SUMMER INTERNSHIP REPORT 2016 (MECHANICAL ENGINEERING)

RAY-HANS PRECISION TOOLS
PRIVATE LIMITED
SUMMER INTERNSHIP
REPORT
(20/06/2016 - 05/07/2016)
MAR ATHANASIUS COLLEGE OF ENGINEERING
KOTHAMANGALAM 686 666, KERALA
Ph. 0485-2822363
SUBMITTED BY:
AMAL BABU
B13ME410
DEPARTMENT OF MECHANICAL ENGINEERING
MAR ATHANASIUS COLLEGE OF ENGINEERING,
KOTHAMANGALAM

DEPARTMENT OF MECHANICAL ENGINEERING, MACE KLM
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Disclosure by the Internship Supervisor
This is to confirm that I have read the report and that the information enclosed is correct and contains
no confidential information.
Company:
Supervisor’s Name:
Supervisor’s Signature:
Date:

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Acknowledgement
I am very thankful to NEST GROUP for giving me the opportunity to undertake my summer
training at their prestigious RAY-HANS PRECISION TOOLS PRIVATE LIMITED. It was a very
good learning experience for me to have worked at this site.
I would like to convey my heartiest thanks to Mr. Arun Kumar M C, General Manager, I would
also like to give my heart-felt thanks to Mr. Naushad M, HR Manager, who heartily welcomed
me for the internship, Mr. Joby Devasia who guided and encouraged me all through the
summer training and imparted in-depth knowledge of the programme, Mr. Sajith Mohan,
QA/QC Head . Also I would like to thank Mr. Kuriakose E.J, who assisted and guided me
whenever I needed. I would like to thank all the department heads of RAY-HANS, for giving
their precious time and valuable guidance during my internship programme.
I am extremely thankful to Dr. Deviprasad Varma P R, Head of department, Mechanical
Engineering, Mar Athanasius College of Engineering, Kothamanagalam for providing me
facilities to work in, without which this work would not have been possible.
Last but not the least; I would like to thank all the staff of RAY-HANS family, for being so
helpful during this summer training.

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Preface
Every student of Bachelor of Technology in Mechanical Engineering, has an essential
requirement to do 15 days of internship in any of the well reputed organization. The purpose
of this program is to acquaint the students with practical applications of theoretical concepts
taught to them during conduct of their course.
Really, it was a nice opportunity to have a close comparison of theoretical concept in practical
field. This report may depict deficiencies on my part but still it is an output of a student’s efforts,
for which I beg pardon.
The output of my analysis is summarized in a shape of Internship the contents of the report
Shows the detail of sequence of these.

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Abstract
The report covers the following aspects of internship:
 Table of contents.
 Introduction of Ray-Hans Precision Tools Private Limited.
 Departments of Ray-Hans.
 Description of tools and techniques learned.
 Schedule of internship.
 Skills learned.
 My role as an internee.
 Conclusion.

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Table of Contents
Acknowledgement......................................................................................Error! Bookmark not defined.
Preface..........................................................................................................................................................3
Abstract.........................................................................................................................................................4
Ray-Hans Precision Tools Private Limited ........................................................................................6
Departments In Ray-Hans Precision Tools Private Limited .........................................................7
Marketing Department..............................................................................................................................8
Store..............................................................................................................................................................8
Heat Treatment Shop...............................................................................................................................8
Design Section ...........................................................................................................................................9
o Drafting........................................................................................................................................... 10
o Sketching....................................................................................................................................... 10
o Computer Aided Design (CAD)............................................................................................... 11
Quality Assurance section ................................................................................................................... 11
Machine Tool Shop................................................................................................................................ 12
o Surface Grinding.......................................................................................................................... 12
o Jig Grinding & Profile Grinding................................................................................................ 12
o Wire EDM ...................................................................................................................................... 13
o Why EDM?.................................................................................................................................... 13
o CNC Milling ................................................................................................................................... 13
o Sink EDM....................................................................................................................................... 14
Tool Assembly......................................................................................................................................... 14
Plastic Moulding Department.............................................................................................................. 14
Internship Rotational Plan.................................................................................................................... 15
Skills and Techniques learned during Internship.......................................................................... 15
Role Of Internee During Internship ................................................................................................... 16
Conclusion................................................................................................................................................ 17
References ............................................................................................................................................... 17

