A REPORT

ON
SUMMER INTERNSHIP
AT
OSWAL CASTINGS PVT. LTD.

SCHOOL OF ENGINEERING AND TECHNOLOGY

GURUGRAM, HARYANA

SUBMITTED BY-

NISCHAY ARORA

15MEU057
ACKNOWLEDGEMENT

An undertaking is never a result of a solitary individual; rather it bears the engravings

of various individuals who specifically or by implication helped in finishing that
venture. We would bomb in my obligations on the off chance that I don't let out the
slightest peep of gratitude to every one of the individuals who helped us in finishing
this task of our own.

Before I start with the details of my projects, I would like to add a few heartfelt words
for the people who were the part of my project in numerous ways, the people who
gave me their immense support right from the initial stage.

The internship opportunity I had with OSWAL CASTINGS Pvt. Ltd. Was a great
chance for learning and professional development. Therefore, I consider myself as a
very lucky individual as I was provided with an opportunity to be a part of it. I am also
grateful for having a chance to meet so many wonderful people and professionals
who led me though this internship period.

I would also like to thank specially MR. AJAY SAGAR for giving me an opportunity
to come to OSWAL CASTINGS Pvt. Ltd. for summer training.. The vision, integrity
and sense of quality that I learnt from him are truly uncommon. I am very thankful to
him for his wise and synergetic help throughout my training period.

I express my gratitude to all the other employees for making my training at the
company a wonderful experience. I perceive as this opportunity as a big milestone in
my career development. I will strive to use gained skills and knowledge in the best
possible way, and I will continue to work on their improvement, in order to attain
desired career objectives. Hope to continue cooperation with all of you in the future.
TABLE OF CONTENT
1. ABSTRACT
2. COMPANY PROFILE
3. CUSTOMERS
4. FACILITIES
4.1 TOOL AND DESIGN SIMULATION
4.2 QUALITY INSTRUMENTS
4.3 TOOL MANUFACTURING
4.4 MACHINING AREA

5. QUALITY ASSURANCE
6. CONCLUSION
7. BIBLIOGRAPHY
1. ABSTRACT
This report describes the internship I spent at the OSWAL CASTINGS Pvt Ltd.

In this report the work experience that I have got in this reputed is explained
broadly.

At first company profile and its overseas customers details are given.

Further those processes and techniques are explained which I was privileged to
Experience and watch closely though no real time photos isn’t available
throughout the report due to rules and regulations of company.

And at the last the quality inspection processes followed in company is explained.

All this include explanation with relatable diagrams for better understanding.

At the last I have concluded my overall experience with OSWAL CASTINGS Pvt.
Ltd.
 2.COMPANY PROFILE
Oswal Group of Industry is one of the leading manufacturer of High Pressure
Aluminum Die Cast Components in India having annual turn over of approx. 70
Million US Dollars, and installed production capacity of about 24000 tons of casting
annually.

Oswal is a certified company with TS 16949 and ISO14001 certifications having

three manufacturing facilities in North India at Faridabad. We also have a machining
& assembly plant in Hosur (TN). This plant in Southern India has been started to
cater to the needs of our customers in South India. We can produce die cast parts
with Vacuum and Squeeze technology. In addition to Pressure Die Casting we also
have CNC Machining, liquid and powder painting & sub assembly of various parts .
We also have in-house facilities for Tool Designing & Tool manufacturing.

The Group has established the activity of "Forward Integration" by way of supplying
Die Cast, machined, painted and assembled parts, which are ready to fit at
customer's end.The future beckons us to be a part of the RESURGENT INDIA of
21st century, where our products and facilities shall be truly global.

The Group Chairman Mr. R.K. Jain, a first generation entrepreneur incorporated
"Oswal Electricals", the first company of "Oswal Group" in 1967. Under his dynamic
approach and far-sighted vision, the company began its operation on a very small
scale.

Today after four decades, the company has grown up to "Oswal Group Of
Industries".

