Summer Internship

Training
Submitted to- Mr. Sandeep Jain
By- Piyush Lavania(2000640400008) & Sparsh Singh(2000640400009
 Objective

The Summer Training Program has mainly two objectives viz. ‘Learning
New Things’ and ‘Gaining Practical Experience’. It helps to get exposure
to the environment of the industry wherein we are to be placed. This
training also enhances our soft skills and meeting so many engineers and
learning from them makes us a confident professional. It also teaches us
the sense of responsibility, taking initiatives, projecting the innovative
ideas and most important management. It is also needed for the completion
of the bachelor’s degree in the field of Mechanical Engineering.

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 Introduction

In this report, we will discuss about engine bearings and bushings, their manufacturing
processes, quality and control procedures taken into consideration while manufacturing them.
This report is concerned with what we have learned in Benara Udyog Limited (BUL), Agra.
BUL is one of the premier manufacturer and exporter of Engine Bearings, Bushings, Thrust
Washers, Bi-metallic strips and Brake components. The imported, fully automated state of the
art manufacturing plants in Agra are equipped with a variety of hydraulic and pneumatic
presses, automatic engine bearing transfer line and various advanced CNC machines.

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 Engine Bearings:

Engine bearings are crucial components within internal combustion engines that serve the
vital function of reducing friction and supporting the rotational motion of various engine
parts. They are primarily found in the engine block, connecting rod, and crankshaft, where
they play a significant role in maintaining the integrity and smooth operation of the engine.
Engine bearings are essential components within internal combustion engines that ensure
smooth operation by reducing friction, distributing loads, and providing support for rotating
components. Their design and materials contribute to the efficiency, durability, and reliability
of modern engines.
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 Importance of Engine Bearings:

• Friction Reduction

• Wear Protection

• Load Distribution

• Vibration Dampening

• Efficiency

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 Bushings:

Engine bushings, often referred to simply as "bushings", are components used within internal
combustion engines and various mechanical systems to provide support, reduce friction, and
absorb vibrations between moving parts. While similar in concept to bearings, bushings
typically have a different design and function. Engine bushings are essential components used
in internal combustion engines and mechanical systems to reduce friction, absorb vibrations,
and provide support between moving parts. Their design and material selection contribute to
overall system efficiency, comfort, and durability.

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 Importance of Bushings:

• Vibration Isolation

• Stability & Control

• Prevention of noise

• Longetivity

• Handling & Performance

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 Manufacturing Processes
A. Material Selection:

• crucial step in ensuring the overall performance, reliability, and longevity

• play pivotal roles in minimizing friction, supporting loads, and facilitating smooth movement

• appropriate materials for these components is influenced by several factors like

1. Mechanical Properties 5. Corrosion Resistance

2. Wear Resistance 6. Friction and Lubrication

3. Fatigue Resistance

4. Thermal Characteristics

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Material Options:

Steel Alloys, Aluminum Alloys, Bronze Alloys, Babbitt Alloys

B. Manufacturing Process

• To make bi-metallic blanks which are the primary product

• Our base material is CR coils of SAE 1010

• To convert it into bi-metallic blanks, powder fabrication is done

• Take powder form of another metal such as copper alloys, lead, zinc, bismuth, etc.

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 Induction Furnace:

• used to melt iron and steel, copper,

aluminum, and other metals.
• a clean, energy-efficient and well-
controlled melting process

Water atomization:

• is used primarily for ferrous

and nonferrous alloys
• is lower in cost than other
modes of atomization but
limitations exist in relation to
powder purity

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 Drying Machine:

• industrial dryer is a high

powered complex device
designed to remove moisture
from products, materials, and
mixtures

Classifier:

• classifier is an industrial machine which

separates materials by a combination of size,
shape, and density
• works by injecting the material stream to be
sorted into a chamber which contains a
column of rising air

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 Blending:
• is where metal powders or
alloys are compressed while
restricted in a die
• materials are blended into a
homogenous mix

Sintering process:
• a process in which particles under
pressure chemically bond to
themselves in order to form a
coherent shape when exposed to a
high temperature

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 • Now once the bi-metallic sheets are made, slitting process is done to convert these sheets into
blanks which are our primary product.
•
• Now with our bi-metallic blanks, we have to make bushes and bearings.
• First process is metal forming in which power presses are used to deform the bi-metallic blanks
into a curved shape which is the base of our final products.

• After forming, bending process is

done to bend the blank into desired
shape.
• Then coining is done on the
deformed blanks so that the shape
would not change to original shape
after bending.

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 • Now the following processes are for
bushes:
• After getting the desired shape bi-
metallic blanks, knuckling is done.
• Then size of the component is
adjusted by facing process and
thereafter, grinding is done.

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 After getting coined, nick is
developed on the blanks for
locking. The meaning of nick is a
small notch, groove, or chip.

• Then wall broach is done with the help of

pneumatic machines.
• Broaching is a machining process where a sharp,
hardened, toothed tool removes material from a
work piece in a consistent, continuous, and
accurate way.
• Then height broach is done. And after, when the
desired shape and size is obtained, de-burn is
done.
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 Quality Control and Testing:
Quality Control in Manufacturing: Inspection Techniques:

 Design and Engineering - Visual Inspection

 Raw Material Inspection - Dimensional Measurement

 Manufacturing Processes - Non-Destructive Testing (NDT)

 Casting and Forging - Surface Analysis
 Machining - Material Testing
 Sintering - Functional Testing:

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 Conclusion:
Bushes and bearings are critical components in the
manufacturing industry, playing a vital role in
minimizing friction, increasing efficiency, and
prolonging the lifespan of machinery and
equipment. Understanding the manufacturing
processes and maintaining high-quality standards are
essential for their successful implementation in
various applications.
 THANK YOU!

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