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KIRAN UDYOG PVT. LTD.

MANESAR(GURGAON)
HARYANA

A TRAINING REPORT


SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE AWARD
OF
THE DEGREE OF

BACHELOR OF TECHNOLOGY
(Mechanical Engineering)

SUBMITTED TO
LOVELY PROFESSIONAL UNIVERSITY, JALANDHAR


SUBMITTED BY
Name of Student Registration No.

Ashish 11106216


08-06-14 to 20-07-14



Lovely Professional University, Jalandhar
PUNJAB



KIRAN UDYOG PVT. LTD.
MANESAR(GURGAON)
HARYANA


A TRAINING REPORT


SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE AWARD
OF
THE DEGREE OF

BACHELOR OF TECHNOLOGY
(Mechanical Engineering)

SUBMITTED TO
LOVELY PROFESSIONAL UNIVERSITY, JALANDHAR


SUBMITTED BY
Name of Student Registration No.

Ashish 11106216


08-06-14 to 20-07-14



Lovely Professional University, Jalandhar
PUNJAB



CANDIDATE DECLARATION
I hereby certify that the work, which is being presented in the project entitled The
manufacturing of stator and rotor by various manufacturing processes in partial fulfilment of
the requirement for the award of the degree of bachelor of technology submitted to the
institution is an authentic record of my own work carried out during the period June-2014 to
july-2014 under the supervision of supervisor Rajesh sir.



Date: - Signature of the Candidate:-














ii.
OBJECTIVE OF TRAINING

The main purpose of this project is:-
To manufacture rack and pinion gears by various manufacturing processes such as:
Die casting
Drilling
Buffing
Broaching

To design motor frame with the help of auto-cad software and unigraphics software
To manufacture cylinder block by various method
To manufacture hub and sprocket




















iii.


ACKNOWLEDGEMENT
It was not easy to prepare this project report without the assistance and encouragement of
other people.

On the very outset of this report, I would like to extend my sincere and heartfelt obligation
towards all the personages who have helped me in this endeavour. Without their active
guidance, help, cooperation and encouragement, I would not have made headway in the
project. First and foremost, I would like to express my sincere gratitude to my faculties.
I also thank to Rajesh Sir who helped me a lot during training.
I am grateful to Sharma sir for their valuable guidance and encouragement to me.

Thanking you
Ashish

(To be signed by the student)
Reg. No.:-11106216







iv.
LIST OF FIGURES

NAME PAGE NO.
Fig.1 Melting Of Raw Material Machine 7
Fig.2 Aluminium Melting Furnace 7
Fig.3 Bolt Wheel Pressing M/C 10
Fig.4 Bolt Wheel 11
Fig.5 Trimming Machine 13
Fig.6 Fettling machine 14
Fig.7 Forging Machine 14
Fig.8 SPM 16
Fig.9 Drilling 17
Fig.10 Pressure Die Casting Machine 17
Fig.11 Buffing Machine 19
Fig.12 Broaching Machine 19
Fig.13 Products 20-30






v.

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 the proper goal in life, an engineer has to enter in professional life.
According to this life, 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 a 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 of 45 days. 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 45 days training at KIRAN UDYOG PVT LTD. This report is based
on the knowledge, which I acquired during my 45 days training period at the plant.






vi.

TABLE OF CONTENTS

Title Page no.

