INDEX

1 Chapter 1

1.1 Introduction 4

1.2 Board of Directors 4

2 Chapter 2

2.1 Company Layout of Menon Alkop 5

3 Chapter 3

3.1 Production Procedure 6

3.2 General Production Procedure 6

3.3 Raw Material 6

4 Chapter 4

4 Case study on External Bypass Chamber

4.1 Introduction 8

4.2 CAD Modelling 8

4.3 Foundry Shop

4.3.1 Furnace 10

4.3.2 Melting Aluminum Using Coreless Furnace 10

4.4 Casting 11

4.4.1 High Pressure Die Casting 12

4.5 Shot Blasting Material Removal Mechanism 13

4.6 Machine Shop 15

4.7 Leakage Testing 16

4.8 Quality Assurance 18

4.9 Metallurgy and Metrology Lab 18

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 4.10 Packing 19

4.11 Dispatching 19

5 Chapter 5

5.1 Conclusion 20

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 List of Figures

Figure No. Title Page No.

2.1 Company Layout 9

3.1 Production Procedure 10
3.3 Colors code for various raw materials 11
4.1 External Bypass Chamber 12
4.2 Die Making 13
4.3.1 Induction Furnace 14
4.4.1 High Pressure Die Casting Machine 16
4.5 Shot Blasting for Steel components 18
CNC Machining center arranged into functional
4.6 19
cellular units for proper work flow
4.6.1 Advance Precision Machining 20
4.7 Manual Leakage Testing Machine 21
4.8 Automatic display dimension testing machine 22

CHAPTER 1
1. Introduction
1.1: Introduction

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 Menon. Alkop Pvt. Ltd. 5 Star MIDC kagal Kolhapur is one of the very few
companies in India to manufacture high integrity & high-tech Aluminum casting using
induction furnace melting system and machine shop with VMC machines
Location of Plant – it is situated 400kms south of Mumbai on Pune- Bangalore highway
no NH-4 in state Maharashtra India

Land Area - 15 Acres (6,50,000 Sq. Feet)

First Phase Plant Area - 60,000 Sq. Feet
(Includes Foundry Machine Shop Tool Room Utility Building)
Second Phase Plant Area - 1,40,000 Sq. Feet
Final Phase Plant Area - 2, 50,000 Sq. Feet
First Phase Project Cost - Rs. 150 Mn. (US $ 3.5 Mn.)
Production Capacity (First Phase) - 500 Tons per
month finished Aluminum casting components
Total Employees: 175

1.2: Board of Directors Menon Alkop Ltd.

Mr. Ram Menon - Chairman

Mr. Nitin Menon - Managing Director
Mr. Sachin Menon - Director
Mr. R.D. Dixit - Director
Mr. T.K. Guha– Director

CHAPTER 2

2. Company Layout

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2.1: - Company layout of Menon Alkop

Figure 2.1: -Company Layout

CHAPTER 3

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3. Production Procedure

3.1: - PRODUCTION PROCEDURE

RAW MATERIAL STORAGE

ALLOY MELTING &METAL TREATMENT PACKING

MATERIAL TRANSFER TO MOULDING FURNACE FINAL INSPECTION

PDC/GDC CYCLE POWDER COATING

RECUTTING & FELIING LEAKAGE TESTING

HEAT TREATMENT IMPREGNATION

SHOT BLASTING MACHINING

Figure 3.1: - Production Procedure

3.2: - GENERAL PRODUCTION PROCEDURE

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 Menon Alkop Kolhapur is one of leading companies of Menon group. Their main
manufacturing product is different types of automobiles product

Different department in the campus are

1. Tool room (die making) Department

2. Foundry Department

3. Machine shop Department

4. Quality control Department

5. Packing and dispatch Department

3.3: - Raw Material

Melting is performed in a furnace. Virgin material, external scrap, internal scrap,
and alloying elements are used to charge the furnace. Virgin material refers to
commercially pure forms of the primary metal used to form a particular alloy. Alloying
elements are either pure forms of an alloying element, like Aluminum or alloys of limited
composition, such as ferroalloys or master alloys.

