Training Report

Industrial Training

Of

Automobile Engineering

Department of Automobile Engineering

Chandigarh university

Submitted by: - SAHIL VERMA

15BAM1114
5AME-1
Industrial Training

Page 1
 Industrial Training

Acknowledgement

The four weeks industrial training project is a golden opportunity for learning and self-
development. I consider myself very lucky and honoured to have so many wonderful
people, lead me through in completion of this project.
I am highly grateful to Chandigarh University for providing this opportunity to carry
out the four weeks Industrial Training at Grover Hyundai, Ludhiana Punjab.
My grateful thanks to Mr. Pradeep Singh, training coordinator at Grover Hyundai,
Ludhiana Punjab, who in spite of being extraordinarily busy with his duties, took time
out to hear, guide and keep us on correct path.
The author expresses gratitude to other faculty members of Automobile department of
Chandigarh University for their intellectual support throughout the course of this work

Scope of Training

One of the fastest growing industries, India is the 7th largest producer in the world with an
average annual production of 17.5 million vehicles. This sector contributes 7% of the country’s
GDP by volume. According to a report of Society of Indian Automobile Manufacturer (SIAM)
2015, our country is also the 4th largest automotive market by mass.

According to industry estimates, automobile sector is expected to sell more than 6 million
vehicles by 2020. The latest report by SIAM also says that in April-March 2015, overall
automobile exports grew by 14.89% over the same period last year.

Page 2
 Industrial Training

Looking at this data, it is clear that India is a potential engineering automobile market and jobs in
this sector is expected to grow significantly. With Modi government’s ‘The Automotive Mission
Plan’ (AMP) II 2016-26, one can expect plethora of job opportunities in this industry. The sector
needs professionals with path-breaking ideas for the production of more such advanced machines

Page 3
 Industrial Training

INDEX

S. no. Title Page No.

1. Introduction 6-12
 Purpose 6

 Scope 7

 Definitions 7

 Classification of automobile 7-10

 Layout of chassis 11

 Components of automobile 11
12
 Overview
2. Agency Training 12-13
 What is agency training? 12

 What is service station 12-13

 4 service station 13

3. Station-1 14-19
 Denting & Painting? 14

 What is a dent? 14

 Equipment’s used 15

 How it can be corrected? 16-17

 Painting process 17

 How it is done? 18-19

19
 Fitting of body parts
4. Station-2 20-30
 Mechanical floor 20

 How a car service is done? 20

20-21

Page 4
 Industrial Training

 In first service 21-22

 In second service 22-23

 In third service 23-25

 Major loss of the car 25-26

 Gas compressor 26-27

 Wheel balancing 27-29

30
 Wheel alignment
 Equipment’s used
Station-3 31-32
5.  Washing station 31

 How it is done? 31

 In full wash 31-32

6. Station-4 33
 Inspection station 33

 How it is done? 33

7. Conclusion 34

Page 5
 Industrial Training

1. Introduction
An automobile (or automotive) is a vehicle that is capable of propelling itself. Since
seventeenth century, several attempts have been made to design and construct a
practically operative automobile.
Today, automobiles play an unimaginable role in the social, economic and industrial
growth of any country.
After the introduction of internal combustion engines, the automobile industry has seen
a tremendous growth.

Page 6
 Industrial Training

1.1) Purpose:
The Purpose of automobile is to get to another places without walking. To get from
point A to point B in the fastest and simplest way automobile is a vehicle, typically
with four wheels, powered by an internal combustion engine or electric motor and able
to carry the transportation of peoples and goods.

1.2) Scope
Automobile Engineering is the fastest growing industry. Considering the current
scenario, it is expected that the Automobile Engineering Scope & career opportunities
will get increased. There is a lot of scope of Automotive industry. Companies look for
cheap mechanical engineers for maintenance and every technical stuff is sort out or
designed prior in other country.

1.3) Definitions
Motorized vehicle consisting of four wheels and powered by an internal engine.
Automobiles are used to transport people and items from one location to another
location. After years or various designs, inventors were able to develop a functional
general design that is utilized by major automakers as the foundation of their designs.
Automobiles generally use gasoline to fuel the internal engine, but technological
advancement have led to the design of cars that run on electricity and even water.

