This document provides information about an internship project completed at Shriram Pistons and Rings Pvt. Ltd. The project aimed to reduce rejections in the composite plating of chrome (CPC) ring process. It includes details about the company profile, various ring manufacturing processes, and specific machines used at different stages like grinding, turning, honing, and profile machining. The document also describes the different types of piston rings and profiles produced at the plant.
The document provides details about an industrial training report completed by two interns at Hardrock Attachments Pvt. Ltd., a manufacturer of fabricated structures for construction machinery. The report describes the company's plant layout, manufacturing processes, machinery, quality systems, products, and maintenance procedures. It aims to provide a comprehensive overview of the heavy fabrication and machining industry for educational purposes.
This document provides a company profile for SPR, an Indian manufacturer of pistons, piston rings, and engine valves. It outlines SPR's history since 1972, vision, mission, milestones and growth over time. It details SPR's key collaborations with global technology leaders and awards/achievements. It also lists SPR's board of directors and provides an overview of its product portfolio and customer base.
This is a 6 week Training report on the topic CNC and Autocad + Delcam + FeatureCam.
This training Report is Submitted by me after completion my 6 week training training in "Krishna Automation Industrial Training Center, Gurgaon".
All the information (Some Standard Values) given in this Training Report is Provided by the KITC , from where i got 6 week training
This document summarizes two types of brakes: simple band brakes and band and block brakes. For simple band brakes, it provides equations for calculating operating force based on parameters like tangential force, radius, and friction. Band and block brakes add wooden or other material blocks that further increase friction between the drum and brake. The document includes an example calculation for each brake type.
Internship report of mechanical studentRitika Vyas
This document is an industrial training report submitted by Sudeep Mathur to fulfill requirements for a Bachelor of Technology degree in Mechanical Engineering. It provides details of a training project completed at VE Commercial Vehicles Ltd from May 10th to July 10th 2018 under the guidance of Mr. Vaibhav Vinayaka. The project focused on improving build quality for UD 1104 export vehicles to Indonesia by addressing part availability, quality, and manufacturing processes over 300 vehicles with a goal of reducing defects from 850 to 100 per vehicle.
Summer Training Report for Diploma (mechanical) StudentsKashifRaza113
This Training is completed at UPSRTC (Lucknow) by a student of polytechnic(mechanical) from Integral University Lucknow. UPSRTC is a Government Organisation for Public Transport in Uttar Pradesh.
12 Speed Gear Box Theory Notes by Prof. Sagar DhotareSagar Dhotare
It contains the following points:-
Requirements of speed gearboxes
Methods for changing speed in gearboxes
Preferred Numbers
Step ratio (or series ratio or progression ratio) (∅)
RAY DIAGRAM (OR SPEED DIAGRAM)
KINEMATIC LAYOUT (OR KINEMATIC ARRANGEMENT)
BASIC RULES FOR OPTIMUM GEARBOX DESIGN
Analysis of Rack and Pinion under dynamic conditionsnagaraju kondrasi
Based on physical and thermal properties graphite cast iron has got more strength than sand cast Mg alloy and it is clear from the results that the load carrying capacity of former is larger than the later. Hence Graphite cast iron is preferred for the manufacture of rack and pinion.
In static structural analysis the total deformation and von - mises stresses are more in sand cast Mg alloy than graphite cast iron. Hence graphite cast iron has better strength than Sand cast Mg alloy.
In modal analysis the number mode shapes are higher for graphite cast iron than sand cast Mg alloy.
Under transient conditions the total deformation of Graphite CI is less than that of Sand cast mg alloy. Hence former is preferred under Transient conditions.
Under fatigue loads the damage is more in sand cast Mg alloy. Hence graphite CI is preferred for manufacturing of Rack and pinion.
Hence Keeping all the analysis in view the graphite cast iron is preferred over sand cast Mg alloy.
The document provides details about an industrial training report completed by two interns at Hardrock Attachments Pvt. Ltd., a manufacturer of fabricated structures for construction machinery. The report describes the company's plant layout, manufacturing processes, machinery, quality systems, products, and maintenance procedures. It aims to provide a comprehensive overview of the heavy fabrication and machining industry for educational purposes.
This document provides a company profile for SPR, an Indian manufacturer of pistons, piston rings, and engine valves. It outlines SPR's history since 1972, vision, mission, milestones and growth over time. It details SPR's key collaborations with global technology leaders and awards/achievements. It also lists SPR's board of directors and provides an overview of its product portfolio and customer base.
This is a 6 week Training report on the topic CNC and Autocad + Delcam + FeatureCam.
This training Report is Submitted by me after completion my 6 week training training in "Krishna Automation Industrial Training Center, Gurgaon".
All the information (Some Standard Values) given in this Training Report is Provided by the KITC , from where i got 6 week training
This document summarizes two types of brakes: simple band brakes and band and block brakes. For simple band brakes, it provides equations for calculating operating force based on parameters like tangential force, radius, and friction. Band and block brakes add wooden or other material blocks that further increase friction between the drum and brake. The document includes an example calculation for each brake type.
Internship report of mechanical studentRitika Vyas
This document is an industrial training report submitted by Sudeep Mathur to fulfill requirements for a Bachelor of Technology degree in Mechanical Engineering. It provides details of a training project completed at VE Commercial Vehicles Ltd from May 10th to July 10th 2018 under the guidance of Mr. Vaibhav Vinayaka. The project focused on improving build quality for UD 1104 export vehicles to Indonesia by addressing part availability, quality, and manufacturing processes over 300 vehicles with a goal of reducing defects from 850 to 100 per vehicle.
Summer Training Report for Diploma (mechanical) StudentsKashifRaza113
This Training is completed at UPSRTC (Lucknow) by a student of polytechnic(mechanical) from Integral University Lucknow. UPSRTC is a Government Organisation for Public Transport in Uttar Pradesh.
12 Speed Gear Box Theory Notes by Prof. Sagar DhotareSagar Dhotare
It contains the following points:-
Requirements of speed gearboxes
Methods for changing speed in gearboxes
Preferred Numbers
Step ratio (or series ratio or progression ratio) (∅)
RAY DIAGRAM (OR SPEED DIAGRAM)
KINEMATIC LAYOUT (OR KINEMATIC ARRANGEMENT)
BASIC RULES FOR OPTIMUM GEARBOX DESIGN
Analysis of Rack and Pinion under dynamic conditionsnagaraju kondrasi
Based on physical and thermal properties graphite cast iron has got more strength than sand cast Mg alloy and it is clear from the results that the load carrying capacity of former is larger than the later. Hence Graphite cast iron is preferred for the manufacture of rack and pinion.
In static structural analysis the total deformation and von - mises stresses are more in sand cast Mg alloy than graphite cast iron. Hence graphite cast iron has better strength than Sand cast Mg alloy.
In modal analysis the number mode shapes are higher for graphite cast iron than sand cast Mg alloy.
Under transient conditions the total deformation of Graphite CI is less than that of Sand cast mg alloy. Hence former is preferred under Transient conditions.
Under fatigue loads the damage is more in sand cast Mg alloy. Hence graphite CI is preferred for manufacturing of Rack and pinion.
Hence Keeping all the analysis in view the graphite cast iron is preferred over sand cast Mg alloy.
This document presents a project report on the design of a box transport mechanism. A group of 5 students - Awadhesh Singh Yadav, Danveer Saini, Gaurav Sagar, Mayank Kumar Jain, and Nitesh Kumar Tripathi - designed an 8-link transport mechanism under the supervision of their professor, Mr. Dharmendra Singh. The project aims to utilize kinematic synthesis to fabricate a working physical model of the transport mechanism. The 8-bar mechanism will allow moving more than one article at a time, as compared to a 4-bar counterpart. The report describes the materials, tools, and procedures used to build the mechanism through modeling in CAD software and physical
ME6601 - DESIGN OF TRANSMISSION SYSTEM NOTES AND QUESTION BANK ASHOK KUMAR RAJENDRAN
This document contains the question bank for the subject ME6601 - Design of Transmission Systems for the sixth semester Mechanical Engineering students of RMK College of Engineering and Technology. It is prepared by R. Ashok Kumar and S. Arunkumar, faculty of the Mechanical Engineering department.
The question bank contains 190 questions divided into two parts: Part A containing conceptual questions and Part B containing design/numerical problems. The questions cover the five units of the subject - Design of Flexible Elements, Spur Gears and Parallel Axis Helical Gears, Bevel, Worm and Cross Helical Gears, Gear Boxes, and Cams, Clutches and Brakes. Most questions are related
Engine service and overhauling involves regularly maintaining a vehicle's engine through procedures like replacing parts. Overhauling specifically involves completely disassembling the engine, testing and replacing components as needed, and reassembling it to improve performance and longevity. The process requires various tools and involves carefully removing, inspecting, cleaning, measuring, and reinstalling all engine parts to factory specifications. Proper service and overhauling helps prevent sudden engine failures and keeps it functioning optimally for longer.
The internship involved hands-on training and observation at the Jaguar Land Rover Service Station in Chennai over the course of a month. The document discusses the operational procedures of the service station, including receiving vehicles, inspection, repair work, and returning vehicles to customers. It also describes common vehicle issues like those with the air conditioning system, and repair processes like refrigerant recharging. The internship provided valuable practical learning experience about vehicle functioning and repair work.
