This document provides an overview of the 15-day industrial training completed by the author at Amtek Auto Ltd. in Bhopal, Madhya Pradesh, India. It begins with an acknowledgement of those who supported the training. It then provides a preface on the importance of practical knowledge. The content sections describe the various processes involved in raw material handling, tool and die making, quality testing, billet production, forging, heat treatment, quality checks, and dispatch at the Amtek facility.

1. 1
AN INDUSTRIAL TRAINING REPORT
Done by
Shubham Chakraborty
Enrollment no: 12345678
At
Amtek Auto Ltd.
Mandideep Industrial Area,
Bhopal, Madhya Pradesh.
Submitted to
Department of Mechanical Engineering
July 2015

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ACKNOWLEDGEMENT
An engineer with only theoretical knowledge is not a complete engineer.
Practical knowledge is very important to develop and apply engineering skills. It gives me great
pleasure to have an opportunity to acknowledge and to express gratitude to those who were
associated with me during my training at Amtek Auto Ltd., Mandideep.
Special thanks to Mr. Ramesh Thakur for providing me with an opportunity to undergo training
under his able guidance and offering me a very deep knowledge of practical aspects of industrial
work culture.
I express my sincere thanks and gratitude to Amtek Auto Ltd. authorities for allowing me to
undergo the training in this prestigious organization. I will always remain indebted to them for
their constant interest and excellent guidance in my training work, moreover for providing me
with an opportunity to work and gain experience

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PREFACE
Practical knowledge means the visualization of the knowledge, which we read in our books. For
this, we perform experiments and get observations. Practical knowledge is very important in
every field. One must be familiar with the problems related to that field so that he may solve
them and become a successful person.
After achieving education, an engineer has to enter professional life. Accordingly, he has to
serve an industry, may be public or private sector or self-own. For the efficient work in the field,
he must be well aware of the practical knowledge as well as theoretical knowledge.
To be a good engineer, one must be aware of the industrial environment and must know about
management, working in such an industry, labor problems etc., so that he can tackle them
successfully.
Due to all the above reasons and to bridge the gap between theory and practical, our engineering
curriculum provides a practical training. During this period, a student works in the industry and
gets all type of experience and knowledge about the working and maintenance of various types
of machinery.
I have undergone my 15 days training at AMTEK AUTO LIMITED. This report is based on
the knowledge, which I acquired during my training period at the plant.

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CONTENTS
1. INTRODUCTION
2. AMTEK AUTO LTD. - An Overview
3. WORK FLOW DIAGRAM
4. RAW MATERIAL GRADING
5. TOOLAND DIE SHOP
6. METALLURGICAL LAB
7. BILLET YARD
 Processes involved in Billet Yard
 Process Flow Chart in Billet Yard
8. FORGESHOP
 Processes involved in Forge Shop
 Process Flow Chart in Forge Shop
9. HEAT TREATMENT
 Heat Treatment Techniques
 Heat Treatment Processes
 Heat Treatment Process Flowchart
10. END CONTROL
 End ControlChecks
11. DISPATCH
12. CONCLUSION
INTRODUCTION

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Amtek Group was established with the incorporation of the flagship company, Amtek Auto in
1985. Since then, it has grown rapidly and emerged as a frontrunner in the global automotive
component industry with a worldwide presence across North America, Europe, and Asia.
Amtek's manufacturing capabilities include Iron and Aluminum Castings, Forgings, Complex
Machining & Ring Gears Flywheel Assembly.
Amtek Auto manufactures components such as connecting rod assemblies, flywheel ring gears
and assembly, steering knuckles, suspension and steering arms, CV joints, crankshaft assemblies
and torque links. It is backed by in–house design and development facilities engaged in
developing new product and processes.
Amtek Group is a leading international manufacturer of automotive components and assemblies
with production facilities located strategically across North America, Europe & Asia. The
Group's extensive manufacturing capabilities encompass Sub assemblies, Iron, Gravity &
Aluminium Castings, Forgings, Complex Machining & Ring Gears Flywheel Assembly.
AMTEK AUTO LTD. - An Overview
The Amtek Group, headquartered in India, is one of the largest integrated component
manufacturers in India with a strong global presence. It has also become one of the world’s
largest global forging and integrated machining companies. The Group has operations across
Forging, Iron and Aluminium Casting, Machining and Sub-Assemblies. It has world-class
facilities across India, UK, Germany, Brazil, Italy, Mexico, Hungary and US. The Amtek Group
is comprised of corporate entities Amtek Auto, JMT Auto, Amtek Global Technologies and
other subsidiaries and associates. With the infrastructure and technology platform developed
over 25 years, the Group is well positioned in the Indian Auto and Non-Auto component
markets.
Different divisions of the company are:
 Amtek Centre of Excellence (ACE)
 Amtek Forging Division (AFD)
 Amtek Iron Casting Division (AICD)
 Amtek Aluminum Casting Division (AACD)
 Amtek Automotive Machining Division (AAMD)
 Amtek Ring Gear Division(ARGD)
 Amtek JVS
Product range of the company includes:

