presentationON

SIX WEEKS VOCATIONAL TRAININGAT

ROOP AUTOMOTIVES LTD.SOHNA, GURGAON (Hr.)

 Submitted In the partial fulfillment of the trainingFor the 5th Semester Curriculum of degree of

Bachelor of TechnologyIn

Mechanical EngineeringOf

Maharishi Dayanand University, Rohtak

ACKNOWLEDGEMENTWe can’t achieve anything worthwhile in the field of technical education until or unless theoretical education acquired in classroom is effectively wedded to its practical approach that is taking place in the modern industries and other means of technical application, the technical education is of equal proportions of practical and theoretical study. The months of industrial training taken at the ROOP AUTOMOTIVES LTD. as a part of my practical study is learning experience for me.

COMPANY PROFILEThe Company was jointly promoted in May, 1990 by Mr. V.K. Jain, Mr. Mohit Oswal, Mr. P.K. Salhotra & M/S Sona Koyo Steering Systems Limited, New Delhi. The Company was established to cater to the need of Sona Koyo Steering Systems Limited, a joint venture of Maruti Udyog Limited & Koyo Seiko Steering, Japan. Company was set up to manufacture components of Steering Column. The Company has since diversified and has the facility to manufacture various components for two wheeler, four wheeler vehicles and agricultural vehicles and equipments.  ADDRESS  ROOP AUTOMOTIVES LIMITED19, ROZ-KA-MEO INDUSTRIAL AREA,SOHNA, GURGAON – 122103PH. :91-124-6362138, FAX: 91-124-6362568e-mail: roopauto@vsnl.comURL: www.roopindia.com

CUSTOMERS M/s Sona Koyo Steering Systems Limited, Gurgaon, the largest manufacturer of steering systems in India and major supplier to M/s Maruti Udyog Limited; Telco Ltd.; Mahindra & Mahindra ltd.; Hyundai Motors India Ltd. Roop Automotives Ltd. is meeting 100% requirement of Yokes to Sona Steering.

M/s Hero Honda Motors ltd., the largest manufacturer of two-wheeler in India.

Delphi Automotives Systems Ltd., the largest auto component manufacturer in the world.

Timken US Corporation at U.S

Exports of automotive/ Engineering components to USA, Canada, Germany & Sweden. 

Other customers include New Holland Tractor, Honda Siel Power Products Ltd. The Company has received enquiries from number of Companies, which are likely to materialize in future.

TRW Automotive U.S.A

Global Steering System U.S.A 

Dauglas Autotach U.S.A

Steering Yokes

CHECKING INSTRUMENTS

Plane Plug Gauges(PPG)

Air Gauges

Magnetic V-Block

Height Gauges

Serration Gauges

Radius Gauges

Hardened and ground plug gauge Replaceable thread and plug gauges

A Go-NoGo gauge (or Go/Nogo) refers to an inspection tool used to check a work piece against its allowed tolerance. Its name derives from its use: the gauge has two tests; the check involves the work piece having to pass one test (Go) and fail the other (No Go).

The tolerance of the part this gauge checks is 0.30mm where the lower size of the hole is 12.60mm and the upper size is 12.90mm, every size outside this range is out of tolerance.

PLAIN PLUG Gauge

Magnetic V-Block

Used for Grinding, Light Milling, Drilling & Inspection of Round & Square Jobs.

"V"block The Bigger V angle &bottom holding surface are equipped with hardened strips for wear resistance.Uniform and strong magnetic pull to all three magnetic surfaces Top, Bottom & V face. Hardness of V face is 60±2 Rc. Powder Coated.  Easy ON- OFF facility. 

Height Gauge

A height gauge is a measuring device used either for determining the height of something, or for repetitious marking of items to be worked on.

These measuring tools are used in metalworking or metrology to either set or measure vertical distances; the pointer is sharpened to allow it to act as a scriber and assist in marking out work pieces.

Serration Gauges

These are the gauges to check the splines in any work piece with in tolerance.Splines are made during the broaching process. 

Radius Gauge

A radius gauge, also known as a fillet gauge, is a tool used to measure the radius of an object.Radius gauges require a bright light behind the object to be measured. The gauge is placed against the edge to be checked and any light leakage between the blade and edge indicates a mismatch that requires correction.A good set of gauges will offer both convex and concave sections, and allow for their application in awkward locations.

Process Assessment

OfUniversal Joint

(Bolt Yoke “Upper”)

Shot blasting That is process used for removing rust & scaling on the outer surface of the component. This operation is done on Shot Blasting M/c with the help of shots.

In this process components put in the drum of machine & start rotating of drum. The shots strike on the surface of the component that makes clean the component. Cycle time of the component to rotate in the drum is 30-40 minutes after that the component is ready for the next operation.