PSG Design Data Book Pages Required For Gear DesignSagar Dhotare
The document discusses the benefits of exercise for mental health. Regular physical activity can help reduce anxiety and depression and improve mood and cognitive functioning. Exercise boosts blood flow, releases endorphins, and promotes changes in the brain which help regulate emotions and stress levels.
More economical automation is not so good at initial stage hence step wise automation need to be done to replace human work with automation, which defines need for low cost automation in india
This document describes a report submitted by three students on their in-plant training at the Salem Steel Plant. It includes an abstract, table of contents, and sections on the introduction to the steel plant, the steel industry profile, SAIL's mission and vision, the company profile, key functions of the plant including HRM and CRM, strengths/weaknesses/opportunities, and a conclusion. The students conducted their in-plant training to study the various production processes and management functions at the Salem Steel Plant, which is one of the largest stainless steel producers in India.
Solutions for machine design by KHURMI and GUPTAAzlan
This document appears to be notes from a machine design textbook created by Eng. Younis Fakher of Thi-Qar University's College of Engineering. It contains solutions to problems from chapters 4-6 of a machine design textbook by Khurmi and Gupta for 4th year mechanical engineering students from the 2010-2011 academic year. The notes are broken down by chapter and contain problem solutions.
Springs are elastic bodies that can be twisted, pulled, or stretched by an applied force and return to their original shape when the force is released. There are several types of springs including helical springs, leaf springs, and spiral springs. Helical springs are further classified as tension springs, compression springs, torsion springs, and spiral springs. Springs are used in many applications to apply forces, store energy, reduce shocks and vibrations, and measure forces. Common spring materials include steel alloys and metals like titanium.
This presentation contains basic idea regarding spur gear and provides the best equations for designing of spur gear. One can Easily understand all the parameters required to design a Spur Gear
difference of NC and CNC ,Part programming,Methods of manual part programming,Basic CNC input data,Preparatory Functions ,Miscellaneous Functions,Interpolation:Canned cycles:part programming on component,Tool length compensation,Cutter Radius,Task compensation:Types of media of NC
A cam is a rotating machine element which gives reciprocating or oscillating motion to another element known as the follower.Though the cams may be classified in many ways, among them we can classify:
1. Radial or disc cam.
2. Cylindrical cam.
Training Report Maruti Suzuki (Imran Alam)IMRAN ALAM
The document provides an acknowledgement and preface for a project report on an automotive training completed at "Harisons Motor Panipat". It thanks the instructors and staff for their guidance and cooperation during the training period. The contents section outlines topics that will be covered in the report, including the history of Maruti Suzuki, vehicle specifications, engine systems, and other automotive parts and their functions.
Lecture 1 introduction to automobile engineeringAnubhav659
This document summarizes the first lecture of an Automobile Engineering course taught by Mr. Deepak Sharma. The lecture introduces automobile engineering and discusses the main components of a vehicle, including the engine, power train, suspension system, steering system, braking system, electrical system, and body. It also classifies vehicles based on purpose, capacity, fuel used, and number of wheels. Common drive types like single, two, four, and six wheel drive are also introduced.
This document provides information about shaper machines. It begins with an introduction to shaper machines, describing their main functions and parts. It then discusses the working principle of shaper machines and how they perform cutting operations. The document outlines the typical construction of shaper machines, including their base, body, cross rail, and ram/tool head. It also describes shaper machine mechanisms, specifications, operations and applications. In under 3 sentences.
This document is an industrial training report submitted by Sumit Kumar from the Institute of Engineering & Management in Kolkata. It describes his 15-day summer training at the Carriage and Wagon Workshop of the Northeast Frontier Railway in New Bongaigaon, Assam. The report provides details about the workshop, including its history and activities. It also describes several shops within the workshop such as the wheel turning shop, roller bearing shop, machine shop, and others. In each shop, it outlines the key machines and operations.
Sandeep Rana has over 10 years of experience in sales and production roles. He has worked for companies in tools, dental equipment, automotive and pneumatics. Currently seeking a new opportunity where he can commit his skills and grow with the company. Highlights include managing sales teams, developing new business, implementing quality processes, and technical experience in production.
Sandeep Rana has over 10 years of experience in sales and production roles. He has worked for companies in tools, dental equipment, automotive and pneumatics. Currently seeking a new opportunity where he can commit his skills and grow with the company. Highlights include managing sales teams, developing new business, implementing quality processes, and technical experience in production.
This document presents a project report on the design of a box transport mechanism. A group of 5 students - Awadhesh Singh Yadav, Danveer Saini, Gaurav Sagar, Mayank Kumar Jain, and Nitesh Kumar Tripathi - designed an 8-link transport mechanism under the supervision of their professor, Mr. Dharmendra Singh. The project aims to utilize kinematic synthesis to fabricate a working physical model of the transport mechanism. The 8-bar mechanism will allow moving more than one article at a time, as compared to a 4-bar counterpart. The report describes the materials, tools, and procedures used to build the mechanism through modeling in CAD software and physical
ME6601 - DESIGN OF TRANSMISSION SYSTEM NOTES AND QUESTION BANK ASHOK KUMAR RAJENDRAN
This document contains the question bank for the subject ME6601 - Design of Transmission Systems for the sixth semester Mechanical Engineering students of RMK College of Engineering and Technology. It is prepared by R. Ashok Kumar and S. Arunkumar, faculty of the Mechanical Engineering department.
The question bank contains 190 questions divided into two parts: Part A containing conceptual questions and Part B containing design/numerical problems. The questions cover the five units of the subject - Design of Flexible Elements, Spur Gears and Parallel Axis Helical Gears, Bevel, Worm and Cross Helical Gears, Gear Boxes, and Cams, Clutches and Brakes. Most questions are related
Engine service and overhauling involves regularly maintaining a vehicle's engine through procedures like replacing parts. Overhauling specifically involves completely disassembling the engine, testing and replacing components as needed, and reassembling it to improve performance and longevity. The process requires various tools and involves carefully removing, inspecting, cleaning, measuring, and reinstalling all engine parts to factory specifications. Proper service and overhauling helps prevent sudden engine failures and keeps it functioning optimally for longer.
The internship involved hands-on training and observation at the Jaguar Land Rover Service Station in Chennai over the course of a month. The document discusses the operational procedures of the service station, including receiving vehicles, inspection, repair work, and returning vehicles to customers. It also describes common vehicle issues like those with the air conditioning system, and repair processes like refrigerant recharging. The internship provided valuable practical learning experience about vehicle functioning and repair work.
PSG Design Data Book Pages Required For Gear DesignSagar Dhotare
The document discusses the benefits of exercise for mental health. Regular physical activity can help reduce anxiety and depression and improve mood and cognitive functioning. Exercise boosts blood flow, releases endorphins, and promotes changes in the brain which help regulate emotions and stress levels.
More economical automation is not so good at initial stage hence step wise automation need to be done to replace human work with automation, which defines need for low cost automation in india
This document describes a report submitted by three students on their in-plant training at the Salem Steel Plant. It includes an abstract, table of contents, and sections on the introduction to the steel plant, the steel industry profile, SAIL's mission and vision, the company profile, key functions of the plant including HRM and CRM, strengths/weaknesses/opportunities, and a conclusion. The students conducted their in-plant training to study the various production processes and management functions at the Salem Steel Plant, which is one of the largest stainless steel producers in India.
Solutions for machine design by KHURMI and GUPTAAzlan
This document appears to be notes from a machine design textbook created by Eng. Younis Fakher of Thi-Qar University's College of Engineering. It contains solutions to problems from chapters 4-6 of a machine design textbook by Khurmi and Gupta for 4th year mechanical engineering students from the 2010-2011 academic year. The notes are broken down by chapter and contain problem solutions.
Springs are elastic bodies that can be twisted, pulled, or stretched by an applied force and return to their original shape when the force is released. There are several types of springs including helical springs, leaf springs, and spiral springs. Helical springs are further classified as tension springs, compression springs, torsion springs, and spiral springs. Springs are used in many applications to apply forces, store energy, reduce shocks and vibrations, and measure forces. Common spring materials include steel alloys and metals like titanium.
This presentation contains basic idea regarding spur gear and provides the best equations for designing of spur gear. One can Easily understand all the parameters required to design a Spur Gear
difference of NC and CNC ,Part programming,Methods of manual part programming,Basic CNC input data,Preparatory Functions ,Miscellaneous Functions,Interpolation:Canned cycles:part programming on component,Tool length compensation,Cutter Radius,Task compensation:Types of media of NC
A cam is a rotating machine element which gives reciprocating or oscillating motion to another element known as the follower.Though the cams may be classified in many ways, among them we can classify:
1. Radial or disc cam.
2. Cylindrical cam.
Training Report Maruti Suzuki (Imran Alam)IMRAN ALAM
The document provides an acknowledgement and preface for a project report on an automotive training completed at "Harisons Motor Panipat". It thanks the instructors and staff for their guidance and cooperation during the training period. The contents section outlines topics that will be covered in the report, including the history of Maruti Suzuki, vehicle specifications, engine systems, and other automotive parts and their functions.
