AN INDUSTRIAL TRAINING REPORT

Done by

Shubham ChakrabortyEnrollment no: 12345678

At

Amtek Auto Ltd.Mandideep Industrial Area,Bhopal, Madhya Pradesh.

Submitted to

Department of Mechanical Engineering

July 2015

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ACKNOWLEDGEMENT

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

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PREFACE

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

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CONTENTS

1. INTRODUCTION 2. AMTEK AUTO LTD. - An Overview3. WORK FLOW DIAGRAM

4. RAW MATERIAL GRADING

5. TOOL AND DIE SHOP

6. METALLURGICAL LAB

7. BILLET YARD Processes involved in Billet Yard Process Flow Chart in Billet Yard

8. FORGE SHOP Processes involved in Forge Shop Process Flow Chart in Forge Shop

9. HEAT TREATMENT Heat Treatment Techniques Heat Treatment Processes Heat Treatment Process Flowchart

10. END CONTROL End Control Checks

11. DISPATCH

12. CONCLUSION

INTRODUCTION

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Amtek Group was established with the incorporation of the flagship company, Amtek Auto in 1985. Since then, it has grown rapidly and emerged as a frontrunner in the global automotive component industry with a worldwide presence across North America, Europe, and Asia. Amtek's manufacturing capabilities include Iron and Aluminum Castings, Forgings, Complex Machining & Ring Gears Flywheel Assembly.

Amtek Auto manufactures components such as connecting rod assemblies, flywheel ring gears and assembly, steering knuckles, suspension and steering arms, CV joints, crankshaft assemblies and torque links. It is backed by in–house design and development facilities engaged in developing new product and processes.

Amtek Group is a leading international manufacturer of automotive components and assemblies with production facilities located strategically across North America, Europe & Asia. The Group's extensive manufacturing capabilities encompass Sub assemblies, Iron, Gravity & Aluminium Castings, Forgings, Complex Machining & Ring Gears Flywheel Assembly.

AMTEK AUTO LTD. - An Overview

The Amtek Group, headquartered in India, is one of the largest integrated component manufacturers in India with a strong global presence. It has also become one of the world’s largest global forging and integrated machining companies. The Group has operations across Forging, Iron and Aluminium Casting, Machining and Sub-Assemblies. It has world-class facilities across India, UK, Germany, Brazil, Italy, Mexico, Hungary and US. The Amtek Group is comprised of corporate entities Amtek Auto, JMT Auto, Amtek Global Technologies and other subsidiaries and associates. With the infrastructure and technology platform developed over 25 years, the Group is well positioned in the Indian Auto and Non-Auto component markets. 

Different divisions of the company are:

Amtek Centre of Excellence (ACE) Amtek Forging Division (AFD) Amtek Iron Casting Division (AICD) Amtek Aluminum Casting Division (AACD) Amtek Automotive Machining Division (AAMD) Amtek Ring Gear Division(ARGD) Amtek JVS

Product range of the company includes:

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Amtek product portfolio consists of an extensive range of components for 2–3 wheelers, Cars, Tractors, LCV, HCV and Stationary engines. The major categories of components manufactured are,

Connecting Rod Assemblies Flywheel Ring Gears and Assembly Steering Knuckles Suspension and Steering Arms CV joints Crankshaft Assemblies Torque Links.

Clientele:

Ashok Leyland Limited Aston Martin Bajaj Auto Limited BMW Briggs & Stratton CNH Global CNH New Holland Cummins CYT Dana Italia Davis Industries Defence Delco Machining Eicher Motors Limited Escorts Fairfield Fiat India Ford General Motors GE Transportation GWK Ltd Hero Honda

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WORK FLOW DIAGRAM

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Raw Material

Dispatch

Tool And Die Shop

Metallurgical Lab

Billet Yard

Cutting

Forging

Heat Treatment

End Control

Store

Metallurgical Lab

Sample for Inspection

Clearance

Clearance

Test certificate for Verification

Die Code & Heat Code

RAW MATERIAL GRADING

Raw Material Grading

S. No Steel Grade Color Code Color

       

