Report3 Mjs

Internship report on Fine Components and Tools Pvt Ltd
Chapter 1 Company Profile

Fine Components and Tools Pvt Ltd, established in the year 1989 by the promoter Mr.
C. Krishnamoorthy. The factory is situated in the well-known industrial area developed by
Karnataka industrial area development board at Bommasandra Bengaluru.
Since its establishment, the company is functioning smoothly with high customer satisfaction.
The huge orders placed by multinational companies and other existing customers enabled us to
expand the premises as well as activities of the company, such as full-fledged toolroom with
its own design and development facility and adding sub-assembly line in its activity. Thus, the
name Fine Components and Tools Private Limited is popular in the industry.
1.1 SCOPE
Manufacturer of Sheet Metal Pressed Parts and Sub-assemblies for Automotive Applications
1.2 VISION
To be best in the field of sheet metal stamping and become a world class manufacturer
1.3 MISSION
Customer
To be innovative and continually provide enhanced quality product and exceed customer
expectation in Quality, Cost and Delivery
1
BTPSP STAVANIDHI NIPANI, MECHANICAL DEPT.
1.4 ORGANIZATION
The organization is managed by a team of managers with very rich experience and long years
of association with the company. The senior team is responsible for all the units, with each
member taking care of the respective function across all the units. Each of the units have
capable and responsible executives well-trained in their respective functions to perform as per
the company's requirement and ultimately satisfy our customer. Due to the conducive
environment to learn and contribute with a sense of security and satisfaction, the attrition rate
is very low.
2
1.5 Products
Fig no 1.1 Air bag housing Fig no 1.2 Air Bag retainer
Fig no 1.3 Anchor plate Fig no 1.4 Bracket and Upper Stay
Fig no 1.5 Mount bracket Fig no 1.6 Steam
3
1.6 ESTEEMED CUSTOMERS
• Toyota Motor
• Maruti Suzuki India Limited
• Autoliv INDIA Pvt Ltd
• Faurecia
• Bridgestone
• Toyota Kirloskar motor pvt ltd
• Bosch
4
Chapter 2 work under taken
During initial phase of internship studied about various operations processed in the industry
for manufacturing component are as follows
Fig no 2.1 Air bag housing
Forging is a metal working process in which useful shape is obtained in solid state by
hammering or pressing metal.
It is one of the oldest metalworking arts with its origin about some thousands of
years back. Some examples of shapes obtained by forging process: Crane hook, connecting
rod of ICengine, spanner, gear blanks ..etc.
2.1 Different Forging Operations

1. Upsetting
The thickness of the work reduces and length increases
Steps: (i) (ii) (iii) Final
Fig 2.2 Upsetting
2. Edging
The ends of the bar are shaped to requirement using edging
5
dies.
Fig 2.3. Edging Fig 2.4. Fullering
3. Fullering
The cross sectional area of the work reduces as metal flows outward, away from centre
4. Drawing
The cross sectional area of the work is reduced with corresponding increase in
lengthusing convex dies.
Fig 2.5 Drawing Fig 2.6 Swaging
5. Swaging: The cross sectional area of the bar is reduced using concave dies.
6. Piercing: The metal flows around the die cavity as a moving die pierces the metal.
7. Punching: It is a cutting operation in which a required hole is produced using a punching

die.
6
Punch
Fig 2.7 Piercing Fig 2.8 Punching
8. Bending: The metal is bent around a die/anvil.
2.2 Classification of Forging Processes
Based on Temperature of the work piece:
1. Hot Forging: (most widely used)
Forging is carried out at a temperature above the recrystallization temperature of the

metal.
Advantages:
• High strain rates and hence easy flow of the metal
• Recrystallization and recovery are possible
• Forces required are less
Disadvantages of Hot Working:
• Lubrication is difficult at high temperatures
• Oxidation and scaling occur on the work
• Poor surface finish
• Dies must withstand high working temperature
7
2. Cold Forging:
Forging is carried out at a temperature below the recrystallization temperature of the

metal.
Advantages:
• Less friction between die surface and work piece
• Lubrication is easy
• No oxidation or scaling on the work
• Good surface finish
Disadvantages of Cold Working:
• Low strain rates, hence less reduction per pass.
• Recrystallization and recovery do not occur.
• Hence, annealing is required for further deformation in subsequent cycles.
• Forces required are high.
Classification of Forging Processes Based on Arrangement of Dies:
1. Open Die Forging: Flat dies of simple shape are used.
Fig. 2.9 Open Die Forging
Features of open die forging:
• Repeated impact blows are given on the work
8
• Less dimensional accuracy
• Suitable only for simple shapes of work
• Requires more skill of the operator
• Usually used for a work before subjecting it to closed die forging (to give
approximateshape)
• Dies are simple and less expensive
• It can be analyzed much easily
• It is the simplest of all forging operations
2. Closed Die Forging:
Work piece is deformed between two dies with impressions (cavities) of