Lecture 1 introduction to automobile engineeringAnubhav659
This document summarizes the first lecture of an Automobile Engineering course taught by Mr. Deepak Sharma. The lecture introduces automobile engineering and discusses the main components of a vehicle, including the engine, power train, suspension system, steering system, braking system, electrical system, and body. It also classifies vehicles based on purpose, capacity, fuel used, and number of wheels. Common drive types like single, two, four, and six wheel drive are also introduced.
This document provides information about shaper machines. It begins with an introduction to shaper machines, describing their main functions and parts. It then discusses the working principle of shaper machines and how they perform cutting operations. The document outlines the typical construction of shaper machines, including their base, body, cross rail, and ram/tool head. It also describes shaper machine mechanisms, specifications, operations and applications. In under 3 sentences.
This document is an industrial training report submitted by Sumit Kumar from the Institute of Engineering & Management in Kolkata. It describes his 15-day summer training at the Carriage and Wagon Workshop of the Northeast Frontier Railway in New Bongaigaon, Assam. The report provides details about the workshop, including its history and activities. It also describes several shops within the workshop such as the wheel turning shop, roller bearing shop, machine shop, and others. In each shop, it outlines the key machines and operations.
Sandeep Rana has over 10 years of experience in sales and production roles. He has worked for companies in tools, dental equipment, automotive and pneumatics. Currently seeking a new opportunity where he can commit his skills and grow with the company. Highlights include managing sales teams, developing new business, implementing quality processes, and technical experience in production.
Sandeep Rana has over 10 years of experience in sales and production roles. He has worked for companies in tools, dental equipment, automotive and pneumatics. Currently seeking a new opportunity where he can commit his skills and grow with the company. Highlights include managing sales teams, developing new business, implementing quality processes, and technical experience in production.
Sandeep Rana has over 10 years of experience in sales and production roles. He has worked for companies in industries such as tools, dental equipment, automotive, and pneumatics. Currently seeking a new opportunity where he can commit his skills and grow with the company. Highlights include managing sales teams, developing new business, and implementing quality processes like 5S, TPM, and poka yoke. He holds a diploma in mechanical engineering and has received training in areas like sales, marketing, and safety.
Chetan H. Vispute is seeking a position that allows him to utilize his skills and abilities to help an organization grow, while gaining exposure to latest technologies. He has over 5 years of experience in quality assurance roles for automotive companies like Chassis Brakes International and Tata Motors. His experience includes new supplier evaluation, product development, project management, inspection and approval processes. Chetan holds a Diploma in Mechanical Engineering and has skills in CAD software like CATIA and AutoCAD. He is looking to further his career with his technical abilities and experience in quality assurance.
The document provides an overview of Hi-Tech Arai Pvt Ltd, an Indian auto ancillary company located in Madurai. It discusses the company's profile, mission, vision, quality and environmental policies. Key details include that Hi-Tech Arai was founded in 1985 and entered a technical collaboration with Japanese companies Arai Seisakusho and Mitsubishi Corporation in 1987. It has expanded significantly over the years and owns multiple manufacturing units producing automotive components like oil seals, O-rings, and reed valves. The company aims to be a market leader and preferred supplier to customers through achieving high quality and on-time deliveries while maintaining environmentally friendly processes.
Indian Companies Recipient of Deming Award & Malcom Balridge Award Past Five ...surabhi agarwal
This document provides information about several Indian companies that have received the Deming Prize and Malcolm Baldrige National Quality Award over the past five years. It lists the companies, the years they received the awards, and in some cases provides a brief description of the company's quality practices and achievements that led to receiving the award. Some of the companies mentioned are Asahi India Glass Limited, Reliance Industries Limited, Tata Steel Limited, National Engineering Industries Limited, and Sanden Vikas (India) Limited.
Rupam Singh is a mechanical engineer seeking a position in mechanical engineering. He has 2 years of experience in production, quality assurance, and team management. He worked as a Production Engineer at Danblock Brakes India and previously as a Production Supervisor at ADOIndia Trading. He has a B.Tech in Mechanical Engineering from Shri Balwant Institute of Technology and participated in various summer projects and training programs in areas like power generation, automotive manufacturing, and rubber pipe production.
The vice president of ACMA discussed the growth of the automotive industry in India and the development of automotive clusters. He noted that the industry has grown from 6 OEMs producing a few models in 1980 to over 1 million vehicles annually by Maruti Suzuki and over 5 million motorcycles by Hero Honda in 2010. This growth led to the development of large clusters of automotive suppliers in three main regions of India. The clusters have helped improve competitiveness, innovation, employment levels and regional prosperity. However, the industry still faces challenges in areas like capital investment, scaling production, infrastructure, productivity, skills and R&D to sustain its high growth trajectory.
Shashi Bhushan Chauhan has over 20 years of experience in automotive manufacturing operations. He is currently the Deputy General Manager of Manufacturing at Kach Motors, where he oversees production planning, quality assurance, maintenance, and team management. Previously, he held leadership roles at several automotive companies, including Unilink Engineering and Hero Motors. He has a proven track record of improving key metrics like on-time delivery, costs, and customer satisfaction through lean initiatives and process improvements. Chauhan has a B.Tech in Mechanical Engineering, an MBA in Operations, and training in manufacturing best practices from companies in India, Japan, and Austria.
Hansraj Prajapati is seeking a managerial role in quality control or process enhancement with a growth-oriented organization. He has over 9 years of experience in quality control and process improvement. He is proficient in quality management systems like ISO/TS-16949 and tools such as 5S, Kaizen, SPC and PPAP.
The document summarizes an industrial tour taken by Poornima University students from 20-22 February 2014. They visited several companies including Havells India Ltd., Dabur India, Sona Koyo Steering Systems Ltd., and Maruti Udyog Ltd. At Havells, they toured the cable production facilities and learned about the company's history, products, marketing, HR practices, and financial performance. Sona Koyo gave an overview of its history, products, clientele, awards, vision, mission, and manufacturing processes for steering components. The tour provided insights into the operations of leading automotive and consumer goods companies in India.
Yogendra Singh Chauhan is seeking a position that allows him to utilize his skills and expand his knowledge through professional growth. He has a Bachelor's Degree in Mechanical Engineering and over 2 years of experience as a Quality Engineer at Agya Auto Limited in Pithampur, Madhya Pradesh, where he has implemented quality control processes and reduced rejection rates.
This document provides a summary of S.B. Chauhan's career experience and qualifications. He has over 21 years of experience in manufacturing leadership roles in the automotive industry. Currently he is the Deputy General Manager of Manufacturing at Kach Motors, where he oversees quality assurance, production planning, new product development, and other manufacturing functions. Previously he held senior production and operations roles at companies such as Unilink Engineering, Hero Motors, and India Yamaha Motor. He has a B.Tech in Mechanical Engineering, an MBA in Operations Management, and leadership training from IIM Calcutta.
Adarsh Bhatt has over 12 years of experience in quality assurance roles in manufacturing industries. He has expertise in failure analysis, corrective actions, customer handling, continuous improvement projects, supplier evaluation, and quality management systems. Bhatt held roles such as Assistant Manager Quality Assurance, Senior Engineer Quality Assurance, and Quality Assurance In-Charge at various companies manufacturing automotive components, furniture, and agricultural equipment.
This document is an industrial training report submitted by Shubhang Jadia to Amity School of Engineering on pneumatic systems and inventory management at Honda Cars India Limited. It provides an overview of Honda's philosophy, departments, and the welding department where the training took place. The objectives were to understand pneumatic circuits, systems, and components, as well as inventory management practices. The report describes the various zones of the welding department, pneumatic system basics like compressors and air treatment, and the goals of inventory management.
The document discusses various documents required for export and import transactions. It defines documentation and its objectives, which include reducing non-completion, foreign exchange, and financing risks. Key export documents discussed are the GR form, export license, inspection certificate, consular/legalized invoices, and certificate of origin. These regulatory documents must be submitted to comply with exporting country and importing country regulations. Operational documents like the shipping bill are also required for customs verification and record purposes.
A Project Report on in depth study on Product Development and A Feasibility S...aditibathla
The document summarizes information about Motherson Sumi Systems Limited (MSSL), a leading automotive components manufacturer in India. MSSL has a diversified product range serving multiple industries, with automotive being the main industry. It has a presence in over 20 countries globally and over 31,000 employees. MSSL is a joint venture between Motherson Group and Sumitomo Wiring Systems, and is a flagship company of Motherson Group specialized in production of wiring harnesses and door trims.
V. Manivannan is seeking a quality role in engineering and has over 10 years of experience in quality control. He currently works as a Senior Engineer in Quality for SS Manufacturing Private Limited in Chennai, where he handles quality inspection, customer relations, training, and continuous process improvement. He has a diploma in Mechanical Engineering and is proficient in Pro/E, AutoCAD, and Microsoft Office.
The production department of Gold Star Battery Pvt Ltd oversees the manufacturing of various battery products through a multi-step process. Key steps include smelting and refining of lead, casting of plates, pasting and drying of plates, formatting, packing, and charging. The installed capacity is 9,500 batteries per month while the current utilization is 7,500 batteries per month. Machinery used includes furnaces, refining machines, casting machines, and charging machines. Quality is ensured at each stage of production.