1.4) Classification of automobile

Automobiles can be classified into several types based on several criteria. A brief
classification of automobiles is listed below:

Page 7
 Industrial Training

1. Based on purpose:
 Passenger vehicles – These automobiles carry passengers – e.g.: Buses, Passenger
trains, cars
 Goods vehicles – These vehicles are used for transportation of goods from one place
to another. E.g.: Goods lorry, goods carrier

2. Based on capacity:
 Heavy Motor Vehicle (HMV) – Large and bulky motor vehicles – e.g.: Large trucks,
buses.
 Light Motor Vehicle (LMV) – Small motor vehicles – e.g.: Cars, Jeeps
 Medium Vehicle – Relatively medium sized vehicles – e.g.: Small trucks, mini buses

3. Based on fuel source:

 Petrol engine vehicles – Automobiles powered by petrol engine – e.g.: scooters, cars,
mopeds, motorcycles
 Diesel engine vehicles – Automotive powered by diesel engine – e.g.: Trucks, Buses
 Gas vehicles – Vehicles that use gas turbine as power source – e.g.: Turbine powered
cars
 Solar vehicles – Vehicles significantly powered by solar power – e.g.: Solar powered
cars
 Hydrogen vehicles – Vehicles that have hydrogen as a power source – e.g.: Honda
FCX Clarity
 Electric vehicles – Automobiles that use electricity as a power source – e.g.: Electric
cars, electric buses
 Steam Engine Vehicles – Automotive powered by steam engine – e.g.: Steamboat,
steam locomotive, steam wagon
 Hybrid Vehicles – Vehicles that use two or more distinct power sources – e.g.:

Page 8
 Industrial Training

Hybrid buses, hybrid cars like Toyota Prius, Honda Insight

 Hybrid Electric Vehicle (HEV) – Automobile that uses both Internal Combustion
Engine and Electric Power Source to propel itself – e.g.: Jaguar C-X75

4. Based on type of transmission:

 Automatic transmission vehicles – Automobiles that are capable of changing gear
ratios automatically as they move – e.g.: Automatic Transmission Cars
 Conventional transmission vehicles – Automotive whose gear ratios have to be
changed manually
 Semi-automatic transmission vehicles – Vehicles that facilitate manual gear changing
with clutch pedal

5. Based on number of wheels:

 Two-wheeler – Automobiles having two wheels – e.g.: Scooters, motorcycles
 Three-wheeler – Automotive having three wheels – e.g.: Tricycles, Auto rikshaws,
Tempos
 Four-wheeler – Vehicle having four wheels – e.g.: Car, Jeep
 Six-wheeler – Automobile having six wheels used for heavy transportation – e.g.:
Large trucks, large buses

6. Based on the side of drive:

 Left hand drive automobile – Vehicle in which steering wheel is fitted on the left-hand
side – e.g.: Automobiles found in USA, Russia
 Right hand drive automobile - Vehicle in which steering wheel is fitted on the right-
hand side – e.g.: Automobiles found in India, Australia.

Page 9
 Industrial Training

7. Based on the shape of car:

 Sedan
 Coupe model
 Hatchback
 SUV
 MPV
 Limousine

8. Based on Suspension system used:

 Convectional – Leaf Spring
 Independent – Coil spring, Torsion bar, Pneumatic Position of Engine
 Engine in Front:
 Most of the vehicles have engine in the front.
Example: most of the cars, buses, trucks in India.
 Engine in the Rear Side:
 Very few vehicles have engine located in the rear.
Example: Nano car.

9. On the Basis of Load:

 (a) Heavy transport vehicle (HTV) or heavy motor vehicle (HMV),
e.g. trucks, buses, etc.
 (b) Light transport vehicle (LTV)
e.g. pickup, station wagon, etc.
 (c) Light motor vehicle (LMV),
e.g. cars, jeeps, etc.

Page
10
 Industrial Training

1.5 LAYOUT OF AN AUTOMOBILE CHASIS

 Layout of an engine chassis is shown below

 It contains the source of power, i.e. engine, the frame, which supports the engine,
wheels, body, transmission, the braking system and the steering.
 It also gives support to suspension system and springs.

1.6COMPONENTS OF THE AUTOMOBILE

 The automobile can be considered to consist of five basic components:
i. The Engine or Power Plant: It is source of power.
ii. The Frame and Chassis: It supports the engine, wheels, body, braking system,
steering, etc.
 The transmission which transmits power from the engine to the car wheels.
 It consists of clutch, transmission, shaft, axles and differential.
 The body fitted on chassis.
 Accessories including light, air conditioner/hearer, stereo, wiper, etc.

