SUMMER TRANING REPORT

AT

NEEL METAL PRODUCTS LIMITED

PROJECT

IMPROVE PRODUCTION WITH THE HELP OF

GANGING OF DIES

SUBMITTED BY

Mohit keshav

R880211030

B.Tech Mechatronics

3RD Year

CERTIFICATE

This is to certify that,

Mr. Mohit keshav

Student of UNIVERSITY OF PETROLEUM AND ENERGY STUDIES have done a Project

“INCREASE IN PRODUCTION WITH THE HELP OF GANGING OF DIES” under my

guidance. This Work is done to my satisfy action under requirement of “SUMMER

INTERNSHIP PROJECT” for the Academic Year 2014.

Mr. Ishwar Singh Hada (Asst. Manager)

NEEL SHEET METAL

PRODUCTS PVT LIMITED

JBM GROUP, PANTNAGAR

ACKNOWLEDGEMENT

It is indeed a great pleasure and privilege to present this report on training at NEEL METAL

PRODUCTS JBM GROUP, PANTNAGAR.

I am extremely grateful to my training and placement officer for issuing a Training letter, which

made my training possible at NEEL METAL PRODUCTS JBM GROUP, PANTNAGAR.

First, I thank The HR Head, MR. B.M Adhikari for considering my potential in doing this

summer internship and providing this wonderful opportunity.

I would like to express my gratitude to Mr. Ishwar Singh Hada for his invaluable suggestions,

motivation,guidance and support through out the training. His methodology to start from simple ant

then deepen through made me to bring out this project report without anxiety.

Thanks to all other JBM officials, operators and all other members of JBM, yet uncounted for

their help in completing the project and see the light of success.

I am very thankful to friends, colleagues and all other persons who rendered their assistance

directly or indirectly to complete this project work successfully.

Dated- June 2014 Mohit Keshav

ABOUT COMPANY

JBM Group began its journey of excellence in 1983. The organization commenced operations as a

manufacturer of LPG Cylinders for the Delhi-NCR region of India. Moving strength to strength, assisted

with experience and knowledge, JBM Group entered into the automotive industry in 1985.

In 1986, the Group signed a joint venture with Maruti Suzuki India Ltd for the manufacturing of sheet

metal components and assemblies. The journey began with a vision to expand the business in the

automotive sector by keeping abreast with market trends and global technology.

Headquartered at Delhi-NCR, JBM Group is a diversified conglomerate with presence in automotive,

engineering & design services, renewable energy and education sectors. The organization’s commitment

towards all stakeholders and community has made it a leading manufacturing and engineering player.

The milestones and achievements of JBM Group gave the energy for diversification and establishment of

multiple business units in order to meet the needs of customers. The organization’s management follow a

unique business model to create empowered companies that enjoy the best of entrepreneurial

independence, assisted with leverage of group-wide synergies.

Overview

JBM Group is a focused, dynamic and progressive organization that provides customers with

value added products, services and innovative solutions. The Group has a diversified portfolio to

serve in the field of automotive, engineering & design services, renewable energy and education

sectors and has an infrastructure of 35 manufacturing plants, 4 engineering & design centres

across 18 locations globally.

With turnover of USD 1.2 billion, JBM Group has broadened its horizons by focusing on quality

delivery, solutions approach, product development processes, flexible manufacturing systems

and contract manufacturing.

JBM Group is primarily a tier- 1 supplier to the automotive OEM industry and caters services to

esteemed clients that include Ashok Leyland, Bajaj Auto Ltd, Fiat, Ford, General Motors

Corporation, Honda, Hero, JCB, Mahindra, Maruti Suzuki, Renault, Nissan, TATA, Toyota,

TVS, Volvo-Eicher, Volkswagen and many more.

The Group has alliances with more than 20 renowned companies globally and the associations

include Arcelor Mittal, Cornaglia, Dassault Systems, JFE Steel Corporation, Magnetto (CLN

Group), Ogihara, Sumitomo and many more. The organization’s structure enables each business

unit to chart its own future and simultaneously leverage synergies across its competencies.

