A REPORT OF SIX WEEKS INDUSTRIAL INTERNSHIP

at
Moonlight Auto Pvt. Ltd.

SUBMITTED IN PARTIAL FULFILMENT OF THE REQUIREMENT FOR THE AWARD

OF THE DEGREE OF

BACHELOR OF TECHNOLOGY
(Mechanical Engineering)

(4Th JUNE - 13Th JULY, 2019 )

SUBMITTED BY:
NAME: Arvind Sharma
UNIVERSITY ROLL NO.: 1706967

DEPARTMENT OF MECHANICAL ENGINEERING

GURU NANAK DEV ENGINEERING COLLEGE LUDHIANA
(An Autonomous College Under UGC ACT)
 CONTENTS

Topic Page No.

Certificate by Company/Industry/Institute i
Candidate’s Declaration ii
Abstract iii
Acknowledgement vi
About the Company/ Industry / Institute v

CHAPTER 1 INTRODUCTION 1
1.1 INFRACTURE 1
1.1.1 Tool Room
1.1.2 Press Shop
1.1.3 Maintenance
1.1.4 Welding Shop
1.1.5 Inspection
1.1.6 Paint Shop
1.2 MACHINE
1.2.1 Grinders
1.2.2 Milling Machine
1.2.3 Drill Machine
1.2.4 Shaper Machines
1.2.5 Lathe Machines
1.2.5 CNC Vertical Machines
1.2.6 Press Machines

CHAPTER 2 TRAINING WORK UNDERTAKEN 20-__

(This chapter should include the sequential learning steps, methodology followed
and project undertaken, if any)

CHAPTER 3 RESULTS AND DISCUSSION __-__

(This chapter should include any results and the related discussions for the projects
made during training. If no project has been made the results and snapshots for the
tools learnt should be included)

CHAPTER 4 CONCLUSION AND FUTURE SCOPE __-__

4.1 Conclusion __
4.2 Future Scope __
REFERENCES _
APPENDIX __
i
GURU NANAK DEV ENGINEERING COLLEGE, LUDHIANA

CANDIDATE’S DECLARATION

I Arvind Sharma hereby declare that I have undertaken six weeks industrial at

Moonlight Auto Pvt. Ltd. During a period from 3th June to 14th July 2019 in partial

fulfilment of requirements for the award of degree of B.Tech Mechanical

engineering at GURU NANAK DEV ENGINEERING COLLEGE, LUDHIANA.

The work which is being presented in the training report submitted to Department of

Mechanical Engineering at GURU NANAK DEV ENGINEERING COLLEGE,

LUDHIANA is an authentic record of training work.

Signature of the Student

The six weeks industrial training Viva–Voce Examination of__________________

has been held on ____________ and accepted.

Signature of Internal Examiner Signature of External Examiner

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 ABSTRACT

The report consists of the learnings, tasks, procedures which were carried out in the
workshop of the company during the summer internship which includes the
observation and understating the working of the company.

The real spirit of achieving a goal is through the way of excellence and
strict discipline. Industrial training is an important phase of a student life. A well
planned properly executed and evaluated training helps a lot in developing a
professional attitude.

It develops an awareness of industrial approach to problem solving, based

on a broad understanding of process and mode of operation of organization. The aim
and motivation of this industrial training is to receive discipline, skills, teamwork
and technical & practical knowledge through a proper training environment, which
will help me as student in the field of mechanical engineering. During a period of 6
weeks training, I was assigned to create a costing report of new product development
and 2D drawings of hand tools like spanners and gear wrenches. As a result I vital to
achieve the minimum requirement of company, it will help the company to
maintaining the data on SQL server.

Throughout this industrial training, I have been learned designing software’s like
AutoCAD that required for the system, the process of the production line and able to
implement what I have learnt for the past year as a student in B tech mechanical
engineer in GNDEC, Ludhiana.

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 ACKNOWLEDGEMENT

It is my pleasure to be indebted to various people, who directly or indirectly

contributed in the development of this work and who influenced my thinking,
behaviour, and acts during the course of study.