1 348C Dia 50/56/60 mmWhite (Sunflag)  

Yellow (Adhunik)  

2 20 MnCr5H Dia 50/52 mm Light Blue  

3 16 MnCr5 Dark Blue  

4 SAE 1141 Dia 40/45/48 mm Purple  

5 MSAE 1541 (B) Dia 60 mmBrown

 

6SCM 420H Dia 58/70 mm Green  

SCM 420H Dia 25/28/36 mmWhite base black cross

 

7 SAE 8260H Dia 56 mm Silver  

8 C35 Dia 50 mm Pink  

9 EN8D Dia 63/70 mm Black  

10 EN8DM Dia 65 mmGray

 

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TOOL AND DIE SHOP

In the Tool and Die shop, the Die on which the forged material is shaped is made.

Here, the raw material comes in the form of metallic cylinders which are then machined

into the form of hollow cavities.

These hollow cavities are then used for forging the billets.

Usually a pair of Dies has a lifespan of 10000 cycles but it varies from type of forge

material.

The Dies are made with highly sophisticated CNC (Computerised numerical control)

lathe and VMC (Vertical milling control) machines.

CNC machine can work in vertical direction i.e. (x-z plane).

VMC machine can work in vertical, horizontal directions i.e. (x-y-z plane).

M codes and G codes are used for the smooth and automatic working of these machines.

Traditional Milling, Drilling and Lathe machines are also utilised for machining the dies

for rough machining works.

There are a series of internal checks n the Tool and Die shop which requires expertise.

These dies are made with high surface finish and dimensional accuracy.

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METALLURGICAL LAB

In this department a large number of tests are done to test the job and the dies obtained at various

stages of the manufacturing process.

Metallurgical microscope

Metallurgical microscope is the optical microscope, differing from other microscopes in the method of the specimen illumination. Since metals are opaque substances they must be illuminated by frontal lighting, therefore the source of light is located within the microscope tube. This is achieved by plain glass reflector, installed in the tube. The optical scheme of metallurgical microscope is shown in the picture.

The image quality and its resolving power are mainly determined by the quality of the objective. The objective magnification depends on its focal length (the shorter focal length, the higher magnification). The eyepiece is the lens nearest the eye. The image is magnified by eyepiece in x6, x8 or x10.

The total magnification of the microscope may be calculated by the formula:

M = L*E/ F

Where

L- Distance from back of objective to eyepiece;

F - Focal length of the objective;

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E- Magnifying power of the eyepiece.

The common magnification of metallurgical microscope is in the range x50 – x1000.

Brinell Hardness test

The Brinell method applies a predetermined test load (F) to a carbide ball of fixed diameter (D) which is held for a predetermined time period and then removed. The resulting impression is measured across at least two diameters – usually at right angles to each other and these result averaged (d). A chart is then used to convert the averaged diameter measurement to a Brinell hardness number. Test forces range from 500 to 3000 kgf.

 Test Method Illustration

D  = Ball diameter d   = impression diameter

F   = load HB = Brinell result

 

Rockwell hardness test

The Rockwell method measures the permanent depth of indentation produced by a force/load

on an indenter. First, a preliminary test force (commonly referred to as preload or minor

load) is applied to a sample using a diamond indenter. This load represents the zero or

reference position that breaks through the surface to reduce the effects of surface finish. After

the preload, an additional load, call the major load, is applied to reach the total required test

load. This force is held for a predetermined amount of time (dwell time) to allow for elastic

recovery. This major load is then released and the final position is measured against the

position derived from the preload, the indentation depth variance between the preload value

and major load value. This distance is converted to a hardness number.

Eddy current test

In this check the cracks present inside the material of the face of job is checked. A current is

passed and detected. If the sensors detect any slight irregularity in composition or cracks then

the job is rejected.

