TRAINING REPORT

OF SIX WEEK INDUSTRIAL TRAINING, UNDERTAKEN AT DAWN MOTORS PVT. LTD CHD ROAD, VILLAGE JANDIALI, LUDHIANA B.TECH ME 4th SEMESTER RIMT-INSTITUTE OF ENGINEERING & TECHNOLOGY

Submitted to: Name: Er. Deepinder Singh Designation:Head Of Department (Mechanical Engg.)

Submitted By: Name: Naman Jain College Roll No.: 10666 University Roll No.: 100641132032

TABLE OF CONTENTS
Title
1 Introduction of Project 1.1 Time Table. 1.2 Need for the Application 1.3 Purpose of the Document

Page no
1-4

Hardware and Software requirements 2.1 User requirements 2.2 System requirements

5-7

Methodology and flow charts 3.1 Feasibility study 3.2 System Development life cycle 3.3 Phases of system development life cycle 3.4 Data flow diagram Results and discussion

8-18

19

5 Bibliography 6 SQL Server tables and Screenshots 5.1 Admin Login 5.2 User Login 5.3 Database file

20 21-41

ACKNOWLEDGEMENT
With profound respect and gratitude, I take the opportunity to convey my thanks to complete the training. I express gratitude to the Program Manager and other faculty members of Mechanical Department of Regional Institute of Technology(RIMT-IET) for providing this opportunity to undergo industrial training at Dawn Motors, Ramgarh, Ludhiana. I do extend my heartfelt thanks to Mr. Amit Sharma for providing me this opportunity to be a part of this esteemed organization. I am extremely grateful to Mr. Vijay Saini, Quality Incharge at Dawn Motors for guidance during whole training. I am extremely grateful to all the technical staff of Dawn Motors for their co-operation and guidance that helped me a lot during the training period. I learnt a lot under them and I will always be indebted of them for this value addition of me.

ABOUT THE COMPANY

INTRODUCTION
The unit is located in the northern region of INDIA in the well known city of LUDHIANA (PUNJAB), which is famous for its engineering and manufacturing capabilities in the state of Punjab. Company is known for it's commitments and customer orientedness, as it depicts from slogan "We believe in doing what we said, and commiting for, WHAT WE CAN DO"

This Unit is the Head Office of Dawn Group. It is approximately 8 Km. away from the Ludhiana Junction and approx. 9 Km away from main Bus stand of Ludhiana city. The approach from either point is very easy.

PROFILE HISTORY
The unit was established in 1976 by SH. B.D. Sharma as a job worker for ancillary of B.H.E.L (Bharat Heavy Electricals Ltd.). The enterprising and innovative leadership added a new chapter in the history of DAWN Engineering Enterprises by adding Punjab Tractor Limited, Mohali, in its Customers list in 1980. After that there was never any lack of acceleration on the path of progress of Company and started Gear Shifting Forks supplies for Eicher Tractor, Parvanoo, Eicher Tractor, Faridabad & Eicher Motor Limited, Indore in 1984, 1986 and 1990 respectively.

PRODUCT RANGE
Categories : Gear Box Component Hydraulic Component Hydraulic Lift Assy. Components: P.T.O. Components Sheet Metal Components Propeller Shaft Components

ACHIEVEMENTS

1.In year 1990, Best vendor of the year Award given by Mr.Vikram Lal (Chairman Eicher Group).

2.Self Certification Supplier Quality Program by Eicher Motors Ltd.

3.Eicher gave a name Fork Man to DAWN in year 2003 in annual Vendor Meet.

4.Quality certification ISO 9001-2000 from DNV.

5.Quality Certification ISO 9001-2000 from BVQI in 2005.

6.Regular participation in Auto Expo from 2004 (Indias Bigget Automobile Exhibition).

7.Udyog Rattan Award from Institute of Economic Studies in year 2005 for Excellence in Productivity, Quality, Innovation & Management by Dr.Bhishma Narain Singh (Honble Former Governor of Tamil Nadu & Assam).

MACHINES USED AT DAWN

TOOL AND CUTTER GRINDERS: These machines

areprimarily intended for tool room work for grinding cyclinderical andtapered multitooth cutting tools, like milling cutters, hobs, drills,rreamers, taps, broaches, gear shaper cutters, etc. They are also capable of doing light cylinderical, surface and internal grinding operations. They are made in various different designs. The most versatile and widely used form is a Universal tool and cutter grinder. It carries a workhead and a tailstock on a uppertable, which is mounted on a lower tableon which the former can be sxivelled to grind the tapered tools. The lower table travels longitudinally on the ways provided on a saddle under it. The saddle travels in cross direction. The saddle and table travels are usually controlled by hand. The wheel head is usually mounted on a elevating coloumn and consists of housing carrying a wheel spindle, which runs in two bearings. Both ends of the spindle are tapered to receive the clamping sleeves, carrying the grinding wheels. The wheel head can be swivelled about a vertical axis together with the coloumnand its driving motor.

