1. Summer training
Training report
Name : Ranjit kandel
Roll no: 12021A0353
College : university college of engineering , Kakinada, A.p , India.
University: Jawaharlal Nehru Technological University, Kakinada
Website: www.jntuk.edu.in/
Company name :Sona BLW Precision Forgings Ltd
Website: www.sonablw.com
HISTORY OF COMPANY
SONA OKEGAYA PRECISION FORGING LTD.
NOW SONA BLW PRECISION FORGING LTD.
SONA BLW PRECISIONS FORGE, INC. designs and manufactures transmission and
axle components for passenger cars and commercial vehicles
Production start in 1998
Site area : 19312 meter sq.
Plant area : 11077 meter sq.

2. Plant : In India – Gurgaon ,pune, Inaugurating new plant in
bawal.
Three branch in Germany and one in usa.
CERTIFIED
ISO14001, ENVIRONMENT MANAGEMENT SYSTEM.
ISO 9001, FOR QUALITY MANAGEMENT SYSTEM.
ISO-TS 16949 ,FOR AUTO MOBILE COMPANY.
MANAGEMENT TEAM:
Chirman : Dr. surendra kapor
Vice chairman : Mr. T.K pal
Company based on TPM(total productive maintenance),
kaizen(continuous improvement)
AND follow 5’s –
 sorting out,
 systematic arrangement
 shine everything ,
 standardization,
 self discipline.

3. GENERAL INDUSTRIAL TRAINING
INFORMATION ON PROCESS.
RAW MATERIAL –
1. BILLET CUTTING
2. BILLET SHOT BLASTING
3. BILLET HEATING
4. FORGING
5. SLOW COOLING
6. SHOT BLASTING
7. COINING
8. ROUGH TURNING

4. 9. FINISH FORGING
10.BROACHING
11. HEAT TREATMENT
12. SHOT BLASTING
13. HARD TURNING
14. FINAL INSPECTION
15. WASHING AND ANTI RUST
APPLICATION
16. PACKING
1. BILLET CUTTING
Billet cutting machine is used to cut the large cylindrical rods in to a
small billets.
Machine : shearing press billet cutting machine
A machine for cutting cloth or bars, sheets, or plates of metal or other material.
Bandsaw machine

5. A bandsaw is a power tool which uses a blade consisting of a continuous band
of metal with teeth along one edge to cut various workpieces.
2. BILLET SHOT BLASTING

6. In this machine small shots are bombarded on the surface of the
component in order to remove the dust, rust , surface defect and burrs
produced during billet cutting.
3. BILLET HEATING
Billet heating is the process to heat the billet to convert them in to
plastic deformation or stage .
Billets are heated at a temp. between 800 to 1130 degree centigrade.
Heating of billet is done with the help of induction heater .

7. 4. FORGING
Forging is the process of working of heated metal into a useful
shape by hammering or pressing.
Forging machine are now capable to make the parts ranging from bolts
to a turbine rotor.
There are three type of forging
1. Hot forging
2. Semi hot forging
3. Cold forging.
There are four type of forging machine.
1. Drop hammer
2. Screw press
3. Crank press
4. Hydraulic press.
5. Power hammer.

8. But i learned about the working principle of servo press and frictional
screw press.
5. FORGING DEFECTS
1. Tooth crack
2. Tooth dent
3. Unfilled radius
4. Misalignment
5. Die lube scaling
6. Temp scaling

9. 6. LUBRICATION USED IN FORGING
1. DIE LUBE
* Die lube is used because of following reasons-
1- To maintain temperature of die
2- For easy removable of components after forging
3- To decrease coefficient of friction
4- To reduce die wear out
5- To increase rate of deformation
2. GRAPHITE BASED
3. SYNTHETIC WHILE LUBE BASED
Graphite based lubricant have also two sub type.
*water based
*oil based
Water based graphite has also two sub type , as
 Natural graphite based
 Synthetic graphite based.
In sona we use natural graphite based lubricant in precision forging .
In this type of die lube , very thin size of graphite is used its size is around
five micron which form very thin layer of graphite on die. This types die lube
is prepare by ratio of 1:20. It means one part of die lube is mixed into 20
part of water.
7. COOLING AND SHOT BLASTING
* Done at room temperature
* To prevent air interruption these components are kept covered for
sometime. If air comes in contact with the component its hardness will
increase.
8. COINING/COLD SIZING
After component shot blasting the component is referred for the coining
process. The purpose of process is to give proper shape to the component. The
component get compressed after cooing to bring. Its back to original
dimension cold coining is done. Lubrication oil is also put in it to reduce the
wear and tear.
9. PURPOSE OF USING COINING OIL
The film of oil oppose the direct contact of die surface and the component
surface.
10. SOFT MACHINING
After coining process soft machining process is done , for this process.