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Jominy apparatus

This apparatus is used for determining the Harden-ability of steel by an experiment called

Quench Test. This provides information about the Harden-ability characteristics of different

alloying element.

Muffle furnace test

A muffle furnace is a furnace with an externally heated chamber, the walls of which radiantly heat the contents of the chamber, so that the material being heated has no contact with the flame. Muffle furnaces are most often utilized in laboratories as a compact means of creating extremely high-temperature atmospheres. They are employed to test the characteristics of materials at extremely high and accurate temperatures. A muffle furnace is also known as a retort furnace.

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BILLET YARD

Processes involved in billet yard

Raw material is supplied in the form of rods of diameters according to demand.

Heat code and color coding is done.

EOT Cranes are used for handling of these pipes due to their weight and size.

The rods are then loaded to the billet shearing machine (MANYO LBS450).

The combination of hydraulic, conveyer and electronic sensors provide a steady rate of input to the shearing machine which is termed as Loader mechanism.

The rod is held by die. Die is held by Die clamp and packing.

The machine applies a 450 kg/mm2 pressure on the rod with help of blade.

The part of rod that is obtained is termed as Billet. It of cylindrical shape.

The billet yard also contains an End pieces area where the diameter and length of billet is reduced with the help of lathe machine and lathe cutting machine.

Process Flow Chart in Billet Yard

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Raw Material

Shearing machine/ Chopper Machine

Billet obtained

End pieces area

FORGE SHOP

In forge shop of Amtek Auto Ltd., Mandideep, Forging is done to transform raw cut billets into required shape according to the die used.

In the Forge Shop of Amtek Auto Ltd., for the forging operation, there are 6 Crank press forging machines and 3 screw press forging machines.

Hot, press forging is done on the billets to shape them as requirement. The crank presses (HANOUL HNFG-1350) apply 1000 ton force on the red hot billet. The crank press runs on the principle of clutch-plate brake mechanism. Power is developed in the press due pressurized air. To provide pressurize air to the presses a number compressors are employed. There are 3 screw presses (Vaccari) which apply a pressure of 730 tonnes. They work on the principle of power screw mechanism.

Processes involved in forge shop

Billet loading

In this process, the raw cut billets are transferred from billet shop in gaskets to be loaded in the induction heater. The loading mechanism consists of conveyer mechanism and electronic sensors for better control and automatic functioning.

Induction Heating

In this process, the billets are passed into an industrial induction heater which heats the billet at above 1100 C usually 1200 C, which recrystallizes the metal for easy forging to commence. The induction heater uses magnetic flux to heat the metal between the coils.

Forging

In this process, the upper die is clamped to the hammer and the lower die remains stationary. The red-hot billet is vertically positioned and hammer blow forces it to acquire the shape of the dies. Extra metal is forced out from the exposed face.

Trimming

Trimming is a process in which the extra metal projecting out of the curved surface of the sides termed as ‘flash’ is removed with the help of a trimming press. It is similar to forging machine, but much less force s applied on the top face. In this the required material is forced vertically downward and the flash remains clamped on the vices.

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Flash removal

In this, the ‘flash’ is obtained and transported to the scrap yard with the help of gaskets.

Process Flow Chart in Forge Shop

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Billet Loading

Induction Heating

Forging

Trimming

Flash Removal

HEAT TREATMENT

Heat treating is a group of industrial and metalworking processes used to alter the physical, properties of a material.

Heat treatment involves the use of heating or chilling, normally to extreme temperatures, to achieve a desired result such as hardening or softening of a material. Heat treatment techniques include annealing, case hardening, precipitation strengthening, tempering and quenching.