thedesired final shape on them.
Fig. 2.10 Closed Die Forging
Features of Closed Die Forging:
Closed die forging involves two or more steps:
• i) Blocking Die: Work is rough forged, close to final shape.
• ii) Finishing Die: work is forged to final shape and dimensions.
• Both Blocking Die and Finishing Die are machined into the same die block.
• More number of dies are required depending on the complexity of the job.
• Two die halves close-in & work is deformed under high pressure.
9
• High dimensional accuracy / close control on tolerances.
• Suitable for complex shapes.
• Dies are complex and more expensive.
• Large production rates are necessary to justify high costs.
Significance of Flash in Closed Die Forging:
• Excess metal is taken initially to ensure that die is completely filled with metal
to avoidany voids.
• Excess metal is squeezed out of the die cavity as a thin strip of metal, called flash.
• A flash gutter is provided to reduce the area of flash.
10
Chapter 3 Study of Forging Equipment
3.1 Forging Equipment

They are classified based on the principle of operation.
1. Forging Hammer
• The force is supplied by a falling weight of ram.
• Deformation of work piece is due to the application of the kinetic

energy of theram.
Types of Forging Press
i) Mechanical board hammer:
• It is a stroke restricted machine.
• Repeatedly the board (weight) is raised by rolls and is dropped on the die.
• Rating is in terms of weight of the ram and energy delivered.
Fig. 3.1 Mechanical Board Hammer Fig.3.2 Steam Hammer
ii) Steam Hammer (Power Hammer) Range: 5 kN to 200 kN
• It uses steam in a piston and cylinder arrangement.
• It has greater forging capacity.
• It can produce forgings ranging from a few kgs to several tonnes.
11
• Preferred in closed die forging
The total energy supplied in a blow:
It is given by : W=1/2mv2 + pAH = (mg + pA)
Where m= mass of ram
v= velocity of ram at the start of
deformationg= acceleration due to
gravity
p= air/ steam pressure on ram on down stroke

A= area of ram
cylinderH=
height of ram
drop
iii) Hydraulic Press:
• It is a load restricted machine.
• It has more of squeezing action than hammering action.
• Hence dies can be smaller and have longer life than with a hammer.
Fig. 3.3 Hydraulic Press
12
3.2 Features of Hydraulic Press
• Full press load is available during the full stroke of the ram.
• Ram velocity can be controlled and varied during the stroke.
• It is a slow speed machine and hence has longer contact time and hence higher
die temperatures.
• The slow squeezing action gives close tolerance on forgings.
• Initial cost is higher compared to hammers.
3.3 Forging defects

1.Incomplete forging penetration:
- Dendritic ingot structure at the interior of forging is not broken. Actual forging
takes placeonly at the surface.
- Cause: Use of light rapid hammer blows
- Remedy: To use forging press for full penetration.
2.Surface Cracking
- Cause: Excessive working on the surface and too low temperature. High
sulfur infurnace leading to hot shortness
- Remedy: To increase the work temperature

• an be controlled and varied during the stroke.
• It is a slow speed machine and hence has longer contact time and hence
higherdie temperatures.
• The slow squeezing action gives close tolerance on forgings.
• Initial cost is higher compared to hammers.
3.Cracking at the flash:
- This crack penetrates into the interior after flash is trimmed off.
- Cause: Very thin flash
- Remedy:-Increasing flash thickness, relocating the flash to a less critical region