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Introduction
Ray-Hans Precision Tools Private Limited
Ray-hans Precision Tools Private Limited is a tooling solution provider located in Special
Economic Zone at Cochin, India, having around 250 employees. Make use world class
equipments and machineries imported from leading manufactures in Germany, Japan, Swiss
and USA. Ray-hans provides end to end solutions for tool and mould industry starting from
design to component production. And capable of supplying precision tooling of International
standards to Electronics, Automotive, Electrical and IT sectors. Customer base includes TE
connectivity, DELPHI Connection Systems, NPOL and Yazaki.
Specialized in:
 Designing of Injection Moulds.
 Manufacturing of Injection Moulds, Press tools and Fixtures
 Manufacturing of Precision Machined Spares
 Production of Molded Components
Capabilities and Capacities:
Methods, Machineries and Accessories used for various machining process allows to produce
complex profiles and shapes required for precision tooling industry at an accuracy level of 2 to
5 microns. In order to achieve quality standards the whole machining activities are carried out
in a controlled atmosphere, so that temperature difference doesn’t cause any deviations in the
jobs when measured at customer end.

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Products and Services
 Mould design
o Multi-cavity molds
o Hot Runner Molds
 Manufacturing of Moulds & Dies & Fixtures.
 Supply of Precision Machined Parts.
 Production of Molded Components.
Departments In Ray-Hans Precision Tools Private Limited
 Marketing Department.
 Store.
 Training Department.
 Designing Department
 Engineering Department.
 Machine Tool Shop.
 N.C. Shop.
 Heat Treatment Shop.
 Quality Control.
 Tool Assembly.

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Marketing Department
Marketing departments fulfill the marketing needs and work to ensure the progress.
o Market research.
o Product development.
o sales support.
Store
Major functions:
o Receipt of incoming goods
o Inspection of all receipts
o Storage and preservation
o Identification of all materials stored
o Materials handling
o Packaging
o Issue and despatch
o Maintenance of stock records
o Stores accounting
o Inventory control
o Stock-taking
Heat Treatment Shop
Best in class machines and furnaces are provided in this section. Equipped with 4 atmospheric
furnaces, which enables hardening, stress-relieving, tempering and annealing on various tool
steel. And also learned about sub-zero treatment.

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Five sections were designed for our internship.
These were first introduced to all of us. To tell us what they are doing and what will be our role
in that internship during this period. We were pleased to get responsibilities and to hand on
experience as it was the aim and purpose behind the programme.
In these sessions we watch closely how the professionals are working to make that center
unique and adorable for outer world, it was an example for us to learn to be a better
professional.
Design Section
Our internship started as we enter into design section as the design is considered as the first
step of any production and it display the end result before wasting material and it’s the best
tool to communicate with your shop men, technician and others, so it compulsory to have basic
knowledge of design for everyone.
In design section you deal with the language of lines how they represent the end results of
your dedicated work. We were first diverted to drafting then to proper design process
The design section is based on three steps
 Sketching
 Manual
 Computer aided Design (CAD)
Design section.
Quality Assurance section.
Machine Tool shop.
Tool Assembly section.
Plastic Moulding Department.

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So we attended a Lecture on sketching on the very first day and started moving. The Trainer
Mr. Joby Devasia introduced us with common sketching techniques and methods.
Sketching is an entering step to design to draw the design on paper is an expert work so we
were drawn into that.
Drafting
Technical drawing also known as drafting ,It is the act and discipline of composing drawings
that visually communicate how something functions or is to be constructed.
Technical drawing is essential for communicating ideas in industry and engineering. To make
the drawings easier to understand, people use familiar symbols, perspectives, units of
measurement, notation systems, visual styles, and page layout. Together, such conventions
constitute a visual language, and help to ensure that the drawing is unambiguous and
relatively easy to understand. These drafting conventions are condensed into internationally
accepted standards and specifications that transcend the barrier of language making technical
drawings a universal means of communicating complex mechanical concepts.
Sketching
A sketch is a quickly executed, freehand drawing that is not intended as a finished work. In
general, sketching is a quick way to record an idea for later use, especially when the finished
work is expensive and time consuming.
We were given a number of tasks to execute them into drawing and we did it for two days and
it was a brainstorming and learning session.

