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A TRAINING REPORT OF EIGHT WEEKS INDUSTRIAL TRANNING
At
CAPARO MARUTI LTD. BAWAL, REWARI (HARYANA)
SUBMITTED IN PARTIAL FULFILMENT OF THE REQUIREMENT FOR THE
AWARD OF THE DEGREE OF
BACHELOR OF TECHNOLOGY
(Mechanical Engineering)
MAY 15-JULY 16, 2018
SUBMITTED BY:
NAME: HARENDER KUMAR
UNIVERSITY ROLL NO: 15EMBME023
DEPARETMENT OF MEHANICAL ENGINEERING
M.L.V TEXTILE & ENGINEERING COLLEGE, BHILWARA
(An Autonomous Engineering College of Government of Rajasthan)

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CANDIDATE’S DECLAIRATION
I AM HARENDER KUMAR hereby declare that I have undertaken eight weeks industrial
training at CAPARO MARUTI LTD during a period from MAY 15 TO JULY 16, 2018 in
partial fulfilment of requirements for the award of degree of B. Tech (Mechanical
Engineering ) at M.L.V TEXTILE & ENGINEERIING COLLEGE, BHILWARA the work
which is being presented in the training report submitted to department of mechanical
engineering at M.L.V TEXTILE &ENGINNERING COLLEGE , BHILWARA is an
authentic record of training work.
SIGNATURE OF THE STUDENT
The eight weeks industrial training viva- voice examination of ………………………….has
been held on………………………and accepted.
Signature of Internal Examiner Signature of External
Examiner

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ABSTRACT
As l am very fond of automobile, It was a great opportunity for me to do eight weeks internship
in Caparo Maruti Ltd. Rewari, Haryana. The internship was concentrated on the car services.
At the beginning of the internship l had several queries in my mind regarding the
different technologies used in maruti and what skills are needed in organization. During my
internship several queries are cleared by doing some activities. The objective of this internship
is to gather information about the quick services and the major-minor problem that can
be observed in day to day life. In the workshop, I have learnt the rules and safety instruction
which helps me in understanding while working on maruti spare parts. So, this internship was a
great experience. I found out how much I am strong in automobile field. I gained new
knowledge and skills and met many new people. I achieved many of my learning goals. I
got insight into the work of an organization. The financing is an important factor and forces to
be flexible in attitude and approach. I learned more about the problems which I have face while
working on the spare parts. Working together with the different background people and by
education these threats have to be approached to succeed in my internship the sharing of
knowledge, ideas and opinions is of importance. There is still a lot of discover and other
methods can be improved. At last this internship has given me new insights and motivation to
pursue a career in mechanical engineering.

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ACKNOWLEDGMENT
First I would like to thank Mr. Sanjay yadav (GM of company), Mr. Rattan yadav (HR of
company), CaparoMaruti Ltd. Rewari, Haryana for giving me the opportunity to do an
internship within the organization. For me it was a unique experience to be in this work
shop. It also helped me to get back my interest in mechanical engineering and to have new
plans for my future career.
I would like to thank all the people also that works in the organization. With their
patience and openness they created an enjoyable working environment. Furthermore I want
to thank all the engineers and students, with whom I did the internship. We
experienced great things together and they taught us many more things regarding
automobile.
At last I would like to thank Mr. Anil kumar (production planning engg.)& Mr. Virat Singh
(senior production engineer) .who told me all about the organization and Quick services and
also about the major-minor problem observed in the production & manufacturing of parts.

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LIST OF FIGURES
Fig. No. Name of figure Page no.
Fig. 1.1 Over view of Company 2
Fig. 1.2 Stamping tool 6
Fig. 1.3 Spot welding 8
Fig. 1.4 Butt welding 8
Fig. 2.1 Cushion bed 14
Fig. 2.2 Lower die 15
Fig. 2.3 Upper die 15
Fig. 2.4 Damping unit 16
Fig. 2.5 Air cylinder 17
Fig. 2.6 Lubrication system 18
Fig. 2.7 Loader and unloader 18
Fig. 2.8 Transfer belt 19
Fig. 2.9 I.T. gun 20
Fig. 2.10 Non I.T. gun 20
Fig. 2.11 Drawing operation 23
Fig. 2.12 Trimming operation 24
Fig. 2.13 Restriking operation 25
Fig. 2.14 Complete structure of part 26