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Amtek product portfolio consists of an extensive range of components for 2–3 wheelers, Cars,
Tractors, LCV, HCV and Stationary engines. The major categories of components manufactured
are,
 Connecting Rod Assemblies
 Flywheel Ring Gears and Assembly
 Steering Knuckles
 Suspension and Steering Arms
 CV joints
 Crankshaft Assemblies
 Torque Links.
Clientele:
 Ashok Leyland Limited
 Aston Martin
 Bajaj Auto Limited
 BMW
 Briggs & Stratton
 CNH Global
 CNH New Holland
 Cummins
 CYT
 Dana Italia
 Davis Industries
 Defence
 Delco Machining
 Eicher Motors Limited
 Escorts
 Fairfield
 Fiat India
 Ford
 General Motors
 GE Transportation
 GWK Ltd
 Hero Honda

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WORK FLOW DIAGRAM

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RAW MATERIAL GRADING
Raw Material Grading
S. No Steel Grade Color Code Color
1 348C Dia 50/56/60 mm
White (Sunflag)
Yellow (Adhunik)
2 20 MnCr5H Dia 50/52 mm Light Blue
3 16 MnCr5 Dark Blue
4 SAE 1141 Dia 40/45/48 mm Purple
5 MSAE 1541 (B) Dia 60 mm
Brown
6
SCM 420H Dia 58/70 mm Green
SCM 420H Dia 25/28/36 mm
White base black cross
7 SAE 8260H Dia 56 mm Silver
8 C35 Dia 50 mm Pink
9 EN8D Dia 63/70 mm Black
10 EN8DM Dia 65 mm
Gray

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TOOL AND DIE SHOP
In the Tool and Die shop, the Die on which the forged material is shaped is made.
Here, the raw material comes in the form of metallic cylinders which are then machined
into the form of hollow cavities.
These hollow cavities are then used for forging the billets.
Usually a pair of Dies has a lifespan of 10000 cycles but it varies from type of forge
material.
The Dies are made with highly sophisticated CNC (Computerised numerical control)
lathe and VMC (Vertical milling control) machines.
CNC machine can work in vertical direction i.e. (x-z plane).
VMC machine can work in vertical, horizontal directions i.e. (x-y-z plane).
M codes and G codes are used for the smooth and automatic working of these machines.
Traditional Milling, Drilling and Lathe machines are also utilised for machining the dies
for rough machining works.
There are a series of internal checks n the Tool and Die shop which requires expertise.
These dies are made with high surface finish and dimensional accuracy.

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METALLURGICAL LAB
In this department a large number of tests are done to test the job and the dies obtained at various
stages of the manufacturing process.
 Metallurgical microscope
Metallurgical microscope is the optical microscope, differing from other microscopes in
the method of the specimen illumination. Since metals are opaque substances they must
be illuminated by frontal lighting, therefore the source of light is located within the
microscope tube. This is achieved by plain glass reflector, installed in the tube. The
optical scheme of metallurgical microscope is shown in the picture.
The image quality and its resolving power are mainly determined by the quality of the
objective. The objective magnification depends on its focal length (the shorter focal
length, the higher magnification). The eyepiece is the lens nearest the eye. The image is
magnified by eyepiece in x6, x8 or x10.
The total magnification of the microscope may be calculated by the formula:
M = L*E/ F
Where
L- Distance from back of objective to eyepiece;
F - Focal length of the objective;