DECLARATION.......................................................................................................ii
OBJECTIVE..............................................................................................................iii
ACKNOWLEDGEMENT.........................................................................................iv
LIST OF FIGURE.....................................................................................................v
PREFACE.................................................................................................................vi

INTRODUCTION....................................................................................................1
COMPANY PROFILE..............................................................................................2
COMPANY OVERVIEW.........................................................................................3
COMPANY INFRASTRUCTURE...........................................................................5
PROCESS..................................................................................................................6
PRODUCTS..............................................................................................................21
PROBLEMS AND SOLUTIONS............................................................................29
IMPLEMENTATION & RESULT...........................................................................30
REFERENCES.........................................................................................................31


INTRODUCTION

Kapsons Industries Ltd. founded in 1982 at Jalandhar by an entrepreneur duo, S. K. Sehgal
and N. K. Sehgal.
Rapid industrialisation in India from 1980 onward propelled the growth in motor
manufacturing. S. K. Sehgal, a techno wizard, correctly sensed the need for laminations
required by the motor industry and the entrepreneur in him anticipated the huge potential. At
the same time, he was fully aware that only quality products could establish Kapsons reliably
and make it grow.
And the wheels were set in motion. Modern machines were installed one-by-one. Skilled
technicians got down to work. Product lines were expanded. Manufacturing capacity
increased manifold year-after-year. Global technology was assimilated and implemented.
New quality assurance methods and testing procedures were adopted.
Today, our range also comprises rotor, stators, aluminium die-castings and enamelled copper
wire and strips for various applications. All manufactured with the same care for highest
possible quality and precision.











COMPANY PROFILE
Kapsons Industries Limited is an IS/ISO 9001:2000 and ISO/TS 16949:2002 (Die Casting
Division) certified company, with a driving force to the crest in the sector of electrical
stamping & Rotor-die castings. A prosperous empire since 1981, Kapsons is an outstanding
pioneer in manufacturing & supplying die-cast automobile & electrical components, all over
India.

Diversifying with the pressure die casting plant in 1997, Kapsons has grown all the taller with
competitive edge in the domestic as well as in the international market. A firm with a strong
endurance, Kapsons Industries operates from Jalandhar with two eco friendly gargantum
units. Each of the unit is fully equipped with the upgraded technology & sufficient manpower
to carry out the detailed & precision production.

Progressing to the foreseen pinnacle, Kapsons merchandise is put to use by the big
manufacturers of large Industrial motors, pumps, windmills, traction motors, generators,
alternators, fans & transformers. Apart from this, at the pressure die cast plant, components of
electric motor bodies, motor terminal boxes, automobiles, table fans, ceiling fan covers are
also die casted. Kapsons Industries is driven by the forceful magic ethos of quality
consciousness, customer satisfaction & assured trust. This is the reason why the company
outstands as a well known recipient in the province offering the best quality products at
competitive rates. Hence with holding the distinction of touching various lives through
different electrical & automobile range, Kapsons has a presence felt everyday & everywhere.













2
COMPANY OVERVIEW

Introduction:
Kapsons is accredited with ISO 9001:2000 and ISO 14000 certification and our Aluminium
Pressure Die Cast division is accredited with TS 16949:2002 certification.
Our range also comprises rotor, stators, aluminium die-castings and enamelled copper wire
and strips for various application.
Kapsons Industries Limited was registered on 13 February, 1987. Kapsons Industries
Limited's Corporate Identification Number (CIN) is U31909PB1987PLC007303,
Registration Number is 007303.Their registered address on file is G T Road Suranussi
Jalandhar, Punjab - 144027, Punjab, India. Kapsons Industries Limited currently have 6
Active Directors / Partners: Nishant Sehgal, Narinder Kumar Sehgal, Surinder Kumar Sehgal,
Prashant Sehgal, Anita Sehgal, Sunita Sikka, and there are no other Active Directors /
Partners in the company except these 6 officials.

Salient Features:
We have production capacity of 20,000 MT/year. A wide range of laminations, castings,
rotors and stators are manufactured and supplied to a number of reputed manufacturers of
motors, pumps, alternators, generators, turbines, windmills, compressors, automobiles, etc.
The company has been operating from the premises of nearly 25000 sq. m. at Jalandhar, near
Delhi where our corporate office and three manufacturing units are situated. A new plant of
5, 574 sq. m. area at Pune, near Mumbai is about to start operations.
We have been achieving growth of nearly 35-40 % in recent years with a major thrust on
exports. During 2007-2008, we crossed the annual turnover of around 62 million USD.
We have consolidated our position in the Indian markets through well equipped
manufacturing set up, efficient service and a wide range of high-quality products and
acquired the top position in the Indian market for laminations.