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Fig. 2.15 I.T. gun 27
Fig. 2.16 Non I.T. gun 27
Fig. 3.1 Defects produced in the sheet 31

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CONTENTS
Training certificate……….……………………………………………………………....I
Candidate’s declaration………………………………………………………………….II
Abstract………….............................................................................................................III
Acknowledgement………………….…………………………………………………....IV
Contents………………..………………………………………………………….….V-VI
List of figure’s…………………………………………………………………….VII-VIII
CHAPTER1:INTRODUCTION………….……….………………….1-11
1.1 Introduction…………..…………….………………..……………………………....1
1.2 Company location………………………………..…………………………………..1
1.3 Company overview……………………………………………………………...........2
1.4 Plant structure…………………………………………………………………………3
1.5 Achievement & awards……………………………………………………………….3
1.6 Objective…………………………………………………………………….………..3
1.7 Department……………………...…………………….…………………………..4-12
CHAPTER 2: MANUFACTURING OF PARTS.......................................................13-28
2.1 Press shop……………………………………………………………………….13-19

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2.2 Welding section…………………………….………….………………………19-20
2.3 Quality section………………..………………..………………………………… .21
2.4 Manufacturing process…………..…………………….……………………… 21-28
CHAPTER 3: RESULT AND DISCUSSION....................................29-31
3.1 Result……………………………………………………………………………29
3.1.1 Successful development of part………………………………...…29
3.1.2 Get the chance to gain the knowledge…………………………29-30
3.2 Discussion……………………………………………………………………….30
3.2.1 Defects produced in sheet………………………………………….30
3.2.2 Problem produced in the presses…………………………………..31
CHAPTER 4: CONCLUSION.......................................................................................32

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CHAPTER-1
INTRODUCTION TO ORGANIZATION
1.1 INTRODUCTION
CAPARO MARUTI LTD. Is a premier industry setup in Bawal, Haryana dedicated for the
production and designing of various sheet metal parts and components associated with
automobiles. It has been a vendor MARUTI INDIA PVT.LTD. It is a multi-disciplinary and
multi-dimensional organization dedicated for the production of number of components.It is
one of the sister company out of group of companies. It is serving several of its clients.
Large number of components ranging from simple to highly sophisticated ones, have been
designed and developed by the company and their know-how’s have been passed on to the
various of its clients.
Over a period of time, CAPARO has acquired state-of-art expertise in designing
components for different applications associated with automobile industry. Keeping pace
with emerging trendsCAPARO has developed various components using state of the art
technologies. It’s anISO / TS 16949 : 2002 Certified company. It performs all of its
operations under the norms as laid by the International Standardization Organization,
keeping in view the well being of its employees and workers at every level It is spread over
an area total of 11406 Sq. Yards and the covering area is being 65196 Sq. Ft. .
1.2 LOCATION
It is located in Bawal, the industrial city of Haryana state.
Plot no. 85 to 102, sec.-7, HSIIDC Industrial Growth Centre , Bawal, Dist. Rewari (Haryana)
INDIA 123501

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One of the great advantages for the location is being that it is situated very near to the
Gurgaon.
1.3 AN OVERVIEW OF CAPARO MARUTI LTD.
Fig 1.1 CAPARO MARUTI LTD .

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1.4 PLANT STRUCTURE
i. Total Area :- 11406 Sq. Yards
ii. Covered Area: - 65196 Sq. Ft.
PowerBack-UpFacility
i. Gen Set :- 500 KVA
ii. Gen Set :- 162 KVA
Plant Spare Capacity
50% Spare Capacity
1.5 ACHIEVEMENTS& AWARDS
 Best vendor award from MUL (Maruti Udyog Ltd.)
 Udyog Ratna Award
 Maintaining ZERO DEFECT Products for GMI ; AVTEC ; M & M since Last
3 Years
 Delivering Products ON TIME – EVERY TIME for all Customers.
1.6 OBJECTIVE
 Aims at producing professionals endowed with technical competence and leadership
qualities.
 To infuse thorough knowledge and impart industry -oriented practical training to make
the students a breed apart.