I express my sincere gratitude to Dr. Sehjpal Singh, worthy Principal for providing
me an opportunity to undergo Six Weeks Industrial Training at Bhartiya Vehicles and
Engineering Co. Ltd. I am thankful to Dr. Paramjit Singh Bilga, HOD Mechanical
Engineering Department for his valuable support, cooperation, and motivation
provided to me during the training for constant inspiration and blessings.
I am also thankful to all the Faculty and Staff Members of Mechanical Engineering
Department for their cooperation, inspiration and support which they provide me
during the training.
I also extend my sincere appreciation to team of Moonlight Auto Pvt. Ltd. for
successful accomplishment of my 6 week industrial internship..
Lastly, I would like to thank the Almighty and my parents for their moral support
and my friends with whom I shared my day–to–day experience and received lots of
suggestions that improved my quality of work.

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 ABOUT THE COMPANY

The Moonlight group was incorporated in the year 1989 with an idea to take over the
established family business of partnership concern started in the year 1968 in
Ludhiana, Punjab, India. Since then .the company has grown steadily in size and
capability. The company became Private Limited in 1990 and subsequently Deemed
Limited in1998 by generating and contributing to the growth of sales every year.
The group is spread over four different plants /Locations with a facility of each plant
spread on sprawling 90,000, 72,000,and 45,000 Sq. ft. area.
The business area involves manufacturing & assembly of sheet metal pressings,
turning components, etc. for wide spectrum of industry including Automobile (2-
wheeler, Passenger Cars, LCV & Trucks, Tractors, etc.), White Goods Industry, etc.
With its outstanding R&D, modern techniques and facilities and state of art design
office with CAD & CAM setup and highly skilled workmanship combined with a
strong commitment to customer service has established MOONLIGHT in the mind
of customers as a highly respected manufacturer. Moonlight has developed handful
of import substitute items required for various reputed concerns in India.
The company has entered into technical licensing agreement with leading component
manufacturing companies of KSR of U.K and Tubsa Automobile of Spain, with the
commitment to continuously upgrade its existing technology with the latest imported
CNC machines.
The company has an annual turnover exceeding $ 18 Million( INR 95 crore) with a
pool of highly trained and motivated workforce of over 525, managed by a team of
professional managers who are second to none.

Figure 0.1 Company Profile

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 CHAPTER 1 INTRODUCTION
1.1 Infrastructure

At Moonlight it is believed that the most important aspect of their infrastructure

comprises the individuals who make up one great family of performers. Every single
member of Moonlight is encouraged to actively come out with suggestions on how a
certain job can be done in a better manner. It is the endeavour of the Management to
keep bureaucracy far away from the functioning of the organization. The aim is to
provide a work atmosphere that exudes co-operational is conducive

1.1.1 Tool Room

Dies for presses are prepared here, also the inspection gauge are made as well.

Figure 1.1 Tool Room

1.1.2 Press Shop

different types of presses that are pneumatic and hydraulic are available here.
Operation that are carried out are-
(a) Blanking
(b) Piercing
(c) Bending
(d) Swagging, etc

Figure 1.2 Press Shop

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1.1.3 Maintenance
Breakdown, Overhauling, Regular maintenance of machines are taken under
maintenance department. Also raw material for manufacturing products are stored
here.

1.1.4 Welding Shop

MIG Welding machines are used to join piped and get products.

Figure 1.3 Welding Shop

1.1.5 Inspection
After being assembled the piece are inspected here before painting

1.1.6 Paint Shop

The finished inspected parts are painted here.

1.2 Machines

A machine (or mechanical device) is a mechanical structure that uses power to apply
forces and control movement to perform an intended action. Machines can be driven
by animals and people, by natural forces such as wind and water, and by chemical,
thermal, or electrical power, and include a system of mechanisms that shape the
actuator input to achieve a specific application of output forces and movement. They
can also include computers and sensors that monitor performance and plan
movement, often called mechanical systems.

1.2.1 Grinders

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.

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 Figure 1.4 Surface Grinder with Electromagnetic Chuck

1.2.1 (a) Process

Surface grinding is the most common of the grinding operations. It is a finishing
process that uses a rotating abrasive wheel to smooth the flat surface of metallic or
non-metallic materials to give them a more refined look by removing the oxide layer
and impurities on work piece surfaces. This will also attain a desired surface for a
functional purpose. The surface grinder is composed of an abrasive wheel, a work
holding device known as a chuck, 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 vice (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.