Prabhat Tiwari completed a summer training project at India Yamaha Motor Pvt. Ltd. in Faridabad, India. The report details Yamaha's history beginning in 1887 producing reed organs. It established a motorcycle division in 1954. In India, Yamaha entered a joint venture in 1996 before becoming a wholly owned subsidiary in 2001. The Faridabad plant manufactures parts for motorcycles including gears, axles, cylinders, cranks, and camshafts through processes like casting, machining, welding, heat treatment, and painting. Quality control testing ensures motorcycles meet performance and safety standards before release.
Similar to Report on REJECTION REDUCTION IN CPC RING (20)
1. A REPORT
ON
SUMMER TRAINING INTERNSHIP IN
ON TITLE
REJECTION REDUCTION IN CPC (COMPOSITE PLATING OF
CHROME) RING
SUBMITED TO
ASET, Amity University, Noida
BATCH: 2011-2015
SHRIRAM PISTONS AND RINGS PVT. LTD. SUBMITTED BY:-
REPRESENTATIVE: K.VENU GOPAL
MR. ROHIT KUMAR ROLL NO. - A2305411030
ENGINEER, C2D1 PLANT
2. i
CERTIFICATE
This is to certify that Mr. K.Venugopal of Amity School of Engineering and Technology, Amity
University, Noida (U.P.) has been provided with industrial training in Shriram pistons and rings
Pvt. Ltd. (Ghaziabad) for the period of 8 weeks from 02/05/2014 to 25/06/2014 under my
guidance. During this period he has successfully completed the project “REJECTION
REDUCTION OF CPC RING”
Rohit kumar K.Venu gopal
(Guide)
3. ii
ACKNOWLEDGEMENT
I would like to express my gratitude to everyone who supported me and gave me a possibility to
successfully complete my project. A special thanks to our project guide, Mr.Rohit kumar,
Engineer, C2D1 Plant, whose help, stimulating suggestions and encouragement helped me to
coordinate my project and especially write this report. His constant support and guidance
throughout the course of the project has made the project reach its successful completion. Their
suggestions were indispensable in preparing ourselves to meet the challenges posed by the
project.
I would also like to thank Shriram Pistons and Rings Pvt. Ltd, which gave me all the liberty to
explore and understand the concepts of manufacturing on shop floor. I would like to thank my
faculty guide Mr. Prashant Gill of Amity University & Mr. Vivek Kumar, H.O.D (MAE) of
Amity University for guiding all my way throughout this project.
Last not the least I would like to thank my parents, seniors and friends without whose kind
support I could not have undergone the project smoothly & successfully.
I thank all those who knowingly and unknowingly have helped me in the fulfilment of this
project, I would like to heartily thank all of them.
4. iii
COMPANY PROFILE
Shriram Pistons & Rings Ltd. (SPRL) is one of the largest and most sophisticated manufacturers
of precision automobile components i.e. pistons, piston rings, piston pins and engine valves in
India. The products are sold under brand name ‘USHA/SPR’ in the markets.
SPRL manufacturing unit is located at Meerut road in Ghaziabad (25 km from Delhi). The plant
has been recognized as one of the most modern and sophisticated plants in north India in the field
of automobile the production capacity of plant is as under:
Piston : 17.06 million per year Actual Production in 2011-2012
Pin : 14.9 million per year Actual Production in 2011-2012
Rings : 76.5 million per year Actual Production in 2011-2012
Engine valves : 33.8 million per year Actual Production in 2011-2012
The company has technical collaboration with:-
M/s. Kolbenschmidt, Germany to produce pistons
M/s. Riken corporation, Japan for piston rings
M/s. Fuji Oozx, Japan for the manufacture of Engine Valves
M/s. Honda Foundary, Japan for technical support
The company supplies its products to several Original Equipment Manufacturers (OEMs) like
Ashok Leyland, Tata Cummin, Tata Motors, Maruti Suzuki, Mahindra & Mahindra, Tafe
Tractors, SML( Swaraj), Kirloskar Oil Engines, Bajaj Auto, Honda Siel Cars, Sundram
Claylon, Honda Scooter, International Tractors, Standard combine in addition to all the Honda
Joint ventures in India. SPRL is also supplying its products to international OEM’s like Renutt,
Nissan, Ford and Riken etc.
At Shriram Pistons and Rings Ltd. Quality is an integral part if whatever we do, which is
reflected in the company’s Quality Policy:
“Total Customer satisfaction through Quality Management and Continuous Improvement”
Quality Objectives:-
Organisation which is sensitive and interactive to the needs of customer.
Continuous upgrading of quality and process to meet changing needs of customer.
Optimization of return on investment by-
Continuous improvement
Technology development
5. iv
Organizational and personnel development
Cost reduction efforts
Effective use of all resources
Harmonious and safe working conditions
Work to international norms of quality and management.
The company has successfully practiced the best work ethics and technology along
with the TPM & Kaizen approach and harmony through teamwork.
Achievements in terms of quality:
SPR received the ISO-9001 certificate from RWTUV, Germany in 1994.
Technology from the collaborators was supplemented with In-house efforts and
by implementing world-class practices.
The company received QS-9000 certificate from TUV, Germany in the year
1999.
The company received ISO-14001 certificate in the year 2001.
SPR received the TS-16949 certificate in the year 2003.
The company received OHSAS-18001 certificate in the year 2003.
Best foundry awards from institute of Indian Foundry men in the year 2003.
Green rating award by CII, U.P.Pollution Control Board & World Bank in
2004.
The company received TPM Excellence award in the year 2004.
Received Diamond Award – overall Best performance in QCDDM, outstanding
performance in cost, bronze award for delivery, gold award for 5S from Honda
Siel Cars(I) Ltd. In 2006.
SPRL has received the Best Vendor Awards from Maruti Suzuki for 4
consecutive times, Best supplier performance awards from Tata Cummins Ltd
for 3 consecutive years. And has self-certified status with most of the OEMs.
Excellence award in Export by government of India.
Excellence award in productivity by ACMA in 2007-08.
Excellence award in quality by Honda Scooters and Motor Cycles Limited,
Excellence award in technology by ACMA in 2007-08.
Excellence award in manufacturing excellence award by ACMA in 2007-08.
Received silver trophy- technology from ACMA in2007-08.
Received outstanding supplier for technology award from Cummins in 2007-
08.
Received vendor performance award Kaizen, vendor performance award
overall commendation, overall achievement trophy from Maruti Suzuki in
2007-08
6. v
The company received recognition award by government of India for In House
R. & D.
Best foundry award received from Institute of Indian Foundry Men.
Received star performer(IC Piston Engine & Parts) award from Engineering
Export Promotion Council (EEPC) India.
Received silver award – Quality & Bronze award – spares from Honda Siel cars
India ltd. In 2007.
The company received TPM special award in march 2008
Received Best Quality Vendor award from Tata Motors ltd. In 2008-09.
Received best vendor award for overall performance (QCLDM) from Ashok
Leyland in 2008-09.
Received overall achievement trophy from Maruti Suzuki in 2008-09.
Received best explorer award from FIEO- Federation of Indian Export
Organisation in 2009-10.
Received Trophy from EEPC “STAR PERFORMER IN PRODUCT GROUP
OF ENGINES, TURBINES & PARTS” in recognition of outstanding
contribution to engineering exports during the year 2008-09.
ISO/TS 16949 achieved for SPR Unit-II – Ghaziabad in year -2009.
ISO/TS 16949 achieved for SPR Unit V pune in year 2010.
Received performance award form Honda siel Power products Ltd. In march -
2012.
Features of SPR factory:
Total area covered by the factory is 27 Acres.
The factory has manufacturing facilities for piston, rings, pins and engine valves.
Classification of the premises:
P.T.E- Production Technology and Engineering
C.A.A- Commercial Administration and Accounts
R & D- Research and Development
Total strength of the company is 5230 nos. consisting of officers, staff and workers.
The turnover/sales for the year 2011-12 are Rs. 1000.00 Cr.
The company is exporting or more than 35 countries.
Exports sales are of Rs. 188 Cr. year 2011-2012.
Over 10% of the production is exported to sophisticated markets such as Europe, UK,
Egypt, USA, Latin America etc.
SPR has been investing 30% of its retained earnings in quality upgradation and
modernization every year.
7. vi
VISION
World Class Company, Preferred by World Class Customers
Motivated, Dedicated and System Oriented Employees
Safe and Healthy Work Place
MISSION
Sales and profit growth/leadership
Strong leadership with collaborators
Preferred OE supplier
Employee development
Superior returns to stake holders
Care for environment and society.
OTHER MANUFACTURERS COMPANY IN INDIA:-
There are following Manufacturers Company of piston, piston ring, piston pin and engine valves
in India which is given below
SAMKRG Piston & Rings – Andhra Pradesh
(IPL)India Piston Limited (A Group of Amalgamations) – Chennai
(SSPPL) Sintered Product Pvt. Ltd. –Headquartered in kosi kalan (North India)
(AIP) Abilities India Piston & Rings Ltd – Ghaziabad
Shriram Piston & Rings Ltd – Bhiwadi.