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 To inculcate a sense of discipline and responsibility coupled with logical thinking, so
that they are an asset for their employers.
 To instill a high level of self-confidence to make them successful in all walks of life
including entrepreneurship.
 To emphasize their all round development, by ensuring participation in cultural
activities, group discussions, social get-togethers, sports, etc.
 To imbibe a quality that makes them better citizens.
 To create professional competence.
1.7DEPARTMENTS
(i) Engineering Department
(ii) Production Department
(iii) Welding department
(iv) Quality section
(i) ENGINEERING DEPARTMENT
1. Engineering department deals with development of the fore coming parts of
Maruti
2. Generally, majority of the parts are from MUL, Ggn. Parts are prepared and
there trial is taken. This department also deals with costing of sheet metal
parts, in which quotation are prepared in order to submit to the customers and
vendors.

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(ii) Production Department
In production department metal sheets are given desired shapes through stamping process
Stamping press is used to produce the stamping operation.
What is a stamping press ?
A stamping press is a machine that houses the stamping tools (tooling) and carries them
around according to the kinematics indicated by the users (process set-up).
The knowledge of the press used for a stamping operation provides us with useful clues
regarding:
• Values and distribution of restraining forces
• Tool deformation caused by stamping forces
Contact and/or gap between tools and
blank
However, we should recall that, at the moment when the die design is carried out, the press
is usually not yet known, so that its characteristics are rather a factor of noise than a useful
information. Therefore it will be important to have a design that is robust with respect to the
press type.

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Fig:1.2 Press machine

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GLOSSARY:
Designsurface Part as designed to fit in the car (after trimming)
Blankholder Surfaces that hold the blank before the forming
surface operation, including the restraining
Production Junction between the two former surfaces, surface/run-offsprotecting
the design surface and controlling material flow
DiefaceRun-offs + blankholder
(iii)WELDING DPARTMENT
Resistance Welding is a welding process, in which work pieces are welded due to a
combination of a pressure applied to them and a localized heat generated by a high electric
current flowing through the contact area of the weld.
(a)SPOT WELDING (RSW)
• Spot Welding is a Resistance Welding (RW) process, in which two or more
overlapped metal sheets are joined by spot welds.
The method uses pointed copper electrodes providing passage of electric current. The
electrodes also transmitt pressure required for formation of strong weld.
Diameter of the weld spot is in the range 1/8‖ - 1/2‖ (3 - 12 mm).
Spot welding is widely used in automotive industry for joining vehicle body parts.

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Fig 1.2: Spot Welding
(b)RESISTANCE BUTT WELDING
• Resistance Butt welding is a Resistance Welding (RW) process, in which ends of
wires or rods are held under a pressure and heated by an electric current passing
through the contact area and producing a weld.
Fig 1.3: Butt Welding

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Butt welding is used for welding small parts. The process is highly productive and clean. In
contrast to Flash Welding, Butt Welding provides joining with no loss of the welded
materials.
(iv)QUALITY CONTROLSECTION
As the name suggests this section houses all sorts of tools and measuring instruments like
vernier calipers, vernier height gauge, slip gauges, surface plates, radius gauges,
inside/outside micrometers, depth gauges and hardness testing machines, torque wrench
testing machine etc. for checking the components purchased from the vendors from outside
the firm before being stored into the store lying adjacent to this section.
This section monitors whether the components supplied by the allied vendor party covers
the quality specifications of the company or not and according takes corrective action as and
when required. It also keeps a track record of the stock of components inside the store.
Being an ISO certified company; the firm is deeply concerned with managing of quality of the
purchased components which ultimately affect the quality of its final product.
The Quality Policy of the company can be quoted as:
• Producing world class tractors in quality and reliability
• Total customer satisfaction through services
• Creating a culture among all employed toward total quality concepts
• Constant up gradation of technology and human excellence
After so many accomplishments, the company is still striving hard to expand its capabilities
and setting up new establishments and manufacturing units in different parts of the country.
Some of the manufacturing units are under construction and soon will be ready to work. It