Page
11
 Industrial Training

1.7 Overview
The automobiles sector is divided into four segments – two-wheelers (mopeds,
scooters, motorcycles, electric two-wheelers), passenger vehicles (passenger cars,
utility vehicles, multi-purpose vehicles), commercial vehicles (light and medium-
heavy vehicles), and three wheelers (passenger carriers and good carriers).
The industry is one of the key drivers of economic growth of the nation. Since the
delicensing of the sector in 1991 and the subsequent opening up of 100 percent FDI
through automatic route, Indian automobile sector has come a long way. Today, almost
every global auto major has set up facilities in the country

2.Agency Training

2.1) What is Agency Training?

Agency Training is also a part of a study in automobile training. In Agency Training
all types of work station are present like body station, mechanical floor, washing
station, assembly line, denting and painting station etc. Agency Training provides a
rough estimate of data to students for gaining knowledge about working in a practical
basis. With the help of this training a student can learn basic work for automobile
industry.

2.2) What is a Service Station?

A service station is originally a full service filling station with a repair garage on-site.
Service Station word meaning is to repair or service an automobile. So it consists of
various stations for performing their different functions over an automobile. The

Page
12
 Industrial Training

stations are body shop, performance shop, detail shop, denting and painting station,
mechanical station, washing station etc.

1. It is a series of maintenance procedures carried out at a set time interval or after

the vehicle has travelled a certain distance.

2.The service intervals are specified by the vehicle manufacture in a service schedule
and some modern cars.

3. The due date for the next service is electronically updated on the instrument panel.
4. The completed services are usually recorded in a service book which is rubber

stamped by the service centre upon completion of each service.

2.3 IN HYUNDAI AGENCY THERE ARE FOUR SERVICE

STATIONS: -

1. Denting and painting station (Body shop)

2. Mechanical Floor (Performance shop)
3. Washing station
4. Inspection

Page
13
 Industrial Training

3. STATION- 1
(BODY SHOP)
3.1) Denting and painting.
Denting is performed for the removal of the dents for the car body. Dents are like scars
in the car body which doesn’t look nice over the car body. It provides an ugly look to
car body and make its value low in the market. So it is necessary to remove dent and
scratches from the car body. By the denting process it can be corrected easily. Painting
is performed to provide colour to the car body and make it looks good.
In denting and painting station both are done properly first denting process is used to
remove the dents from the car after that the car is moved to the painting booth for
painting.

3.2) What is a dent?

A slight hollower a depression in a hard surface even made by a blow or pressure.
A dent is caused by hitting of two bodies into each other. So it makes a scar or
unevenness surface on the car which we can called as a dent.

3.3) Equipment’s Used: -

1.Grinder Tool 2.SanderTool &Disk 3.Dent Pooler

Page
14
 Industrial Training

Machine

4.Jerk Dent Pooler 5.AirPressureMachine 6.MigWelding

3.3) How it can be corrected?

 It can be corrected in following ways: -
First Step: -
1. Remove the paint from the dent and scratch with the help of hand grinder tool.
Only remove the paint from scratch and dent carefully.

Page
15
 Industrial Training

2. Clean the scratched part with the help of air pressure gun.
3. With the help of jerk dent Pooler pull up the dent part area by providing a force over
it. It may weld into the body and when pull up the body gets its proper shape but it
may leave over a small hole over the body.

4. Now the body gets its proper shape

5. Again with the help of hand grinder peal the body and remove the small patches or
dots from it.

Page
16
 Industrial Training

6. Now use the polyester putty and provide a one coat over it. Use the sander tool over
it for making it smooth.

7. After the rubbing check dots if they are present then use putty again and rubber it
gently with sander.

8. Now use 180 number disk for providing smoothness to the body.
9. Check with hand and see the dented area becomes smooth.
10.After this car is move on to the painting process.

3.4 Painting Process

Painting is the practice of applying paint, pigment, color or other medium to a solid surface.
The medium is commonly applied to the base with a brush, but other implements, such as
painting booth and with the help of robots. Painting is done to provide color to anybody.
With the help of painting the body looks good and attractive.

Page
17
 Industrial Training

3.5 How it is done?

After the car comes from denting station it moves next to the painting station.
1. With the help of air pressure gun the dust is cleaned from the body.

2. 80 number disk is used for cleaning the denting area.

3. Primer is used for providing a coat over the body which is to be painted.

4. After 30 minutes check the primes painted part that it becomes dry and smooth.
5. Masking is done on the car for painting.

Page
18
 Industrial Training

6. Clean the car with air pressure gun and wash thoroughly.
7. Then the car is moved into the painting booth for paint.
8. With the help of sprays the paint is spread over the car and left for dry it in the
painting booth.

9. After 1 hour the car comes out from the paint booth for washing.
10. In this way the car is painted.

3.6) Fitting of Car Body Parts: -

In body shop the car body parts are also fitted such as bumpers, lights etc.