MISSION:

 To become a world leader in Die Casting and precision machining by year 2020.
 To expand product horizon to service global customers.
CORPORATE SOCIAL RESPONSIBILITIES
The CSR Policy of the Oswal Castings Private Limited is to:

 Eradicating hunger, poverty and malnutrition, promoting preventive health

care and sanitation and making available safe drinking water;
 Promoting education, including special education and employment enhancing
vocational skills especially among children, women, elderly and the differently
abled and livelihood enhancement projects;
 Promoting gender equality, empowering women, setting up homes and
hostels for women and orphans; setting up old age homes, day care centres
and such other facilities for senior citizens and measures for reducing
inequalities faced by socially and economically backward groups;
 Ensuring environmental sustainability, ecological balance, protection of flora
and fauna, animal welfare, agroforestry, conservation of natural resources
and maintaining quality of soil, air and water;
 Protection of national heritage, art and culture including restoration of
buildings and sites of historical importance and works of art; setting up public
libraries, promotion and development of traditional arts and handicrafts;
 Measures for the benefit of armed forces veterans, war widows and their
dependents; Training to promote rural sports, nationally recognized sports,
Paralympic sports and Olympic sports;
 Contribution to the Prime Minister’s National Relief Fund or any other fund set
up by the Central Government for socio-economic development and relief and
welfare of the Scheduled Castes, the Scheduled Tribes, other backward
classes, minorities and women;
 Contribution or fund provided to technology incubators located within
academic institutions which are approved by the Central Government;
 Rural development projects; and Slum area development.

Responsibilities of the CSR Committee:

 Evaluate various opportunities available to the Company, shortlist the most

promising ones and formulate the CSR Policy.
 Recommend the budget for CSR expenditure.
3.CUSTOMERS
 HERO MOTOCORP PVT. Ltd.
 BAJAJ AUTOMOBILES
 ABB GROUP
 GENERAL ELECTRIC
 SCHNIEDER ELECTRICALS PVT. LTD.

4. FACILITIES
4.1 TOOL AND DESIGN SIMULATION-

Components made by company (automotive and non- automotive) are designed

through software where simulation of each part is checked.

1300 tonne 1 IDRA

1000-900 TONNE 4 BUHLER/ZITAI
850-730 tonne 4 UBE/ZITAI
500-660 tonne 18 ZITAI/HMT
350-420 tonne 25 UBE/ZITAI/TOSHIBA
250-280 tonne 26 ZITAI/LK/HMT
120-180 tonne 8 BUHLER
TOTAL 86
Fig 1.1
 4.2 QUALITY DEPARTMENT
TOOLS USED
4.2.1 SURFACE TABLE
A surface plate is a solid, flat plate used as the main
horizontal reference plane for precision inspection, marking
out (layout), and tooling setup. The surface plate is often used as
the baseline for all measurements to a workpiece, therefore one
primary surface is finished extremely flat with tolerances below
11.5 μm or 0.0115 mm per 2960mm for a grade 0 plate. Today
most surface plates continue to be made of black granite, more
accurately referred to as black diabase, with the more wear-
resistant surface plates being made of quartz-bearing granite. The
quartz content of these granite surface plates increases the wear
resistance of the plate as quartz is a harder stone. Black granite is
dominantly used in machine bases, granite accessories, and
custom applications for its superior stiffness, excellent vibration
dampening, and improved machinability. Quartz-bearing granite
(usually pink, white, or grey) is often made thicker than black
granite to provide equal load-bearing capabilities of the types of
material used for surface plates as it is not as stiff as black granite.

A 500*500 surface plate

4.2.2 SNAP GAUGE

A Snap Gage is a go/no go gage for outside diameters. The
Snap Gage will have anvils similar to a micrometer. Snap
Gages have different shapes and sizes. They can be "C" type,
 "A" type, "U" type as well as include a digital or dial indicator.
They are used for attribute measurement of outside
diameters, groove diameters and width. There are also double
ended snap gages, progressive snap gages and adjustable snap
gages.