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 Figure 3.3: - color code of various raw material

CHAPTER 4
4. CASE STUDY ON EXTERNAL BYPASS CHAMBER
4.1: -Introduction
The External Bypass Chamber is also known as the External gas reservoir
piggyback Which is mounted on shock absorber to controlled the ultimate position
sensitive damping externally by individual metering tubes that allow precise amounts of
oil to bypass the shock piston. Designate the number and location of bypass tubes to
match performance requirements. In a matter of seconds, each tube can be easily adjusted
to alter compression, rebound or bleed resistance at specific travel sectors. For
manufacturing of the External Bypass Chamber there are the different process are
followed these processes are CAD, CAM modeling and programming ,die making,
foundry process, machining, inspection, packing to dispatching to the their customers this
all processes I studied between the Industrial Training in Menon Alkop Division of
Menon Bearing at 5 Star MIDC Kagal Kolhapur.

4.2: -CAD Modeling

Figure 4.1: - External By Pass Chamber

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 In Company the manufacturing of the product there is preparing a drawing or
sketch before manufacturing of product but this drawing or sketch is not preparing on the
drawing sheets this drawing is prepare by using software. Generally, the company uses
software like UNIGRAPHICS and PRO-E. As per the customer requirement the company
is taken information about the product their dimensions. After that by using Unigraphics
Software, Company is designing the product that is External Bypass Chamber by proper
dimensions by design expert in less time. After the completion on the design on
Unigraphics they can analysis on the software after they prepare a CAM program for
CNC machine and VMC machines.
This program and design of print is further given to the tool room shop where
there is preparing a die for the particular components on VMC machines. In VMC
machine there are prepare two dies one is fix die and another is the movable die. The fix
die is fixed in the high pressure die casting machine in fixed side and the movable die is
fixed at the movable side high pressure die casting machine. Company is offering their
valued clients with the best VMC machines die patterns at an economical price,
manufactured by making use of supreme-grade raw- material and components, these
VMC Machines pattern Dies at with the industry laid parameters. Company VMC
Machines pattern Dies are widely appreciated for their attributes such as smooth texture
and light weight. Furthermore, to meet the varied needs of the clients.

Figure 4.2: - Die making on VMC

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4.3: - FOUNDARY SHOP
4.3.1: - Furnace
Menon alkop is one of the few companies to use induction furnaces melting
process for aluminum alloy hydrogen pick up is minimum due to absence of hydrogen
fuel there by ensuring improving quality of molten alloy. Company hi tech furnaces are
equipped with microprocessor controlled automatic digital control system that raise the
metal temperature to the set point, automatically reducing to hold power efficiently
complicated alloy can be made with higher accuracy of element in composition.
Impurities from commercial alloy are eliminated. Electrical energy is applied directly into
the crucible and molten metal eliminating the need for fragile electrical heating element
and fuel burners clean induction technology guarantees metal of exceptional purity with
at the correct temperature

4.3.2: - Melting Aluminum Using Coreless Induction Furnace

An induction melting furnace for aluminum is designed specifically for the
purpose of melting lower density metal, employing the exactly the right temperatures and
evenly distributing the heat. This is vital in melting such metals as aluminum if you want
to preserve the expected lifetime of aluminum and its quality. The ideal melting furnace
for aluminum will offer precise temperature controls in order to achieve this goal.

Figure 4.3.1: - Induction Furnace

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 The induction melting furnace uses alternating current to melt aluminum. The
pure aluminum, being heavy, will sink and any impurities will rise, allowing them to take
out from top using tilting mechanism, and leaving with pure aluminum. Water cooling
systems keep the coils cool. This type of modern process allows for much more precise
temperature control and faster melting of aluminum. The water circulating also helps to
prevent overheating of the metals.
Induction melting furnace for aluminum offers a 60% to 75 % rate of efficiency,
reduction of losses due to oxidation, low emissions.
It is easy to see why the induction melting furnace for aluminum is the best option
for recycling aluminum to extract the pure aluminum element or creating cast aluminum
alloys. While they are performing these both processes, the induction melting furnace is
using far less energy than other traditional types of furnaces. Aluminum melting furnaces
can be custom built to the exact capacity which is needed for any specific industry. There
are also many additional extra options which may be chosen for inclusion with the
furnace to make operation easier and more user-friendly for furnace operations.

