This document provides an internship report summarizing the internship of Shameek Kulkarni at Bharat Forge Ltd. from July 7, 2014 to August 6, 2014. It includes an introduction to Bharat Forge, acknowledgments, contents, details of the induction program and overview of various departments visited including forging, heat treatment, machining and quality control. The report provides insights into the manufacturing processes and equipment used at the different facilities.

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INTERNSHIP REPORT
( 7 / 7 / 2 0 1 4 T O 6 / 8 / 2 0 1 4 )
BY:
S H A M E E K .S .K U L K A R N I
A CH A R YA IN S T IT U T E O F T E CH N O L O G Y
U S N : 1 A Y1 2 M E 1 0 8
U N D R E T H E G U ID A N CE O F :
M R . P .M .T A L E (H O D , A P P . S H O P )
In BHA RA T FORGE LTD. PUNE

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ACKNOWLEDGEMENTS
First of all, I would like to thank Mrs. Leena Deshpande for providing us
with this opportunity to do my Internship at Bharat forge ltd. I would
also like to thank Ms. Shobha Ronimath and Ms. Sapna Gadh for their
continuous guidance during our induction as well as the whole project.
I extend my gratitude to Mr. P.M.Tale for giving me an opportunityto
study the Die shop department and also to do this project on
visualisationimprovement.His guidanceand encouragement has
helped me throughout the internship study. A token of thanks also
goes to all the people working in Die shop for making my study even
better by helping me.

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CONTENTS
 INTRODUCTION
1. About BHARAT FORGE LTD.
2. PRODUCTS
3. INDUCTION PROGRAMME
 OLD & NEW DIE SHOP
 MAIN INTERNSHIP REPORT
 CONCLUSION

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INTRODUCTION
ABOUT BHARAT FORGE LTD. PUNE :
Bharat ForgeLimited (BFL), the Pune based Indian multinational is a technology driven
global leader in metal forming having transcontinental presenceacross eight manufacturing
locations, serving severalsectors including automotive, power, oil and gas, construction &
mining , locomotive, marine and aerospace.
Part of Kalyani Group - a USD 2.5 billion conglomerate with 10,000 globalwork force; BFL
today has the largest repository of metallurgical knowledgein the region and offers full
servicesupply capability to its geographically dispersed marqueecustomers from concept
to productdesign, engineering, manufacturing, testing and validation.
The world's largestforging company with manufacturing facilities spread across India,
Germany and Sweden, Bharat Forgemanufactures a wide range of high performance,
critical & safety components for the automotive & non-automotivesector. Itis India's
largest manufacturer and exporter of automotive components and leading chassis
component manufacturer in the world. BFL's customer base includes virtually every global
automotive backed by severaldecades of experience in component manufacturing &
metallurgy, the company is now looking beyond automotive and has embarked on an
ambitious and exciting journey to redefine its already existing presence across several
critical business verticals such as oil & gas, power, locomotive & marine, aerospace, metals
& mining, construction and general engineering.
Bharat Forgewill useits strong platform of metallurgical knowledge, design & engineering
capability and manufacturing prowess, to create a strong position for itself in these sectors.
‘Expanding into new horizons’ will give BharatForge a completely new growth perspective.
Itwill begin the transformation of the company from an auto component supplier to an
engineering company with diversecomplementary businesses in new high growth sectors.

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CORE OBJECTIVE OF THE COMPANY IS :
1. To be committed to listening and responding to the needs of our customers,
associates and business partners and honouring their individual value.
2. To be committed to an entrepreneurialspirit that fuels the growth of our companies
and increases shareholder value.
About the various facilities of the company in India and abroad –
 In India –
1. Mundhwa – All operations
2. Chakan – Machining operations
3. Baramati – Ring Rolling Operations
4. Satara – Heavy Forging Facility.
 InternationalFacility –
1. Germany(GmBH)
2. China
3. Sweden
4. USA.

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BHARATFORGE TIMELINE :
1. 1961 : Bharat forge is started by Mr.Nilkanthrao kalyani in mundhwa
Pune.
2. 1966 : Commercial production of Bharat Forgebegins. Forgeshop
Hammer technology is introduced.
3. 1985 : Initial exporting of parts manufactured in Bharat Forgestarts in
Europe.
4. 1990 : Investmentis made on State of the art forging technology.16000
MT press line is commissioned.
5. 1991 : Major breakthrough in Japan, USA and UK for critical supply of
power-train & chassis components.
6. 2001 : Commissioning of second 16000 MTpress line. FirstM&A
Acquired order book of dana.
7. 2002 : Investmentin research and development, Testing and validation
and State-of-the-artHeavy Duty Truck CrankshaftMachining facility.
8. 2003 : Established Global Manufacturing Footprintacross Europe, North
America and China.
9. 2004 : Joined hands with India’s PremiereInstituteof technology, BITs
Pilani, to enhance internal talent.
10. 2007 : Center for advanced Manufacturing takes shapein Baramati.
11. 2008 : Bharatforge commissioned India’s largestcommercialopen
forging place.
12. 2009 : Inauguration of forging and high housepower, Industrial,
locomotive, marine and oil & gas crankshaftmachining facility at
baramati.
13. 2010 : Inauguration of the Ring rolling facility at Baramati.
Establishment of the Kalyani center for Technology and Innovation.
14. 2013 : Supply of crankshaftfor Indian locomotives, Becoming the first
Indigenous supplier of crankshaft.