4.2.3 AIR PLUG GAUGE

It consist of a cylindrical hardened steel body hard chrome plated
and precisely ground to provide the guide needed for air jets
positioning inside bore.The nozzles through which air is guided are
recessed below the body diameter of the plug.This has a two fold
function, one to protect the jets from damage by direct contact and
secondly make the air gauge measurement essentially non-contact
The flow of air also has a self cleaning effect on the gauging
surface.The hard chrome provides excellent wear resistant
property.
4.2.4 X-RAY MACHINE
The X-ray is a highly versatile machine for radioscopic spot
tests and inspection of automotive or aerospace samples
such as light metal castings, steel components, plastics,
ceramics and special alloys with 160, 225 or 320 kV. Its
design allows a great flexibility in applications such as
production, incoming inspection, failure analysis or research
& development. The ease of operating and programming
and image enhancement enable the user to make the
correct inspection decisions.
BENEFITS
 Wide application range from automotive fast
throughput requirements with 30 fps at full resolution
to aviation's casting requirement of premium
resolution
 Visual real-time inspection combined with optional 3D
CT capabilities
 Panel Inspection task programming with teach and
learn functions
 Automated defect recognition (ADR) for high sample
throughput
 Optional basic automatic defect recognition for
aluminum casting defects
 AN X-RAY SYSTEM FOR QUALITY INSPECTION

4.3 TOOL MANUFACTURING

In tool manufacturing process different components are prepared through different
processes which includes camshafts, crankcase, cylinder block, cap crank bearing
etc.

4.3.1 HIGH PRESSURE DIE CASTING

Die casting is a moulding process in which the molten metal is injected under high
pressure and velocity into a split mould die. It is also called pressure die casting. The
split mould used under this type of casting is reusable. Die casting is categorized two
types namely- hot chamber and cold chamber .Metals like Zinc, tin and lead alloys
are casted in hot chamber die casting having melting point below 3900C whereas
aluminum alloys are casted in cold chamber die casting machine. Aluminum
dissolves ferrous parts in the die chamber and hence preferred to be used in cold
chamber die casting. Continuous contact of molten metal is avoided by using a ladle
for introducing molten metal directly to the machine.
 Fig 2.1

Advantages of the die casting process

1. High production rate.

2. High accuracy in part dimensions.
3. Smooth surface finish for minimum mechanical finishing.
4. Ability to make many intricate parts such as hole opening slot trademark
number etc.
5. Much thinner wall sections can be produced which can’t be produced by other
casting methods.
6. Varieties of alloys can be used as per design requirements. For example zinc
can be used for intricate forms and plasticity, aluminum for higher structural
strength, rigidity and light weight.
7. Ability to cast inserts such as pins studs shafts, fasteners etc.
Disadvantages of the die casting process

1. Microporosityinthe die casting products is a common problem because

of faster solidification, trapped air and vaporized die lubricants.
2. Undercuts cannot be found in simple two piece dies.
3. Hollow shapes are not readily casted because of the high metal
pressure.
4. Limited sizes of the products can be produced based on the availability
of the equipment
5. High melting temperature alloys are practically not die casted
6. Flash is present except for very small zinc die casting.

General design consideration

The following design guidelines need to be followed for die casting:

1. Identify the possibility of incorporating several functions in to one
die casting. Full advantages must be taken for the reduction of
machining that die casting can afford.
2. Before the design and construction of die begin the designer should
finalize the design of die casted product and its producibility. Dies
after machined undergo heat treatment for hardening.
3. The designer must consult die cater about the location of the ejector
pin as early as possible in the product design stage itself. If the
impression left by the pins are not tolerable or can’t be cored out, as
an alternative solution rings or sleeve ejection can be opted.
4. Abrupt section changes, sharp corners and wall at an acute angle
to one another need to be avoided. These features disturb the
continuity of metal flow and lead to form a porous structure and
surface irregularities. Therefore, it is recommended to provide radii
as generous as possible with differing sections blending into one
another.
 A high pressure diecasting machine

A WORK PIECE
 Fig 2.2 and 2.3

4.3.2 GRAVITY DIE CASTING

GDC is a repeatable casting process used for non-ferrous alloy parts, typically
aluminium, Zinc and Copper Base Alloys.