INTRODUCTION TO THE COMPANY

COMPANY PROFILE

Name: JAY BHARAT MARUTI LTD.

Division: NEEL METAL PRODUCTS LIMITED

Head Quarters: DELHI

Established: 1983

Turnover: Rs.4500 Crores(overall)

Employees (No.): AROUND 15,000

Vision

“Expanding leadership in our business through people, keeping pace with market trends and

technology.”

Core Values

We believe in ...

Simplicity,by keeping a low profile externally and having clear, open and effective

communication within the organization.

Teamwork, with well-defined responsibilities and accountability.

Relationships of trust amongst people, through well-defined job responsibility and authority.

According top priority to customer focus,through prompt and appropriate response.

Respect and care for all those dedicated to meeting commitments.

TECHNOLOGY

Technology, Innovation and People serve as the 3 key pillars of the JBM foundation. Core to this

philosophy is a constant quest for excellence by enhancing technology, enabling innovation and

empowering people, thereby, creating consistent value for all stakeholders.

JBM Group has always kept a close watch on the dynamic needs of its customers and continues

the journey of efficiency by enhancing the technology at every stage. The organization has

collaborated with best global technology partners; possess state-of-the-art manufacturing

facilities and highly automated processes. These advantages have established new benchmarks

that have aided in providing superior quality and flawless technical perfection to the

organization's deliverables.

The continuous commitment towards excellence and consistent efforts to innovate have brought

excellent growth results for the Group. Apart from incorporating sophisticated technology, JBM

Group aims to not only exceed expectations, but to create value through innovation. The long

standing commitment to nurture research and development has brought the organization a long

way since its commencement 3 decades ago.

Environment, Health & Safety

At JBM, sustainability is the way of doing business. The Group aligned its goals for

environment, health and safety, making an impact across its value chain worldwide. Together

with the suppliers, customers and stakeholders, JBM strives to maintain highest standards to

preserve and protect the environment, as well as enhance the health and safety of the Group’s

employees and communities.

DEPARTMENT IN THE NEEL METAL PRODUCTS JBM, PANTNAGAR

1) Press shop

2) Paint shop

3) Quality department

4) Engineering department

5) IT department

6) Weld shop

7) Finance department

8) Purchase department

9) Maintenance department

PROJECT TITLE

TO INCREASE THE PRODUCTION OF PRESS SHOP WITH THE HELP OF

GANGING OF DIES.

ABSTRACT

Now a days we see industry works on 6 factors. These factors are very much responsible for the

growth of a industry. These are

1) Safety

2) Productivity

3) Quality

4) Cost

5) Delivery

6) Moral

But here in this project we are concentrating on only on factor i.e. increase in productivity. Here

we are using a method of ganging of dies in which two similar dies are mounted on a press

machine. This help us reduction of productivity time. Which will enhance the productivity. So

this method is very much effective in increase the productivity of the material. This is cost and

time saving method which will help in the betterment of the industry.

PART NO.-DZ161013

PART NAME : GUSSET HEAD

THEORY:-

Here the work is done on 250T press machine. In the production of gusset head there are mainly

4 steps are involved. These processes are also shown in table according to there steps. Suitable

dies are used with respect to the process followed. Gusset head is generally a BAJAJ part which

are used in platina bikes. These parts gives the support to the engine.

The pictorial view of gusset head is shown in the figure which is given below.

METHODOLOGY:-

1. First step all the sheets of metal is procured from the vendor.

2. The grade of the material is checked by the inspection department. In inspection these

three things are checked. Wrong size of the metal sheet, grade of the metal sheet and the

visual defects of the metal sheet.

3. Now the first operation is to be performed i.e. Blanking. It is done to extract the profile

sheet from the metal sheets. In this the operation the profile sheet should be according to

our need . it should be dent, scratch and burr free.

