Sterling Tools Limited is a leading manufacturer of fasteners in India. It produces special, standard, chassis, and engine fasteners. The industrial training document describes Sterling's manufacturing process, which includes forging wire, forming heads through cutting, forming, and trimming, rolling threads, machining parts through turning and other operations, heat treating through hardening and tempering, electroplating for surface finishing, and implementing pollution controls and energy conservation efforts.

1. INDUSTRIAL TRAINING AT
STERLING TOOLS LIMITED
(INDUSTRIAL ESTATE, DLF 5A, FARIDABAD)
BY:
PRINCE NASWA
12MEU067
ITM UNIVERSITY GURGAON

2. ABOUT STERLING TOOL’S
• Sterling tools limited (STL), is a well-established,
dynamic and professionally managed company, is a
leading manufacturer of fasteners in India.
• The company was incorporated as a private limited
company in 1979 and was turned into a public
limited company in 1994.
• STL is the third largest fastener manufacturing
company in asia.
PRODUCTS:
1. Special Fasteners
2. Standard Fasteners
3. Chassis Fasteners
4. Engine Fasteners

3. INTRODUCTION
• An industrial fastener comprises a very wide
range of items like nuts and bolts, washers, studs,
nails etc. Nuts and bolts consist a major link in
the family of industrial fasteners and are used by
every industry. Bolt is a piece of metal rod, whose
one end is unsettled and other end is threaded.
Nut is the item, which rolls on these threads.
RAW MATERIAL
• Quality of bolts depends on the composition of
various elements in raw material. According to
the composition required there are total 17
grades of raw material available. Grade is decided
according to the costumer requirement.

4. Raw
Material
Forging
Machining
Lab Test Dispatch
Surface
finishing
Heat
Treatment

5. FORGING
• Forging is a process in which material is shaped by the
application of localized compressive forces exerted manually
or with power hammers, presses or special forging
machines.
• In cold forging production rates are very high with
exceptional die life. It improves mechanical properties and
makes it rigid.

6. WIRE STRAIGHTENING:
• The wire is in the form of rolls. So it needs to be
straightened before being forged.
• After straightening:
FEED
TUBE
STOPPER CUTTER DIE’S

7. HEAD FORMATION:
It is a 4 station process:
1. Cut off
2. Cone formation
3. Heading
4. Final trimming

8. THREAD ROLLING
• Thread rolling is a metal rolling process used extensively
in manufacturing industry to produce screws, bolts and
other fasteners.

9. PROCESS:

10. MACHINING
• Machining is a metal removal process in which excess
material is removed to obtain desired shape, size.
Machining is done by using CNC machines which are
highly efficient as they are more accurate, less time
consuming. So, more productivity and are cost
effective also.
• OPERATIONS PERFORMED:
1. Parting off
2. Threading
3. Grooving
4. Turning
5. Profiling
6. Undercutting
7. Face-grooving

11. LUBRICANT:
• Cutting oil used in lubricant is Mobil Cut- 100.
• Lubricant composition is 3 to 5% of cutting oil.
• DM water or RO water is used in lubricant.
• Lubricant is changed after every 6 months.
Concentration of lubricant is checked daily using
refractometer.

12. HEAT TREATMENT
• Heat Treatment is the controlled heating and cooling
of metals to alter their physical and mechanical
properties without changing the product shape.
Length of furnace is about 14.5m

13. PROCESS FLOW
LOADER
OIL
SKIMMER
WATER
SUPPLY
HARDENING
CONVEYOR
QUENCH IN
OIL
TEMPERING
FURNACE
DYEING
TANK
UNLOADING

14. • Gas flow meter is used to set LPG and
Methanol concentration.
• Minimum 100KGs stock of methanol and LPGis
must. This prevents the entrance of oxygen
and maintains appropriate carbon content.
Gas flow meter Control panel

15. SURFACE FINISHING
• ELECTROPLATING:
Electroplating is the application of a metal coating
to a metallic or other conducting surface by an
electrochemical process.

16. PROCESS FLOW
• PRE-TREATMENT:
• PLATING:

17. • POST PLATING:
• H
HOT AIR DRYER

18. POLLUTION CONTROL
• Heat treatment industry has a share in the present
environmental degradation.
• Two methods for control of pollution in an Industrial
unit :
 Use of equipment like gas scrubbers, ventilation fans,
washers etc. require considerable capital investment
and also in value running expenses.

19.  Use of high stack chimney and operating the unit
at a time of favorable natural draught through
chimney, helps to successfully disperse the dust
and gases emitted from the unit at zero or
negligible cost.

20. ENERGY CONSERVATION
• It has become essential these days that the energy
conservation efforts are needed to be strengthened
substantially.
• Various factors which affect fuel economy in
industrial furnaces may be stated as :
1. Complete combustion with minimum excess air.
2. Proper heat distribution.
3. Operating at the desired temperature.
4. Reducing heat losses from openings.
5. Minimizing wall losses.
6. Waste heat recovery from flue gases.

21. THANK YOU