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E- Magnifying power of the eyepiece.
The common magnification of metallurgical microscope is in the range x50 – x1000.
 Brinell Hardness test
The Brinell method applies a predetermined test load (F) to a carbide ball of fixed diameter
(D) which is held for a predetermined time period and then removed. The resulting
impression is measured across at least two diameters – usually at right angles to each other
and these result averaged (d). A chart is then used to convert the averaged diameter
measurement to a Brinell hardness number. Test forces range from 500 to 3000 kgf.
Test Method Illustration
D = Ball diameter
d = impression diameter
F = load
HB = Brinell result
 Rockwell hardness test
The Rockwell method measures the permanent depth of indentation produced by a force/load
on an indenter. First, a preliminary test force (commonly referred to as preload or minor
load) is applied to a sample using a diamond indenter. This load represents the zero or
reference position that breaks through the surface to reduce the effects of surface finish. After
the preload, an additional load, call the major load, is applied to reach the total required test
load. This force is held for a predetermined amount of time (dwell time) to allow for elastic
recovery. This major load is then released and the final position is measured against the
position derived from the preload, the indentation depth variance between the preload value
and major load value. This distance is converted to a hardness number.
 Eddy current test
In this check the cracks present inside the material of the face of job is checked. A current is
passed and detected. If the sensors detect any slight irregularity in composition or cracks then
the job is rejected.

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 Jominy apparatus
This apparatus is used for determining the Harden-ability of steel by an experiment called
Quench Test. This provides information about the Harden-ability characteristics of different
alloying element.
 Muffle furnace test
A muffle furnace is a furnace with an externally heated chamber, the walls of which radiantly
heat the contents of the chamber, so that the material being heated has no contact with the
flame. Muffle furnaces are most often utilized in laboratories as a compact means of creating
extremely high-temperature atmospheres. They are employed to test the characteristics of
materials at extremely high and accurate temperatures. A muffle furnace is also known as a
retort furnace.

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BILLET YARD
Processes involved in billet yard
Raw material is supplied in the form of rods of diameters according to demand.
Heat code and color coding is done.
EOT Cranes are used for handling of these pipes due to their weight and size.
The rods are then loaded to the billet shearing machine (MANYO LBS450).
The combination of hydraulic, conveyer and electronic sensors provide a steady rate of
input to the shearing machine which is termed as Loader mechanism.
The rod is held by die. Die is held by Die clamp and packing.
The machine applies a 450 kg/mm2 pressure on the rod with help of blade.
The part of rod that is obtained is termed as Billet. It of cylindrical shape.
The billet yard also contains an End pieces area where the diameter and length of billet is
reduced with the help of lathe machine and lathe cutting machine.
Process Flow Chart in Billet Yard

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FORGE SHOP
In forge shop of Amtek Auto Ltd., Mandideep, Forging is done to transform raw cut billets into
required shape according to the die used.
 In the Forge Shop of Amtek Auto Ltd., for the forging operation, there are 6 Crank press
forging machines and 3 screw press forging machines.
 Hot, press forging is done on the billets to shape them as requirement.
 The crank presses (HANOUL HNFG-1350) apply 1000 ton force on the red hot billet.
 The crank press runs on the principle of clutch-plate brake mechanism.
 Power is developed in the press due pressurized air.
 To provide pressurize air to the presses a number compressors are employed.
 There are 3 screw presses (Vaccari) which apply a pressure of 730 tonnes.
 They work on the principle of power screw mechanism.
Processes involved in forge shop
Billet loading
In this process, the raw cut billets are transferred from billet shop in gaskets to be loaded in the
induction heater. The loading mechanism consists of conveyer mechanism and electronic sensors
for better control and automatic functioning.
Induction Heating
In this process, the billets are passed into an industrial induction heater which heats the billet at
above 1100 C usually 1200 C, which recrystallizes the metal for easy forging to commence. The
induction heater uses magnetic flux to heat the metal between the coils.
Forging
In this process, the upper die is clamped to the hammer and the lower die remains stationary. The
red-hot billet is vertically positioned and hammer blow forces it to acquire the shape of the dies.
Extra metal is forced out from the exposed face.
Trimming
Trimming is a process in which the extra metal projecting out of the curved surface of the sides
termed as ‘flash’ is removed with the help of a trimming press. It is similar to forging machine,
but much less force s applied on the top face. In this the required material is forced vertically
downward and the flash remains clamped on the vices.