1.2.1 (b)Types of surface grinders

(1) Horizontal-spindle (peripheral) surface grinders

The periphery (flat edge) of the wheel is in contact with the workpiece, producing
the flat surface. Peripheral grinding is used in high-precision work on simple flat
surfaces; tapers or angled surfaces; slots; flat surfaces next to shoulders; recessed
surfaces; and profiles.

(2) Vertical-spindle (wheel-face) grinders

The face of a wheel (cup, cylinder, disc, or segmental wheel) is used on the flat
surface. Wheel-face grinding is often used for fast material removal, but some
machines can accomplish high-precision work. The workpiece is held on a
reciprocating table, which can be varied according to the task, or a rotary-table
machine, with continuous or indexed rotation. Indexing allows loading or unloading
one station while grinding operations are being performed on another.

(3) Disc grinders and double-disc grinders.

Disc grinding is similar to surface grinding, but with a larger contact area between
disc and workpiece. Disc grinders are available in both vertical and horizontal
spindle types.Double disc grinders work both sides of a workpiece simultaneously.
3
1.2.2 Milling Machine

The milling machines are also known as the multi-tasking machines (MTMs) which
are multi-purpose machines capable of milling and turning the materials as well. The
milling machine has got the cutter installed up on it which helps in removing the
material from the surface of the work piece. When the material gets cooled down

then it is removed from the milling machine.

Figure 1.5 Milling Machine

1.2.2 (a) Types of Milling Machines

The two main configurations of the milling machining operations are the types of
milling machines. These are the vertical mill and the horizontal mill. They are
further discussed below:

(1) Vertical Milling Machines

The vertical mill has a vertically arranged spindle axis and rotate by staying at the
same axis. The spindle can also be extended and performing functions such as
drilling and cutting. Vertical mill has got two further categories as well: turret mill
and bed mill.

(2) Horizontal Milling Machines

The horizontal mill is also the similar cutter but their cutters are placed on a
horizontal Arbor. A lot of horizontal mills have got rotary tables that help in milling
in various angles. These tables are called the universal tables. Apart from this all the
tools that are used in a vertical mill can also be used in the horizontal mill.

1.2.3 Drill Machine

The drilling machine or drill press is one of the most common and useful machine
employed in industry for producing forming and finishing holes in a workpiece. The
unit essentially consists of:
1. A spindle which turns the tool (called drill) which can be advanced in the
workpiece either automatically or by hand.
2. A work table which holds the workpiece rigidly in position.
4
 Figure 1.6 Drill Machines

1.2.3 (a)Types of Drilling Machines

A wide variety of drilling machines are available ranging from the simple portable to
highly complex automatic and numerically controlled machines are as follows:

(1) Portable drilling machine:

It is a small light weight, compact and self contained unit that can drill holes upto
12.5 mm diameter. The machine is driven by a small electric motor operating at high
speed. The machine is capable of drilling holes in the workpieces in any position.

(2) Sensitive drill machine/press:

This is a light weight, high speed machine designed for drilling small holes in light
jobs. Generally the machine has the capacity to rotate drills of 1.5 to 15.5 mm at high
speed of 20,000 rev/min.

1.2.4 Shaper Machines

A shaper is a type of machine tool that uses linear relative motion between the
workpiece and a single-point cutting tool to machine a linear tool path. Its cut is
analogous to that of a lathe, except that it is (archetypally) linear instead of helical.

Figure 1.7 Shaper Machine

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1.2.5 Lathe Machines

A lathe is a machine tool which is used to rotate a work piece to perform various
operations such as turning, facing, knurling, grooving etc., with the help of tools that
are applied to the work piece.

1.2.5 (a) Types of Lathe Machine

Lathe machine are generally divided into three types.

1. Engine lathe
2. Turret lathe
3. Special purpose lathe

Figure 1.8 Lathe Machine

1.2.5 CNC Vertical Machines

The process of milling uses a specialized rotary cutting tool to remove material from
a workpiece surface. The process can be used for cutting and creating details, such as
holes or notches, as well as for sculpting a three dimensional piece.
Unlike drilling or traditional cutting, the tool in a mill advances perpendicularly to a
workpiece on a dedicated axis, performing countless unique, small cuts to remove
material from a surface in chips.
With Computer Numerical Control (CNC) technology, machinists and engineers can
control vertical milling machine operations using sensitive computer systems. These
systems collect design information directly from drawings and models in CAM or
CAD software, which is converted into codes (NC code, G-code, and ISO code) and
then translated into operational commands through the system.