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Computer Aided Design (CAD)
Computer-aided design (CAD) is the use of computer systems to assist in the creation,
modification, analysis, or optimization of a design. CAD software is used to increase the
productivity of the designer, improve the quality of design, improve communications through
documentation, and to create a database for manufacturing. CAD output is often in the form of
electronic files for print, machining, or other manufacturing operations.
Ray-hans engineer’s subject knowledge along with systematic approach in performing each
task ensures best quality and shorter lead time. A team of Tool makers and process engineers
review each design to ensure Manufacturing easiness.
Design center uses Creo 2.0 (ProE) software for designing activities and supported by mold
flow analyzing software. Ray-hans expertise in hot and cold runner systems allows serving
customer seeking high as well as low volume productions. Hardened core and cavity plates
and inserts are used for moulds with higher volume components which ensure millions of shots
without major overhauling.
Duration of 7 days pass in no time but we learn a lot about mechanical designing as we were
given some tasks to complete, which really helped us to understand PTC CREO 2.0 clearly. As
an addition jigs and fixtures standards and their various design types were also elaborated.
We are thankful to all design team members for their attention and co-operation.
Quality Assurance section
Precision tool manufactures requires high end quality assurance which is a part and parcel of
the activity. We got exposed to a well defined Quality system, consisting of in process and final
inspection which ensure 100% inspection for the entire die & mould parts and also sampling
inspection for molded components to meet the customer requirements.

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In this section we got basic knowledge of Advanced measuring equipments like CMMs, Profile
projectors, Digital height gauges, tool maker’s microscope and surface texture measuring
machine.
Machine Tool Shop.
Creativity of designer and skill of tool engineer will not integrate unless supported by equally
competent manufacturing expertise and advanced machineries. Ray-hans facility Machine tool
shop is managed by senior managers and qualified and skilled workers they have all
machining and manufacturing machinery. As well a dye fitting section along with calibration
shop.
In machine tool shop section we observe different machining and noted how they are making
raw material valuable for industry. There was a job in process at that time.
Manufacturing facility comprises of:
 Surface Grinding
There were 20 Surface Grinding machines of German and Japanese origin out of which,
two are CNC Surface Grinding machines. We experienced Carbide Grinding, which is
inevitable for High speed stamping and feed grinding which produces unconventional blind
profiles in Surface Grinding.
 Jig Grinding & Profile Grinding
Jig Grinding and profile grinding facility is capable of producing spare parts for High-speed
stamping. Complex and accurate Carbide punches and dies are made using Profile
Grinding machine. Precise guiding parts for moulds and dies are finished in Jig Grinding
machine.

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 Wire EDM
Wire EDM machines imported from Swiss, uses wires of diameter ranging from 0.1 mm to
0.25 mm and EDM Drilling machines can do the drilling up to a diameter of 0.3 mm.
Various grades of Steels, copper and carbides were also machined in these machines.
These sophisticated machines process complex geometric shapes up to height of 150 mm.
Why EDM?
EDM can easily machine parts with very thin walls, complex geometry, narrow slots,
small corner radii, very small features, etc. with virtually no mechanical stress.
EDM can cut hardened steel, titanium, Inconel and other difficult materials without the
limitations of traditional machining.
EDM can achieve an excellent surface finish with no burrs right out of the machine.
EDM can reduce production costs with stacked parts machining using wire EDM as well
as multi-up fixturing for wire, sinker and hole pop EDM.
Use EDM over broaching for better precision, accuracy and finish, no need to make a
custom broach, and no risk of introducing unwanted debris into the finished part.
Use EDM instead of short-run stamping for straight-edge cuts with sharp corners and no
shear or break as well as reduced costs by eliminating the need for special tooling.
 CNC Milling
Equipped with 5 axis CNC machining centers, which are capable of producing complex
shapes in Tool steels, graphite and copper. We saw the working of dedicated machine for
graphite machining equipped with 42000 rpm spindle head.