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 VARIOUS PRODUCTS OF THE BFL :
1. AUTOMOTIVE:
a) Forged Crankshaft – Passenger Car 3ltr engine, Utility vehicle
2.2ltr engine, Passenger car 1.5ltr engine.
b) Machined crankshaft –Heavy Duty Truck 14ltr engine, HCV/MCV
5.9ltr engine, Heavy duty Truck 9ltr Engine.
c) Connecting Rod – 5.9 or 6.7ltr Engine.
d) Piston – Monotherm Piston powertrain component10kg.
e) Steering knuckles.
f) FrontAxle beam.
2. POWER:
a) 500MW HP rotor Steam turbine
b) Exciter shaftsteam turbine
c) Forged turbine blades
d) Tube sheets of heat exchanger.
3. OIL AND GAS :
a) Gate valve body
b) Casing head surface
c) Shell surface
d) Blow out preventor
e) Annular BOP
4. RAILWAY:
a) Forged locomotive crankshaft
b) Machined locomotive crankshaft
5. MARINE:
1. Machined crankshaft
6. AEROSPACE :
2. Wheel lever forging

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INDUCTION PROGRAM:
We were given an Induction programmeto get to know the whole facility and every
department of the Bharat Forge ltd. The Various departments which I saw were –
 Closed Die Forging Division Engg:
In order to produce a customer’s product, it first has to be designed virtually. This task comes
under CDFD Engg. which makes use of many designing and simulating softwares to estimate,
design and optimize a given specimen. The process starts with estimation of force and energy
required for the job by using Ansys which is determined by the 2-D or 3-D drawings given by the
customer.
Then it is sent to the design team which designs the tooling and die required for the job with the
help of AutoCAD. Once the die is designed, it is sent to CAD department for its 2-D drawings to be
generated which is carried out with the help of softwares like Unigraphics, Catia and ProE.
Afterwards, a 3-D simulation software (Forge or Deform) gives necessary data about the thermal,
defect, stress and energy distribution in the forging. Finally, the drawing and model are sent to the
CAM department which writes the program for the CNC machines to produce the required die.
Finally the drawing is optimized using various software.
 Die Shop
Once the CDFD Engg. has issued the programs for CNC machines, the dies are manufactured in the
die shop. The general process outlook is as follows.
Firstly planning of the die to be manufactured for the given product is made i.e. the amount of
time required for the manufacturing of the die prior to product manufacturing. . Finally dies are
manufactured as per the required specifications in High Speed Milling Machines (HSM). After this if
there is any wear or irregularities are there in the dies, then it is removed either through welding
(in case of smaller dies) or CNC machines (for bigger dies). Finally surface finishing of the dies are
made through Electron Discharge Machine (EDM) followed by Benching (i.e. polishing of the die).
Then the die is checked in CMM and LMM machine for any defect present in the die after final
finishing of the die.
 Heat Treatment
After press forging, the products are quenched and thus, develop brittleness or sometimes, a
customer has a special demand of heat treatment of the product. Whatever the case maybe, all
the heat treatments are carried out by this department. Various processes available are annealing,
normalizing, hardening, nitriding (exclusively for dies), carbo-nitriding, iso-annealing and carbon
restoration. Annealing is process by which any residual stress due to thermal or mechanical
loading is relieved by heating. Carbo-nitriding is the process by which case hardening is achieved
for gears and other products. The shop has both batch-type and continuous-type furnaces. Various
quenching media are used which include water, oil, polymer and even air.

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 Forge Modernization Division I (FMD I)
This department came into existence in 1991. It is a press forge and houses 5 presses namely,
 PTS 900 (16500 MT): It is a mechanical press and is the largest in BFL.
 PSH 4.560 (4560 MT): It is a screw press and uses a large flywheel for energy transfer.
 LKM 400 (4000 MT)
 LKM 2.500 (2500 MT)
 LMZ 2500 (2500 MT)
The general process of the division is as follows:
 First billets are cut into suitable sizes and heated in an oil-fired surface to a
temperature of 1280 degrees Celsius.
 The heated billets are de-scaled with water jets at high pressure.
 Then they are put into dies and pressed till they take the shape completely.
 Forge Modernization Division II
This shop also follows the same process of forging as that of the FMD I/III. Firstly raw material as
per the given specification of the product are sorted and cut in a band saw to the required
dimensions. Then similar to FMD I here also the cut billet is heated in the oil furnace where 72
billets are heated simultaneously. After this the same procedure as that of FMD I/III is followed of
that of upsetting, trimming and padding.
 Forge Modernization Division III
This division of Bharat Forge Ltd. comes under closed die Forge division. Generally in this division
the process used for forging is similar to that of FMD I/II. In this division firstly the raw materials in
the forms of billets are cut into the required dimensions as per the customers specifications for the
product. Then after this jobs were heated simultaneously in the oil furnace for a temperature
range of 1230-1300 Celsius. Then we pass the heated job through rolling machine in order to
increase its length and reduces the cross sectional area. After that job is sent to main press where
firstly job is placed in the blocker die followed by finishing die in order to give the required shape.
Then it is sent to trimming press where the flash produced during the forging is cut out. After this
job is moved to padding press where it is straightened i.e. any bending that is present in it is
removed. Finally finishing is performed using short blasting or short peening.
 Heavy Forge Division I/II