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Flash removal
In this, the ‘flash’ is obtained and transported to the scrap yard with the help of gaskets.
Process Flow Chart in Forge Shop

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HEAT TREATMENT
Heat treating is a group of industrial and metalworking processes used to alter the physical,
properties of a material.
Heat treatment involves the use of heating or chilling, normally to extreme temperatures, to
achieve a desired result such as hardening or softening of a material. Heat treatment techniques
include annealing, case hardening, precipitation strengthening, tempering and quenching.
Metallic materials consist of a microstructure of small crystals called "grains" or crystallites. The
nature of the grains (i.e. grain size and composition) is one of the most effective factors that can
determine the overall mechanical behaviour of the metal. Heat treatment provides an efficient
way to manipulate the properties of the metal by controlling the rate of diffusion and the rate of
cooling within the microstructure. Heat treating is often used to alter the mechanical properties
of a metallic alloy, manipulating properties such as the hardness, strength, toughness, ductility,
and elasticity.
Heat Treatment Techniques
Annealing
Annealing consists of heating a metal to a specific temperature and then cooling at a rate that
will produce a refined microstructure. The rate of cooling is generally slow.
In ferrous alloys, annealing is usually accomplished by heating the metal beyond the upper
critical temperature and then cooling very slowly, resulting in the formation of pearlite. In both
pure metals and many alloys that cannot be heat treated, annealing is used to remove the
hardness caused by cold working. The metal is heated to a temperature
where recrystallisation can occur, thereby repairing the defects caused by plastic deformation.
Ferrous alloys are usually either "full annealed" or "process annealed." Full annealing requires
very slow cooling rates, in order to form coarse pearlite. In process annealing, the cooling rate
may be faster; up to, and including normalizing. The main goal of process annealing is to
produce a uniform microstructure.
Normalizing
Normalizing is a technique used to provide uniformity in grain size and composition throughout
an alloy. The term is often used for ferrous alloys that have been austenitized and then cooled in
open air. Normalizing not only produces pearlite, but also sometimes martensite, which gives
harder and stronger steel, but with less ductility for the same composition than full annealing.
Aging

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Some metals are classified as precipitation hardening metals. When a precipitation hardening
alloy is quenched, its alloying elements will be trapped in solution, resulting in a soft metal.
Aging a "solutionized" metal will allow the alloying elements to diffuse through the
microstructure and form intermetallic particles. These intermetallic particles will nucleate and
fall out of solution and act as a reinforcing phase, thereby increasing the strength of the alloy.
Alloys may age "naturally" meaning that the precipitates form at room temperature, or they may
age "artificially" when precipitates only form at elevated temperatures.
Quenching
Quenching is a process of cooling a metal at a rapid rate. This is most often done to produce a
martensite transformation. In ferrous alloys, this will often produce a harder metal, while non-
ferrous alloys will usually become softer than normal.
To harden by quenching, a metal (usually steel or cast iron) must be heated above the upper
critical temperature and then quickly cooled. Cooling is done with Liquids, due to their
better thermal conductivity, such as oil. Upon being rapidly cooled, a portion of austenite
(dependent on alloy composition) will transform to martensite, a hard, brittle crystalline
structure.
Tempering
Untempered martensitic steel, while very hard, is too brittle to be useful for most applications. A
method for alleviating this problem is called tempering.
. Tempering consists of heating steel below the lower critical temperature, (often from 400 to
1105 ˚F or 205 to 595 ˚C, depending on the desired results), to impart some toughness.
Flame hardening
Flame hardening is used to harden only a portion of a metal. Unlike differential hardening, where
the entire piece is heated and then cooled at different rates, in flame hardening, only a portion of
the metal is heated before quenching.
Case hardening
Case hardening is a thermochemical diffusion process in which an alloying element, most
commonly carbon or nitrogen, diffuses into the surface of a monolithic metal. The resulting
interstitial solid solution is harder than the base material, which improves wear resistance
without sacrificing toughness.