Vision:

Cost competitive global company.
Costumer delight.
Enhancing stake holders value.
Mission:
To install and maintain efficient quality management system as per International Standards,
Continuously improve quality through up gradation of products, process, design and quality
system. These objects are achieved through dedicated team workand continuous training of
each member of Kiran family.
Quality Policy
An IS/ISO 9001:2000 and TS16949:2000 & ISO 14001 (Die Casting Division) certified
company. At Kiran every individual is committed to ensure complete customer satisfaction
by supplying best quality products at competitive.














4.
COMPANY INFRASTRUCTURE

COVERED AREA
UNIT II 6740 Sq. meter
TOOL ROOM CAPABILITIES
We are having, in addition to our production activities, a well-established Tool Room
Infrastructure including Heat Treatment Facility. We are making Stampings and Aluminium
components Dies upto the accuracy of 0.02mm in-house. The manufacturing cost of Dies &
Tools because of in-house tool room is very economical and development is also completed
at a very fast pace. In addition to the in-house facilities available with us, we have also to
CAD/CAM & CMM facilities and all complex tools and electrodes are being manufactured
on VMC/Turning Centre using the above facilities.
PRESSURE DIE CAST ACTIVITIES
At present we are die casting a wide range of automobile components for leading
manufacturers in India. These include Motor Frame, Rack Housing ,Pinion Housing, Hub,
Sprocket, Cylinder Block, Crank Case , Automobile Components .


5.

PROCESS

MELTING FURNACE
Melting Of Raw Material
Square regenerative aluminium melting furnace, adopting regenerative burner, can rapidly
melt solid materials (e.g., aluminium ingot, deformative aluminium alloy flotsam) that can be
charged by special charging tools (such as forklifts, special charging cart). After melting,
liquid aluminium will be effective, full mixed so that it can be more uniform in temperature
and composition. The furnace is mainly used for the melting of re-melting aluminium ingots,
and deformative aluminium alloy flotsam. It also has the function of heating, refining &
slagging-off, insulating and draining of liquid aluminium for casting. This series of furnace is
mainly applied in the aluminium casting plant of aluminium profile and aluminium board.
Technical Parameters
Furnace type square; tilting
Control accuracy of molten aluminum
temperature/
5(After mixing & refining)
Maximum working temperature 1150
Fuel Natural gas, LPG, heavy oil, diesel
Temperature control method PLC automatic control
Ways of molten aluminum drain off Manually or tilting draining off
Burner mode Regenerative
Burner amount 2-4pcs
Furnace pressure Slight positive pressure control
Energy consumption (kcal/T.Al)
62*104Kcal/T.Al
(For pure aluminum ingots, temperature of
molten aluminum 720)
Testing standards of energy consumption
According to "JB T50168-1999 Aluminum
Melting Fuel Furnace Energy Consumption
Classification Standard"







6.

Fig.1 MELTING OF RAW MATERIAL

Fig.2 ALUMINIUM MELTING FURNACE



7.

BOLT WHEEL PRESSING

A Bolt Wheel Pressing is a type of machine press in which the ram is driven up and down by
a screw. The screw shaft can be driven by a handle or a wheel. It works by using a
coarse screw to convert the rotation of the handle or drive-wheel into a small downward
movement of greater force. The overhead handle usually incorporates balls as flyweights. The
weights helps to maintain the momentum and thrust of the tool to make it easier to operate.
The screw press was first invented and used by the Romans in the first century C.E. It was
used primarily in wine and olive oil production. The screwpress was also used in Gutenberg's
printing press in the mid-15th century.
[1]

A press is a metalworking machine tool used to shape or cut metal by deforming it with a die.
It is frequently used to punch holes in sheet metal in one operation, rather than by cutting the
hole or drilling.
If used as a punch, the tool itself consists of a punch and a matching die, into which it very
closely fits. Both are usually precision machined and then hardened. The material is
introduced between the punch and die, and the machine operated. The punch will cut through
the material in one movement by shearing it. The punch and die may be of any desired shape,
so odd shaped holes and cutouts may be created.
If used as a forging tool the dies can be many different shapes varying from flat to various
shapes that will mold the metal to the desired configuration.