4. Second operation which to be performed is Forming. In this draw is done on the blanked

profile sheet. In this operation complete bend should be done, scratch should be taken

care of through oiling, crack/ thinning should be regularly checked.

5. After this Piercing is to be performed. It a type of operation which is totally opposite of

blanking. In this pierced profile sheet is avoided rest is considered. Dimension of us/os

has to be maintained,& location of hole should not be displaced.

6. Last step is Bending and Trimming. In this side part of gusset is bend and extra part of

the sheet is trimmed.

TABLE:-

Process

Description

Incoming source

of variation

Product

characterstics

Expected/actual

strokes (per

hour)

Receiving

Inspection

Wrong size

Wrong grade

Visual defects

1.5+/-0.1

260*1250 +/-2mm

Blanking Improper profile

Dent/scratch

Free from

Burr

Dent

Crack

250/150

Forming Incomplete bend

Scratch

Crack

Dislocation

Free from

Burr

Crack

Scratches

250/160

Piercing Dim us/os

Hole/slot size

Location

Free from

Burr

Crack

Visual defects

250/170

Bending-trimming No thinning

Incomplete profile

Scratch

burr

Free from

Burr

Crack

Thinning

Visual defects

250/180

Blanking-

FORMING

Piercing

Bending-

NOW IF APPLY 2 DIES IN SAME PRESS THEN THE OPERATION CAN BE

PERFORMED AT FASTER RATE

TO USE GANGING OF DIES THE FOLLOWING THINGS SHOULD BE TAKEN INTO

CONSENDERATION

1. Power of the press.

2. Size of the bluster bed.

3. Size of the dies.

4. Shut height of the die.

5. Shut height of the press.

6. Tonnage required for the die.

Now let’s assume that the die is having the same shut height and is between in given range of

shut height of the press.

Condition for dies are :-

Length – 910mm

Shut height -650mm

Width – 500mm

Now consider we are having a press which is having the bluster bed which can accommodate

approximately 2 dies. We are having such presses in our industry.

CALCULATION :- (Cost Estimation)

Procurement for the metal sheet- 45 rupees per kg

Dimensions of sheet -1230x260mm

Weight of on sheet- 1.020 kg

Thickness of the sheets- 1.5mm

Scraps cost -25 rupees per kg

Generally cost is estimated with the help of 5 M. These are

1. Man

2. Machine

3. Material

4. Management

5. Method

but as per general idea we are calculating as cost 2 rupees per strokes ignoring all the all other

hidden cost.

Now according to table

Cost estimated for blanking- 2x150=Rs300

Cost estimated for forming- 2x160=Rs320

Cost estimated for percing-2x170=Rs340

Cost estimated for bending-trimming- 2x180=Rs360

Total cost-Rs1320

This is a rough calculated cost in this hidden cost are not involved like maintainace, worker

availability etc. are not included.

Now if re plan our process and mount 2 dies in one press

For example

Blanking and forming at a time in a single press having different dies. This will save time as well

as machine cost.

And similarly at the same time piercing and bending trimming operation can be done.

Now the calculation of cost

Cost for blanking and forming-2x150=Rs300

Cost for piercing and bending-2x170=Rs340

Total cost=Rs640

This is a rough calculated cost in this hidden cost are not involved like maintainace, worker

availability etc. are not included.

Advantages of ganging of dies

1. Cost saving

2. Time saving

3. Man power saving

4. Less press machine required

5. Utility of press machine increases

6. Pace of work is fast

7. Production is high

Disadvantages of ganging of dies

1. Require bigger bluster bed

2. May require a dummy cushion when one die require cushion and other’s didn’t so

dummy cushion is given to the second die in order to balance it.

3. Tonnage of press should be greater or equal to the die required.

4. Shut height of both the dies should be same and should be in press shut height range.

Conclusion of Project

This method is very much effective in increasing the production rate. This works quite

efficiently. By using this method we can cover some parameter which is very much important for

every industry.