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has signed MOU’s with several international firms to match up with the latest trends in the
automobile industry, the fastest growing industry of its kind in the current scenario.
QUALITY IMPROVING STEPS FOLLOWEDBY CAPARO
1.5S
2.Kaizen
3.3R
4.3M
1. 5S:-
5S is the name of a workplace organization methodology that uses a list of five
Japanese words which are seiri, seiton, seiso, seiketsu and shitsuke
ENGLISH MEANING OF 5S
I. SORTING (SEIRI):
Eliminate all unnecessary tools, parts, and instructions. Go through all tools,
materials, and so forth in the plant and work area. Keep only essential items and
eliminate what is not required, prioritizing things per requirements and keeping
them in easily-accessible places. Everything else is stored or discarded.
II. STRAIGHTENING OR SETTING IN ORDER / STABILIZE (SEITON)
There should be a place for everything and everything should be in its place. The
place for each item should be clearly labeled or demarcated. Items should be
arranged in a manner that promotes efficient work flow, with equipment used most
often being the most easily accessible. Workers should not have to bend

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repetitively to access materials. Each tool, part, supply, or piece of equipment
should be kept close to where it will be used – in other words, straightening the
flow path. Seiton is one of the features that distinguishes 5S from "standardized
cleanup". This phase can also be referred to as simplifying.
III.SWEEPING OR SHINING OR CLEANLINESS / SYSTEMATIC
CLEANING (SEISO)
Clean the workspace and all equipment, and keep it clean, tidy and organized. At
the end of each shift, clean the work area and be sure everything is restored to its
place. This makes it easy to know what goes where and ensures that everything is
where it belongs. Spills, leaks, and other messes also then become a visual signal
for equipment or process steps that need attention. A key point is that maintaining
cleanliness should be part of the daily work – not an occasional activity initiated
when things get too messy.
IV. STANDARDIZING (SEIKETSU)
Work practices should be consistent and standardized. All work stations for a
particular job should be identical. All employees doing the same job should be able
to work in any station with the same tools that are in the same location in every
station. Everyone should know exactly what his or her responsibilities are for
adhering to the first 3 S's.
V. SUSTAINING THE DISCIPLINE OR SELF-DISCIPLINE (SHITSUKE)
Maintain and review standards. Once the previous 4 S's have been established, they
become the new way to operate. Maintain focus on this new way and do not allow a
gradual decline back to the old ways. While thinking about the new way, also be
thinking about yet better ways. When an issue arises such as a suggested

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improvement, a new way of working, a new tool or a new output requirement,
review the first 4 S's and make changes as appropriate.
2. Kaizen:-
Masaaki Imai definedKaizen as ―a means of continuing improvement in personal
life, home life, social life, and working life. At the workplace, Kaizen means
continuing improvement involving everyone—managers and workers alike. The
Kaizen business strategy involves everyone in an organization working together to
make improvements without large capital investments.‖
Mark R. Hamel has a slightly different definition: ―Kaizen is much more than an
event; it is a philosophy, mindset and, for breakthrough performance, a most critical
vehicle to achieve strategic imperatives and execute value stream/process
improvement plans.‖
The five main elements of kaizen
• Teamwork
• Personal discipline
• Improved morale
• Quality circles
• Suggestions for improvement
Kaizen is a daily process, the purpose of which goes beyond simple productivity
improvement. It is also a process that, when done correctly, humanizes the
workplace, eliminates overly hard work ("muri"), and teaches people how to
perform experiments on their work using the scientific method and how to learn to

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spot and eliminate waste in business processes. In all, the process suggests a
humanized approach to workers and to increasing productivity.
3. 3R:-
Reduce, Reuse, Recycle, a hierarchy of waste management strategies to
minimize waste
4. 3M:-
i. Muda
ii. Mura
iii. Muri
"muda" meaning activity that is wasteful and doesn’t add value.
"mura", meaning "unevenness"
"muri" meaning "overburdening".