8. C O N T E N T
i. CERTIFICATE
ii. ACKNOWLEDGEMENT
iii. COMPANY PROFILE
1. INTRODUTION………………………………………………………………………[1]
1.1 COMPRESSION RING…………………………………………………………...[1]
1.2 SECOND RING…………………………………………………………………...[2]
1.3 OIL CONTROL RING…………………………………………………………….[2]
2. ABOUT THE PLANT………………………………………………………………....[2]
3. PISTON RING SHAPE………………………………………………………………..[4]
4. TYPES OF RING MADE IN THE PLANT………………………………………….. [5]
5. TYPES OF RING PROFILE…………………………………………………………..[6]
6. PROCESS SEQUENCE……………………………………………………………….[7]
7. MACHINING OPERATION DETAIL………………………………………………..[8]
7.1 GRINDING SECTION…………………………………………………………….[8]
7.1.1 ROUGH SIDE FACE GRINDER………………………………………….[8]
7.1.2 SEMI FINISH GRINDER………………………………………………….[9]
7.1.3 FINISH SIDE FACE GRINDER…………………………………………..[9]
7.2 LINE 1 SECTION………………………………………………………………….[10]
7.2.1 CAM TURNING AND GAP CUTTING MACHINE……………………..[10]
7.2.2 INTERNAL BORING MACHINE………………………………………...[11]
7.2.3 HONING MACHINE……………………………………………………...[12]
7.2.4 PROFILE TURNING MACHINE…………………………………………[13]
7.2.5 GROOVING MACHINE…………………………………………………..[14]
7.3 PCM SECTION……………………………………………………………………[14]
7.3.1 GAP GRINDING MACHINE……………………………………………[15]
7.3.2 GAP EDGE CHAMFER MACHINE……………………………………[15]
7.3.3 PROFILE GRINDING MACHINE………………………………………[16]
7.3.4 PARKERISING……………………………………………………………[17]
8. DEFECTS OCCURRED DURING MACHINING OPERATION……………………[18]
9. REJECTION ANALYSIS METHODOLOGY………………………………………[18]
9.1 TRACK OF THE LOT FOR REJECTION ANALYSIS…………………………[19]
9.2 PARETO ANALYSIS……………………………………………………………[20]
10. PREVIOUS IMPROVEMENTS TO REDUCE REJECTION………………………[20]
10.1 PROCESSING OF ALL CPC RINGS BELOW 120MM DIAMETER ON AUTO
OD GAP CHAMFER MACHINE…………………………………………………[20]
10.2 BEARING UNIT NECK THICKNESS REDUCED TO AVOID CHROME
BROKEN AT GAP DURING PROCESSING OF RINGS ON BORING
OPERATION…………………………………………………………………….[21]
11. SUGGESTION FOR REJECTION REDUCTION FOR FUTURE SCOPE………..[22]
11.1 SUGGESTION OF IMPROVEMENT………………………………………[23]
12. CONCLUSION………………………………………………………………………[24]
13. REFERENCE………………………………………………………………………….[24]
9. 1. INTRODUCTION
Piston ring can be perfectly defined as the split ring with slight adjustment of diameter which fits
around the groove of the piston and seals the gap between the piston and cylinder wall.
Piston rings are widely classified into two types:
1. Compression ring
a. Top ring
b. Second ring
2. Oil control ring
Each of these rings uses distinct combination of materials, shape, heat treatment and surface
coating in contemplation of performance of its assigned function in optimality manner. The
design of these rings is a very critical job to carry upon to make it function properly. Its design
are made with respect to the combination of number of these rings in an engine. Some engine
requires 2 or 3 rings ranging till 6 per piston.
Functions of the rings –
Piston rings must accomplish three major principle functions,
Seal off the combustion chamber from the fuel mixture entering the crankcase
Limit and controlled regulation of oil consumption
Transfer the heat absorbed by the piston in the combustion process to the cooled cylinder
walls.
1.1 TOP RING-
This ring sit on top portion of the piston also referred as the upper compression ring. This ring is
operated at high thermal and mechanical loading. Its function is to form a gas-tight barrier
between the cylinder walls and the piston in order to the seal the combustion chamber. Another
function is to transfer the heat generated to the cylinder wall from piston and act like a bridge
between them.
Figure 1 Top ring
10. 1.2 SECOND RING-
This is known as the lower compression ring. Its function is to work cumulatively with the top
ring to seal the combustion chamber and transfer the heat to the cylinder walls. These rings also
control oil ring. It does the job of both compression ring and oil ring.
1.3 OIL CONTROL RING-
It regulates and limit oil consumption. They scrape off excess lubricating oil from the cylinder
walls and return it to the crankcase. They are designed to provide a thin oil film to ensure piston
and ring lubrication. Improper control results in carbon residues or blue smoke in the exhaust gas
and results excessive oil consumption.
Application of piston ring is very wide. Some of them listed below-
Motor cycles, Passenger cars, Buses, Trucks, Motorsports, Large agriculture power generations,
Marine propulsion, Leisure RV’s, Small agriculture lawns and garden, Leisure crafts.
2. ABOUT THE PLANT
The factory located at Ghaziabad produces mainly three products pistons, piston rings and engine
valves. The piston ring has two plant namely C.I. Ring plant and the C2D1 Ring plant. The
C2D1 Ring plant is the point of interest in this project. The C2D1 plant is technically named
after the size of diameter made in this plant. C2 refers to the size range 121-140 mm and D1
refers to the size range 141-150 mm. C2D1 plant is the only plant which produces the chrome
rings.
Material used for manufacturing these piston rings are S.G. iron which is also known as the
ductile iron. Material which are widely used are as follow-
RIK- 10, RIK- 20a, RIK- 40B, RIK- 40S, SPR-02
Elemental composition chart of these materials are below-
Figure 2 Second ring
Figure 3 Oil control ring
12. 3. PISTON RING SHAPE:
Piston ring shape can be classified into three part according to the ovality namely:
1. Positive ovality: The measurement of the positive ovailty is done with the ring at its
free state. If the dimension of the ring measures from the back of the ring to the tip is
larger than the diameter measured across 90 degree, then the ring is said to be having
positive ovality. This causes an effect at the tips by the joint exert a high pressure against
the cylinder than other area of ring. This prevents the ring tips ‘fluttering’ at higher
engine speeds. Such rings are normally only specified on engines with higher RPM.
2. Negative ovailty: The measurement of the negative ovailty is done with the ring at its
free state. If the dimension of the ring measures from the back of the ring to the tip is
smaller than the diameter measured across 90 degree, then the ring is said to be having
negative ovality. Rings are specified with negative ovality to compensate for expansion at
operating temperature. As the ring warms, the heat can be concentrated at the ring tips.
These try to expand outwards, and by designing a ring with negative ovality, this effect
can be negated to create a ring exerting more even pressure around its circumference.
Rings with negative ovality were formerly used on slow speed 2-stroke diesel engines,
and are today widely specified on medium speed 4-stroke diesel engines.
3. Zero ovality: The measurement of the zero ovailty is done with the ring at its free state.
If the dimension of the ring measures from the back of the ring to the tip is equal to the
diameter measured across 90 degree, then the ring is said to be having zero ovality. Rings
with zero ovality are frequently specified for the latest slow speed 2-stroke diesel
engines.
Figure 5 Diagram depicting all the types of ovality
13. 4. TYPES OF RING MADE IN THE PLANT:
Oil Ring
Plain Oil ring Oil chrome
HTCR
HTCR PGV
Compression ring
Chrome
Compression ring
K.S. Chrome
Taper K.S.
Chrome
Taper Chrome
K.S. Chrome
PGV
Plain
Compression ring
Taper
K.S. Compression
Taper K.S.
Taper Comp. IDB
Taper Comp. IDS
Plain
Taper napier
ODS Plain/Taper
14. 5. TYPES OF RING PROFILE:
Napier ring: The Napier ring (also known as a Nasen ring) has a step machined into the lower
part of the running face. The upper part of the running face may be either square or with a taper.
Such a ring has a twisting effect when closed which allows the ring to
present a sharp downward edge to the cylinder which is effective at scraping
excess oil from the liner. The step provides a large area into which this oil
can be stored.
Rectangular Ring: Simple design with a square running face. Such rings are often un-coated, and
since the full ring face sits against the cylinder liner, such rings have a
relatively low contact pressure.
Taper faced: The taper faced ring allows the contact area between the ring and cylinder liner to
be reduced, thus proportionately increasing the contact pressure with the cylinder. Additionally
there is some pressure relief due to combustion gas pressure between the
top of the ring and the liner pushing the ring inwards. Such rings have
reduced running-in times and also provide some oil scraping function.
Internally Stepped Ring/Internal Chamfered Ring: By machining a step or a bevel onto the top
inside corner of the compression ring, the ring becomes subject to a twisting
or torsion effect when closed to working size and fitted into the liner. This
feature causes the bottom outside corner of the ring to make contact with the
cylinder liner thus providing good running-in characteristics and improved
oil scraping function. When combustion gas pressure is applied, the ring
running face is pushed flat against the liner.