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This division comes under open die forging. These two shop is generally used to produce products
of critical shapes , which cannot be produced by the closed die forging method. The products
which are usually produced in this shop are wind mill shafts, gear blanks, mining manifolds,
camshafts etc. HFD I shop contains a hydraulic press of 1600 Ton capacity (ZDAS). The shop also
contains QKK12T manipulator having carrying capacity of 12 Ton and travel speed of 20-40 m/min.
Similarily HFD II contains hydraulic press of 4000 metric ton as well as manipulator similar to that
of HFD I.
 Forge Shop
This the oldest forging shop in Bharat Forge which uses Manual forging technique unlike FMD
I/II/III which uses automatic forging machines. This shop contains Hammer Machine that is used
for the forging of the job. Generally it is used to produce heavy or complex shape products, which
cannot be manufactured, by FMD I/II/III shop. This shop can forge the given job both vertically as
well as horizontally unlike FMD in which only vertical forging is done. Hammer used for forging in
this shop is around 25000 pound. Hence it is not used for mass production but only for the
production of the complex shapes.
 MachinedComponentsDivision(MCD I)
MCD I is responsible for the grinding and finishing of the crankshafts that come out of the pressing
shops. This shop has 11 lines for crankshaft finishing and 6 lines for non-crankshaft products (such
as FAB assembly, knuckle, reinforcement brackets and Al forgings). All the output of this shop is for
domestic sales only.The processes carried out on each line are roughly the same which include
milling of crank pin and journal, grinding of pin, journal, flange and thrust collar, cutting of key-slot,
drilling of centre holes and super-finishing of the pin and journal to an average roughness of
0.07μm. Finally it is checked for the correct dimension using different types of gauges.
 MachinedComponentsDivisionII(MCD II)
This department was set up in 2004 and is fully automated. It has 4 production lines and produces
fully- finished crankshafts exclusively for export. The gantry system is fully automatic which
reduces production time and lot rejection, even with 24 machines per line. The process sequence
is similar to that of MCD I which includes grinding of flange, pin, journal, thrust collar, super-
finishing of pin and journal, cutting of keyways, drilling of end-holes. The division produces 800
jobs per day. Tac time is 6.88 minutes per job.
 MetallurgicalQualityControl Division
MQC division is responsible for the control of material quality that is used in the forging, both for
dies and forgings. It houses apparatus for Jominy end-quench test, Kinematic viscosity test,
Universal tensile test machine, Hardness machine etc. It carries out various tests on materials to
find out the different physical and chemical properties of raw materials which are different grades
of steels. Physical properties are also determined through microstructures which are seen through

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high magnification microscopes. Chemical properties are determined from the composition of the
forging material.
 MachineTool Building(MTB)
MTB is a research and development department which caters to the needs of the other
departments. It’s main objectives are to procure machinery for BFL, re-condition grinding and
milling, make super-finishing, gear-cutting and hobbing machines. Another important objective of
this division is to procure old machines and repair them for further usage. A brand-new machine is
very expensive whereas an old machine can be bought and repaired quite cheaply. These
machines are for BFL plants only and are not sold outside the company.
 A2 Line
This shop is generally performed the final machining and painting of the products like crankshafts
and front axle. Firstly the parting line grinding of the job is done through a robotic machine (special
purpose machine). Then end grinding of the job is done followed by straightening and untwisting
of the job. After this job is sent for visual inspection in MPI (Magnetic Particle Inspection) where
job is magnetized and then seen under UV rays in order to find whether there is any crack is
present in work piece or not.
 Safety
It employs 39 safety engineers and 23 fire engineers which are trained in fire-fighting and safety
measures should the need arise. Each department has an HSE (Health, Safety and Environment)
Representative who is responsible for the safety regulations to be followed.
For safety regulations to be employed, one needs HIRA (Hazard Identification and Risk
Assessment). BFL employs Croner’s method for HIRA. Another lever is the BBS or the Behaviour
Based Safety which divides workers’ behaviours into two categories – Safe and Atrocious. Safe
behaviour is what the worker should exhibit as is expected from him/her as per the guidelines.
Each department is to carry out the following safety drills:
o Plant safety inspection of one line per section per week.
o Identification of two hazards per line per section and implementation of its
control.
o One safety meeting per month.
o Weekly tool box talk per line per section.
o Reduction of oil consumption by eliminating oil leakage and spillage.
o One department of fire audit per month.
o Fire Risk Assessment of one line per section per week
o One equipment audit per month.
o One safety Kaizen or suggestion per line per section per month.