1. Fitting of bumpers2. Fitting of lights

Page
19
 Industrial Training

4. STATION-2

4.1) Mechanical Floor

Mechanical is a floor where service equipment’s, utility lines and various machinery is
located. On mechanical floor usually the service of the car work is performed. But there are
some other cars which needs some more work to perform function normally. It is a place
where the service of the car is done respectively.

4.2) How a service of car is done?

Usually the first service of the car is done after 1500 or 1600 km. Second service of the car
is done after 5000km. Third service of the car is done after 15000km.And same like this the
process moves on.

 4.3) In first service: -

1. Air filter, ac filter is cleaned in first service of the car.

2. All the lighting system is checked lights, lamps, wipers, bonnet opening, boot space
opening, horn operation, dashboard lighting system are checked.
3. Brake oil, coolant level, battery water container, wiper water bottle is filled if
necessary.

Page
20
 Industrial Training

4. Navigation is updated if necessary.

 4.4) Second service of the car: -

1. In second service the ac filter, oil filter cap and air filters are changed.

2. Change of engine oil with the help of oil container the oil is removed and new
oil is filled.

3. Brake shoes and drum brakes are cleaned with the help of sand paper.

Page
21
 Industrial Training

4. Interchanging of the tires.

5. Lighting systems are checked.
6. Battery water level, coolant level, brake oil, wiper water bottle container, engine oil is
filled.

 4.5) In third service: -

1. In third service wheel alignment and wheel balancing of the car tire is done.

2. Inter changing of the car tires.

3. Brake shoes are changed brake drums are cleaned with sand paper respectively in
a proper way.
4. Change of oil filter cap, ac filter, and air filter.

Page
22
 Industrial Training

5. Change of engine oil.

6. Filling of brake oil, battery water level, wiper water bottle, coolant also.

7. Navigation is updated of the car.

 4.6) Major loss of the car: -

1. Total loss of the engine and it’s all parts.

2. Front chassis is damaged.

Page
23
 Industrial Training

3. Both tires are destroyed in accident.

4. Front windshield and dashboard also breaks in accident.

 After Repairing
1. New axles, tie rod, nickel joint, shocker, ball joint, stub axles, steering tie rod, front
axle are fixed.

2. After installing axles new tires are fixed, new steering system is fixed. New axle
is fixed over the shocker.

3. Dashboard is fitted with its all parts and gear handle is fixed.

Page
24
 Industrial Training

4. Inter coolent , turbo charger, radiator, condensor, head light spot, new engine all
the parts are fixed.

5. After installing all the parts which are damaged in accident.

 4.7) Gas compressor: -

 A gas compressor is a mechanical device that increases the pressure of a gas by
reducing its volume. An air compressor is a specific type of gas compressor.
Compressors are similar to pumps: both increase the pressure on a fluid and both can
transport the fluid through a pipe. As gases are compressible, the compressor also

Page
25
 Industrial Training

reduces the volume of a gas. Liquids are relatively incompressible; while some can
be compressed, the main action of a pump is to pressurize and transport liquids.

 4.8) Wheel Balancing: -

Out-of-balance tires will cause a car to vibrate at certain speeds, usually between 50 and 70
mph. A tire out of balance when one section of the tire is heavier than the others. One ounce
of imbalance on a front tire is enough to cause a noticeable vibration in the steering wheel at
about 60mph. To balance a wheel, the technician will mount it on a balancing machine
which spins the wheel to locate the heavier part. He will then compensate for the heavy part
by attaching a lead weight on the opposite side. Many people are pleasantly surprised at how
smooth their car drives after balancing all four wheels

Page
26
 Industrial Training

 How It Is Done: -
1. Tire size is feed in the computer in correct form in inches and width.
2. By taking the slider with hand touch on the corner of the tire so that it should
checked the data which is feed is correct or not.
3. Putt the tire on the slider stand which is supposed to be rotated.
4. Place the lock on the tire and tight it properly.
5. Place the cover on the tire so it supposed to be run properly after that see on
computer.
6. It will show the uneven wheel balancing of the tire.
7. Make it correct and putt the weight on the tire on the same side of the slider.
8. Resin the tire again
9. It would say ok so the wheel balancing of the tire is done.