Keystone Ring: This ring has a wedge shaped section. Thus the side faces of the ring are tapered.
This allows the clearance between the ring and the piston groove to vary as
the ring moves radially within the groove. This feature greatly reduces the
ring sticking in the piston groove, and is useful where the engine is for
some reason producing heavy combustion residues.
Slotted Oil Scrapper: Otherwise designated as SOC type this ring, has two scraping edges
separated by a groove. In the bottom of the groove are a number of slots
running to the inside of the ring. These allow oil gathered by the two scraping
edges to flow through, and be dispersed back into the engine via drain holes
drilled into the bottom of the piston groove. Such a ring can be supplied in
many different forms. The simplest and oldest is shown to the right with
square scraping edges.
16. 7. MACHINING OPERATIONS DETAIL
In C2D1 plant has a wide and huge space to accommodate various high-tech machining
equipment. The machining operations are divided into mainly three categories:
1. Grinding section
2. Line 1 section
3. PCM
The making of piston rings starts with the casting of the ring from molten metal
7.1 Grinding section-
Grinding section consist four machines namely rough grinder, semi-finish grinder, finish grinder,
and plunge grinder.
7.1.1. Rough side face grinder- Rough grinding machine is where the first operation starts. The
casted ring is first grinded in the rough grinding machine. In this operation the axial height of the
ring is decreased. About 1000-2000 microns of material is scraped out during this process. This
machine has got two grinding wheel horizontally placed in-between which the ring is passed. In
the input of the machine a slow moving v belt carrying the rings pass it to the machining portion,
where the grinding wheel is placed. The two grinding wheel are responsible for the stroke
removal. The output is constantly inspected for its axial height using a screw gauge.
Following are the brief detail of the machine unit:
Materials machined: - RIK -40B, RIK-40S, RIK-10, RIK-20A, RIK-25H and SPR-02
Tooling detail: -
1. Grinding wheel- 760x70x25.4 mm
2. Grinding wheel surface structure- Honeycomb
3. Grinding wheel material carborundum
4. Grinding wheel R.P.M.- 600-660 rpm
5. Dresser- Single pipe diamond dresser (0.75 carat)
6. Coolant- CIMSTAR (4.5-6 % max)
7. Guide strip- Thickness< axial height
Defects occurred-
1. Bad face- Irregular pattern on the radial face
2. Burn- Surface burned with black patch
3. Broken ring- Ring broken due to cracks
Figure 7 Diagram showing an
example of burn defect
17. 7.1.2. Semi-finish side face grinder- Semi finish grinding machine is where the second operation
starts. The rings after rough grinding is further machined in this machine. In this operation also
the axial height of the ring is decreased. About 150-200 microns of stroke is removed out during
this process. In input the rings are placed on the v shaped platform. This platform is attached
with a vibrator which helps in the forward movement of the rings. After this the rings are
displaced to the magnetic rotary drum which carries the ring to the grinding wheels for
machining to be done. Machined rings are brought adjacent to the input side by means of a
conveyor belt. On output the rings are inspected for the axial height.
Following are the brief detail of the machine unit:
Materials machined: - RIK -40B, RIK-40S, RIK-10, RIK-20A, RIK-25H and SPR-02
Tooling detail: -
1. Grinding wheel- 760x70x25.4 mm
2. Grinding wheel surface structure- Honeycomb
3. Grinding wheel material carborundum
4. Grinding wheel R.P.M.- 600-660 rpm
5. Dresser- Single pipe diamond dresser (0.75 carat)
6. Coolant- CIMSTAR (4.5-6 % max)
7. Guide strip- Thickness< axial height
Defects occurred-
1. Bad face- Irregular pattern on the radial face
2. Burn- Surface burned with black patch
3. Broken ring- Ring broken due to cracks
7.1.3. Finish side face grinder (plunge/diskus grinder) - Finish grinding machine is where the
third operation starts. The rings after semi finish grinding is further machined in this machine. In
this operation also the axial height of the ring is decreased. About 4-5 microns of stroke is
removed out during this process. These machines are vertical type whereas the rough and semi
finish grinders are horizontal type. These are fully autonomous machine. It is also built with two
grinding wheels but are vertically placed. The rings are stacked at input which is then passed to
the carrier plate. Carrier plate are circular disc with holes at 120o
each. With the ring engaging to
the hole, the plate rotates and the rings are machined. After that the rings are robotically
collected through collector unit.
18. Following are the brief detail of the machine unit:
Materials machined: - RIK -40B, RIK-40S, RIK-10, RIK-20A, RIK-25H and SPR-02
Tooling detail: -
1. Grinding wheel- 760x70x25.4 mm
2. Grinding wheel surface structure- Honeycomb
3. Grinding wheel material carborundum
4. Grinding wheel R.P.M.- 600-660 rpm
5. Dresser- Single pipe diamond dresser (0.75 carat)
6. Coolant- CIMSTAR (4.5-6 % max)
7. Guide strip- Thickness< axial height
Defects occurred-
1. Bad face- Irregular pattern on the radial face
2. Burn- Surface burned with black patch
3. Broken ring- Ring broken due to cracks
7.2 Line 1 section:
After the grinding operation is done at line 1 the ring gets into the shape and profile. This section
consists of machines like cam turning, internal boring, honing, grooving, I.D. step and profile
turning.
7.2.1 Cam turning and gap cutting machine: Cam turning machine is a special turning
machine designed specifically for machining the piston ring. Since the rings are
initially oval in shape round turning is not possible, cam turning machine is used to
turn the oval shape. In order to start the process a no. of rings are stacked and
clamped in a cylindrical rod and levelled using a v block. The cylindrical rod is then
clamped to the machine. With the required setting according to the type of ring the
machining takes place over the outer surface i.e. along the axial height. After this the
rod is transferred to the gap cutting machine. Here using two parallel milling cutter
the gap is cut on the rings. With the rings with the gap is oval shaped and closing the
gap the shape changes to round. With the oval shape the gap is called free gap and
the round shape is called as closed gap with the precision of 0.00 mm.
19. Following are the brief detail of the machine unit:
Materials machined: - RIK -40B, RIK-40S, RIK-10, RIK-20Aand SPR-02
Tooling detail: -
1. CAM%- Selected as per process card
2. Ovality- Selected as per process card
Gap cutting tooling detail:
Material Diameter Feed value reading RPM Cutting material
RIK-40B/40S 40-100 400-450 250-300 H.S.S / Carbide
RIK-10/20A, SPR-02 40-100 400-450 250-300 Carbide
RIK-40B/40S 100.1-120 350-400 250-300 H.S.S / Carbide
RIK-10/20A, SPR-02 100.1-120 300-350 250-300 Carbide
Defects occurred-
1. Face dent- Dent present on the axial face
2. OD unturn- Incomplete machining on the outer surface
3. Unshape- Irregularity in dimension of radial distance
7.2.2 Internal boring machine: Internal boring machine is used to bore the internal side
face of the ring. This operation is followed by the cam turning operation. Tool used
in this operation is a five single point cutting tool attached to a thick disc shaped
attachment. This machine consist of vertical motor which rotates the spindle which
is attached to the tool. Rings are stacked to the machine in such a way that the
spindle is right at the internal portion of the ring. As the vertical motor starts the tool
rotates and bore the internal part of the ring.
Following are the brief detail of the machine unit:
Materials machined: - RIK -40B, RIK-40S, RIK-10, RIK-20A, RIK-25H and SPR-02
20. Tooling detail: -
RING DIAMETER BEARING UNIT DIA.
57-74(& 74 OVER SIZE) 50,55
76-96(& 96 OVER SIZE) 65
98-108(& 108 OVER SIZE) 75
110-128(& 128 OVER SIZE) 90
130-150(& 150 OVER SIZE) 100
HOUSING RING DIA.
SMALL HOUSING 38~96
MEDIUM HOUSING 97~140
LARGE HOUSING 141~150
Defects occurred-
1. ID lining- Incomplete machining on the inner surface
2. ID burr- Burr at the inner surface
3. Gap broken- Gap is broken
4. Chrome broken- Chrome coating is broken
5. ID unturn- Incomplete machining on the inner surface
6. ID vibration- Irregular pattern due to vibration
7.2.3 Honing machine: Honing operation is one of the crucial operation in piston ring
production. During the cam operation the outer surface is machined with lining. This
lining has to be polished in order to get a smooth outer surface for further machining.
Honing sleeve selection is the first step in this operation, which is selected according
to the process card. After this the rings are stacked in the mandrel with intermediate
collars. The mandrel is inserted into the sleeve. The abrasive texture in the inner
surface of sleeve is responsible for polishing the outer lining of the ring. This
abrasive operation takes place through two motions, one is rotational and other is
translation motion. The spindle rotates along with vertical linear moment. This
process goes through no of cycles for specified time. This time is known as the
lapping time.