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 Security
Bharat forge Ltd is in 86 acres Surrounded with 6 feet high stonewalls and barbed wire. There are
100 guards in total at Bharat forge working in groups of 30 in 3 shifts. The next step in the security
is the access control where each of the employees are given the smart card and the visitors as well
as the contract workers are given the manual or smart passes. There is DFMA and Security gate in
order to check the access of the individuals coming inside the premises

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OLD AND NEW DIE SHOP
In my Internship training in Bharat Forge, I was assigned under Mr.P.M.Taleat the Die shop.
Mr. Tale was our Training Coordinator and as I started my Training the firstthing which I did
was the Induction programof both the die shops. The Induction was splitinto two parts –
 Old Die shop
 New Die shop
And the following departments were under the old Die shop –
 PPC(ProductionPlanning and control) – This department is present at the new die
shop, Itcontrols the planning and scheduling of the die production and the routine
checking of the dies which are used. There areabout 7 main functions this shop is
performing at the moment. they are –
1. Die inventory monitor and control
2. Data collection for die history
3. Business plan analysis for resources requirement.
4. Die cost analysis and monitoring
5. MIS and weekly reporting
6. Computerised scheduling of work centres
The basic aim of PPC is to reduce the inventory cost and the amount of inventories. It
refers to the goods and the materials which are required for production.
 SIZING – This department is located in the old die shop. Its function is to give dies
their basic features so that they can be given to the new die shop for their further
processing thus saving the time of the processing. In this department CNC machines
are present, they are responsiblefor the sizereduction of the used dies or the
machining of the new dies.
Milling machines are used for machining the dies and they are horizontalas well as
vertical milling machines. The outer surfaces aremachined over here and ejector
holes are also drilled over here. The Zig-Zag milling method is used for milling the
deviations in the Die given for machining. Reduce rolls are also machined over here.

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 WELDING – This Department is located behind the Old die shop near the 10 ton
Hammer line. Its main function is to weld and fill the cracks and defects developed in
the used Dies. There are 2 types of welding used over there – Submerged arc welding
and metal inert gas welding. Submerged arc welding includes a high voltage source
and electrode responsiblefor the filling of the cracks. Metal inert gas welding
includes the welding using Argon and Carbon dioxide(80% Ar and 20% CO2).
Gouging – Itis a process in which Graphite rod with copper covering is used as
welding electrode. In this welding is done to melt and removethe material, on which
again welding is done to fill the material an which machining is done to get the
defects rectified.
Die penetration test is also done over here to check the cracks presentin the used
die. Dies are preheated to around 500o
C which are having carbon equivalent equal to
1.Dies are preheated in bio diesel furnace.
Descaling is done to remove the scales formed due to welding done on the defective
area, Pneumatic grinder is used for removing the scales. Peening is done to remove
the stress form the dies using a ½ kg hammer.

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 TOOL CRIB – This department is located in the new die shop. This department is
responsiblefor the supplying of the tools to various machines presentin the New die
shop. A man is assigned to the tool crib or tool room who is responsiblefor the tool
supplying. There are 2 types of tools they are – Solid tool and brazetool.
Solid tool is fixed onto the chuck using shrink fit process in which the chuck is heated
and the hole expands giving spaceto fit the tool onto the chuck.
Braze tools are fit into the powerjetchuck using a collet arrangement,the proper
sized collet are used fit the tool using screw fitting.
Types of holders which are used there are -
 BT-40
 BT-50
 HSK-40
 HSK-63 and
 HSK-63A
Even the Inserts used for fitting into the tools are also supplied by the tool crib.
Carbide tool inserts are used for metal removalwhich can be replaced easily.
 CNC(Computer numerically controlledmachines) –These machines are presentin
the Old die shop as well as New die shop. These machines are used for machining the
dies according to the given design by the CAM department. various operations are
carried out like Roughing, semi-finishing, finishing, sinking and etc.CNC machine
consists of a base, worktable, spindle head which consists of the spindle and the
chuck and the tool. A controlling unit is presenton each of the CNC machine like-
FANUC, FIDIA and Siemens.
DOT(Daily operator task) sheet is given to each machine on which the daily work
routine is given. Similarly job information sheet is given to each machine about a
particular job in which the specifications of the job are given. The CNC coding is
Initially generated by the CAM department and then uploaded to the DNC machine,
Then the code is transferred from DNC server to the CNC machine. Adjustments to
the codes are made and the code is run.
For initial setup of die on the worktablethe origin of the die is located, using this tool
then this origin is fed into the cnc code and the code is run.
Holding devices used for the dies are clamps which can be fitted onto the T-slots on
the bed of the machine.

