com

8. www.scribd.com

9. www.blogger.com

10. Tool and Manufacturing Engineers Handbook (TMEH), Volume 3, Materials,

Finishing and Coating. Society of Manufacturing Engineers, 1985.

11. https://en.wikipedia.org/w/index.php?title=Burr_(edge)&oldid=852765256

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