Following are the brief detail of the machine unit:
Materials machined: - RIK -40B, RIK-40S, RIK-10, RIK-20A, RIK-25H and SPR-02
21. Tooling detail: -
1. Honing sleeve- Punch mark for diameter
2. Collar- Punch mark for diameter & Angle
3. Honing mandrel- As per ring diameter
4. Coolant- Fresh servo 46 mixed with 35gm 1000 grit emery
5. Dummy ring- 2-3 rings
Defects occurred-
1. Chrome broken- Chrome plating at outer surface
2. Granular plating- Granular patch on the surface
3. Dechrome- Chrome coating removal
4. Rehoning- This occurs improper machining
5. Gas leakage- Minute hole due to casting defect
6. Patch- Patch on the surface of the ring
7. Twisted ring- Twist in the split ring
8. Chrome at gap- Chrome plating broken at gap
7.2.4 Profile turning machine: Profile turning machine is where the ring is distinctly get
into shape. Each ring has specific function to accomplish and this is done through
ring profile design. Profile of ring is designed by a team of engineers with the
demand of the customer. Profile are made on the ring using computer controlled
lathe machine. In order to increase productivity and rejection five single point
cutting tool are combined and used to machine five ring at a time. Rings are stacked
in a string wrench with a dummy disc in between two rings. After that the rings are
clamped to the lathe machine and tightened. Following this machining takes place
and profile are generated.
Following are the brief detail of the machine unit:
Materials machined: - RIK -40B, RIK-40S, RIK-10, RIK-20A, RIK-25H and SPR-02
Tooling detail: -
1. Basic collar left- D2= (D+0.5/D+0.3) SDE1.3/TD
2. Basic collar right- D2= (D+0.5/D+0.3) SDE1.3/TD
3. Distance collar- D1 Thickness as per chart
4. Clamping sleeve- D+0.5/ D+0.7/ D+0.3/ D+0.09 mm
22. 5. Tool- as per the chart
Defects occurred-
1. OD unturn- Incomplete machining on the outer surface
2. Face dent- Dent present on the axial face
3. Vibration- Irregular pattern due to vibration
4. Profile centre- Shift in the centre of the profile due to improper machining
7.2.5 Grooving machine: Grooving machines are used to create groove on the side face of
the ring. Grooves are made to dispense the scraped oil around the piston groove.
These scraped oil is passed through the groove and transferred to the oil drain hole.
Groove machine contain a stack of multi point cutting tool clamped in a cylindrical
rod structure. Stack of ring is also clamped parallel to the cutting tool in such a way
that the middle portion of side face of the ring is exactly adjacent to the cutting tool.
With the rings remaining static cutting tool rotates and make the groove. The
machine is computer controlled and the cutting tool retracts back then stack of ring
rotates to change the side face for new grove machining.
Following are the brief detail of the machine unit:
Materials machined: - RIK -40B, RIK-40S, RIK-10, RIK-20A, RIK-25H and SPR-02
Tooling detail: -
LIMITING PRESSURE
HTCR PGV/ IDCR (D+0.15) mm
HTCR (D+0.35) mm
PLAIN OIL (D+0.75) mm
HTCR CHROME (D+0.75) mm
SLEEVE/ COLLAR SIZE
25-30 kg/cm2
30-35 kg/cm2
Defects occurred-
1. Chrome broken- Chrome is broken at the slot
2. Face dent- Dent present at the surface
3. Vibration- Irregular pattern on the surface of the ring
7.3 PCM section:
PCM section is most intricate section in piston ring production. Every machining has to be taken
care of, even small irregularity could cause increased rejection. The word PCM stands for post
chrome machining which by name suggest that this section is works on ring after chrome plating
23. is done. This section consist of machines like gap grinder, gap edge chafer, profile grinder,
honing, and keystone grinding.
7.3.1 Gap grinding machine: After the chrome plating procedure one of the main
operation is gap grinding. This operation is very critical because of its contribution
to the rejection of the ring. Due to this reason this machine is always been a point of
interest for many engineers working on rejection reduction. Gap grinder is a
computer controlled machine having a grinding wheel which fits in between the ring
gap and grind it. A no. of ring are stacked and hanged in a T shaped bar. An arm is
provided to release single or a set of rings at a time. Ring is then grinded at the gap
with heavy supply of coolant in order to reduce chrome broken. Single ring or set of
rings are machined at a time according to the axial height of the ring. After the
machining the ring is then pushed through the sleeve and collected at the other end
of the machine.
Following are the brief detail of the machine unit:
Materials machined: - RIK -40B, RIK-40S, RIK-10, RIK-20A, RIK-25H and SPR-02
Tooling detail: -
1. Grinding wheel- 125x1.5x22.23 mm
2. Grinding wheel designation- CB200R100BK8
3. Grinding wheel material- CBN (Cubic boron nitride)
4. Grinding wheel R.P.M.- 6000±200 rpm
5. Coolant- CIMSTAR (4-6 % min)
No. of rings per stroke Axial height
4 Up to 1.7 mm
3 1.7< B <2.5
2 2.5< =B <6
1 6< = B & Above
Defects occurred-
1. ID gap broken- Gap is broken at the inner surface
2. Slant gap- Gap cut is not proper
3. Chrome broken- Chrome coating is broken
4. OD scratch- Scratch at the outer surface
7.3.2 Gap edge chamfer machine: Gap edge chamfer machine is used to create chamfer at
the gap edge. Chamfering is done to reduce stress concentration at the gap edge. This
24. machine is fully computerised, the ring is stacked in a T-shaped bar. Then a picker
arm picks few no. of ring and pass it for the machining. Two abrasive belt are
clamped of either side to chamfer the edge on both side. After then the rings are
collected in the T bar on the other side.
Following are the brief detail of the machine unit:
Materials machined: - RIK -40B, RIK-40S, RIK-10, RIK-20A, RIK-25H and SPR-02
Tooling detail: -
1. Belt specification- 240 grit (10x350)
2. Sand paper- 80 grit (20mm dia.)
Defects occurred-
1. Chrome broken at gap- Chrome coating is broken at the gap
2. Chamfer unequal- Unequal machining of the chamfer
7.3.3 Profile grinder machine: Profile grinding machine is used to grind and polish the
outer surface of the ring. This machine uses a huge grinding wheel which grinds the
outer surface. Rings are clamped to the machine and grinding wheel grinds the side
face of the ring.
Following are the brief detail of the machine unit:
Materials machined: - RIK -40B, RIK-40S, RIK-10, RIK-20A, RIK-25H and SPR-02
Tooling detail: -
1. Collar diameter- As per process card
2. Collar thickness- As per stage card
3. Dresser point- R0.2, 55o
4. Sleeve dia.- As per process card
5. Mandrel dia.- ɸ 69.6~ 106=58 mm, ɸ 106>80 mm
Defects occurred-
1. OD edge broken- Outer surface edge is broken
2. OD vibration- Irregular surface on the outer face
3. OD unground- Irregular machining on the outer surface
25. 7.3.4 Parkerising: Parkerising is a chemical process done to make corrosion resistant ring.
A Piston ring has to work in extreme condition in such case corrosion is unbearable.
In order to prevent the ring from corrosion and make it wear resistant Parkerising
coating is applied on the ring. It is a method of protecting a steel surface from
corrosion and increasing its resistance to wear through the application of an
electrochemical phosphate conversion coating. Parkerizing is usually considered to
be an improved zinc or manganese phosphating process, and not to be an improved
iron phosphating process, although some use the term parkerizing as a generic term
for applying phosphating (or phosphatizing) coatings that does include the iron
phosphating process. Parkerizing is commonly used on firearms as a more effective
alternative to bluing, which is another electrochemical conversion coating that was
developed earlier. It's also used
extensively on automobiles to
protect unfinished metal parts
from corrosion. The Parkerizing
process cannot be used on non-
ferrous metals such as
aluminium, brass, or copper. It
similarly cannot be applied to
steel containing a large amount
of nickel, or on stainless steel.
Passivation can be used for
protection. Detailed flowchart of
the Parkerising process is shown.
Figure 8 Process flow diagram of parkerising operation
26. 8. DEFECTS OCCURRED DURING MACHINING OPERATION:
The following list is the visual standard of the defect-
9. REJECTION ANALYSIS METHODOLOGY:
The process of analysis for rejection goes through various steps. To start with, the initial process
is to track and record rejection in each lots of ring. Then with all the recorded data Pareto
analysis is done. Pareto analysis is done in such cases where many possible causes are competing
and have to prioritize which cause is to be taken care of first. With the results from Pareto
analysis the defect contributing the most is selected and analysis are done on that particular
defect first. Following this there is a brainstorming session, where people operating the
respective machine causing the defect are called and asked for the reason for the defects. Then
after various careful calculation and experimentation solution for the rejection reduction is
established.
27. 9.1 Track of the lot for the rejection analysis:
After tracking two lot of ring for the characteristics of defects occurred at each step of operation
it is been observed that chrome broken has a major contribution to the rejection. The lot which
was tracked are model XXX and YYY
1. Model name- XXX
Model type- CPC RING with KEYSTONE PROFILE
Material- RIK- 20A
Nominal dia. - 104.00 mm
Initial no. of rings in the lot- 2680
No. of rings before keystone operation- 2465
No. of rings at final inspection- 2236
Total rejection- 444
Rejection percentage- 16.56 %
2. Model name- YYY
Model type- CPC RING with KEYSTONE PROFILE
Material- RIK- 20A
Nominal dia. - 88.90 mm
Initial no. of rings in the lot- 2625
No. of rings before keystone operation- 2440
No. of rings at final inspection- 2312
Total rejection- 313
Rejection percentage- 11.92 %
CRI Inspection report for the YYY
28. It is been observed from the CRI report that the chrome broken has the major effect on rejection
rate. An average of 61.5 % of the whole rejection is chrome broken. After tracking and analysis
of the rejection rate it is been finalised that chrome broken is major contributor to the rejection
and studies is to be done on this defect.