Dies and its Types:

Die: The die may be defined as the female part of a complete tool for producing work in a press. It is

also referred to a complete tool consists of a pair of mating members for producing work in a press.

Types of dies:

The dies may be classified according to the type of press operation and according to the method

of operation.

(A): According to type of press operation:

According to this criterion , the dies may be classified as cutting dies and forming dies.

1: Cutting Dies:

These dies are used to cut the metal. They utilize the cutting or shearing action. The common

cutting dies are : blanking dies , perforating dies , notching dies , trimming , shaving and nibbling

dies.

2: Forming Dies:

These dies change the appearance of the blank without removing any stock. Theses dies include

bending, drawing and squeezing dies etc.

(B) According to the method of operation:

According to this criterion, the dies may be classified as : single operation or simple dies ,

compound dies , combination dies , progressive dies , transfer dies and multiple dies.

1: Simple Dies:

Simple dies or single action dies perform single operation for each stroke of the press slide. The

operation may be one of the operation listed under cutting or forming dies.

2: Compound Dies:

In these dies, two or more operations may be performed at one station. Such dies are considered

as cutting tools since, only cutting operations are carried out. Figure shows a simple compound

die in which a washer is made by one stroke of the press. The washer is produced by simulation

blanking and piercing operations. Compound dies are more accurate and economical in production

as compared to single operation dies.

3: Combination Dies:

In this die also , more than one operation may be performed at one station. It is difficult from

compound die in that in this die, a cutting operation is combined with a bending or drawing

operation, due to that it is called combination die.

4: Progressive Dies:

A progressive or follow on die has a series of operations. At each station , an operation is performed

on a work piece during a stroke of the press. Between stroke the piece in the metal strip is

transferred to the next station. A finished work piece is made at each stroke of the press. While the

piercing punch cuts a hole in the stroke , the blanking punch blanks out a portion of the metal in

which a hole had been pierced at a previous station. Thus after the first stroke , when only a hole

will be punched , each stroke of the press produces a finished washer.

6: Transfer Dies:

Unlike the progressive dies where the stroke is fed progressively from one station to another. In

transfer dies the already cut blanks are fed mechanically from one station to other station.

7: Multiple Dies:

Multiple or gang dies produce two or more work piece at each stroke of the press. A gang or

number of simple dies and punches are ganged together to produced two or more parts at each

stoke of the press.

HYDRAULIC AND MECHANICAL PRESSES

The press represents a specific type of machine tool, essential in the performance of industrial

manufacturing processes. Presses deliver energy through a force that acts over a distance or

stroke. One important application is in metal forging manufacture. The energy of the press is

used to close the die, forging the part within. Press machine tools apply force/energy to the work

differently than drop hammers, (that deliver energy to the work through a collision), hammers

are the other class of machine tools used to forge metal parts. Drop hammers are covered on the

previous page. This page will cover different types of press machines, their function, and

capabilities, although it is located in the metal forging section, forging is only one class of

manufacturing processes that employ presses.

Press machines are also the primary machine tool used in metal extrusion and sheet metal

fabrication processes. Hydraulic and mechanical presses are employed during sheet metal

forming to the extent that sheet metal processes, in general, are often referred to as press

working. Presses may be used in the manufacture of plastic parts. Machining operations, such as

broaching, may also require presses.

Press machine tools vary in size and in the amount of force they can output. The energy from a

press is often used to do work requiring a tremendous amount of force, such as a large amount of

plastic deformation of a sizable piece of metal. The method and nature by which a press machine

will deliver its energy will vary, dependent on its type.

Machine presses shown here are vertical, meaning that the force vector is up and down relative

to gravity. In many cases these same machine types are utilized horizontally, meaning the force

is delivered in a path perpendicular to the direction of the force of gravity. If the force be exerted

vertically, horizontally, or at some intermediate angle, the working principles of each type of

machine tool are the same.