Figure 1.8 CNC Vertical Machine

6
 1.2.6 Press Machines

A forming press, commonly shortened to press, is a machine tool that changes the
shape of a workpiece by the application of pressure. The operator of a forming press
is known as a press-tool setter, often shortened to tool setter.

Figure 1.9 Press Machine

According to the Power Source These power source are categorized as:

Manually Operated These presses are used to process thin sheet metal working
operations where less pressure or force is required. These are operated by manual
power.
Most of manually operated presses are hand press, ball press or fly press.
Power Presses Power presses are normally driven by mechanical mechanism or
hydraulic system. Power source of these presses may be electric motor or engine

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 CHAPTER 2 TRAINING WORK UNDERTAKE

(Ⅰ) Making of rear Brake arm (of two wheeler)

Following are the operations include the manufacturing of rear brake arm:
i. Blanking: The blanks of desired shape are cut down through a
pneumatic press.
ii. Piercing: The holes are made on the required position.
iii. Bending: The work piece is then bended from a point on middle
leaving a precised gap on the other end.
iv. Welding: A nut is welded on the approximated position and gap
on the other side is also filled with welding.
v. Gear Cutting: A set of teeth across the depth of the diameter is
obtained by piercing is cut with the help of form tool on the upper
end of the die of the press.
vi. Inspection: special gauges are prepared to inspect the work piece.
vii. Paint and Dispatch: The work piece is then painted, packed and
Dispatched.

(Ⅱ) Making of rear brake paddle

The raw material is a pipe of uniform diameter diameter through its length

i. The pipe diameter is reduced from one end by swaging.

ii. This reduced is then subjected to two different presses for
punching operation at both ends.
iii. A hole is punched in the middle of pipe.
iv. Bending of pipe is done through pneumatic press.
v. A flat coined small plate is welded on one end and a pipe of length
equal to outer diameter of paddle. Pipe is welded on other end.
vi. Now Inspection of welding and Fitting is done.
vii. Paint is applied to the work piece and work piece is ready to dispatch
after final inspection.

(Ⅲ) Testing of Link Engine Hanger (KOLA, KOPA)

Ovality (Pipe) = Maximum Diameter – Minimum Diameter

Normal (Standard diameter before bending)
8
 Ømin

Ømax

Maximum diameter – 25.4mm Ovality – 8.7%

Minimum diameter – 23.18mm ( Ovality should not exceed 10%)

Procedure of Testing: After bending in a single stroke diameter of the pipe from two
sides pipe is checked.
i. Diameter obtained on the horizontal axis is maximum .
ii. Diameter obtained from vertical axis of bend is minimum.
iii. After applying the formulae we got the ovality of the pipe.

Standard Ovality Rule In Bending

When a plate or pipe is subjected to bending, the product obtained should
not have thickness less than 90% of original thickness.

(Ⅳ) Frame of Display Meter od hero motorcycles

Number of operations = 3
Number of tolls used = 4

Sequence of processes – Blanking, piercing, Punching, Bending.

Procedure –
1. A blank is obtained from plate is subjected to diameter of pnumetic
press.
2. Holes are obtained after piercing, along with cutting of two specific
shapes on the blank.
3. Bending is done separately on the pneumatic press.

Thickness of plate – 220mm.

Diameter of holes pierced – Ø12×3, Ø6×2, Ø3×3.
Bending angle – 90o.

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 (Ⅴ) Making of Plate Hanger

Material – M.S. Plate.

Thickness – 2mm.

The plate of thickness 2mm is subjected to a load of 50 tons. A simple die

is used to make a blank.
Then holes of 6mm diameter are pierced in that blank. Then sides are
bent to 90o on 30 tons pneumatic press. Then two holes are punched of
desired shape on the blank of work piece. After this a final pressure is
applied from the sides to align the job as per requirement.

