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Training1

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  • 1. TRAINING REPORT EMKAY AUTOMOBILES SAMPREET SINGH GORAYA 400807025 Department of Mechanical Engineering THAPAR UNIVERSITY, PATIALA 1
  • 2.  Emkay Group was founded in the year 1978 with the vision of bringing a new dimension to the two business sectors; automotive, & distillery. Headquartered in New Delhi. In Ludhiana (2 units), Nashik (2 units), Haridwar, Pant Nagar, Indore, Gurgaon and Latur (Sakole).  Springs  Deep drawn & precision pressed components  Deep drawn and heavily pressed components  Tubular parts  Forged components 2
  • 3. MY ROLE trained in the research and development of emkay automobiles. My work was to construct and understand the sheet metal components. My work was to model the tools in 3D- software. 3
  • 4. DESIGN APPROACH/CONSTRAINTS CONCEPT DEVELOPMENT Concept development is the basic force behind the particular design and development. It is based on various factors-  Customer requirements- These are specifications demanded by the customer which are most necessary for us.  Technology requirements- Sometimes there are technology constraints in the way of designing of a component , so we have to go some other way by making some changes in the design process.  Economic considerations- Economic considerations are related to cost constraints .we have to complete a project under some allotted resources. 4
  • 5. 5 ADVANCED PRODUCT QUALITY PLANNING INITIATIATION PHASE I PLAN AND DEFINE PHASE II DESIGN INPUT DESIGN OUTPUT, VERIFICATION & RELEASE PHASE III PROCESS DESIGN & DEVELOPMENT PHASE IV INSPECTION PHASE V FEEDBACK ASSESSMENT & CORRECTIVE ACTION DIFFERENT PHASES IN THE DEVELOPMENT OF A COMPONENT
  • 6. PROJECTS ASHOK LEYLAND CAB MTG BRKT 18 PARTS OF D09 FRAME 6 OUTER TUBE SUB ASSEMBLY
  • 7. 7 Parts of d09 1-Rear brkt 2-Fixing plate relay 3-lower brkt fix radiator 4-enginr fix external brkt LH-RH 5-Footrest brkt LH-RH 6-Middle brkt RH-LH 7-Front engine brkt RH-LH 8-Brkt head pipe RH-LH 9-Support brkt battery RH- LH 10-Radiaator mtg brkt 11-upper pad cover 12-control unit Parts of assembly of cab mtg bracket 1- Cup 2- Cab mtg bracket Parts of outer tube assembly 1-Spring seat 2-Knuckle brkt 3-Outer tube 4-Lower cup 5-stabilizer brkt
  • 8. 2D & 3D MODELING OF PARTS AND REQUIRED SOFTWARE Modeling give us an idea and outlook of the features of components Designer forms an opinion about the set of operation that are required for the development of the part Formation of different tools SOFTWARES- Solid works, NX6, Autocad, Dwg editor 8
  • 9. 9 PROTOTYPING  PROTOTYPING here refers to the manufacturing of parts with the help of manufacturing machines like Computer numerical control, direct numerical control, wire cut etc.  Drilling machines for the holes from 2mm to 50 mm dia.  VMC and CNC Wire cut for profile cutting  Grinding machines  75 Ton press  Milling and turning machine Spring seat Blanks with wire cut Bending by bending tool Trimming by cnc Forming tool Holes by cnc
  • 10. STRUCTURE AND TYPES OF TOOLS 10  TOP AND BOTTOM PLATE  DIE PLATE  PUNCH  GUIDE PLATE  GUIDE BACK PLATE  STRIPPER PLATE  SIMPLE TOOL  COMPOUND TOOL  PROGRESSIVE TOOL
  • 11. 11 EXAMPLE OF PROGRESSIVE TOOL STRIP LAYOUT
  • 12. BLANKING The success of other operation is totally depends on the accuracy of the size of blank. Blank size is determined by a software called BLANK WORKS but that does not give the exact size of blank so HIT and TRAIL method is used to get down to the actual size. 12 Blanking of do9 parts
  • 13. 13 Blank of spring seat Blanking tool Pillar set guide plate
  • 14. 2D DRAWING FOR WIRE CUT  Wire cut is machine which can only read 2d data. The problem is overlapping of multiple lines due to such geometry of component. Overlapping force the designer to remake the whole geometry again. 14 Blank of brkt. battery
  • 15. FINALISATION OF LAYOUT W. R. T RAW MATERIAL YIELD This ensures the optimized use of material. As the standard length of sheet is 1250mm so we have to convert that sheet into max. no. of blanks. As this will reduce the cost of manufacturing. SRTIP LAYOUT AND BLANKS OF DIFFERENT PARTS 15 STRIP LAYOUT AND BLANKS OF DIFFERENT PARTS
  • 16. 16 Strip layout of spring seat 2d drawing of spring seat
  • 17. 17 BENDING BENDING is performed to get desired curves on the component and also making out of plane geometries. . Bending deform the component making it weaker at some sections and also decreasing the size of blank 1. Cracking due to drawing 2. Deformation of holes 3. Displacement of internal geometry 4. Wrinkling 3D model of spring seat for bending
  • 18. 18 2d drawing of bending & trimming of Spring seat
  • 19. 19 TRIMMING 2d drawing of spring seat trimming tool Die plate Guide plate Punch block Component
  • 20. 20 BENDING & TRIMMING FOR DIFFRENTIATING TWO PARTS TRIMMING TOOL OF BRKT BATTERY Punch back plate Trimming punch block Bending punch block component Guide plate Bracket battery
  • 21. 21 PUNCHING 3d view of punching tool Blank of brkt main frame punch to be created we all know use to make holes or any kind of shapes through the body. Punching demands high level of accuracies because any deviation in hole can lead to the failure of component and leads to scrap
  • 22. 22 Blank movement pillar set punch 1 punch 2 top plate die plate
  • 23. 23 punching tool of rear brkt main frame REAR BKT (MAIN FRAME)
  • 24. FORMING 24 The feature formed is abruptly out from the plane of component. 2d drawing of forming tool of spring seat die
  • 25. 25 WELDING FIXTURES - A fixture is a work-holding or support device used in the manufacturing industry. What makes a fixture unique is that each one is built to fit a particular part or shape. The main purpose of a fixture is to locate and in some cases hold a workpiece during either a welding operation welding fixtures of i10 outer tube assembly
  • 26. RELATION GAUGES Rec. gauges are tools which are used for the fast inspection of component. this make sure that defected goods should not passes to next stage 26
  • 27. Materials  MS(C- .90-1.60)  EN-31(C-.90-1.20, Mn-.30-.75, Si- .10-.35, S-.040, P- .040, Cr- 1.00-1.60)  HCHCR(C=1.55%, Mn=0.3%, Si=0.3%, Cr=12%, Mo=1%) 27
  • 28. HEAT TREATMENT & ITS EFFECTS  SOFT ANNEALING (850-650)C  STRESS-RELIEVING (650-500)C  HARDENING Preheating temperature: 1110–1290°F (650–750°C). Austenitizing temperature: 1810–1920 F (990– 1050 C) but usually 1830–1905 F (1000–1040 C). QUENCHING MEDIA Oil ,Vacuum (high speed gas, Forced air/gas, Martempering bath -EFFECTS ON length , breadth, height 28
  • 29. THANK YOU 29

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