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Summer Training Project Report 2011. A Summer Training Report taken under Caparo Maruti Lmt. Gurgaon. Submitted by : Submitted to : Sunny Sh.S.K.Bagga (H.O.D)
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ASummer Training Reporttaken underCaparo Maruti Lmt. Gurgaon. Submitted by : Submitted to : Sunny Sh.S.K.Bagga (H.O.D) Roll No. 12327 ME (5th Sem.)
Contents • Acknowledgement • Caparo Group • Caparo History • Caparo Companies • Gurgaon’s Manufacturing Plant • Caparo Products • Product Info
Acknowledgement I express my deep sense of gratitude to Caparo Maruti Lmt. for providing me an opurtunity to have my Summer Training in their company in Production Department. I am highly thankful to Mr. Rajesh Sharma who was kind enough to familiarize me to the plants operations. And I am also very much thankful from bottom of my heart to My Parents. Without there kindness it could have never ever be possible.
Caparo Group “Caparo is more than a successful business enterprise - it is a story of people, of values and human effort.” - Lord Paul, Chairmen and Founder. Caparo Vehicle Products (CVP) is a grouping of innovative well established Tier 1 and 2 component design, engineering and manufacturing companies providing advanced solutions to the automotive, motor sport, commercial and niche vehicle markets as well as other sectors. Offering design, rapid prototyping and sample development, as well as series production and line side delivery, the division is able to provide full vertical integration as well as component solutions to its customers.
Caparo Maruti History • In 1968 Lord Paul took out a £5,000 loan and opened Natural Gas Tubes. The company, based in Huntington in Cambridgeshire, manufactured spiral weld tubes and achieved first year sales of £14,000. In 2006 Caparo group’s sales exceeded £625m.
Companies • The Caparo group is a collection of over 40 companies operating on over 60 sites in UK, INDIA, North America, Spain, Canada and Dubai. With business interest mainly in manufacturing of steel, automotive and general Engineering products, the group’s wider activities encompass Material testing, film distribution and bespoke furniture. In 2006 the alone the group acquired 22 companies.
Gurgaon’s Manufacturing Plant • Operational since - Feb. 1996 • Total area - 12,100 Sq.m. • Build up area - 5,600 Sq.m. • Capacity - 2.4 mn line stroke p.a. • Investment - INR 100 cr • Man power employed - 330 employees
PRODUCTS • Outer Body Panel • Large Inner Panel • Reinforcement • Brackets • Cross Members and Chasis Parts • General Stampings
Introductional Topics Main topics of discussion of this presentation are here as : • General Stampings & their Production Processes
Stampings • Metal Stamping manufacturing is the process of creating metal parts by applying extreme pressure to a blank piece of metal and forming the metal into a desired shape. The stamping machine includes a specially made form or die which gives the stamped part shape. • Most metals may manufacture using the stamped process these include: Aluminium(most alloys) , Brass, Steel, Galvanized Steel, Titanium, Zinc etc. • Machines used in stamped manufacturing range from a simple hand press or “Hydraulic Press”, to the much larger machines referred to as “Drop Hammers”. All stamping machines incorporate a form or die to give the stamped metal the desired shape.
The operations associated with stamping are blanking, piercing, forming, and drawing. • These operations are done with dedicated tooling also known as Hard Tooling. This type of tooling is used to make high volume parts of one configuration of part design. (By contrast, soft tooling is used in processes such as CNC turret presses, laser profilers and press brakes). All these operations can be done either at a single die station or multiple die stations — performing a progression of operations, known as a progressive die.
Equipments • The equipments of stamping can be categorized to two types: • Mechanical Presses • Hydraulic Presses • Mechanical Presses: Mechanical presses has a mechanical flywheel to store the energy, transfer it to the punch and to the workpiece. They range in size from 20 tons up to 6000 tons. Strokes range from 5 to 500 mm. and speeds from 20 to 1500 strokes per minute. Mechanical presses are
well suited for high-speed blanking, shallow drawing and for making precision parts. • Hydraulic Presses:Hydraulic Presses use hydraulics to deliver a controlled force. Tonnage can vary from 20 tons to a 10,000 tons. Strokes can vary from 10 mm to 800 mm Hydraulic presses can deliver the full power at any point in the stroke; variable tonnage with overload protection; and adjustable stroke and speed. Hydraulic presses are suitable for deep-drawing, compound die action as in blanking with forming or coining, low speed high tonnage blanking, and force type of forming rather than displacement type of forming.