Metallic materials consist of a microstructure of small crystals called "grains" or crystallites. The nature of the grains (i.e. grain size and composition) is one of the most effective factors that can determine the overall mechanical behaviour of the metal. Heat treatment provides an efficient way to manipulate the properties of the metal by controlling the rate of diffusion and the rate of cooling within the microstructure. Heat treating is often used to alter the mechanical properties of a metallic alloy, manipulating properties such as the hardness, strength, toughness, ductility, and elasticity.

Heat Treatment Techniques

Annealing

Annealing consists of heating a metal to a specific temperature and then cooling at a rate that will produce a refined microstructure. The rate of cooling is generally slow.

In ferrous alloys, annealing is usually accomplished by heating the metal beyond the upper critical temperature and then cooling very slowly, resulting in the formation of pearlite. In both pure metals and many alloys that cannot be heat treated, annealing is used to remove the hardness caused by cold working. The metal is heated to a temperature where recrystallisation can occur, thereby repairing the defects caused by plastic deformation.

Ferrous alloys are usually either "full annealed" or "process annealed." Full annealing requires very slow cooling rates, in order to form coarse pearlite. In process annealing, the cooling rate may be faster; up to, and including normalizing. The main goal of process annealing is to produce a uniform microstructure.

Normalizing

Normalizing is a technique used to provide uniformity in grain size and composition throughout an alloy. The term is often used for ferrous alloys that have been austenitized and then cooled in open air. Normalizing not only produces pearlite, but also sometimes martensite, which gives harder and stronger steel, but with less ductility for the same composition than full annealing.

Aging

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Some metals are classified as precipitation hardening metals. When a precipitation hardening alloy is quenched, its alloying elements will be trapped in solution, resulting in a soft metal. Aging a "solutionized" metal will allow the alloying elements to diffuse through the microstructure and form intermetallic particles. These intermetallic particles will nucleate and fall out of solution and act as a reinforcing phase, thereby increasing the strength of the alloy. Alloys may age "naturally" meaning that the precipitates form at room temperature, or they may age "artificially" when precipitates only form at elevated temperatures.

Quenching

Quenching is a process of cooling a metal at a rapid rate. This is most often done to produce a martensite transformation. In ferrous alloys, this will often produce a harder metal, while non-ferrous alloys will usually become softer than normal.

To harden by quenching, a metal (usually steel or cast iron) must be heated above the upper critical temperature and then quickly cooled. Cooling is done with Liquids, due to their better thermal conductivity, such as oil. Upon being rapidly cooled, a portion of austenite (dependent on alloy composition) will transform to martensite, a hard, brittle crystalline structure.

Tempering

Untempered martensitic steel, while very hard, is too brittle to be useful for most applications. A method for alleviating this problem is called tempering.

. Tempering consists of heating steel below the lower critical temperature, (often from 400 to 1105 ˚F or 205 to 595 ˚C, depending on the desired results), to impart some toughness.

Flame hardening

Flame hardening is used to harden only a portion of a metal. Unlike differential hardening, where the entire piece is heated and then cooled at different rates, in flame hardening, only a portion of the metal is heated before quenching.

Case hardening

Case hardening is a thermochemical diffusion process in which an alloying element, most commonly carbon or nitrogen, diffuses into the surface of a monolithic metal. The resulting interstitial solid solution is harder than the base material, which improves wear resistance without sacrificing toughness.

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Heat treatment processes Heat treatment of the forged material obtained from forge shop is done in a furnace.

The temperature of furnace ranges from 880 C to 1100 C according to the requirement.

The Burner fuels used in the furnace maybe Diesel, LDO or Gas.

Usually the temperature required for hardening process is 870 to 900 C.

Temperature required for tempering process is 580 C.

The forged jobs are loaded in a gasket and put inside the furnace with the help of pulley

mechanism.

The doors are the shut using a combination of sliding mechanism and electronic sensors

to provide a sealed environment for heat treatment.

The gasket is obtained from the other end of the furnace.

At any point of time there are 6-8 gaskets within the furnace.

These gaskets are slowly moving towards the other end of the furnace due to rolling

mechanism in the furnace.