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CINCINNATI MILACRON CNC MACHINE
 HSM(Highspeedmachining) – These machines are present only in the new die
shop.In totalthere are about 24 HSM machines.HSMmeans high speed machining
machines ,they are called so because of their high machining speed their speed
ranges from600 rpm to 15000rpm.They can behence used for rough machining and
also can be used for finishing operations. For low speed machining bigger sizeof tools
are used and for finishing operation smaller diameter tools are used.
HSMalso have separatecontrolling unit for each of the machine,HAAS machines
have their own controlling unit and the DMG machines have FANUC controlling unit.
In HSMmachines the fixtures used for holding the die is magnetic bed. Tools are
loaded onto the ATC(Automatic tool changer) and then the tools arechanged
automatically by the ATC as per the CNC code which is imported by the DNC server.
In this HSMaccucenter is used which gives us the origin of the given die.This die’s
origin is fed into the cnc coding and machining is started.The same chucks areused
for CNC machines as well as the HSMmachines.

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Various types of die’s are machined on the CNC and the HSM machine –
 Crankshaftdie
 Connecting Rod die
 Steering Knuckle Die’s
 CamshaftDie’s
 Crank rod Die
 Other parts of the chassis and etc
 ELECTRON DISCHARGEMACHINE(EDM) –This department is located in the new die
shop.EDMstands for Electronic dischargemachine, it is called becauseof the
principle on which it works.Itworkson the princinple of Anode-Cathode
interaction,when anode and cathode come in contact a spark is produced in between
which causes the metal to melt and hence the job is machined.The EDM is used for 2
purpose– machining and stamping.After the productis forged and before sending it

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to the customer stamping is done to identify the productby giving a serialno. and its
manufacturers logo.
The tool or the electrode always acts as the cathode and the job or product is the
anode. Differenttypes of electrodes are used – copper(Big sizework),graphite(All)
and Tungsten(Hard materials).Atthe surfaceof contact lot of heat is produced hence
a dielectric medium is used as the lubricant which keeps the material from
deforming.
EDM machining is used for jobs which have large depth, wherethe sufficientamount
of cutting tool is not reachable. As wirecut machine can be extended to any length
hence the machining of the workpiecewith large depth can be done easily.
The Dielectric medium used for the lubrication of the contact surfaceis EDM-30
which is a Kerosene based oil.
As the Wire cut machine is sensitive hence a different cabin is made for the EDM
section and the operations are done in the cabin.
EDM MACHINE

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WORKING DIAGRAM OF THE WIRE CUT METHOD
 DIE INSPECTION - This Department is located in the New die shop. Itis responsible
for the Inspections of die’s for sending them back to the forging line. After all the
rectifications, the cracks and the marks areinspected manually as well as using
machines. The various machines used in the Inspection departmentare –
 LMM(Layoutmeasuring machine) – for large die’s .
 CMM(Coordinatemeasuring machine) – for small and medium die’s.
 FARO ARM - for all kinds of die’s.
LMM – Layoutmeasuring machine is a machine used for measuring the coordinates of
a die and compares the derived value to the inbuilt design of the die, it works on VDMIS
software.
CMM – Coordinate measuring machine is an automatic CNC machine which takes the
points measurementand compares its value with the fed design and dimensions. Itworks
on CAPPS Basic 6.8. software.
FARO ARM – FARO arm is an advanced type of machinery which is very handy in use
and can be used for coordinatemeasuring at any position or angle on any type of die. It
uses the sameprinciple as that of the CMM machine. Italso gives us the amenities of Laser
scanning of the 3-d surface, Itis done using polyworks software.

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All the parameters like the Ejector holes ,sprue,land are checked and then the die is
certified by sticking a sticker tag which says OK on it.
CMM MACHINE

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 BENCHING –This department is present in the New die shop.Themain function of
this department is to finish the die’s which come after machining. The area is called
benching, because the die’s after machining are finished on a bench ,on which the
grinding process is done.
The benching process is done in stages, initially the die is grinded using a grinding
machine,then the die’s are manually checked for any cracks or defects and then if the
die’s are defective then welding is done on the area and the welded area is again
ground to make it even.
Finally polishing is done on the die’s using Polishing paper.
Pnuemablaster – it is a device used for strengthening the die’s.In this Graphite shots
are given to the die using high intensity pneumatic pump which causes the graphite
to strike the die’s surfaceand it also increases the life of the die.
Template fitment – For the trimmer die’s the inside cavity is checked using solid
metal plates which have the exact measurement for the cavity.Thetemplate acts as a
gauge for the trimmer die’s.
Ejector hole are checked using ejector pins ,which are used as gauge.
Threading operation on the die’s is also done here in the benching area.
Lock fitment is checked that whether the top and the bottom die lock into each other
firmly or not.
GRINDER MACHINE MOUNTED POINT WHEELS