Press machine tools are of two main types, hydraulic presses and mechanical presses. Selection

of a type of machine press depends on the factors of the manufacturing process. The first

consideration would be the basic type of process the press tool will be employed to perform. For

example, a press for metal forging, a press for extrusion, a press for impact extrusion, or a press

for sheet metal working will all have different general requirements. The next very important

factor in machine press selection for a manufacturing operation is the press capacity required.

Required press capacity is likely related to the size of the work stock, and type of process.

Length of stroke over which the press delivers force is another primary factor when choosing a

press machine tool, this also will be related to the basic type of process being employed. These

initial considerations should give an immediate idea of the general type of press required. After

this, all the specific factors of the manufacturing process should be weighed, to determine the

best choice for a press machine tool.

Hydraulic Presses

Hydraulic presses are a powerful class of machine tools, they derive the energy they deliver

through hydraulic pressure. Fluid pressure, in a particular chamber, can be increased or

decreased by the use of pumps, and valves. Sometimes devices and systems may be used to

increase the capacity of the pumps in more powerful presses. These presses can operate over a

long distance and at a constant speed. Hydraulic presses are generally slower relative to other

press machine types. This involves longer contact with the work, therefore the cooling of the

work can be an issue when hot forming a part with hydraulic force. Hydraulic presses are

capable of being the most powerful class of presses. Some may be as large as buildings, and can

deliver awesome pressure. The largest hydraulic presses are capable of applying 75,000 tons,

(150,000,000 lbs), of force. The hydraulic press shown is being used to manufacture a metal

forging. Extrusion is also a very common use for such a press, although extrusion is often

performed horizontally.

The basic working principles of the hydraulic press are simple, and rely on differences in fluid

pressure. Fluid is pumped into the cylinder below the piston, this causes the fluid pressure under

the piston to increase. Simultaneously, fluid is pumped out of the top channel, causing the fluid

pressure above the piston to decrease. A higher pressure of the fluid below the piston than the

fluid above it causes the piston to rise. In the next step, fluid is pumped out from below the

piston, causing the pressure under the piston to decrease. Simultaneously, fluid is pumped into

the cylinder from the top, this increases the fluid pressure above the piston. A higher pressure of

the fluid above the piston, than the fluid below it, moves the piston downward.

Mechanical Presses

Mechanical presses belong to a class of machine tools that encompass a wide range of different

machine types. Primarily, the mechanical press transforms the rotational force of a motor into a

translational force vector that performs the pressing action. Therefore, the energy in a

mechanical press comes from the motor. These types of presses are generally faster than

hydraulic or screw presses, (actually the screw press may also be classified as a mechanical

press). Unlike some presses, in a mechanical press, the application of force varies in both speed

and magnitude throughout the distance of the stroke. When performing a manufacturing

operation using a mechanical press, the correct range of the stroke is essential.

Presses are chosen based on the characteristics of the manufacturing process. Mechanical press

machine tools are commonly used in metal forging manufacture, and sheet metal working. The

desired application of force will dictate the type of machine required. Extrusion will often

necessitate a more consistent force over a longer distance. However, a mechanical press may

often be a good choice for impact extrusion, since a fast, quickly repeatable application of force

over a limited distance is what is needed for that type of manufacturing process. The most

powerful mechanical presses in modern manufacturing industry will have a press capacity of

about 12,000 tons, (24,000,000 lbs).

SHEET METAL WORKING

1. Introduction

Sheet metal is simply metal formed into thin and flat pieces. It is one of the fundamental forms

used in metalworking, and can be cut and bent into a variety of different shapes. Countless

everyday objects are constructed of the material. Thicknesses can vary significantly, although

extremely thin thicknesses are considered foil or leaf, and pieces thicker than 6 mm (0.25 in) are

considered plate.