of theforging, hot trimming and stress relieving.
13
4.Cold shut (Fold)
• Two surfaces of metal fold against each other without welding completely
• Cause: Sharp corner (less fillet), excessive chilling, high friction
• Remedy: increase fillet radius on the die
5.Scale pockets and Underfills:
• They are loose scale/ lubricant residue which accumulate in deep recesses of the die.
• Cause: Incomplete descaling of the work
• Remedy: Proper decaling of work prior to forging
6.Internal cracks
Cause: Secondary tensile stresses developed
during forging
Remedy: Proper die design
14
Chapter 4
In industries there are various department like production, quality, planning, which makes
work smooth operation.
4.1 Operations performed
• Progressive Stamping
• Tandem Press Line
• Robotic Spot Welding
• Robotic Toxing/Clinching
• Spot and Projection Welding
4.1.1 Progressive Stamping
Progressive Die Stamping is a metal stamping process used to cut and form raw sheets of
metal using a stamping die. It comprises several individual workstations which perform one
or more operations on that part. The progressive die can perform various actions like cutting,
coining, punching, bending, lancing, shaving, extruding, drawing and embossing, etc.
As the name suggests, progressive die stamping encompasses many progressive steps
where the raw material is pressed simultaneously and sequentially in an automatic feeding
system. Each step is built on the previous step until the desired shape is achieved. All these
steps have the same basic setup with some possible variations.
4.1.2 Tandem Press Line
Tandem press lines are typically used to produce large parts that require multiple operations,
such as large or medium inner and outer body panels for automobiles.
Presses, automation and other peripheral items are part of a highly interconnected ecosystem
with advanced control integration to optimize the output while guaranteeing quality and
safety.
15
4.1.3 Robotic Spot Welding
Spot welding is a resistance welding process that uses large electrical current to join two or
more sheets of metal in a single location. Spot welding technology has evolved through its
extensive use in automobile manufacturing using articulated robots
4.1.4 Robotic Toxing/Clinching
The clinching process is a method of assembling sheet metal without welding or

fasteners. With this joining technique, metal parts are deformed locally without the use of
any consumables.
Multiple materials, with different individual thicknesses can be assembled at the same time
based on this cost effective, fast and clean process: steel and stainless steel, aluminium
and/or non-ferrous materials. Coated and painted sheet metals can also be joined together
without altering the surface finish.
Compared to traditional joining methods such as spot welding, riveting, screwing or gluing,
clinching presents different characteristics including low production costs, little
preparatory work, safety and environmentally friendly, reproducibility and durability.
4.1.5 Spot and Projection Welding
Projection welding is a form of resistance welding which uses pressure and electrical current
to join two or more metal parts that have been designed to meet at one or more specific points
with the maximum amount of contact. This allows for more efficient welding with less
energy and greater weld strength
Advantages of Projection Welding
When projection welding, the component parts must be specifically manufactured with
dimples or projections, in order to ensure that they fit together and maximize contact between
the parts. The welding process is tailored to the material and component’s intended use.
The welder applies force and electrical current through the welding machine at one point of
contact. The pressure, current strength, and amount of time that the current is applied will
vary depending on the material and processing specifications.
Projection welding offers a wide range of benefits over more traditional welding methods,
including:
• Increased production. The process allows for more than one weld to be completed at
one time, thereby increasing production output.
• Extended lifetime. Projection welds have a longer life expectancy than spot welds, as
it requires less heat and pressure during the welding process.
16
• Versatility. Projection welding equipment is easy to adjust to different parameters, so

it can be used for a wide variety of parts and components.
• Ease of use. Projection welding uses highly automated equipment and multiple welds
can be handled at one time.
• Clean finish. The point of contact is on one side and the pressure is minimized, so
projection welding allows for reduced surface imperfections at the welded joint and
results in a smoother finish.
• Closer welds. Projection welding equipment allows for welds that are closer spaced,
because there is less pressure applied to each joint.
Machine used in industry
Fig no 4.1 Double Crank Power Presses
Change Traditional C Type Frame Into Straight Side Frame
• High rigidity frame structure eliminating the opening distortion, fully realizing the
highly efficient blanking and deep drawing operation.
17
• Eight long right angled slide guide rails provide confidence on installing high accurate
die. Ensuring high accuracy manufacturing to be possible.
• Improved back side operability and die conformability of the presses.
• Large side opening for simple installation to complete single and fully automated
operation on coiled material.
• High quality machine accuracy improving machine endurance, providing lasting

value.
High quality machine accuracy improving machine endurance, providing lasting
value.
GAP FRAME MECHANICAL PRESSNC1SINGLE POINT, FROM 35 - 250 TONS
Fig 4.2
18
Photo gallery
19
CURRICULUM VITAE
Manoj Sansuddi
Mobile: +917829899985
+918152946727
Mail: manojsansuddi@gmail.com
EDUCATIONAL QUALIFICATION
University Institution Passing Marks

year
%
SSLC Karnataka secondary S D HIGH 2012

52.16
education examination board SCHOOL,SANKESHWAR
ITI Department of Employment VASANT NILAJAGI PVT,ITI 2015 70.33

and Training HUKKERI
B.T PATIL & SON’S

DIPLOMA Board of technical 2021 PASS
POLYTECHNIC, SAVANTAVADI
1ST YEAR
NIPPANI
B.T PATIL & SON’S