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ASSIGNMENT
VISUALISATIONAL IMPROVEMENT OF
BENCHING AREA.
 INTRODUCTION :
What is Benching?
Benching Area is presentin the New die shop, it is responsiblefor the Finishing
operation in the die. Grinding operation takes place in this area. The die’s after
machining are broughtover here and then the die’s are grinded to make the surface
of the die smooth and finished. The die shop is divided into 3 parts – one of them is
for big die’s and the other part is for smaller die’s and another part is for finishing of
the inserts.
The benching area is well lit by the flashlights provided on the walls behind,
Barricades are made to separate the various regions of grinding.4 barricades are
made which seperates the benching area into 5 parts – 1 for small die benching,1 for
inserts benching,3 for big die benching.
Refreshment area is also given for the workers atthe corner of the benching area
wherebenches are given for workers to take rest in between their work.
Cupboards arestacked to the walls which are used for storing the tools and
machines, documents and etc. behind the benching area lockers are given for the
workers to keep their belongings inside, hence while working they do not have to
worry abouttheir belongings.
Pneuma blaster is kept at the end in the small die benching area,Itis used seldomly
and hence kept a little far fromworking area.
The dies to be finished or the already finished die’s are kept on the frontside of the
grinding area and behind the Walkway.
High voltage supplier for welding is placed centrally such that the wire can be taken
to any part of the benching area,This is the arc welding setup for the benching area.
For gas welding a trolley is made which is movable and taken to any position that is
required for welding.the trolley contains the acetylene and oxygen cylinders.

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 INITIAL STUDY : Initially we studied about the grinding process and the tools and
tackles used and also aboutthe 5s program followed by the people in the benching
area -
 BENCHING PROCESS – The benching process is required only after the
machining of the die’s. benching process involves the finishing of the surface
of the die,welding process,polishing,tapping and inspection.
1. Die finishing process - it is the major task of the benching department
which involves the grinding of the die surfaceand the adjacent sides.
The process flow is like this –
- Die in
- Grinding
- Checking inspection(manually)
- Welding
- Grinding
- Polishing
- Die out
Initially the die is broughtinto the benching area and according to the
plan given by the PPC the die’s are then loaded onto the bench and
according to the requirement of the die speed of the work varies.
Once the die is loaded onto the bench the die is grinded on the whole
surfaceusing a pneumatic grinder machine.On this pneumatic grinder
machine mounted point wheels are attached which are nothing but
the abrasivewheels which are manufactured in differentshapes for
the ease of work.using this grinding machine the grinding of all the
die’s is done.
After grinding the die is manually inspected by a personnel fromthe
inspection department.and the defects are highlighted by the marker
then rework is done on this area ,initially welding is done using arc
welding to fill the area with metal and then again the welde are is
grinded to get a required surface.
once all the defects are removed by this process then polishing is
done on the whole die surfaceto get a super finish on the die
surface.

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Polishing is done using the same pneumatic grinder but the toll is
changed and a polishing paper of grade either 120 or 320 is put on
the spindleof the grinder machine and polishing is done which gives
a fine finish on the surface.
After all these process the die is again checked by the quality
inspection personneland the OK tag is put on the die and then the
die sentto the forging line.
This is total process which goes on in the die finishing.
2. Tapping – Tapping or threading operation is done on the die’s which
require threads in the holes provided for lifting purposeand inserting
pins. The threading is done manually using Taps of different sizes.
3. Inspection – Inspection is done by the Inspection personnelfromthe
die inspection department,He is responsiblefor the identification of the
flaws and the cracks in the die and he gives the authorisation of the die
to proceed to the forging line.
 GRINDING MACHINES AND GRINDING WHEELS –
Then I studied about the grinding machines and the grinding wheels which
were used in the benching area .
Grinding machines – There weretwo major types of grinding machines used
in the benching area -
- Pneumatic hand die grinder – CP 3050 Ngrinder.
- High frequency electrical grinder – FEINgrinder
Pnuematic hand die grinder – Initially to know that what is a pneumatic die grinder.Itis a
grinding machine which works on the pressurised air,and it is called hand die grinder
because it is used in hand.the grinder which is used in our benching area is CP 3050 N which
is manufactured by the CHICAGO PNEUMATICSPVT. LTD. Itis a very reputed company with
good quality pneumatic products. Itworks in pressurised air which is got from the motor
supply of the air fromthe outside.The motor is placed outside the die shop for air lnlet and
pipe lines are given to the inside of the die shop at the benching area.
Working of the pneumatic grinder – the pneumatic grinder works on the principle of the
stator and rotor motion on the basis of pressurised air.initially air enters the grinder base
through the pipelines which is coming from the motor,This air then goes inside and strikes
the stator of the grinder.As the air hits the stator the it gets expanded and the rotors which
are embedded in the stator come out and due to the high impinging pressurefrom theair
the rotors starts to rotate.