2. Sheet metal processing

The raw material for sheet metal manufacturing processes is the output of the rolling process.

Typically, sheets of metal are sold as flat, rectangular sheets of standard size. If the sheets are thin and

very long, they may be in the form of rolls. Therefore the first step in any sheet metal process is to cut

the correct shape and sized ‘blank’ from larger sheet.

3. Sheet metal forming processes

Sheet metal processes can be broken down into two major classifications and one minor classification

Shearing processes -- processes which apply shearing forces to cut, fracture, or separate

the material.

Forming processes -- processes which cause the metal to undergo desired shape changes

without failure, excessive thinning, or cracking. This includes bending and stretching.

Finishing processes -- processes which are used to improve the final surface

characteristics.

3.1 Shearing Process

1. Punching: shearing process using a die and punch where the interior portion of the sheared

sheet is to be discarded.

2. Blanking: shearing process using a die and punch where the exterior portion of the shearing

operation is to be discarded.

3. Perforating: punching a number of holes in a sheet

4. Parting: shearing the sheet into two or more pieces

5. Notching: removing pieces from the edges

6. Lancing: leaving a tab without removing any material

Fig.1Shearing Operations: Punching, Blanking and Perforating

3.2 Forming Processes

Bending: forming process causes the sheet metal to undergo the desired shape change by

bending without failure. Ref fig.2 & 2a

Stretching: forming process causes the sheet metal to undergo the desired shape change

by stretching without failure. Ref fig.3

Drawing: forming process causes the sheet metal to undergo the desired shape change by

drawing without failure. Ref fig.4

Roll forming: Roll forming is a process by which a metal strip is progressively bent as it

passes through a series of forming rolls. Ref fig.5

Fig.2 Common Die-Bending Operations

Fig.2a Various Bending Operations

Fig.3 Schematic illustration of a stretch-forming process.

Fig.4 Schematic of the Drawing process.

Fig.5 Eight-roll sequence for the roll forming of a box channel

3.3 Finishing processes

Material properties, geometry of the starting material, and the geometry of the desired final

product play important roles in determining the best process

4. Equipments

Basic sheet forming operations involve a press, punch, or ram and a set of dies.

5.1 Marking and measuring tools

Steel Rule - It is used to set out dimensions.

Try Square - Try square is used for making and testing angles of 90degree

Scriber – It used to scribe or mark lines on metal work pieces.

Divider - This is used for marking circles, arcs, laying out perpendicular lines, bisecting lines, etc.

Fig.9 Marking and measuring tools

Cutting Tools

Straight snip - They have straight jaws and used for straight line cutting.

Curved snip - They have curved blades for making circular cuts.

Striking Tools

Mallet - It is wooden-headed hammer of round or rectangular cross section. The striking

face is made flat to the work. A mallet is used to give light blows to the Sheet metal in

bending and finishing. Ref fig.11

Fig.11 Types of Mallets

6. Merits

High strength

Good dimensional accuracy and surface finish

Relatively low cost

7. Demerits

Wrinkling and tearing are typical limits to drawing operations

Different techniques can be used to overcome these limitations

o Draw beads

o Vertical projections and matching grooves in the die and blank holder

Trimming may be used to reach final dimensions

8. Applications

Roofings

Ductings

Vehicles body buildings like 3 wheelers, 4 wheelers, ships, aircrafts etc.

Furnitures, House hold articles and Railway equipment.

CONCLUSION

It’s always a great opportunity to experience the valuable exposure of an industry. There is lot of

difference between the Theories and Practices. This Training enables me to understand the aspects

of professional life. I like the working environment followed at NEEL METAL PRODUCTS

LTD. and come to know how to deal with our colleagues. The company’s members are well

cultured & well mannered.

An effective process is followed at NEEL METAL PRODUCTS LTD. but it would become

more valuable and impressive by implementing certain efficient measures. The company is

constantly focusing on providing better services, quality and reliability to customers, and running

successfully in this era of competition.