The process differs from HPDC in that Gravity- rather than high pressure- is used to
fill the mould with the liquid alloy.
GDC is suited to medium to high volumes products and typically parts are of heavier
sections than HPDC, but thinner sections than sand casting.
There are three key stages in the process.

1. The heated mould [Die or Tool] is coated with a die release agent.
The release agent spray also has a secondary function in that it aids
cooling of the mould face after the previous part has been removed
from the die.
2. Molten metal is poured into channels in the tool to allow the material
to fill all the extremities of the mould cavity. The metal is either hand
poured using steel ladles or dosed using mechanical methods.
Typically, there is a mould “down sprue” that allows the alloy to enter
the mould cavity from the lower part of the die, reducing the
formation of turbulence and subsequent porosity and inclusions in
the finished part.
3. Once the part has cooled sufficiently, the die is opened, either
manually or utilising mechanical methods.

Fig 2.4
Advantages

1. Good dimensional accuracy

2. Smoother cast surface finish than sand casting
3. Improved mechanical properties compared to sand casting
4. Thinner walls can be cast compared to sand casting
5. Reverse draft internal pockets and forms can be cast in using
preformed sand core inserts
6. Steel pins and inserts can be cast into the part
7. Faster production times compared to other processes.
8. Once the tooling is proven, the product quality is very repeatable.

Disadvantages

1. Low volume production.

2. Processes like addition of sprue system ,cooling system and ejection
system is need to be carried out separately.

4.3.3 LOW PRESSURE DIE CASTING

High quality castings, of aluminium alloys, along with magnesium and other low
melting point alloys are usually produced through this process. Castings of
aluminium in the weight range of 2-150 kg are a common feature.

The process works like this, first a metal die is positioned above a sealed furnace
containing molten metal. A refractory-lined riser extends from the bottom of the die
into the molten metal. Low pressure air (15 - 100 kPa, 2- 15 psi) is then introduced
into the furnace. This makes the molten metal rise up the tube and enter the die
cavity with low turbulence. After the metal has solidified, the air pressure is released
. This makes the metal still in the molten state in the riser tube to fall back into the
furnace. After subsequent cooling, the die is opened and the casting extracted.

With correct die design it is possible to eliminate the need of the riser also. This is
because of the directional freezing of the casting. After the sequence has been
established, the process can be controlled automatically using temperature and
pressure controllers to oversee the operation of more than one diecasting machine.

Casting yield is exceptionally high as there is usually only one ingate and no feeders.
 Fig 2.5

4.3.4 COLD CHAMBER DIE CASTING

During cold chamber die casting, the molten charge, which consists of more
material than is required to fill the casting, is ladled from the crucible into a shot
sleeve where a hydraulically operated plunger pushes the metal into the die. The
extra material is used to force additional metal into the die cavity to compensate for
shrinkage, which takes place during solidification. Injection pressure of over
10,000psi or 70,000KPa can be obtained from this type of machine .

Unlike the hot chamber die casting process, cold chamber solves the corrosion
problem by separating the melt pot from the injector components. In the cold-
chamber process, metal is transferred by ladle, manually or automatically, to the shot
sleeve. Actuation of the injection piston forces the metal into the die—this is a single
shot operation. This procedure minimizes the contact time between the hot metal
and the injector components, which helps to extend their operating life.
4 MACHINING AREA
The machining at oswal is done on a CNC machine with various tools places inside
for the required design of the work piece

4.1 CNC MACHINE

CNC Machining is a process used in the manufacturing sector
that involves the use of computers to control machine tools.
Tools that can be controlled in this manner include lathes, mills,
routers and grinders. The CNC in CNC Machining stands for
Computer Numerical Control.