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This rotary motion is transferred to the spindleas it is attached to the stator, as the stator
of the grinder starts to rotate the spindlealso starts to rotate and due to light weight of the
rotor and spindle high amount of rotary speed is produced which gives rise to the cutting
speed of the machine.
CP 3050 N
Machine specifications –
Free speed - 21000
Spindle thread size– M10
collet capacity – 6mm
approx. weight – 2.5 kg
overall length – 317 mm
High frequency Electrical grinder – This is another type of grinding machine used in the
benching area, this type of machine is used very seldomly.Itis an electrical grinder ,it works
on electricity and it is called high frequency because - In electrical engineering, frequencies
above 10 kHz aredescribed as high-frequency. But for power tools this term is commonly
used to describeall frequencies above the standard mains frequency of 50/60 Hz. Modern
high-frequency power tools usually operate at a frequency of 300 Hz.
But why is the currentfromthe socketat a higher frequency? One reason is the need for
enhanced performance. By increasing the frequency, you can achieve a higher speed. The
motor’s output power increases as a direct proportion of increased frequency: at 300 Hz,

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performanceis sixtimes better because the frequency is six times greater than at 50 Hz.
The frequency converters required for this, that bring the power up to the higher
frequency, areconnected to the national three-phasegrid.
The high frequency grinder has a frequency converter which gives high frequency supply to
the grinder this supply is taken by the grinder and the motor inside the grinder rotates with
higher speed due to the high frequency of the voltage,the motor is directly connected to
the spindleand the constantspeed is got from the spindlehead which helps in the earlier
removalrate of the die.
This grinder is very usefulin the die shop but is not used regularly due to the high
maintenance cost of the grinding machine.
FEINHIGH FREQUENCYDIEGRINDER
Machine specification –
Frequency (Hz) - 300
Voltage/type of current V(3~) - 200
Power consumption (Watts) - 410
Power output (Watts) - 290
No-load speed (rpm) - 18,000
Cable ft (m) - 16
Weight according to EPTA in lbs (kg) - 4.6 (2.1)
Tool holder Collet dia.in (mm) - ¼ (6.35)
Grinding wheel max. dia.in (mm) - 2 (50)

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 GRINDING TOOLSAND BURRS - Various types of grinding tools are used in the
benching area the tolls are classified into 3 types –
- Mounted point wheels
- Carbide burrs
- Polishing papers.
Mounted point wheels – These are the grinding wheels which are available in different
shapes and forms and can grind the surfaceaccording to the shape of the die.They are
made up of abrasiveparticles of Aluminium oxide and the boding material used is the
vitrified bonding. This type of grinding wheels havecrystallike structureand the ones used
in our benching area are pink in colour. The shaftbeneath the grinding wheel is exactly the
fitting sizeinside the collet of the grinding machine. The grinding abrasiveparticles used are
pink in colour. Various shapes and sizes available and used in the benching area are –
- A1
- A3M
- A3
- W-188
- A24
- A25(Ballwheel)
- A36(Umbrella Big)
- A37(Umbrella small)

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CARBIDEBURRS – After welding the welded area is deposited with surplus amountof metal
material thereforethe extra material is to be removed.This extra metal material is removed
using carbide burrs, they are nothing but single side flute cutting tools which are made up
of carbide and Very strong in nature. They are available in various shapes and sizes –
- Cylindrical burrs
- Ball burrs
- Oval/egg burrs
- Tree carbide burrs
- Taper carbide burrs.
Material removalis easier in this tool than the grinding wheel, as the material is removed
faster.
POLISHING PAPER –Polishing paper is used for giving super finishing to the die’s surface
they are wound to the spindle of the grinding machine or they are folded and fixed onto the
screw wheel ,these polishing papers are then used to give finishing to the surface.Different
grades of polishing papers are used on the die’s in the benching area –
- 60 grade(rough finishing)
- 120 grade(finefinishing)
- 320 grade(very finefinishing)

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POLISHING PAPEROF 320 GRADE
 5S – Then we learnt about what is 5S and why it is used, how it is used and
whereit is used -
5s is the name of a workplaceorganization method that uses a list of five
Japanese words: seiri, seiton, seiso, seiketsu, and shitsuke. Transliterated or
translated into English, they all start with the letter "S".
The list describes how to organizea work spacefor efficiency and
effectiveness by identifying and storing the items used, maintaining the area
and items, and sustaining the new order. The decision-making process usually
comes from a dialogue about standardization, which builds understanding
among employees of how they should do the work.
Itis a practice that can be used anywhereand at any time.
The meaning of the 5s and the functions of the 5s aregiven below -

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1. Seiri - Sort
 Remove unnecessary items and disposeof them properly
 Make work easier by eliminating obstacles
 Reduce chance of being disturbed with unnecessary items
 Preventaccumulation of unnecessary items
 Evaluate necessary items with regard to debt/cost/other factors.

