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
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
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
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
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
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
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