4.4: - CASTING
Foundry section boasts of a wide range of high end HPDC and Tilt Die Casting
Machines having locking forces ranging from 250 to 660 tons. All machines are
microprocessor controlled and fully integrated with all necessary peripheral equipment’s
including integrated robotic pouring and separate Electric Molten Metal Holding Furnace
for every HPDC machine. Locking force selection can be customized and adjusted to the
component being cast and the die size. This allows for dimensional accuracy, porosity
free cast components and overall enhanced consistency and quality demanded by the
customers.

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4.4.1: - HIGH PRESSURE DIE CASTING
High pressure aluminum die casting is a manufacturing process in which molten
metal (aluminum) is injected with a die casting machine under force using considerable
pressure into a steel mold or die to from products. The temperature of the furnace is up to
780 degree Celsius because of the from Induction furnace to the crucible furnace some
distance because of that the decreasing in the temperature and melting point of the
Aluminum is 660.32 degree Celsius so in crucible furnace it is again it given heat and to
maintain the temperature nearly up to melting point temperature.
Because of the excellent dimensional accuracy and the smooth surface, most high
pressure dies castings require no machining except the removal of flash around the edge
and possible drilling and tapping holes. High pressure die casting production is fast and
inexpensive relative to other casting processes.

Figure 4.4.1: - High Pressure Die Casting Machine

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 Aluminum is used in 80-90% of the high pressure die casting alloys available in
the world today. In many cases aluminum high pressure die casting can replace steel
increasing strength and reducing part weight. We produced high pressure die casting
parts in small sizes of less than a once up to large sizes of 10 pounds. We usually can
produce and ship high pressure die casting parts within two weeks of receipt of your
purchase order if we have the high pressure die casting, dies are already and have
completed our first article inspections.

4.5: - SHOT BLASTING MATERIAL REMOVAL MECHANISM

Shot blasting refers to a metal finishing process used primarily for surface
preparation. It is a post finishing technique carried out by imparting the part surface using
certain abrasive materials for preparing its surface. Compared to other methods, shot
blasting can help in the preparation of the surface of the part to produce a much higher
quality finish. It can provide an exceptional level of surface cleaning than any other
finishing methods used. Company uses shot blast for surface preparation before the part
is subjected to other operations like electroplating, galvanizing, welding, enameling, glass
coating and rubberizing .In shot blasting, several abrasive materials are used to rapidly
affect the surface of the part such as acrylic, aluminum oxide corn cob, crushed glass grit,
glass beads etc. Its application includes improving the metal’s fatigue life, cosmetic
finish, increased adhesion, improved mechanical function and descaling of the product
surface.
Shot blasting has several benefits for aluminum die casting since, shot blasting
can cause an increase in the surface area of the part due to the rising of the roughness. It
can eliminate surface dirt better that will significantly improve the adhesion properties of
the surface. This will further increase by painting the surface or other methods. Surface
stress concentration is something that happens in die cast parts due to the uneven rate
cooling process and wall thickness.

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 Figure 4.5: - Shot blasting for Steel Components

The part, when subjected to shot blasting can enhance the surface structure of the
part and remove any prevailing surface stress concentration. This will also aid in
enhancing the overall any fatigue strength and surface hardness of the part. By
undergoing shot blasting treatment, the general character of the part can be restored and
eliminating any attachments on the surface such as stains, scratches, thing edges etc.
Another great benefit of shot blasting in die casting aluminum parts is that it can
considerably enhance the overall cosmetic appearance. During shot blasting, the impact
of projectile will leave a small concave hole that can improve the reflectivity of the
surface. This reflectivity is further increased if the part is then subsequently coated with
paint or other components. Shot blasting can considerably improve the durability.

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4.6: - MACHINE SHOP
Company fully integrated and state of the art manufacturing setup at Menon
Alkop Plant at the Five Star MIDC in Kagal is organized into cellular structures based on
JIT principles and our high-speed machines are flexible to handle a wide variety of
operations and range of volumes, for casting as well as machining.