On the surface, it may look like a normal PC controls the

machines, but the computer's unique software and control
console are what really sets the system apart for use in CNC
machining.Under CNC Machining, machine tools function
through numerical control. A computer program is customized for
an object and the machines are programmed with CNC
machining language (called G-code) that essentially controls all
features like feed rate, coordination, location and speeds. With
CNC machining, the computer can control exact positioning and
velocity. CNC machining is used in manufacturing both metal and
plastic parts.
irst a CAD drawing is created (either 2D or 3D), and then a code
is created that the CNC machine will understand. The program is
loaded and finally an operator runs a test of the program to
ensure there are no problems. This trial run is referred to as
 "cutting air" and it is an important step because any mistake with
speed and tool position could result in a scraped part or a
damaged machine.
There are many advantages to using CNC Machining. The
process is more precise than manual machining, and can be
repeated in exactly the same manner over and over again.
Because of the precision possible with CNC Machining, this
process can produce complex shapes that would be almost
impossible to achieve with manual machining. CNC Machining is
used in the production of many complex three-dimensional
shapes. It is because of these qualities that CNC Machining is
used in jobs that need a high level of precision or very repetitive
tasks.

5 QUALITY ASSURANCE
5.1 QUALITY INSPECTION – in inspection department different quality
and dimensional checking tools were used like vernier caliper , screw gauge, height
gauge.

A report is maintained where if any error found in dimension is noted down to check
the percentage of defects per 100 parts.
fig 3.1

Fig 3.2
5.2 QUALITY ASSURANCE – 5S
The 5s is defined as-
1S- sort: it is the process of sorting out components as critical or non-critical with the
help of red tag . The components which are considered to be more essential than
non-essentials are given red tag. Therefore sorted out.

2S- Straighten or set in order – in this phase every component is placed at right
place with optimum space accumulation required for it therefore making the view
more pronounceable .

3S – Shine – cleaning the work area .It is considered to be the moral duty of every
worker in industry to keep everything at its place with cleanliness

4S – Standardize - Establishing a system to maintain and make 5S a habit .

5S- Sustain - Establishing a safe and sanitary work environment.

5.3 QUALITY ASSURANCE 3R

3R refers to :
Reduce – reduction of use of raw material as much as possible in optimum way.
Reuse – reusing of scrap separated out from processed product for further use.
Recycle – using of recyclable materials.
Fig 3.4

fig 3.5
2.4 CONCLUSION

During the industrial training at Oswal Castings Pvt. Ltd., I have been exposed to
various activities and task in this company indirectly, trainees also have to know
everyday responsibility and role in the company. Exposure to real working
environment is good for student as trainers , especially to open the minds and brains
to be more creative and providing acknowledgement which is basic for every trainee
out there. In this training period I was also exposed to real time situations and how to
handle them therefore encouraging the courage of trainee at basic level .
In future I would love to be part of Oswal Castings sPvt. Ltd. Because the
environment provided to every worker is equal and I could feel the enthusiasm in
them .
 BIBLIOGRAPHY
 http://www.oswalcastings.co.in/index.htm
 http://mc-cast.com/Gravity-Die-
Casting.html
 https://www.youtube.com/watch?v=OI3pIvL
hVcc
 https://quality-one.com/5s/
 https://www.investacast.com/outsourcing/g
ravity-die-casting
 http://www.foundryinfo-
india.org/images/pdf/2A2.pdf
 https://www.harrisoncastings.com/casting/
aluminium-gravity-die-casting/
 https://nptel.ac.in/courses/107103012/modu
le2/lec3.pdf
 http://jntuhceh.org/web/tutorials/faculty/229
_I-07.pdf