The time required for the total process for one gasket is 10 minutes.

After this, oil quenching is done.

The obtained treated job is handled with the help of stretcher and is either sent for further

heat treatment or to End Control for final inspection.

The oil becomes hot after the heated metal is immersed in it.

To prevent overheating of oil, a Plate Type Heat Exchanger (PHE) is employed which

circulates cold oil in the quenching bucket.

The PHE is itself cooled with the help of Natural circulation wet type cooling towers.

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Heat treatment Process Flowchart

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Furnace1(Annealing,

Normalising, etc.)

Furnace2(Hardening, Tempering

etc)

Oil Quenching

Plate type Heat Exchanger

Cooling Tower

Hot oil out

Cold oil in

Hot water out

Cold water in

Cold air in

Hot air out

Forged Material

To End Control

END CONTROL

End Control is the department in which the final quality checks and finishing of the product is

done.

In End Control, there are various processes.

Shot Blasting

Cold Coining or Knuckle press

Visual Check

Total Parameter Check

Eddy Current Check

Ultrasonic Check

Magnetic Crack Detection

End Control Checks

Shot Blasting

In shot blasting, steel shots are passed in a shot blasting machine through small holes in a

rotating, hollow, rubber-lined surface. The heat treated material has a rough surface due to

accumulation of oxide layer.

To remove this oxide layer, the metals are loaded in the shot blasting machine and the abrasive

action of the spherical steel shots remove the oxide layer. The oxide layer is the sucked in

through an ash handling pump and is disposed off as dust.

Cold Coining

It is a process through which the flatness and Total Indicated Runout of the job is altered by

applying a hammer blow to the face of the crankshaft. The machine used in this process is called

knuckle press.

Total parameter check

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In this the dimensions of the material are checked and compared with the standard values. It also

checks the phenomenon of under-height of job and improper trimming.

Visual check

Visual check encompasses a large number of checks for various defects like Pitting, Stem

underfilling, Boss underfilling, Shoulder underfilling, Die marks, Corner underfilling, Top

Flange underfilling, Rib underfilling, Dent Fitting etc.

Eddy current check

In this check the cracks present inside the material of the face of job is checked. A current is

passed and detected. If the sensors detect any slight irregularity in composition or cracks then the

job is rejected.

Ultrasonic Check

In this check the vertical internal cracks present in the stem of job is checked. An X-ray is passed

through a probe positioned at the bottom face of the stem and penetrating x-rays detect the

number of cracks. If the sensors detect any slight irregularity in composition or cracks then the

job is rejected.

Magnetic Crack Detection

In this the microscopic cracks present on the surface of the job is determined and checked and if

the job is found faulty then it is rejected. For this a magnetic flux is passed and sensors detect the

overall flux produced.

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DISPATCH

After all the checks are performed in the End Control, the finished product is oiled and loaded

into gaskets for transporting to the customers.

Oiling is done on the product to prevent corrosion to the metal surface.

Schematic Diagram of Sample crankshaft’s face:

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Manufacturer Company Code

Customer Company Code

Die number Month code

Heat Code

CONCLUSION

As an undergraduate I would like to say that this training program is an excellent opportunity for

us to get to the ground level and experience the things that we would have never gained through

going straight into a job.

The main objective of the industrial training is to provide an opportunity to undergraduates to

identify, observe and practice how engineering is applicable in the real industry. It is not only to

get experience on technical practices but also to observe management practices and to interact

with fellow workers. It is easy to work with sophisticated machines, but not with people. The

only chance that an undergraduate has to have this experience is the industrial training period. I

feel I got the maximum out of that experience. Also I learnt the way of work in an organization,

the importance of being punctual, the importance of maximum commitment, and the importance

of team spirit. In my opinion, I have gained lots of knowledge and experience needed to be

successful in a great engineering challenge, as in my opinion, Engineering is after all a

Challenge, and not a Job.

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