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CHAPTER-2
MANUFACTURING OF PARTS
For the manufacturing of the parts first of all the Overview Of The plant is given.
Different operations are performed during the manufacturing of the different parts.
The operations performed during the manufacturing of different parts the following
processes are involved
(1) Press Shop
(2) Welding Shop
(3) Quality Section
2.1 PRESS SHOP:
During the press shop firstly the sheet of Aluminum passes through the different
presses and performed different operations on it. The different presses & different
operations which are performed on the sheet are:
The different kind of presses used in the press shop is:
Type Of Press No. Of.
(1) 800 Tones 2
(2) 400 Tones 3
Table 2.1
The various operations are performed on the sheet during the press shop are
(1) Drawing
(2) Trimming
(3) Restrike
(4) Piercing/ Punching

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During the drawing the sheet can be passed through the press of 800 Tones & the
specific shape of the given part provided to the sheet and during trimming the extra
part of the sheet which is not in work can be trim by the press and the extra part can
be thrown into the scrap. During the process of restriking the die can be strike on the
part again so that it can acquire the exact shape of the part & during the process of
punching the different holes can be drawn on the part according to the shape. Press
contains different parts such as:
(1) Cushion Bed
(2) Lower Die
(3) Upper Die
The inner parts of a press which help to support the die are:
(1) Damping Unit
(2) Air Cylinder
(3) Lubrication System
The parts are shifted from one press to another by the loader & unloader.
The transfer belt is used to transfer the part from first press to another.
The different parts of press are:

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(I) CUSHION BED:
Fig 2.1: Cushion Bed
(ii) LOWER DIE:
Fig 2.2: Lower Die

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(iii) UPPER DIE:
Fig 2.3: Upper Die
The different internal parts of the press are:
(i) DAMPING UNIT:
Fig 2.4: Damping Unit

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(ii) AIR CYLINDER:
Fig 2.6: Air Cylinder

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(iii) LUBRICATION SYSTEM:
Fig 2.7: Lubrication System
(iv) LOADER & UNLOADER:
Fig 2.8: Loader & Unloader

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(v) TRANSFER BELT:
FIG 2.9: TRANSFE BELT
2.2 WELDING SECTION:
Spot welding can be done on the parts for the joining of different small parts on the main
part. For example studs are attached to the different parts with the help of spot welding.
Spot welding mainly of two types
(i) Integrated Transformer Gun
(ii) Non-Integrated Transfer Gun
These are the two methods mainly used for the spot welding.

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Integrated transformer gun means a gun which is used for the spot welding contains the
transformer inside the gun. There is no outside transformer placed for the working of the
gun.
On the other hand Non Integrated Transformer gun can be used for the spot welding of the
parts contain a transformer side from the gun.
(i) INTEGRATED TRANSFORMER GUN :
Fig 2.10: I.T. Gun
(ii) NON INTEGRATED TRANSFORMER GUN :
Fig 2.11: Non I.T. Gun
These are the two guns which are used for the
welding purpose of the parts manufactured.

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2.3 QUALITY SECTION:
In the quality section the part manufactured can be checked out completely. In
quality section these things can be checked out in the part:
(i) Overlapping
(ii) Wrinkle
(iii) Deformation
(iv) Crack
(v) Dent
(vi) Material Strength
These are different facts that can be checked out in quality section which are
necessary to be checked out for the strength and accuracy of the part.
 MANUFACTURED PARTS:
• Dash Waganor
• Dash Versa
• Wheel Housing
• Chessy
• Quarter Inner Lower
• Frame Floor
• Door Hinge
2.4MANUFACTURING PROCESS:
For the manufacturing of the above discussed parts a part is to be followed by the
different operations. Firstly, a part is to be moved from the press shop where the
drawing, trimming, restrike & piercing/punching can be & the shape can be
provided to the sheet of the given specific die & then it can be send to the welding