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 Sink EDM
There were Swiss and Japanese made 10 CNC Sink EDM machines, which are capable of
making 5 to 10 microns dimensional accuracy and surface roughness value up to 0.2 Ra.
These Machines have Quick Change Robotic interface up to 92 positions to perform
continuous feeding of electrodes without manual interventions. For enhancing productivity
they are equipped with “System 3R” reference system.
Tool Assembly
As we enter into 2nd week we were sent to Tool assembly section. After the first day the very
next day we were involved in discussions to clear the concepts of Tool assembly, what the
process is and how it is done.
Tool assembly is an art which requires mechanical aptitude, experience and high hand skills. A
well assembled mould or die calls for very few trials and corrections. Workers handful
experience is in line to meet International manufacturing standards and practices.precision
machined parts are individually suited for perfect matching. The systematic approach in
assembling process ensures longer life for moulds and dimensional consistency in
components.
Plastic Moulding Department
We move toward PMD section after the completion of Tool assembly there were last 2 days for
the plastic molding section. That section was most modernized section of PITAC equipped with
two modern medium capacity injection moulding machinery.
These machines are specially designed for obtaining high dimensional accuracy and
consistency. They were equipped with interchangeable screw diameter with inbuilt Hot Runner
Controller system. To support precise moulding activity, make use ABONI FMX3-01 moisture
analyzer

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Internship Rotational Plan
o Design Section 1 WEEK 20/6/16-----26/6/16
o Quality Assurance section 1 DAY 27/6/16-----28/6/16
o Machine tool shop 2DAY 28/6/16-----30/6/16
o TOOL ASSEMBLY 2DAY 30/6/16-----02/7/16
o Plastic molding section 1DAY 04/7/16-----05/7/16
Skills and Techniques learned during Internship
An internship assists with career development by providing real work experiences that provide
students with opportunities to explore their interests and develop professional skills and
competencies. During internships, We are provided with opportunities to apply what We
learned in classes to actual practice. It is expected that we will also be challenged to examine
how our attitudes, beliefs, and values influence the process.
It was valuable time here in RAY-HANS PRECISION TOOLS PRIVATE LIMITED and we learn
unlimited here are a few point I have summarized.

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We learnt about the leadership & Team work to do an effective work.
We learnt about tactics to maintain discipline & How to deal with workers.
We learnt How to control quality problems, defects in material, Laboratory Testing of
Hardness of a material and How to meet the demands of customers.
We also learnt about Designing.
Further, important software like AutoCAD,Creo2.0 , Solid Works.
We have learnt how to make a powerful team to achieve target and to solve their
problem.
We have learnt about all machining process and heat treatment process.
We have learnt about CNC machining process in CNC cell
Learn how to face Problems in industrial sector.
We observe the heat treatment section more closely and that help us understand heat
treatment process .
Plastic moulding process was complete elaborated to us and we collected knowledge.
We observe modern machine like Spark erosion and CMM machines along with
advance machining center and small hole drilling machines.
Role of Internee during Internship
“I learned how to adjust myself in the work environment, how to deal with people at work - from
the boss to the janitors. It’s a good and quality experience; The necessary kind of experience
as it helps you realize what you want in future. “Also got the opportunity to evaluate myself
under these stressful conditions”.

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Conclusion
It was a wonderful learning experience at RAY-HANS PRECISION TOOLS PRIVATE LIMITED
for two weeks in kochi. I gained a lot of insight regarding almost every aspect of plant. I was
given exposure in almost all the departments at the plant. The friendly welcome from all the
employees is appreciating, sharing their experience and giving their peace of wisdom which
they have gained in long journey of work. I am very much thankful for the wonderful facility
from RAY-HANS. I hope this experience will surely help me in my future and also in shaping
my career.
I am pretty sure that this facility has ability to achieve its goals as stated in vision statement.by
following their quality statement.
“We are committed to comply with customer requirements and Quality Management System
Requirements and shall strive to continually improve the effectiveness of our Quality
Management System to exceed customer expectations”
References
 http://tools.ray-hans.com/about_us.html
 http://tools.ray-hans.com/Brochure.zip
 http://www.slideshare.net

SUMMER INTERNSHIP REPORT 2016 (MECHANICAL ENGINEERING)

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SUMMER INTERNSHIP REPORT 2016 (MECHANICAL ENGINEERING)