9.

Fig.3 BOLT WHEEL PRESSING M/C









10

Fig.4 BOLT WHEEL











11.
FORGING PROCESS
Forging is a manufacturing process involving the shaping of metal using localized
compressive forces. Forging is often classified according to the temperature at which
it is performed: "cold", "warm", or "hot" forging. Forged parts can range in weight
from less than a kilogram to 580 metric tons. Forged parts usually require further
processing to achieve a finished part. Today, forging is a major world-wide industry
that has significantly contributed to the development of the manufacturing cycles.

TRIMMING PROCESS
Trimming is a manufacturing process that is used as a finishing operation for forged
parts, in order to remove flash. Flash is a characteristic common in most metal
forgings. For that reason trimming, while not technically a forging or even a forming
operation in general, is discussed in this section. Trimming basically presses a part
through a cutting die that runs the periphery of the work. The cutting die are precisely
designed to remove the flash from a particular part. Most often it is desirable to
perform this operation while the work is still hot for maximum efficiency, therefore it
is usually incorporated into the larger production process. For more delicate forgings,
flash can be ground or cut off using different methods. For certain metal forgings, this
is an extremely quick and easy method for the removal of the extra material.

FETTLING PROCESS
Fettling is a word that is used in several different senses. Most of the
uses of the word relate to cleaning, polishing, and maintaining systems so that they will be
functional or will remain functional. The word itself is derived from a root word referring to
condition, as seen in the phrase in fine fettle, which is meant to convey that the person or
object being described is in good condition, shape, or health.
In the railroad industry, this term is used to describe routine maintenance performed on
tracks. It includes confirming that the rails are aligned properly, checking drainage systems,
replacing ties if necessary, and conducting other tasks which will keep the tracks in good
condition. It is important for this maintenance to be performed on a regular basis since a wide
variety of situations can cause damage to the tracks, and this can result in damage to trains
passing over the tracks, most spectacularly in the case of a derailment.
Track fettling is usually accomplished with the assistance of a small handcar or truck
specially fitted to roll on the tracks, which allows track workers to carry tools and
replacement parts as they traverse the track to inspect it. This is done in constant rotation to
make sure that all of the track is seen at some point or another.








12.

Fig.5 TRIMMING









13.

Fig.6 FETTLING


Fig.7 FORGING
14.
DRILLING PROCESS

Drilling is a cutting process that uses a drill bit to cut or enlarge a hole of circular cross-
section in solid materials. The drill bit is a rotary cutting tool, often multipoint. The bit
is pressed against the workpiece and rotated at rates from hundreds to thousands
of revolutions per minute. This forces the cutting edge against the workpiece, cutting
off chips (swarf) from the hole as it is drilled.
Exceptionally, specially-shaped bits can cut holes of non-circular cross-section;
a square cross-section is possible
Drilled holes are characterized by their sharp edge on the entrance side and the presence
of burrs on the exit side (unless they have been removed). Also, the inside of the hole usually
has helical feed marks.
Drilling may affect the mechanical properties of the workpiece by creating low residual
stresses around the hole opening and a very thin layer of highly stressed and disturbed
material on the newly formed surface. This causes the workpiece to become more susceptible
to corrosion at the stressed surface. A finish operation may be done to avoid the corrosion.
Zinc plating or any other standard finish operation of 14 to 20 m can be done which helps to
avoid any sort of corrosion.
For fluted drill bits, any chips are removed via the flutes. Chips may be long spirals or small
flakes, depending on the material, and process parameters.
[3]
The type of chips formed can be
an indicator of the machinability of the material, with long gummy chips reducing
machinability.
When possible drilled holes should be located perpendicular to the workpiece surface. This
minimizes the drill bit's tendency to "walk", that is, to be deflected, which causes the hole to
be misplaced. The higher the length-to-diameter ratio of the drill bit, the higher the tendency
to walk. The tendency to walk is also preempted in various other ways.