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section where the spot welding of the manufactured part can be done & different
studs, nut & bolt can be attached to the part according to the specification of the
part. `
MANUFACTURING PROCESS IN PRESS SHOP:
In press shop first of all a sheet of aluminum can be taken then it can be
placed in the different dies where different operations can be done on it.
DRAWING:
Firstly, the process of draw can be done where the given specific shape can be
applied on the sheet by placing it on the die of that specific shape. The die can be
placed on M.B. in which cushion pins can be put according to the shape these
cushion pins pull up the die &a upper die is attached to upper M.B. with the help of
studs. For the manufacturing of part first of all power is put on and then pressure is
applied to upper die by the air cylinder situated at the top of press and with the
pressure the upper die moves towards down and hit on the lower die. When the
upper die strikes on the lower die the sheet present on the lower die attain the shape
of the die. The lower die does not move towards down because of cushion pin
which support the die. The cushion plays an important role during the
manufacturing of the parts because it support the die if any cushion is placed in a
wrong way inside the M.B. then it will damage the die so it is necessary to place
the cushion pins inside the M.B. correctly. The M.B. is placed on the cushion bed
which helps to absorb the damps which produced when the upper die strikes on the
lower with a pressure of 800 Tones. During the drawing the specific shape can be
applied to the sheet. According the part the can be loaded on the M.B. and the
placed on the cushion bed and then the process of manufacturing starts. Loader

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takes the sheet from the shelf where it can be provided by the workers. The loader
picks the sheet and placed it on the die. Then the operation of draw is started and
the shape of the die can be applied on the sheet. There is a big importance of angle
of stroke during the press operations. The accuracy of the part depends upon the
stroke of press, commonly the stroke is 180*(Degree). Lubrication system also
plays an important role during the operation of press because without lubrication it
can’t be easier to drive such kind of heavy press so it is necessary that lubricating
pump should work properly.
Fig 2.12: Drawing Operations
TRIMMING:
Trimming is a operation in press shop in which after the process of drawing the remaining
part which is useless on behalf of the structure of part is to cut by this press. In trimming the
upper die contains blade on the edges of it and when it strike on the lower die where the part
with extra useless part is placed is to be trimmed. So trimming is a necessary operation on
behalf of the structure of the part. This press is of 400 Tones and strikes on the lower die
which is placed on the M.B. and supported by the cushion pins which are necessary to hold

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the die during the striking operation. If any of the cushion pin put in wrong way inside the
M.B. then it will damage the die & sometimes die will breakdown due the pressure of the
press and can’t be able to absorb the vibrations produced by the cushion bed and as a result
the die will damage so it is necessary to placed the cushion pins correctly according to the
drawing of the part. During trimming it is necessary to take care of angle of stroke and the
lubrication system because it is necessary for the accurate working of the press. The press
contains a air cylinder on the top of the press in these cylinder air is to be compressed and it
helps in the stroke of the press so there are so many things which can be checked during the
working of press.
Fig 2.12: Trimming Operation
So trimming is an operation in which the remaining portion of the part which is not useful is
to be removed by the cutting operations
RESTRIKING:
Restriking is an operation in which after the trimming operation the part is taken by the
unloader and put it on the transfer belt which takes it up to the another press from where the
unloader takes the part and put it on the press where the die of same kind is already placed

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and the part is placed on the die and then operation of restrike done again. In the operation
of restrike the upper die is again strike on the part which is placed on the lower die. The
lower die is placed on the M.B. and the operation of restrike can be done because during the
operation of drawing some design can be missed and during the restriking operation these
designs can be made on the part so restriking operation is the important operation on behalf
of the design of the manufacturing of part because the accuracy of the part depends upon the
operation. During this operation the stroke of press can be take care so that the complete
process of the designing of part can be completed with complete accuracy because the
accuracy of the part is necessary because the complete design of the car can be based on the
accuracy of that part. So restriking operation can be done on the part after the trimming
operation so that the complete design can be made on the part. In this process again the
cushion pin plays important role on the die because the cushion pins support the die to
absorb the damps which are produced by the striking of upper die on the lower die and the
die press is of 400 Tones which is used for the restriking operation.
The part on which the restriking operation be done:
Fig 2.13: Restriking Operation
So restriking operation is done for the accurate design of the part by restrike the press on the
part placed at the die.

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PUNCHING/PIERCING:
Punching is operation in which the punch can be made on the part for the complete accuracy
of it. During the punching the punches can be made on the part because punches can be
necessary according to the construction and working of it, because without punches a part
can’t be fit into the car, so the punches are necessary according to the constructional
accuracy of it. After the operation of restrike the unloader picks the part from the press and
put it on the transfer belt which transfer it up to the another press where the punching
operation can be done. The loader takes the part from the belt and put it on the die which is
placed at the M.B. the upper part of the M.B. contains a die on it with the punches so that
when it strike on the lower die the punches can be made on the part according to the
construction of the die. So the punching operation is necessary according to the construction
of the part. The press works fully automatically and the different parts of the press such as
loader- unloader, transfer belt works automatically and plays an important role for the
construction of the part during the all operations of the press. The lubricating system is also
necessary for the accurate working of the press because without the complete and accurate
lubrication it can’t be possible to drive such kind of heavier press. The punching operation is
the last operation that can be done in the press shop and the die used for the punching
operation is of 400 Tones and upper die strike on the lower die with the pressure of 400
Tones and this pressure can be maintained by the air cylinders which are placed at the top of
the press. The part which is to be punched is complete in its construction and then sends it to
the quality check department for checking the accuracy and the defects producing during the
press shop operations. The part manufactured after the press shop operation is:

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Fig 2.14: Complete Structure Of the Part
So during the Press Shop Department the four operations can be done
(i) Drawing
(ii) Trimming
(iii) Restrike
(iv) Punching/Piercing
After these four operations the part is completely ready according the construction and
shape of it. These four operations can be done on the dies of different loads the die used for
the Drawing Operation is of 800 Tones and the presses used for the remaining three
operations are of 400 Tones.
WELDING OPERATION:
After the press shop operation the part is ready for adding the different nut and bolts to be
attached on it the part is sends to the welding section where the spot welding can done on it.

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The Spot Welding can be done on it with two different kind of welding:
(i) I.T. Gun Spot Welding
(ii) Non-I.T. Gun Spot Welding
(i) I.T. GUN SPOT WELDING: In I.T. Gun Spot Welding the spot welding can be
done with the help of a gun which contain the transformer in it. This kind of
press called as the I.T. Gun and the spot welding can do on it more easily as
compare to the other welding operations. The gun used for the I.T. Gun Spot
Welding is:
Fig 2.15: I.T Gun
(ii) NON I.T. GUN SPOT WELDING: In Non I.T. Gun Spot Welding operation
the gun used for spot welding does not contain transformer in it. The transformer
is placed outside of the gun. The name of the Non I.T. Gun is Non Integrated
Transformer Gun for spot welding. The gun used for Non I.T. Gun Spot Welding
Fig 2.16: Non I.T. Gun

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Spot Welding can be done on the parts because it support the aerodynamic condition
because it is light in weight as comparison to the other welding techniques and its cost is
less as compare to other welding techniques.
After the welding process the part is sends to the final Quality Section where the quality of the
part and the accuracy of the part can be checked.
QUALITY SECTION: After the welding process the part is sends to the quality section
where the quality checker checks the quality and accuracy of the part because it is essential
to check the accuracy of part. The defects can be checked at that department because it is
necessary that a part should be accurate because without the accuracy it can’t be fitted into
the car. So it is necessary to checked out and solves these problems of the part the certain
defects that can be produced on the surface of the sheet during the press shop operations are:
(i) Overlap
(ii) Cracks
(iii) Wrinkle
(iv) Deformation
(v) Dent
These are the different defects that produced on the surface of the sheet during the press
operation such as drawing, trimming, restriking and punching. During these operations these
defects can produced so it is necessary to check these defects because these defects are not
to be favorable according to the structure of the part. So in quality checking section the
checker check this defects and solves these by different operations.

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So this is the manufacturing process of the parts in which following three stages can be used:
(i) Press Shop Operations
(ii) Welding Shop Operations
(iii) Quality Checking Section
And after these three stages the part is ready for the supply and fitted into the car. So this is the
manufacturing process of the different parts.