Sheet Metal Stamping • Stamping presses and stamping dies are tools used to produce high volume sheet metal parts. These parts achieve their shape through the effects of the die tooling. • Production stamping is generally performed on materials .020” to .080” thick, but the process also can be applied to foils as thin as .001” or to plate stock with thickness' approaching 1.000” • Formability is the primary attribute of sheet metal material. Formability is further defined as the materials ability to be: 1. Bending 2. Stretching 3. Drawing
The metallurgical term for these qualities is “ductility”. Ductility is the materials ability to deform and elongate without fracture. The extent to which a stamping is subjected to such deformation is directly related to the part’s overall shape and geometry. Other factors also influence the material’s formability. They include: The die design The press The press speed Lubrication Sheet metal feeding mechanisms Monitoring and control systems
The stamping manufacturing process in very capable of high production runs. Depending on the complexity of the part, and additional manufacturing steps ( progressive stamping ) required for the final part, will drive the effective cost-per-part of stamping manufacturing. Typical stamping speeds do vary, however many high production stamping manufacturers are capable of 30 to 80 stamping stokes per minute. The main process followed in stamping production are as : 1. Blanking 2. Drawing 3. Forming 4. Machining 5. Piercing
Blanking • Blanking is cutting up a large sheet of stock into smaller pieces suitable for the next operation in stamping, such as drawing and forming. Often this is combined with piercing. • Blanking can be as simple as a cookie cutter type die to produce prototype parts, or high speed dies that run at 1000+ strokes per minute, running coil stock which has been slit to a specified width. • For production parts, the final configuration of the drawn or formed shape needs to be established before the blank die can be built-since the blank size and the slit width size needs to be established precisely.
Drawing • In drawing, a blank piece of sheet metal is restrained at the edges, and the middle section is forced by a punch into a die to stretch the metal into a cup shaped drawn part. This drawn part can be circular, rectangular or just about any cross-section. • Drawing can be either shallow or deep depending on the amount of deformation. Shallow drawing is used to describe the process where the depth of draw is less than the smallest dimension of the opening; otherwise, it is considered deep drawing. • Drawing leads to wrinkling and puckering at the edge where the sheet metal is clamped. This is usually removed by a separate trimming operation.
Forming • Forming is similar to bending. Complex parts such as U-sections, channel sections of different profiles can be produced by doing multiple bends. • There is no change in thickness. Good dimensional repeatability as well as close tolerances is possible with this process.
Machining Machining is consisting of many different processes such as Drilling, tapping, counterboring, and countersinking. They are as following : • Drilling: Drilling is done in sheet metal only when piercing cannot deliver the accuracy required. For example, on a formed part, when holes on different features need to be coaxial, the accuracy obtained by machining may be required. • Tapping: Tapping can be done using cut threads or formed threads. Formed threads (thread rolling) is preferable for the following reasons :
Thread rolling is faster than cutting. • Fewer burrs are generated, so no clean up is required or risk of future hazards such as shorting with electronic components. • Larger sized holes are required for thread rolling vs. tapping, resulting in improved tap life. • Rolled threads are stronger due to cold working. Typically, rolled threads are 20% stronger than cut threads. • For very thin stock, either threaded fasteners such as clinch nuts, or forming thread in extruded holes is recommended. OR • The material is upset in the sheet metal hole to form one thread pitch.
Counterboring: Counterboring is often done to provide clearance and a bearing surface for the fastener's head. • Countersinking: Countersinking allows for flush mounting of flat head fasteners. Countersinking cannot always be done for very thin stock or for very large fasteners.
Piercing • Piercing is the operation of cutting internal features (holes or slots) in stock. Piercing can also be combined with other operations such as lance and form (to make a small feature such as tab), pierce and extrude (to make an extruded hole). All these operations can be combined with blanking. • Piercing of all the holes is best done together to ensure good hole-to-hole tolerance and part repeatability. However if the material distorts, the method described below can be done. • When there are large numbers of holes, in a tight pitch, there could be distortions, due to the high amount of tension on the upper surface due to stretching and compression on the bottom surface. This causes the material not to lay flat. This can be avoided/lessened by staggering the piercing of the holes. Holes are punched in a staggered pattern; then the other holes are punched in the alternate staggered pattern.