Machine used in shot blasting•Shot blasting m/c

Tool used•Steel shots

Gauge•Visual

Shaft hole drilling, Facing & Core drilling

This operation is done on SPM m/c & three operations done once a time. The indexing fixture used on the m/c. There are four jaws on index table, fix one component on one jaw. The table rotates on its axis for change its position one by one according to the operation. Drilling, facing, core drilling are respectively operations. After complete an operation the table rotate on its axis and change its position. Fix another pcs on the next jaws, like this the process is regular on running.

M/c used in operation

SPM Shaft Hole M/c

 

Type of gauge

Vernier Caliper

Plain Plug Gauge

Height Gauge

Mandrel

ChamferingChamfering is a process used for removing the sharp edges on the component. Drilling machine is used for this operation. Counter shank tool is clamp in the M/c spindle & rotate with spindle. Pcs clamp on Base plate & feed given by manually.

M/c used in operation•Chamfering machine

Type of gauge•Vernier Caliper

Type of fixture•Base plate•Side plate•Back plate

Serration broaching

The broaching process may be applied in machining hole or other internal surfaces and also to many flat or other external surfaces. Broaching originally was utilized for such a work as forming splined holes and for a large variety of other internal operations. The broaching process is very rapid, accurate, and it leaves a finish of good quality. Internal broaching is used in yokes to make splines inside the shaft hole.

M/c used in operation•Broaching machine

Type of gauge•PPG•Serration gauge

Type of fixture•Puller jaw•Broaching base•Guide plate•Vertical plate

Gang milling

Milling is a machining process in which metal is removed by a rotating multi-tooth cutter. As the cutter rotates, each tooth removes the small amount of material A number of cutters are used in combination produce the desired shape on the work piece. Side and face cutters are use for cutting.

M/c used in operation•SPM gang milling machine

Type of gauge•Dial Vernier•Height gauge•Mandrel

Type of fixture•Locating pin•Rest block•Clamping pad

V milling

That operation is done on horizontal milling machine with conventional milling or up milling. In that machine, eight fixtures are given for doing operation on eight pcs at the time. From milling, cutters are use for cutting.

M/c used in operation•SPM horizontal milling machine

Type of gauge•Dial Vernier•Height Gauge•Mandrel

Type of fixture•Locating Pin•Clamp•Clamp Locater

Eyehole drilling

Drilling is a machining process by which a hole is produced or enlarged by the use of a specific type of end cutting tool called the drill. It is usually the most effective and economical method of producing holes in solid material. Drilling of holes can be regarded as once of man’s earliest machining achievements and it is one of the most widely used manufacturing processes. And this operation has done for pre operation of eyehole boring.

M/c used in operation•SPM Eye hole drilling machine

Type of gauge•PPG•Height gauge•Mandrel

Type of fixture•Locating pad•Clamp pad•Drill bush Ø 13.50•Rest V-block

Eyehole boring

It is an operation of enlarging of internal size that is made by drilling. It is the more accurate operation than that of drilling .

M/c used in operation•SPM fine boring machine

Type of gauge•Air plug gauge•Height gauge•Mandrel

Type of fixture•Locating pad•Clamp pad

Step drilling

The operation as same as the counter boring. This is machining process for enlarging a hole to a given depth. A shoulder is formed after counter boring, at the bottom of the enlarged hole. This operation is done on the yokes for rest of the shank of the bolt, which use to clamp the shaft.

M/c used in operation•SPM for bolt hole drilling.

Type of gauge•PPG•Height gauge

Type of fixture•Locating pin•Drill bush Ø8.5 • Clamp

Spot facing

Spot facing is a machining operation for producing a flat seat for bolt head, washer, nut, or a similar element at the opening a drill hole.

M/c used in operation•SPM spot face machine

Type of gauge•PPG

Type of fixture•Locating pin• Clamp

Slitting

Slitting is the operation of cut the pcs from one side to create gap for tighten the shaft in the yoke. It is the same operation of milling. With the help of milling cutter on horizontal milling m/c they do this operation.

M/c used in operation•SPM slitting m/c

Type of gauge•Height gauge•Slitting gauge

Type of fixture•Slitting pad Slitting clamp

Tapping

Tapping is machining process for producing internal thread. A tap with the desired form on the periphery is used as a cutting tool and the thread is formed by imparting a combined rotary and axial motion to the tap. Tapping is done mostly on drilling m/c, tapping m/c, turret lathes, canter lathes and automatic lathes. Tapping can also be done manually.

M/c used in operation•SPM tapping machine

Type of gauge•Thread plug gauge

Type of fixture•Locating pin •Sensing pin•Eye hole locating pin

Honing

Honing a low velocity abrading process in which bonded abrasive sticks remove stock from metallic or nonmetallic. It is finishing operation implied not only high finish but also to correct out of roundness, taper, and axial distortion in work pcs. In honing, since a simultaneously rotating and reciprocating motion to the stick.

M/c used in operation•Horizontal honing machine

Type of gauge•APG•Mandrel•Roundness tester

THANKING YOUROHIT JAIN

MECHANICAL 5th sem 12316