DIPLOMA Board of technical 2022 PASS
POLYTECHNIC, SAVANTAVADI
2ND YEAR
NIPPANI
COMPUTER LITERACY
ONE YEAR COURSE
CTTC ( Computer Teacher training Course )
20
PERSONAL STRENGTH
• Good Communication Skill

• Self Confidance
• Positive Mental Attiudes
• Hardworking
• Creavite Thinking
PERSONAL DETAILS
Name : Manoj Dundappa Sansuddi
Father Name : Dunndappa K Sansuddi.
Mother Name : Ambika D Sansuddi
Sex : Male
Nationality : Indian
Marital Status : Unmarride
Language Known : Kannada, English, Hindi, Marathi
Date of Birth : 16 july 1996
Permanent Address: At/Post- Sankeshwar,591313
Tq - Hukkeri,
Dist - Belgavi-591309
Current Address: Seetharam Nagar,
Hebbagodi – 560099,Bangalore
21
DECLARATION
I hereby declare that all the particulars stated above are true and correct to the best of my knowledge.
Date: Yours Sincerely,
Place:
Manoj Sansuddi.
22
REFERANCE
[1] Khan. M. S, project done by DKTE students, online launched on Textile learner –“ Air-bag for
automobiles”, http://www.textilelearner.blogspot.com , pp 1-14.
[2] Dupont , Sun. J, Barnes J. A, Airbag EndUse Technology, “Marerial selection for Air-bags” , pp 1-8.
[6] NHTSA data presented at http://www.hwysafety.org, “Airbags questions and Answers.
[3] Smith W. C , “Automotive air-bags”, Industrial Textile Associates Greer, SC 29650 , pp 1-26.
Www.intexa.com.
[4] Khan. M. S , project done by DKTE students, online launched on Textilereview “ Theory behind Air
bags application in automobiles”, pp 7-11
23

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Internship report on Fine Components and Tools Pvt Ltd

Chapter 1 Company Profile

Fig no 1.5 Mount bracket Fig no 1.6 Steam

1.6 ESTEEMED CUSTOMERS

• Maruti Suzuki India Limited

• Autoliv INDIA Pvt Ltd

• Toyota Kirloskar motor pvt ltd

Chapter 2 work under taken

Fig no 2.1 Air bag housing

2.1 Different Forging Operations

The thickness of the work reduces and length increases

Steps: (i) (ii) (iii) Final

Fig 2.2 Upsetting

The ends of the bar are shaped to requirement using edging

Fig 2.3. Edging Fig 2.4. Fullering

Fig 2.5 Drawing Fig 2.6 Swaging

7. Punching: It is a cutting operation in which a required hole is produced using a punching

Fig 2.7 Piercing Fig 2.8 Punching

8. Bending: The metal is bent around a die/anvil.

2.2 Classification of Forging Processes

Based on Temperature of the work piece:

1. Hot Forging: (most widely used)

Forging is carried out at a temperature above the recrystallization temperature of the

• High strain rates and hence easy flow of the metal

• Recrystallization and recovery are possible

• Forces required are less

Disadvantages of Hot Working:

• Lubrication is difficult at high temperatures

• Oxidation and scaling occur on the work

• Poor surface finish

• Dies must withstand high working temperature

Forging is carried out at a temperature below the recrystallization temperature of the

• Less friction between die surface and work piece

• No oxidation or scaling on the work

• Good surface finish

Disadvantages of Cold Working:

• Low strain rates, hence less reduction per pass.

• Recrystallization and recovery do not occur.

• Hence, annealing is required for further deformation in subsequent cycles.

• Forces required are high.

Classification of Forging Processes Based on Arrangement of Dies:

1. Open Die Forging: Flat dies of simple shape are used.

Fig. 2.9 Open Die Forging

Features of open die forging:

• Repeated impact blows are given on the work

• Less dimensional accuracy

• Suitable only for simple shapes of work

• Requires more skill of the operator

• Dies are simple and less expensive

• It can be analyzed much easily

• It is the simplest of all forging operations

2. Closed Die Forging:

Work piece is deformed between two dies with impressions (cavities) of

Fig. 2.10 Closed Die Forging

Features of Closed Die Forging:

Closed die forging involves two or more steps:

• i) Blocking Die: Work is rough forged, close to final shape.

• ii) Finishing Die: work is forged to final shape and dimensions.

• High dimensional accuracy / close control on tolerances.

• Suitable for complex shapes.

• Dies are complex and more expensive.

• Large production rates are necessary to justify high costs.

Significance of Flash in Closed Die Forging: