Industrial Training Report

AT

FUEL INSTRUMENTS AND ENGINEERS PVT. LTD.

ICHALKARANJI

SUBMITTED TO

WALCHAND COLLEGE OF ENGINEERING, SANGLI.

(AN AUTONOMOUS INSTITUTE)

DEPARTMENT OF MECHANICAL ENGINEERING

(POLYTECHNIC WING)

SUBMITTED BY
202. SHRINIVAS MAHESH KULKARNI
ACADEMIC YEAR 2021-22

1|P ag e
 ACADEMIC YEAR 2020-21
Walchand College of Engineering, Sangli
(An Autonomous Institute)

DEPARTMENT OF MECHANICAL ENGINEERING

Polytechnic Wing

CERTIFICATE
This is to certify that Mr. Shrinivas Mahesh Kulkarni of
Diploma (Mechanical Engineering) Roll No.202 has completed
his Industrial Training during the academic year 2021-2022 as
partial fulfillment of the Diploma (Mechanical Engineering)
course.

Mr. A.V. Kamble Mr. A.V. Kamble.

Mentor H.O.D and Vice Principle

2|P ag e
 Self – Assessment of Industrial Training

1. Name: Shrinivas Mahesh Kulkarni

2. Enrollment no: 1900090127
3. Roll no: 202
4. Industry Name: Fuel Instruments and Engineers PVT. LTD.
5. Industry Address: Plot no 1, Old Industrial Estate,
Ichalkaranji, Maharashtra, India.416-115
6. Industry Contact no: 9850058587
7. Period of tanning: 03/08/2021 to 15/09/2021
8. Methods of Training: Online

3|P ag e
 Acknowledgement

It is always a pleasure to remind the fine people in

the Engineering Workshops for their sincere
guidance. I received to uphold my practical as well as
theoretical skills in engineering.
Firstly I would like to thank Prof.
A.V.Kamble (Vice Principle, HOD Mechanical
Department/ Lecturer) for convincing me the fact
“Whatever a man can imagine, that can be achieved”,
guiding me to taste the real flavor of engineering,
who made is understand Knowledge is power and
unity is strength.
Secondly I would like to thank to all staff
Of Fuel Instrument And Engineers privet L.T.D. for
the positive attitude he showed for my work, always
allowing me to question him and giving prompt
replies for my uncertainties in all the fields including
educational, social and managerial to labor work.
And I always great him for his aspects of crew
resource management.
Finally I apologize all other unnamed who
helped me in various ways to have a good training.

4|P ag e
 Index
S.R. No Content Page no
1. INTRODUCTION 6

2 LEVER GAUAGE DIAL 7

3. DIGITAL HEIGHT GUAGE 10

4. DIGITAL VERNEIR CALIPER 13

5. PROFILE PROJECTOR 16

6. CONTRACER MACHINE 19

7 ROUGHNESS TESTER 20

8 RING GUAGES 24

9 PH METER 27

10 PLUNGER INDICATOR 29

11 PLUG GUAGES 31

12 PROCESSES 33
13 CONCLUSION 41
14. REFERENCES 42

5|P ag e
 INTRODUCTION
Fuel Instruments and Engineers Pvt. Ltd. - FIE a
Ichalkaranji based group has grown since its inception in
1953 to emerge as a leader in the testing machines,
SPM's, Auto components Manufacturing sector. From
developing variety of machines and Research,
Carburetor,CNCs , Forging and Castings - FIE has been
there.

Backed by modern infrastructure and highly qualified &

experienced staff, the machines and components
developed by FIE comply with the world quality
standards in manufacturing technology & Software,
making them useful for industry.
With more than 1,00,000 installations FIE has created an
unmatchable knowledge-base in the testing machine
segment.

6|P ag e
 LEVER GAUAGE DIAL
The dial indicator or the Plunger dial gauge is one of the
simplest and the most widely used mechanical
comparator.
First of all the use of plunger dial gauge used to compare
work-pieces against a master.Lever Dial Gauge also knew
as Test Indicator. It used to measure sensitive
contact.Lever Dial gauge usually measure up to 0.80 mm.
But some special type lever dial design for measurement
up to 2 mm.
Lever dial gauge used to measure variations in height,
flatness, or roundness. It usually combined with a Digital
height gauge or Vernier Height gauge to fix the same
measuring force.
Therefore lever dial widely used in manufacturing
industries, laboratories and in workshops.