10. It include the following steps.
1. Rough turning
2. Drilling
3. Boring
4. chamfering
5. Deburring
6. Broaching
7. Hobbing
1. TURNING: In this process removal of excess material from the component in
minimum time take place.
2. DRILLING : In this process cylindrical hole is produced by means of rotating
edges of cutter knows as drill bit.
3. BORING : it is done to give finishing and accurate size for broaching
operation.
4. CHAMFERING: in this process sharp edge of the drilled hole of the
component caused during drilling is removed.
5. DEBURRING: It is the metal removing process in which sharp edge of the
component tooth are changed in to flat edge.
6. BROACHING: In the process we do spline generation . we use two machine
of 16TON & 5TON each for this is used for cutting.
7. HOBBING: It is that process in which groves are made by using gear hobbing
machine.
11. BATCH CODE PUNCHING
HEAT TREATMENT
PURPOSE OF HEAT TREATMENT
 For improving ductility
 Reliving internal stresses
 For refining of grain size

11.  For increasing hardness
 Increasing tensile stress
PROCESS FOLLOWED
1. Charge preparing : This is the first process in which charge is prepared
for further heating process.
 Machine used :charge car
 Tool used : * round grid
*plus grid
* base plate
*mesh
*gear link
2. Pre washing :The component are washed for removing the dust and oil
which was applied in previous process.
* chemical process : hiclean, and water
Operation is done on sealed quench furnace
3. soaking : Time- 20 min
Temp-920 degree centrigrade
Carbon potential (c.p)- 0.40
4. carburisation: Time -135 min
c.p- 1.20
temp- 920 degree centigrade
5. Diffusion :Carbon atmosphere mixing in metal.
TIME- 175 min
Temp -920 degree centigrade.

12. 6. Hardening: In this process, steel component is heated upto hardening temp,
holding it at sufficient temp and for followed by rapid cooling such as
quenching in oil or lubricant. Due to this highly hard component is obtain.
* machine used- sealed quenched furnace (SQF)
Fule used: LPG, methanol.
7. Post washing: In this process washing of hardened component takes place
for removing of oil which was used during quenching purpose.
* Chemical used: HI clean, water.
8. Tempering: It is the process of heating the hard component to some temp
below the critical temp and holding sometimes for cooling at room temp. to
remove stresses.
*machine used: Tempering furnace.
HARD MACHINING
In this process some operation is prepared to give the finished shape , size and
look to the component with the help of several machine. In this process all
unwanted material are removed and the surface of the component become
smooth .
The product extremely become hard and internally soft so that it doesn’t break
while being pressurized.
Hard machining operation
1. Hard turning: This process required high cutting speed feed and a very
small depth of cut to generate the smooth surface in hard turning . the
depth of the cut range from 0.15 to 0.25 mm and feed 0.08 to 0.1 mm
per revolution.
It is done to maintain Ra (roughness surface) upto 0.8mm.
2. Granding : To get more accurate and smooth surface.
3. Honing:A hone is a bonded abrasive stone used in manufacturing of
precision bores to improve geometry, surface finish and dimension
control of the finished part.
This process is called honing. It is also done for smooth surface and finishing.

13. 4. COUNIER BORE: countering is a process of enlarging the hole through a
distance from one end instead of enlarging the hole drilled surface.
MACHINING DEFECTS
⬛ Bore unclean
⬛ bore oversize
⬛double hobbing
⬛over deburring
⬛without deburring
⬛chip rubbing
⬛without broach
⬛ insert broken
⬛boss unclean
⬛broaching dent
⬛boss undersized
⬛teeth dent
5.Phosphating
The main purpose of Phosphating is to give protection against rust or
corrosion.
Product