(Ⅵ) Making of Cross Pipe

The product is used as the frame of the front light of hero motorcycle.
However, whole work piece is not prepared here. There are some
processes that are carried out which majorly include welding.
The pipe of M.S. is purchased and tested small blanks are bent
and a nut is spot welded to it.
Spot welding parameters
Time – 3 to 4 seconds.
Gas – 4 to 6 Kg/cm2
Frequency – 20 pc/ min.
Then the pipes are welded after placing them in the
fixture. This is done through MIG welding under following parameters;
Penetration – 10%
Current – 160 to 220 amp.
Voltage – 28 volts
Another blank is welded at the head of the work piece.
The spot welding is the last operation before inspection as a stripe is weld.
To avoid distortion fixtures are used and holes that are used to
hold bolts are aligned to each other and the angle at which stripes were to
be weld are also checked these by nearly 230 +150

RAW MATERIAL

The type of material used, grade and their standards

Cold rolling carbon (CRC) sheets- there different grades of CRC that are
Being used form IS513 to IS1079
Hot rolled carbon (HRC) sheets- the grade that are preferred here for hrc
Are G3101, G3116, G3131 etc.
Other material used are not rolled picked and oiled (HRPO)
10
 Steels. Some other materials are sheets or pipes of MS that are purchased
Their grades is EN-313, EN-353, EN-31.

CNC TUBE BENDING MACHINE

A hydraulic CNC tube bending machine composes a larger slide,

rocker drive, middle slider, slowing ring, etc.
overall machine the structure work or numeric control. There can be
several bends given to a pipe in single cycle operation, the slewing ring is
replica of pipe diameter to be bent.
The tube is placed flat on two groove plates, the pressing cylinder
drives punch to be pressed. Bending part adopts the gear rack servo motor
control, the bending rotation is controlled by servo motor high bending
accuracy.
BROACHING (REAR BRAKE ARM)

Teeth cutting through broaching on rear brake arm.

Broaching material- HSS.
Broaching diameter- 13.46mm.
Depth of teeth- 1.4mm
Number of teeth- 24

Operations-
1. A broach is fitted to the machine with two pieces at the
time
2. 24 pieces per hours are processed.
3. The machine capacity is 3 tons.
4. The machine is hydraulically operated
5. The type of machine is vertically broaching machine.

VMC (PROGRAMMING RUNNING

OPERATINGS)

For FANUC control panel.

1. Select Edit mode on the panel
2. Turn off memory protect key switch
3. Press the PRGRM key to display the program
4. Press insert key
5. Press EOB key, press insert
6. Select location e.g. SD Card
7. Enter program number
8. Select run
9. Press DNC select
10. Run the machine.
Spindle speed can be varied along with direction of
rotation the spindle according to the requirement.
11
 CHECKING OF GROOVING OF REAR BRAKE ARM

Profile projector- Type- vertical, square parameter under inspection

1. Outer diameter
2. Root diameter
3. Hole depth
4. Circulate pitch
5. Number of teeth.
Outer diameter- 13.5mm, inner diameter – 12mm, thickness of plate – 2mm.
Ht – 13.5 – 12 = 1.5mm
P = Ht – 0.002 = 1.94mm
0.7003
Addendum = 0.3183P = 0.618mm
Diameter pitch = 1.619mm
N = 26 teeth

12
 MAKING OF LEG GUARD
Number of parts – 5
Pipe diameter – 50mm
Welding – TIG
Part 1 –
1. PLATE - The plate is made from blanking of 2mm thick object
2. CLAMP – first the clamp is made then it is bent according to pipe diameter
3. INSERT – it is the purchased component of the product. It is directly welded
to the workpiece
4. INSERT – it is a blank with holes pierced to it. It is then bend twice and
welded to workpiece.
5. MAJOR PIPE – two pipes are bent on the CNC bending machine

Then welded from one end. On the other end of plates are welded, while pipe
clamps are used to holds the pipe together.

13
 CONCLUSION AND FUTURE SCOPE

The six weeks of summer training at Moonlight Auto PVT. limited. Unit
generated a lot more interest in my subject.

It made me more aware of the future scope of

Mechanical Engineering. It has also made me appreciative of an
industrial work environment.

Undergoing training on the indoor substation has helped me

integrate conceptual knowledge with real life application. I was
fortunate have personal guidance from experienced professionals who
took been interests in explaining the working details of various
equipment’s.

I feel that without this opportunity, my own

understanding of this subject and also the motivation to acquire the more
knowledge would have remained incomplete.

Well, regarding future scope I think my training has given me enough

motivation and an exposure.

“To know the technical knowledge, industrial training is the best way to
move forward”

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 References

https://www.wikipedia.org/
https://www.google.com/
http://www.moonlightstampings.com/
http://www.slideshare.net/

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