7|P ag e
The main manufacturers of this gauge are Mahr,
Mitutoyo, Baker etc which is known for its quality
product.
The pointer and carbide contact point are only slightly
magnetizable, and so they are hardly affected by a
magnetic environment. In addition, models with a ruby
contact point are available. The ruby contact point also
has several times the abrasion resistance of carbide
contact point and is safely usable with an electric
discharge machine thanks its being a non-conductor.
Flat crystal makes graduations easy to read. Moreover, the
O-ring sealing method used for the bezel prevents water
or oil penetration. (Note that this type is NOT
waterproof.)

8|P ag e
9|P ag e
 DIGITAL HEIGHT GUAGE
Height gauges can be used to determine an object or
workpiece’s height with extremely high accuracy and
precision.
These precision measuring instruments also provide
marked locations on an item relative to one reference
plane for subsequent use.
Center-line distances, internal/external diameters, and
step heights are some of the different measuring tasks that
can be carried out by high-specification digital height
gauges.
They claim consistency of ±0.0001 inch and can be
extremely precise up to 0.001 inch. Of course, the
consistency and precision of such instruments still depend
on their overall quality.
The metric scale usually ranges from zero to 300
millimeters, while the imperial scales range from zero to
12 inches.

10 | P a g e
The beam also has an electronic measuring slider, which
comes with the Power ON/OFF, HOLD, TOL, SET,
MM/INCH, ON/OFF/ZERO, and ABS buttons.
On one of the jaws, the slider also comes with a carbide
scriber tip. Along the scale, the attached scriber, together
with the slider, can slide up and down and be locked in
place.
To be locked in place with the help of a second locking
screw, a fine-tune wheel is used to make the final
adjustment. Sending data to a printer or computer via a
special cable is also possible through a data output port.
Electronic height gauges can perform several
measurement types. They’re usually used in quality
control applications of the manufacturing industry for the
following tasks:

11 | P a g e
  measuring the perpendicularity or
squareness/straightness of parts;
 angle measurement;
 measuring flatness;
 verification of center-to-center dimensions;
 performing 2D measurements of part features;
 scribing features from a datum place or a certain part
with accurate vertical dimensions to make additional
machining possible.

12 | P a g e
  DIGITAL VERNEIR CALIPER
The Digital Caliper (sometimes incorrectly called the
Digital Vernier Caliper) is a precision instrument that
can be used to measure internal and external distances
extremely accurately. The example shown below is a
digital caliper as the distances/measurements, are read
from a LCD display. The most important parts have
been labelled.

Earlier versions of this type of measuring instrument

had to be read by looking carefully at the imperial or
metric scale and there was a need for very good
eyesight in order to read the small sliding scale.
Manually operated vernier calipers can still be bought

13 | P a g e
 and remain popular because they are much cheaper than
the digital version. Also, the digital version requires a
small battery whereas the manual version does not need
any power source.
Digital calipers are easier to use as the measurement is
clearly displayed and also, by pressing the inch/mm
button the distance can be read as metric or imperial.
The material to be measured is placed between the
external jaws and they are carefully brought together.
The locking screw is tightened so that the jaws do not
move apart. The digital display can then be read. The
distance can be read by in metric and imperial by
pressing the inch/mm button.
The display is turned on with the on/off button. The
external jaws should then be brought together until they
touch and the zero button should be pressed. The digital
caliper can then be used to measure distances. Always
go through this procedure when turning on the display
for the first time.

14 | P a g e
15 | P a g e
 PROFILE PROJECTOR
Also known as an optical comparator, or even called a
shadowgraph, a profile projector is an optical
instrument that can be used for measuring. It is a useful
item in a small parts machine shop or production line
for the quality control inspection team. The projector
magnifies the profile of the specimen, and displays this
on the built-in projection screen. On this screen there is
typically a grid that can be rotated 360 degrees so the
X-Y axis of the screen can be aligned with a straight
edge of the machined part to examine or measure