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CHAPTER 3
RESULTS &DISCUSSION
3.1 RESULTS:
3.1.1 SUCCESSFUL DEVELOPMENT OF THE PART:In the final we
getting the result of the successful development of the part. The part can be developed
according to its profile which is provided by the company to the engineers. According to its
structure a die can be used for the manufacturing of the part. For the manufacturing of the
different parts different dies can be used which are according to the shape of the part. The
die is loaded on the M.B. and M.B. can be placed inside the press as the lower unit and a
upper portion of the die can be attached to the upper M.B. with the help of studs. When the
die is loaded then the complete automatic process of the press starts and the pressure starts
creating in the cylinders which are attached at the top portion of the press. When the
pressure completes then the upper die completes its stroke and the single- single operations
can be completed on different presses. The presses used for these different operations are of
different pressures the press used for the drawing operation is of 800 Tones and the presses
used for the remaining operations are of 400 Tones that means the upper die strikes on the
lower one with that pressure. The damps produced in the press by this strike are absorbed by
the damping unit which is under the cushion bed. The M.B. is placed on the cushion bed and
the damps can be absorbed by the damping unit. After the every operation complete the part
sends to the welding shop where the nut and bolts are attached to the part according to the
constructional detail of the part with the help of the spot welding and at last the part is
checked by the quality checkers and ready for delivery. So this is the successful
development of the part.

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After the different press phenomenon the different welding operations are performed on it.
The welding operation is used is the Spot Welding operation in which spot welding can be
done in different two ways:
(i) I.T. Gun
(ii) Non I.T. Gun
These are the two welding operation which are used for the spot welding so we get the
knowledge about the different spot welding techniques and machines which are used for
spot welding. By watching this complete we are able to get the knowledge of the different
processes that can be used in the factory for the manufacturing of different parts. So after
getting the complete training we get the knowledge of different processes.
3.2 DISCUSSIONS:
3.2.1 DEFECTS PRODUCED IN SHEET: During discussion we discuss about the
problem facing during the manufacturing process of the different parts. Basically the main
problem can be faced is of different defects produced during the manufacturing
phenomenon. The different defects produced are:
(i) Wrinkle
(ii) Overlapping
(iii) Crack
(iv) Deformation
(v) Dent.
These are the main problems that are faced during the manufacturing process of part.
These defects can be discussed during the training

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Fig 3.1: Defects Produced In the Sheet
3.2.2 Problem Produced In The Presses: There are different problem that
produced during the working condition of press and these defects can be studied or
discussed during training. The different defects produced in the presses are:
(i) Lubrication Problem
(ii) Pressure Problem
These are the problems that are produced during the working condition of the press. So
these defects can be discussed or solved out during training.

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CHAPTER-4
CONCLUSION
In conclusion we are discussed to solve the problems produced during the working condition
of the press and manufacturing of the parts. To solve the defects produced on the surface of
the sheet during different press operations different processes can be used if the damage is
small and it can easily be repaired then it can be machined and repaired it but if the defect is
not be able to correct then the sheet can be thrown into the scrap. If the problems are small
and it can easily be repaired then different operations such as hammering, machining can be
used. After applying these processes the defects can be removed the surface of sheet
because without removing these defects it can’t be possible to use these parts. A defected
piece can’t be used in the manufacturing of the car so it is necessary to remove theses
defects. In conclusion we discussed the process used for the removal of the defects.
There are certain defects produced during the working of press. The different defects
produced during the press operation are lubrication problem, less pressure produced in the
cylinders. It is necessary to solve these problems because without solving these problems
the press can’t work automatically. If any operation of the press stops working then press
stops working so it is necessary to solve these problems. Sometimes the pump of lubrication
stop working and the press stops working. So this effect can be checked out and clear it so
that the press should work properly. Sometimes the cylinder cannot produce proper pressure
for the stroke of the die so it is necessary to solve this problem that the press should stroke
properly. The pump stops working and the pressure stops producing in the cylinders and due
to this the press stops working so we find out the problem and solve this so that press should
work properly. So these are the basic conclusions that are made to solve the problems
produced during the different operations.