Fig.8 SPECIAL PURPOSE MACHINE



16.

Fig.9 DRILLING PROCESS






17
DIE CASTING

Die casting is a metal casting process that is characterized by forcing molten metal under
high pressure into a mold cavity. The mold cavity is created using two hardened tool
steel dies which have been machined into shape and work similarly to an injection
mold during the process. Die castings are made from non-ferrous metal such as
Aluminium in the above process.
Die castings are characterized by a very good surface finish (by casting standards) and
dimensional consistency.
Two variants are pore-free die casting, which is used to eliminate gas porosity defects;
and direct injection die casting, which is used with zinc castings to reduce scrap and
increase yield.
PROCESS
There are four steps in die-casting process:
i. Die preparation
The dies are prepared by spraying the mold cavity with lubricant. The lubricant
both helps control the temperature of the die and it also assists in the removal of
the casting.
ii. Filling
The dies are then closed and molten metal is injected into the dies under high pressure;
between 10 and 175 megapascals (1,500 and 25,400 psi). Once the mold cavity is filled,
the pressure is maintained until the casting solidifies.
iii. Ejection
The dies are then opened and the shot (shots are different from castings because there can
be multiple cavities in a die, yielding multiple castings per shot) is ejected by the ejector
pins.
iv. Shakeout
Finally, the shakeout involves separating the scrap, which includes
the gate, runners, sprues and flash, from the shot. This is often done using a
special trim die in a power press or hydraulic press. Other methods of shaking out
include sawing and grinding.


18.
TYPES OF DIE CASTING MACHINES USED:
PRESSURE DIE CASTING MACHINE


Fig.10 PRESSURE DIE CASTING MACHINE

BUFFING
Drilled holes are characterized by their sharp edge on the entrance side and the
presence of burrs on the exit side (unless they have been removed). Also, the inside of
the hole usually has helical feed marks.
[3]

Drilling may affect the mechanical properties of the workpiece by creating
low residual stresses around the hole opening and a very thin layer of
highly stressed and disturbed material on the newly formed surface. This causes the
workpiece to become more susceptible to corrosion at the stressed surface. A finish
operation may be done to avoid the corrosion. Zinc plating or any other standard
finish operation of 14 to 20 m can be done which helps to avoid any sort of
corrosion.
For fluted drill bits, any chips are removed via the flutes. Chips may be long spirals or
small flakes, depending on the material, and process parameters.
[3]
The type of chips
formed can be an indicator of the machinability of the material, with long gummy
chips reducing machinability.
When possible drilled holes should be located perpendicular to the workpiece surface.
This minimizes the drill bit's tendency to "walk", that is, to be deflected, which causes
the hole to be misplaced. The higher the length-to-diameter ratio of the drill bit, the
higher the tendency to walk. The tendency to walk is also preempted in various other
ways, which include:


Fig11 Buffing Machine

BROACHING
Broaching is a machining process that uses a toothed tool, called a broach, to remove
material. There are two main types of broaching:linear and rotary. In linear
broaching, which is the more common process, the broach is run linearly against a
surface of the workpiece to effect the cut. Linear broaches are used in a broaching
machine, which is also sometimes shortened to broach. In rotary broaching, the
broach is rotated and pressed into the workpiece to cut an axis symmetric shape. A
rotary broach is used in a lathe or screw machine. In both processes the cut is
performed in one pass of the broach, which makes it very efficient.
Broaching is used when precision machining is required, especially for odd shapes.
Commonly machined surfaces include circular and non-circular
holes, splines, keyways, and flat surfaces. Typical workpieces include small to
medium sized castings, forgings, screw machine parts, and stampings. Even though
broaches can be expensive, broaching is usually favored over other processes when
used for high-quantity production runs.
[1]