16 | P a g e
This projection screen displays the profile of the specimen
and is magnified for better ease of calculating linear
measurements. An edge of the specimen to examine may
be lined up with the grid on the screen. From there,
simple measurements may be taken for distances to other
points. This is being done on a magnified profile of the
specimen. It can be simpler as well as reduce errors by
measuring on the magnified projection screen of a profile
projector.
The typical method for lighting is by diascopic
illumination, which is lighting from behind. This type
of lighting is also called transmitted illumination when
the specimen is translucent and light can pass through
it. If the specimen is opaque, then the light will not go
through it, but will form a profile of the specimen.
Measuring of the sample can be done on the projection
screen. A profile projector may also have episcopic
illumination which is light shining from above. This
useful in displaying bores or internal areas that may
need to be measured.
Usage
Profile projector is widely used for complex shape
stampings, gears, cams, threads and comparing the
measured contour model. It’s easy to use and high

17 | P a g e
 efficient. It is a commonly used measurement of optical
instruments. Thus, profile projector is widely used in
major machinery manufacturing including aviation,
aerospace industry, watches and clocks.

18 | P a g e
 CONTRACER MACHINE
Using a Contour Measuring Machine customers are
able to perform dimensional measurements such
as angle, radius, and distance measurements, the
contour tolerancing function for evaluating “form” and
the report creation function for outputting measurement
results in a specific format are provided as
standard, measuring both ease of operation and
powerful analysis capabilities. Contour measurement
using a contracer machine is a powerful system for
automatic high-volume measurement. Event
with greater precision in all axis for difficult stationary
contour testing in production environment or in the test

room.

19 | P a g e
 Contracer CV-1000:
Mobile contour measurement with “stationary”
performance profile.
Sophisticated digital technology for site-independent
identification and evaluation of profiles –with the
precision and performance of stationary systems.
Contracer CV-2000:
The state of the art in economic measurement.
Stationary contour measurer with convincing price-
performance ratio. For efficient use in production or in
the laboratory in every respect.
Mitutoyo Contracer CV_1000_2000 Click to see
Brochure for Contracer CV1000, CV2000

20 | P a g e
 ROUGHNESS TESTER
Roughness is an important parameter when trying to
find out whether a surface is suitable for a certain
purpose. Rough surfaces often wear out more quickly
than smoother surfaces. Rougher surfaces are normally
more vulnerable to corrosion and cracks, but they can
also aid in adhesion.

21 | P a g e
A roughness tester is used to quickly and accurately
determine the surface texture or surface roughness of a
material. A roughness tester shows the measured
roughness depth (Rz) as well as the mean roughness value
(Ra) in micrometers or microns (µm). Measuring the
roughness of a surface involves applying a roughness
filter. Different international standards and surface texture
or surface finish specifications recommend the use of
different roughness filters. For example, a Gaussian filter
often is recommended in ISO standards.
Roughness testers can measure several predetermined
lengths. Shorter distances are used to measure finer
surfaces, while longer lines are traced for rougher
surfaces. It is good to ask about the different options
available when considering a roughness tester.
Some roughness testers have an interchangeable stylus or
probe for measuring different shapes, offsets, and curves.
To measure either the inner diameter or an outer diameter,
make sure the roughness meter under consideration can
meet your requirements.
If you prefer either empirical or metric, some roughness
testers are able to display the results of the surface finish
in either micro-inches or micrometers, saving you the step
of having to convert it manually.

22 | P a g e
Typical roughness testers provide a linear roughness
measurement, tracing a mechanical tip along a surface to
measure roughness along an arbitrary line.

23 | P a g e
 RING GUAGES
A ring gauge, or ring gage, is a cylindrical ring of a
thermally stable material, often steel, whose
inside diameter is finished to gauge tolerance and is used
for checking the external diameter of a cylindrical object.
Ring gauges are used for comparative gauging as well as
for checking, calibrating, or setting of gauges or other
standards. Individual ring gauges or ring gauge sets are
made to variety of tolerance grades in metric and English
dimensions for master, setting, or working applications.
There are three main types of ring gauges: go, no go, and
master or setting ring gauges.

Go ring gauges provide a precision tool for production

comparative gauging based on a fixed limit. Go gauges

24 | P a g e
consist of a fixed limit gauge with a gauging limit based
on the plus or minus tolerances of the inspected part. A go
ring gauge's dimensions are based on the maximum OD
tolerance of the round bar or part being gauged. A go plug
gauge's dimensions are based on the minimum ID
tolerance of the hole or part being gauged. The go plug
(ID) gauge should be specified to a plus gaugemakers'
tolerance from the minimum part tolerance. The go ring
(OD) gauge should be specified to a minus gaugemakers'
tolerance from the maximum part tolerance.