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Heat treatment processes
 Heat treatment of the forged material obtained from forge shop is done in a furnace.
 The temperature of furnace ranges from 880 C to 1100 C according to the requirement.
 The Burner fuels used in the furnace maybe Diesel, LDO or Gas.
 Usually the temperature required for hardening process is 870 to 900 C.
 Temperature required for tempering process is 580 C.
 The forged jobs are loaded in a gasket and put inside the furnace with the help of pulley
mechanism.
 The doors are the shut using a combination of sliding mechanism and electronic sensors
to provide a sealed environment for heat treatment.
 The gasket is obtained from the other end of the furnace.
 At any point of time there are 6-8 gaskets within the furnace.
 These gaskets are slowly moving towards the other end of the furnace due to rolling
mechanism in the furnace.
 The time required for the total process for one gasket is 10 minutes.
 After this, oil quenching is done.
 The obtained treated job is handled with the help of stretcher and is either sent for further
heat treatment or to End Control for final inspection.
 The oil becomes hot after the heated metal is immersed in it.
 To prevent overheating of oil, a Plate Type Heat Exchanger (PHE) is employed which
circulates cold oil in the quenching bucket.
 The PHE is itself cooled with the help of Natural circulation wet type cooling towers.

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Heat treatment Process Flowchart

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END CONTROL
End Control is the department in which the final quality checks and finishing of the product is
done.
In End Control, there are various processes.
 Shot Blasting
 Cold Coining or Knuckle press
 Visual Check
 Total Parameter Check
 Eddy Current Check
 Ultrasonic Check
 Magnetic Crack Detection
End Control Checks
Shot Blasting
In shot blasting, steel shots are passed in a shot blasting machine through small holes in a
rotating, hollow, rubber-lined surface. The heat treated material has a rough surface due to
accumulation of oxide layer.
To remove this oxide layer, the metals are loaded in the shot blasting machine and the abrasive
action of the spherical steel shots remove the oxide layer. The oxide layer is the sucked in
through an ash handling pump and is disposed off as dust.
Cold Coining
It is a process through which the flatness and Total Indicated Runout of the job is altered by
applying a hammer blow to the face of the crankshaft. The machine used in this process is called
knuckle press.
Total parameter check
In this the dimensions of the material are checked and compared with the standard values. It also
checks the phenomenon of under-height of job and improper trimming.

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Visual check
Visual check encompasses a large number of checks for various defects like Pitting, Stem
underfilling, Boss underfilling, Shoulder underfilling, Die marks, Corner underfilling, Top
Flange underfilling, Rib underfilling, Dent Fitting etc.
Eddy current check
In this check the cracks present inside the material of the face of job is checked. A current is
passed and detected. If the sensors detect any slight irregularity in composition or cracks then the
job is rejected.
Ultrasonic Check
In this check the vertical internal cracks present in the stem of job is checked. An X-ray is passed
through a probe positioned at the bottom face of the stem and penetrating x-rays detect the
number of cracks. If the sensors detect any slight irregularity in composition or cracks then the
job is rejected.
Magnetic Crack Detection
In this the microscopic cracks present on the surface of the job is determined and checked and if
the job is found faulty then it is rejected. For this a magnetic flux is passed and sensors detect the
overall flux produced.

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DISPATCH
After all the checks are performed in the End Control, the finished product is oiled and loaded
into gaskets for transporting to the customers.
Oiling is done on the product to prevent corrosion to the metal surface.
Schematic Diagram of Sample crankshaft’s face:
Manufacturer
CompanyCode
CustomerCompany
Code
Die number Month code
Heat Code
Boss
CornerTop

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CONCLUSION
As an undergraduate I would like to say that this training program is an excellent opportunity for
us to get to the ground level and experience the things that we would have never gained through
going straight into a job.
The main objective of the industrial training is to provide an opportunity to undergraduates to
identify, observe and practice how engineering is applicable in the real industry. It is not only to
get experience on technical practices but also to observe management practices and to interact
with fellow workers. It is easy to work with sophisticated machines, but not with people. The
only chance that an undergraduate has to have this experience is the industrial training period. I
feel I got the maximum out of that experience. Also I learnt the way of work in an organization,
the importance of being punctual, the importance of maximum commitment, and the importance
of team spirit. In my opinion, I have gained lots of knowledge and experience needed to be
successful in a great engineering challenge, as in my opinion, Engineering is after all a
Challenge, and not a Job.