 4.9) Wheel Alignment: -

Alignment refers to an adjustment of a vehicle's suspension – the system that
connects a vehicle to its wheels. It is not an adjustment of the tires or wheels
themselves. The key to proper alignment is adjusting the angles of the tires which
affects how they make contact with the road

Page
27
 Industrial Training

 Toe-in & Toe-out-Negative toe, or toe out, is the front of the wheel pointing
away from the centreline of the vehicle. Positive toe, or toe in, is the front of the
wheel pointing towards the centreline of the vehicle. Toe can be measured in linear
units, at the front of the tire, or as an angular deflection

 Caster Angle- The caster angle or castor angle is the angular displacement of
the steering axis from the vertical axis of a steered wheel in a car, motorcycle,
bicycle or other vehicle, measured in the longitudinal direction.

 Camber-Camber angle is the angle made by the wheels of a vehicle; specifically,

it is the angle between the vertical axis of the wheels used for steering and the
vertical axis of the vehicle when viewed from the front or rear. It is used in the
design of steering and suspension.

 King pin inclination- It is a line between the two pivot points of a wheel
(upper/lower ball joints, or lower ball joint and McPherson Strut tower bearing) and
is the sister to the Caster angle in determining vehicle stability while going down a
straight.

 How it is done?
1. Place the cameras on the tires and select the start button.

Page
28
 Industrial Training

2. Start the machine.

3. Select when alignment option from the pop up menu.

4. Then type the name and model of the car.
5. Give information about the owner of the car and click on start button.
6. It will start and show the information about the tires.
7. It will show the information about the caster angle, camber, toe-in and toe-out.

8. Correct the angle if needed by tightening and losing the ball joint rod and check
the computer display
9. When both the angle becomes same then tight the rod from both sides.
10. In this way the car wheel alignment is done.

 Equipment’s Used for Servicing: -

Page
29
 Industrial Training

1.HYDROLIC 2.TOOL BOX 3.AIR

LIFT TROLLEY PRESSURE M/C

4.OIL 5.TYRE 6.GREASE

COLLECTOR INFLATOR PUMP

Page
30
 Industrial Training

7.GAS 8.WHEEL 9.WHEEL

COMPRESSOR BALANCING ALIGNMENT

5. STATION-3

5.1) Washing Station: -

In washing station, the cars are washed respectively from all sides properly. It is the main
station because after washing the car gets its original shine over the body. Washing is a
facility that is given to cars for cleaning. Washing station is a place where cars are generally
comes for cleaning. Thus washing is also an important part of a car.

5.2) How It Is Done?

It is done in following methods: -

 In Full Wash: -
1. The car is lifted upward with the help of hydraulic lift for washing purpose.
2. With the help of water pressure gun the car is washed respectively from all the
sides and also from the floor of the car.

Page
31
 Industrial Training

3. With the help of shampoo clean it’s all body and tires also respectively and wash
properly again.

4. Then take out the car from the hydraulic lift and dry all the water from the car
with the help of clean cloth and air pressure gun.
5. Clean the car seats, floor, boot space properly with the help of vacuum cleaner.

6. Wipe out all the dirty things with a clean cloth.

7. Provide polish to the car dashboard, car seats, doors and over it’s all body
8. Thus these are the steps which are used for washing and cleaning of the car.

Page
32
 Industrial Training

After washing and cleaning the car may looks like this.

6 . STATION-4

6.1) Inspection Station

In inspection station generally the cars are inspected after completion of their work.
Inspecting of a car ensure that the car is inspected carefully and not have any
problem.

6.2) How it is done?

 It is done in following ways: -
1. A proper check sheet is given for inspecting the car.

2. This check sheet is used for inspecting the parts of body shop.
3. Inspector have to be ensure about the work which he is doing.
Page
33
 Industrial Training

4. With the help of this sheet inspector checks the body parts properly and its
quality.
5. Same like this there are another check sheets available for station.
6. After inspection of the car it is delivered to the owner respectively.

Thus these are steps for inspecting the vehicle.

7 . Conclusion
During summer training period, a lot of experience, knowledge and exposure that I have handy.
All disclosures were awakened myself in a boost of self-confidence to face life more challenging
now. Practical is a complement to the science or theory learned. This is clearly the concept of
science and charity, where they have learned without practice will be lost and will not give
anything - what effect. So if we do without the knowledge of course there will be problems in
terms of grip and stance ever - changing.

During my industrial training, there are many changes from the point of learning environments
and discussion among colleagues. It can directly increase the dedication and rational attitude
toward myself.

Page
34
 Industrial Training

However, there are still some weaknesses that can be improved in the future. Therefore, I
conclude that the industrial training program has provided many benefits to students even if there
are minor flaws that are somewhat disfiguring condition, so that this weakness can be rectified in
the future.

Page
35
Industrial Training

Page
36
Industrial Training

Page
37