2. Seiton - Straighten or Set in order
 Arrangeall necessary items in order so they can be easily picked for use
 Preventloss and waste of time
 Make it easy to find and pick up necessary items
 Ensurefirst-come-first-servebasis
 Make workflow smooth and easy
 Can also be translated as "set in order"
3. Seiso - Shine or Clean
 Clean your workplacecompletely
 Use cleaning as inspection
 Preventmachinery and equipment deterioration
 Keep workplacesafeand easy to work
 Can also be translated as "sweep"
4. Seiketsu - Standardize
 Maintain high standards of housekeeping and workplaceorganization at all times
 Maintain cleanliness and orderliness
 Maintain everything in order and according to its standard
5. Shitsuke - Sustain
 To keep in working order
 Also translates as "do without being told"
 To keep the cycle of 5s going

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 POINTS OF IMPROVISATION – After the initial studying of all the aspects of the
Benching area,I was assigned to find the points for improvisation in the Benching
area,The points which I thoughtwere the mostimportant for improvising the
benching are listed below –
1. FEINGRINDERMACHINE – The FEINgrinder which is used in the benching
area is a very usefulequipment and can increase the productivity of the
die shop by grinding the die’s surfacemuch faster than the already used
pneumatic grinder.
Some of the points of FEINwhich makes it a suitable user of grinding in
the Benching Area –
- All types of tools including the large diameter wheels can be used
in FEINgrinder.
- RPM is constantfor a given power and does not vary like the
present pneumatic grinder.
- Itis a heavy duty grinder and can grind all types of die’s.
- Working rate is faster than the present pneumatic grinder.
- And it does not give any maintenance issuetill 5 years.
These points makethe FEINgrinder a perfect point for improvisation in the
benching area.
2. DOUBLECUT BURRS – The carbideburrs presently used in the benching
area is single cut or has single sided flutes.They havegood removalrate
but the surfacefinish got by them is not that good.Hence instead of the
single cut carbide burr we can usedouble cut carbide burr.Dueto the
double sided flute the material removalrate increases as well as the
surfacefinish of the die is increased. The double cut burr comes with the
same shank diameter and with the same specifications as that of the single
cut carbide burrs, butas the removalrate of the double cut carbide burr is
much higher than the single cut hence the time of work is reduced. One of
the disadvantages is that we have to keep cleaning the burrs flutes to
remove the dust as it may reduce the removalrate.

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DOUBLE CUT BURR SINGLECUT BURR
3. UNDERGROUND PIPELINES–In the Benching Area the backsideof the
workers near the wall there are a lot of stray and useful pipes which are
left there and workers haveto use that path for their movement,hence
these pipes make a hinderance in their path of movement and also there is
a serious risk of accident as the workers they can get caught in the pipes
by their foot and they can injured seriously, hencethe pipes in the
backsidecan be made underground such that the pipes are not visible on
the outsideand the pipes areconnected till the work table of the die’s.All
the pipes can be made to go through one hole and then after they can be
branched to all the work tables.
4. ROTARY TABLE – In the benching area the tables on which the workers
work on are round in shapehence,The workers keep the workpieceon this
workatbleand they work along the sides of the table. Every time the
worker has to move along the table to reach the other parts of the die or
any corners of the die’s. Hence they get fatigued early, we can reduce their
fatigue by making the table rotary, with this enhancement the table can
rotate and the worker can rotate the table according to the area of
requirement of the grinding. Table can be made rotary by using Ball
bearings at the bottom of the table and applying some lubricant between
the table base and the table top.

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5. STORAGEOF USED GRIDING WHEELS –In the benching department the
grinding wheels are used extensively and hence there are lots of new and
old grinding wheels present in the area.The new grinding wheels are
opened and used time to time but the old grinding wheels are not
disposed properly hence they create a lot of untidiness in the benching
area, the used grinding wheels are lying around everywherein the
shop.Hencethe proper disposalof grinding wheels is to be done.For
systematic disposal2 boxes should be made they should be present at
every barricade–
 BLUE BOX – This box is used to keep the new grinding wheels and the
grinding wheels which are half used.This box will contain the useful
grinding machines.
 RED BOX – This box is used to keep the used and exhausted grinding
wheels.thesebox can be emptied with a repetitive frequency.
6. FRL(FILTERREGULATORAND LUBRICATOR) – In the benching department
the pressurized air is given by the motor present on the outside of the
shop. The air in the pipe comes from the compressor this air needs to be
lubricated such that the parts inside the grinding machine is not damaged.
The air also need to be de-moisturized, hence this work is done by the FRL.
But unfortunately there are very less no. of FRL present in the die shop.
There are 2 or 3 FRLs used in the die shop, if the proper amountof de-
moisturizing is not done then there is a chance of damaging of the grinding
machine.
Hence the FRLs should be applied on each of the pipeline or the FRL should
be placed centrally wherethe air inlet is present. Hence the no. of FRLs
should be increased in the Die shop.

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CONCLUSION
The summer internship at Bharat forgewas very helpful to me and it helped me learn
many things through the process, I am very thankful to the people who have helped
me gain the knowledgeat the utmost level. It was a very wonderfulexperience for
me and I would never forget it. The company is very diversified and all the
departments are well organised and I am very much satisfied with the term of 1
month over here in BHARAT FORGE LTD. PUNE.
Here are some of the points of experience which I have gained –
 Working of a big organisation like Bharat forgeltd.
 Systematic workflow and process involved in the forging processes.
 Study about the production planning
 Machining of the Die’s using CNC and HSMmachines
 Working of CNC and HSM machines.
 Grinding process involved in the finishing of the die
 Inspection process of the die’s and the products.
And there are many more topics. I am very grateful for the Training centre of the BFL
to help me gain the Knowledgein a proper manner.