Broaches are shaped similar to a saw, except the height of the teeth increases over the
length of the tool. Moreover, the broach contains three distinct sections: one for
roughing, another for semi-finishing, and the final one for finishing. Broaching is an
unusual machining process because it has the feed built into the tool. The profile of
the machined surface is always the inverse of the profile of the broach. The rise per
tooth (RPT), also known as the step or feed per tooth, determines the amount of
material removed and the size of the chip. The broach can be moved relative to the
workpiece or vice-versa. Because all of the features are built into the broach no
complex motion or skilled labor is required to use it. A broach is effectively a
collection of single-point cutting tools arrayed in sequence, cutting one after the other;
its cut is analogous to multiple passes of a shaper.

Fig12 Broaching Machine
PRODUCTS
1. Bracket Compressor


2. Alternator


3. Case Gear Shift Guide


21.
4. Case DLI Sensor


5. Crank Case -R


6. cup





22.
7. Cylinder Block



8. End Shield




9. Hub Comp Scooter


23.
10. Mid Shield



11. Motor Frame


12. Pinion Housing D2-l




24.

13. Rack Housing For Houndai


14. Rear cover


15. Rear Half



25.
16. Retainer Input



17. Sprocket RR



18. Wheel Assembly Motorcycle


26.



Fig.14 PRODUCTS














28.
PROBLEMS & SOLUTIONS
S. No. NATURE OF PROBLEM SUGGESTION

1. Unskilled and unexperienced
workers
Recruitment of workers on the basis of their
past experience and their skills. It is not
necessary to have recruitment in mass but
only skilled labours.
2. Misalignment of Die As we have already discussed it occurs due to
carelessness of the labours.
3. Development of Burr Burr is developed due to misalignment of die.
So workers should be careful during alignment
of die.
4. Time Setting for Changing Die As we have to make a workpiece of different
diameter, so die needs to be changed which
takes an hour or half an hour. Time setting for
changing die occurred due to less number of
machines. So this problem can be solved by
increasing number of machines.
5. Target not fixed to the worker Target should be assigned to the worker.
6. Inspection not done on Regular
basis.
During our training we observed that
whenever we entered any of the shops the
workers started doing their work properly on
seeing us. This means if there is regular
inspection, workers will work properly.
Table No.1




29.
RESULT & DISCUSSION

I visited the Industry and visualized every machine in the unit II of the Kiran Udyog Pvt. Ltd.
Gurgaon and perceived knowledge about the various processes being carried out. The details
of every machine and tools used were given to me by my supervisor Mr. Rajesh Chokkar.
Then me, as a part of the Kiran Udyog Pvt. Ltd., enrolled myself in the manufacturing of Die
Casting of Aluminium & Zinc. I came to know practically about every process performed and
problems related to every shop became known to me while the training. I also gave
suggestions on my part to the industry so as to improve their production.
I learnt about how such large machines like High Speed Press Machine can increase the
production by a large difference. But it depends on the demand of the clients.















30.

REFERNCES
1. www.fiecpowerpresses.co.in
2. www.pearlengineeringco.com
3. www.directindustry.com
4. www.ahmedabadstrips.com
5. www.tmaintl.com
6. www.researchgate.net
7. John L., Jorstad (September 2006), "Aluminum Future Technology in Die Casting",
Die Casting Engineering: 1825, archived from the original on 11-12-2010.
8. www.diecasting.com/general-die-casting
9. www.kiranudyogindia.com


















31.

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