Figure 4.6: - CNC machining centers arranged into functional cellular units for proper work flow

Company machines include the following: -

1: - 6 Nos. HPDC – Buhler make machines of 250-660 tons capacity.
2: - 2 Nos. Tilt Gravity Die Casting (GDC) machines with Auto Ladlers.
3: -Incoterm Melting Furnace, which shall produce uninterrupted good quality alloy melt.
4: - Thermotronix –USA make Hydrogen analyzer, to detect hydrogen gas content in the
melt so that degassing can be done precisely.
5: - Very effective German makes Rotary degasser for removal of unwanted entrapped
gases and inclusions.

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6: - Molten metal transfer through fork lift mounted non wetting, highly insulated ladle,
and metal holding in Electric Resistance furnaces.
7: - Shell core making machines and shell core Decoding machine.
8: - Shot Blasting Machine and casting trimming presses.
9: - Auto pour ladles to help in accurate pouring of metal in the die with respect to
weight, time and angle.
10: - Optical Emission Spectrometer for online chemical composition Analysis.
11: - DeckleMaho- German makes Vertical Machining Center (VMC) for manufacturing
of Dies.
12: - Electro Discharge Machine (EDM) for die sinking.
13: - CAD/CAM Software back-up –Unigraphics (UGS) and Pro-E
14: - Horizontal machining center for Cylinder Head Machining.
15: - CNC Machining Centers, SPM’s for component Machining.

Figure 4.6.1: - Advance precision machining

4.7: -Leakage testing

The differential testing of parts with higher pressures poses additional challenges
for leak testing. Generally, the high pressure is not suitable for making accurate leak test
calculations as it is too unstable. In these cases, one arranges for the test volume to be on
the opposite side of the leak path and the instrumentation is arranged to use the
differential pressure rise. Parts are placed into a chamber possibly with infill pieces to
reduce the test volume as much as possible. With this setup, the internal volume of the

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test piece can be pressurized to high pressure whilst the test system monitors the pressure
in a volume outside the part.

Figure 4.7:- Manual leakage testing

4.8: -QUALITY ASSURANCE

The Menon Group has a historic and unwavering commitment to quality. At
Menon. Alkop, Quality assurance is a continuous activity integrating people,
communication process controls, designing, engineering, production and inspection. The
quality process starts at the very beginning of each production schedule and our quality
control operations use documented quality systems to control each and every process
efficiently .

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 Figure 4.8: - Automatic display dimension testing machine

4.9: -METALLURGY AND METROLOGY LAB

Our state-of-the-art labs are housed in a temperature and environment controlled
clean rooms and deploys the most advanced and sophisticated equipment’s in inspection
and testing technology calibrated to NABL standards. Chemical composition of metals
their purity and metallurgical characteristics are regularly checked using a variety of
sophisticated equipment’s like Spectrometer, Micrometer tester, Gravimetric Electro
analyzer, Image Analyzer, Stress Tester in our Metallurgical and chemical Labs.

4.10: - PACKING
Safe, quick and undamaged that’s how our products reach any destination all round
the world. The appropriate packaging ensures quality, because what matters is to deliver
the pipes and components safely to the end user in quality.

- Shorter loading and unloading times.

- Less effort and expense for securing the load.
- Easy transshipment of general cargo.
- Recyclability.
- Storage without additional equipment.

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 - Within the scope of picking each order or suborder is directed to a particular
packing location. The completeness of whole order can be checked here
optionally. Then the packing list gets printed to be included into the packing and
the whole order is packed.

4.11: - DISPATCHING
After the whole order is packed the shipping process follows. The address labels
get printed on the term transfer printer along with data about the consignee, order
number, shipping note number, weight or any other by user optional data. Each consignee
can theoretically use different format of labels with different information. Then the
cartons/pallets are moved to transit location and definitely shipped out of the warehouse.
Within the framework of truck loading the data like truck license number, driver name
etc. can be added to each shipment. Then the data about the shipped goods are exported
into the ERP System.

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 CHAPTER 5
5. CONCLUSION
In this training I have studied various process for manufacturing the components
or product like CAD modeling and required programming, die making, foundry
processes, casting, machine shop department, quality control department etc. This
training offered an exposure to industrial environment, which can be stimulated in
engineering college. It helps me to understand the scope and job responsibility of the
various department of an engineering organization. I came to know the latest
technologies which were unknown to me thus broadening my knowledge base Thus this
training will beneficial for me in my future and also it will help me to build my career.

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