9.2 PARETO ANALYSIS:
Pareto analysis is done on these models for prioritizing the causes and selecting the key
contributing cause. Pareto analysis graph is shown below-
From the graph top 4 defects are chosen along with the action plan which are as follow-
Chrome broken at gap (9.5%) - Action plan has been made for chrome broken at gap
Chrome broken at O.D. (2.3%) – 64% reduction
O.D. scratch (0.6 %) – 78% reduction
O.D. gap edge chamfer (0.09%)
10. PREVIOUS IMPROVEMENTS TO REDUCE REJECTION:
Processing of all CPC rings below 120mm diameter on auto OD gap chamfer machine
Processing of all CPC rings on D-150 cam turning machine
Buffing of entry portion of honing sleeve started to avoid chrome broken at O.D. during
insertion of mandrel in sleeve
Bearing unit neck thickness reduced to avoid chrome broken at gap during processing of
rings on boring operation
10.1 Processing of all CPC rings below 120mm diameter on auto OD gap chamfer machine:
Auto gap edge chamfer machine is used to create chamfer at the gap edge. Chamfering is done to
Figure 9 Pareto analysis chart
29. reduce stress concentration at the gap edge. This machine is fully computerised, the ring is
stacked in a T-shaped bar. Then a picker arm picks few no. of ring and pass it for the machining.
Two abrasive belt are clamped of either side to chamfer the edge on both side. After then the
rings are collected in the T bar on the other side.
All CPC ring below 120mm diameter are more prone to defects and has to be carefully handled.
For this purpose automatic gap edge chamfering machine is used. Figure of gap chamfering
machining process is given below.
10.2 Bearing unit neck thickness reduced to avoid chrome broken at gap during processing
of rings on boring operation: Internal boring machine is used to bore the internal side
face of the ring. This operation is followed by the cam turning operation. Tool used in
this operation is a five single point cutting tool attached to a thick disc shaped
attachment. This machine consist of vertical motor which rotates the spindle which is
attached to the tool. Rings are stacked to the
machine in such a way that the spindle is right at the
internal portion of the ring. As the vertical motor starts
the tool rotates and bore the internal part of the ring.
After the rings are machined they are passed through
the bearing unit. Since the neck of bearing unit is
thick it leads to slight expansion of gap and
ultimately the chrome is broken at the gap. To overcome
this the thickness of neck is reduced. Detailed diagram of
the bearing unit is given below.
Figure 10 Diagram depicting the edge chamfer operation Figure 11 Diagram depicting internal
edge chamfering operation
Figure 12 Diagram depicting the neck thickness
change in bearing unit
30. 11. SUGGESTION FOR REJECTION REDUCTION FOR FUTURE SCOPE:
After observations it is been witnessed that gap grinding has a key role in chrome broken defect.
Gap grinding machine: After the chrome plating procedure one of the main operation is gap
grinding. This operation is very critical because of its contribution to the rejection of the ring.
Due to this reason this machine is always been a point of interest for many engineers working on
rejection reduction. Gap grinder is a computer controlled machine having a grinding wheel
which fits in between the ring gap and grind it. A no. of ring are stacked and hanged in a T
shaped bar. An arm is provided to release single or a set of rings at a time. Ring is then grinded
at the gap with heavy supply of coolant in order to reduce chrome broken. Single ring or set of
rings are machined at a time according to the axial height of the ring. After the machining the
ring is then pushed through the sleeve and collected at the other end of the machine.
Following are the brief detail of the machine unit:
Materials machined: - RIK -40B, RIK-40S, RIK-10, RIK-20A, RIK-25H and SPR-02
Tooling detail: -
1. Grinding wheel- 125x1.5x22.23 mm
2. Grinding wheel designation- CB200R100BK8
3. Grinding wheel material- CBN (Cubic boron nitride)
4. Grinding wheel R.P.M.- 6000±200 rpm
5. Coolant- CIMSTAR (4-6 % min)
No. of rings per stroke Axial height
4 Up to 1.7 mm
3 1.7< B <2.5
2 2.5< =B <6
1 6< = B & Above
Defects occurred-
1. ID gap broken- Gap is broken at the inner surface
2. Slant gap- Gap cut is not proper
3. Chrome broken- Chrome coating is broken
4. OD scratch- Scratch at the outer surface
During the ring is inside the sleeve the grinding operation initiates and grind the ring. After this
the ring is pushed by a pusher, while pushing the ring leans backward and the gap is regrinded
and chrome is broken at the gap. Another problem arose due to the sudden expansion of the ring.
31. When the ring is pushed outside the sleeve, ring in closed position is freed and ring expands.
This sudden expansion lead to chrome broken. Final problem which is been the most critical one
is the chrome broken at gap due to impact of the fall from upper T- shaped slide to lower T-
shaped slide.
11.1 SUGGESTION OF IMPROVEMENT:
Rubber support underneath the sleeve for preventing the ring from leaning backward
Welding a slope joint between upper T-slide to lower T-slide to supress the impact of fall
- Rubber support underneath the sleeve for preventing the ring from leaning backward-
Gap grinding operation starts with the stacking of the ring at the input area. These stacked
rings are released one by one through an automated arm actuating system. According to
diameter of the ring 2 or more rings are machined in a single cycle. After these set of
rings are released from the stack a jet stream of coolant is directed on these rings to wash
of the gap area and to tightly organise it. These rings are then pushed into the sleeve
through a pusher. Pusher diameter is slightly less than the sleeve diameter such that the
pusher fits exactly into the sleeve. Ring is then grinded inside the sleeve and then pushed
further by the pusher. During this pushing action the ring leans slightly backward. This
lean cause the ring to regrind when the ring touches the grinding wheel. This effect
caused the chrome broken defect at the gap. The reason for this failure was analysed and
came to a conclusion. The reason is the looseness of the sleeve which caused the free
movement in the ring and due to self-weight it lean backward. To overcome this failure a
rubber attachment is suggested to recover this loss. The logic behind this attachment is to
add more grip and tighten the loose joint between the ring and the sleeve. The rubber
attachment size may vary with different sleeve size. This suggestion might be
experimented for better results.
Figure 13 Diagram showing rubber attachment in the sleeve bottom: SIDE VIEW
32. - Welding a slope joint between upper T-slide to lower T-slide to supress the impact of fall-
After the machining operation the rings are then pushed out from the sleeve. Then the
fully machined rings are collected at the ring collector slide. Before reaching the ring
collector the ring has to follow a bumpy path. As shown is the figure above the rings has
to follow the path of upper T-Slide and the lower T-slide by finally reaching the end
portion i.e., ring collector slide. The upper T-Slide is an inverted T shaped stainless steel
rod designed such that it can accommodate rings. The ring gap fits into the inverted T-
shape with the lower flat portion bearing the ring. These T-rods are given a slight slope in
order to slide the ring in its path. When the ring passes from Upper T-slide to lower T-
slide it has to fall from a height of 3-4 cm. This fall creates an impact force on the ring
gap. The effect of impact leads to breakage of the chrome coating at the gap. Chrome
broken is the major drawback in the production of CPC ring. The chrome broken defect
at the gap grinding machine is quiet enlarged as in this machine once machining is done
and if there is any defect it has to be rejects. While in case of honing operation if
rehoning occurs the lapping time is increased to recover the defect. The solution for the
defect caused due to the fall can be recovered by welding a slide attachment to the upper
T-slide. The logic behind this suggestion is to allow a smooth path without any impact to
the ring. The ring will slides effortlessly from upper T-slide to the lower T-slide with no
impact which leads to chrome broken. The upper T-slide is adjustable to accommodate
grinding wheel adjustment. Due to this reason the slide attachment is to be welded to the
upper portion only by making the upper T-slide detachable.
Figure 15 Diagram showing the two T-Slide of the gap grinding machine Figure 14 Diagram of the concept of slide attachment
33. 12. CONCLUSION:
Methodology for rejection reduction was successfully submitted to my industry guide and
discussed about the outcome. In near future the new suggestion might be implemented if
successfully experimented. I feel proud in rendering my service to SHRIRAM PISTONS AND
RINGS LTD.
The internship gave me an opportunity to get a hands on experience of shop floor and the
required engineering problem solving techniques. Granted a chance to visit the complete
manufacturing line, I now understand the mechanisms concerned to the industry and my
curriculum. Being in the C2D1 ring manufacturing plant I gained an opportunity to closely
observe the working and management of manufacturing operations along with the live hurdles
and their solutions. After viewing the world class manufacturing process by myself, I feel
honored to get associated with such a well renowned company and with such a hard working
team.
13. REFERENCE:
Website:
www.shrirampistons.com
Books:
Company catalogue book