No-go or not-go gauges provide a precision tool for

production comparative gauging based on a fixed limit.
No-go gauges consist of a fixed limit gauge with a
gauging limit based on the minimum or maximum
tolerances of the inspected part. A no-go ring gauge's
dimensions are based on the minimum OD tolerance of
the round bar or part being gauged. The no go ring (OD)
gauge should be specified to a plus gaugemakers'
tolerance from the minimum part tolerance.
Master and setting ring gauges includes gauge blocks,
master or setting discs, and setting rings are types of
master gauges used to calibrate or
set micrometers, optical comparators, or other gauging

25 | P a g e
systems. Working gauges are used in the shop for
dimensional inspection and periodically checked against a
master gauge.

26 | P a g e
 PH METER
A pH meter is a scientific instrument that measures
the hydrogen-ion activity in water-based solutions,
indicating its acidity or alkalinity expressed as pH. The
pH meter measures the difference in electrical
potential between a pH electrode and a reference
electrode, and so the pH meter is sometimes referred to as
a "potentiometric pH meter". The difference in electrical
potential relates to the acidity or pH of the solution. The
pH meter is used in many applications ranging
from laboratory experimentation to quality control.

The rate and outcome of chemical reactions taking place

in water often depends on the acidity of the water, and it
27 | P a g e
is therefore useful to know the acidity of the water,
typically measured by means of a pH meter.

Knowledge of pH is useful or critical in many situations,

including chemical laboratory analyses. pH meters are
used for soil measurements in agriculture, water
quality for municipal water supplies, swimming
pools, environmental remediation; brewing of wine or
beer; manufacturing, healthcare and clinical applications
such as blood chemistry; and many other applications

Advances in the instrumentation and in detection have

expanded the number of applications in which pH
measurements can be conducted. The devices have
been miniaturized, enabling direct measurement of pH
inside of living cells.[6] In addition to measuring the pH
of liquids, specially designed electrodes are available to
measure the pH of semi-solid substances, such as foods.
These have tips suitable for piercing semi-solids, have
electrode materials compatible with ingredients in food,
and are resistant to clogging.

28 | P a g e
 PLUNGER INDICATOR

The classic mechanical version, called a dial indicator,

provides a dial display similar to a clock face with clock
hands; the hands point to graduations in a circular scales
on the dial which represent the distance of the probe tip
from a zero setting. The internal works of a mechanical
dial indicator are similar to the precision clockworks of a
mechanical wristwatch, employing a rack and pinion gear
to read the probe position, instead of a
pendulum escapement to read time.

29 | P a g e
The side of the indicator probe shaft is cut with teeth to
provide the rack gear. When the probe moves, the rack
gear drives a pinion gear to rotate, spinning the indicator
"clock" hand. Springs preload the gear mechanism to
minimize the backlash error in the reading. Precise quality
of the gear forms and bearing freedom determines the
repeatable precision of measurement achieved. Since the
mechanisms are necessarily delicate, rugged framework
construction is required to perform reliably in harsh
applications such as machine tool metalworking
operations, similar to how wristwatches are ruggedized.
Other types of indicator include mechanical devices
with cantilevered pointers and electronic devices with
digital displays. Electronic versions employ
an optical or capacitive grating to detect microscopic
steps in the position of the probe.
Indicators may be used to check the variation
in tolerance during the inspection process of a machined
part, measure the deflection of a beam or ring under
laboratory conditions, as well as many other situations
where a small measurement needs to be registered or
indicated. Dial indicators typically measure ranges from
0.25 mm to 300 mm (0.015in to 12.0in), with graduations
of 0.001 mm to 0.01 mm (metric) or
0.00005in to 0.001in (imperial/customary).
30 | P a g e
 PLUG GUAGES
A go/no-go gauge refers to an inspection tool used to
check a work piece against its allowed tolerances via
a go/no-go test. Its name is derived from two tests: the
check involves the work piece having to pass one test (go)
and fail the other (no-go).

For example, ISO 1502 sets a standard for screw threads

and gauging to test them. It establishes the
31 | P a g e
attribute T as go for the major diameter and the
attribute Z as no-go for the pitch diameter.[1] The
inspection tool has two threaded components. For
example, there would be two female sections on a gauge
to test a threaded male workpiece such as a screw. If the
major diameter of a screw is too large, it will not fit in
the T test thread at all (fail). If the major diameter is too
small, the fit is sloppy (fail). If the thread has been cut too
deep, it screws into the Z test thread (fail). If it is the right
size and only does about three turns, the fit is right
(pass).[2]
A go/no-go gauge is an integral part of the quality process
that is used in the manufacturing industry to ensure
interchangeability of parts between processes or even
between different manufacturers. It does not return
a size or actual measurement in the conventional sense,
but instead returns a state, which is either acceptable (the
part is within tolerance and may be used) or unacceptable
(the part must be rejected).
They are well suited for use in the production area of the
factory as they require little skill or interpretation to use
effectively and have few, if any, moving parts to be
damaged in the often hostile production environment.

32 | P a g e
 Process
1.Forging

2.Rough Grinding

3.First Operation

4.Second Operation

6.Finish Grinding

7.Washing

8.Rotary

10.Hard mite

33 | P a g e
1. Forging
a. Cold Forgoing
Cold forming or cold working is any metalworking
process in which metal is shaped below its
recrystallization temperature, usually at the ambient
temperature. Such processes are contrasted with hot
working techniques like hot rolling, forging, welding, etc.
b. Heat Treatment
Heat treatment is the process of heating metal without
letting it reach its molten, or melting, stage, and then
cooling the metal in a controlled way to select desired
mechanical properties.
c. Aluminum Grade
Forged aluminum is ideal for applications where
performance and safety are critical but a lighter-weight
metal is needed for speed or energy efficiency.

34 | P a g e
2. Rough Grinding
Grinding is machining process that's used to remove
material from a work piece via a grinding wheel. As the
grinding wheel turns, it cuts material off the work piece
while creating a smooth surface texture in the process.

35 | P a g e
3. First Operation

 Machine sets job’s height in tolerance

 After it machine clean the face part of the job
(rough bore).
 Machine sets job’s thickness and depth in
tolerance.

36 | P a g e
4. Second Operation

(After first operation Job comes to second operation)

 In second operation firstly job gets O.D. (outer
diameter) chamfer
 After it I.D. (inner diameter) Chamfer and angle give
to job by machine .
 Machine drills a hole on a horizontal surface of the
job .

37 | P a g e
5. Center Drilling

 On this machine single work is done, job get drilled

in center of it of specific diameter and
length

(after it finish grinding gives to job)

(After finish Grinding job is washed )

38 | P a g e
7.Rotary

 In this process job get chamfer.

 Then job get counter drill.
 Then it get taper on face side.
 After it machine gives slot on opposite of tapered
side.
 And machine cut another slot on the side of drill.
 It get chamfered.
 After all machine cut small slot on middle of the
edge.

39 | P a g e
 8. Hardening Process (Heat treatment)

Heat treatment is the process of heating

metal without letting it reach its molten, or melting,
stage, and then cooling the metal in a controlled way
to select desired mechanical properties

40 | P a g e
 Conclusion

Industrial training is significantly beneficial to all

concerned parties in contributing towards the development
of the nation. Being a student, one can acquire Industrial
experiences and at the same time familiarize themselves
with the real working environment at the Industrial training
site. This opportunity also enables them to further expand
their creativity while seizing the profession ethical values
as basis to venture into professional career in the future.
Therefore, students must develop themselves to become a
valuable asset to the esteemed organization or industry. For
some organizations, the students undertaking the Industrial
training have in fact overcome the scarcity of professional
workforce within the organization. By realising the
advantages and the limitless amount of benefits that can be
accomplished by all parties through this Industrial training,
the excellent collaboration between the University and the
industry must be greatly considered. Through our assigned
industry we learned about various casting, molding,
patterns, machines, etc. in the foundry. The knowledge we
gained through this training will be forever useful in our
future.

41 | P a g e
 REFERENCES

https://fuelinstrument.com

https://www.mitutoyo.co.jp › eng

https://mitutoyoindia.com

42 | P a g e