SURFACE GRINDER: surface grinders do do almost the same operation as the planers, shapers or millingmachines, but with more precision. Primarily they are intended to machine flat surfaces, although irregular, curved or tapered surfaces can also be ground on them.

Horizontal spindle reciprocating table grinder:

Figure . illustrates this machine with various motions required for grinding action. A disc type grinding wheel performs the grinding

action with its peripheral surface. Both traverse and plunge grinding can be carried out in this machine .

PILLAR DRILLING MACHINE: These drilling machines,

usually called pillar drills, are quite similar to the table top drilling machines but of little larger size and higher capacity (0.55 ~ 1.1 kW) and are grouted on the floor (foundation). Here also, the drill-feed and the work table movement are done manually. Fig. typically shows a pillar drill. These low cost drilling machines have tall tubular columns and are generally used for small jobs and light drilling.

COLUMN DRILLING MACHINE: These box shaped column

type drilling machines as shown in Fig. are much more strong, rigid and powerful than the pillar drills. In column drills the feed gear box enables automatic and power feed of the rotating drill at different feed rates as desired. Blanks of various size and shape are rigidly clamped

on the bed or table or in the vice fitted on that. Such drilling machines are most widely used and over wide range ( light to heavy) work.

RADIAL DRILLING MACHINE: This usually large drilling

machine possesses a radial arm which along with the drilling head can swing and move vertically up and down as can be seen in Fig.. The radial, vertical and swing movement of the drilling head enables locating the drill spindle at any point within a very large space required by large and odd shaped jobs. There are some more versatile radial drilling machines where the drill spindle can be additionally swivelled and or tilted.

GANG DRILLING MACHINE: In this almost single purpose

and more productive machine a number (2 to 6) of spindles with drills (of same or different size) in a row are made to produce number of holes progressively or simultaneously through the jig.

VERTICAL BROACHING MACHINE: In pull-up type

machine the ram is provided at the top which carries the pulling heads at its bottom. The elevators are provided inside the bed to hold the broach in vertical position. The work piece is clamped to the underside of the table and elevators raised to pass the pass the front pilots of the broaches through the work piece and the table, where they are gripped by the pulling head.

HORIZONTAL MILLING MACHINE: Its principal parts

are shown in fig. The vertical column serves as a housing for electrical, main drive, spindle bearings, etc. The knee acts as a support for the saddle, worktable and other accessories. The arbor carrying the cutter rotates about a horizontal axis.

MACHINING PROCESSES
Boring : Boring is an operation of enlarging and finishing the
complete hole with a single point cutting tool. This operation is normally done on boring machines but can also be accomplished on lathe group of machine tools. Boring corrects the positon of the hole and makes it cocentric with the axis of rotation of spindle.

Boring tools: A boring tool consists of a single point cutting

tool held in a tool holder known as boring bar, where the boring bit is held in a cross-hole at the end of a boring bar. The boring bit is adjusted and held on postion with the help of set screws. The material of the boring bit can be: Solid H.S.S, Solid carbide, Brazed carbide, Dispisable carbide tips or Diamond tips. Boring tools are of two types: 1. Fixed type 2. Rotating type

Fixed type of boring tools are used on work rotating machines, such as lathes, whereas rotating type boring tools are used ont tool roating machinessuch as drill presses, milling machines and Boring machines. Lathes, drill presses and milling machines can be used only for smalljobs. However, for large jobs, boring machines are used. The boring bar or the boring head in the case of rotating type tools, is held in the main spindle of the machine.

MILLING PROCESS

MILLING: Milling may be defined as a machining process

for removal of excess material from a work piece with a rotating cutting tool. The rotating cutting tool call the Milling Cutter is a multiple cutting tool having the shape of a solid of revolution with cutting arranged either on the periphery or on end face or on both. Milling process involves simaltaneously rotary cutter and usually linear motion of the work, with the work fed against the cutter. Milling process is used for producing flat, contoured, helical surfaces, for cutting threads and toothed geared and for making helical grooves.

Types of milling cutters : There are many different kinds

of milling cutters, according to the design may be of the solid or inserted blade type that are mechanically retained and are usually adjustable.

Some of the common kind of cutters are discussed below:

1. PLAIN MILLING CUTTER : these cutters are cylinderical in shape and have cutting teeth on the periphery only. They are used for milling plain or flat surfaces. A plain cutter may have either straight or helical teeth. In the operation of a cutter with straight teeth each tooth enters the cut simaltaneously along its full length. The leads to intermmitent loads acting on the machine and impairs the quality of the surface machined. Cutters with helical teeth operate more smoothly since the cutter enter the cut gradually and the load on the machine is uniform.

If a set of two cutters operate side by side to mill wide surface, one has right hand helix and the other has left-hand helical flutes so that the axial forces are counterbalanced. 2. FACE MILLING CUTTERS: Face milling cutter, with teeth on the end face are used for maching large, flat surfaces. The cutter may be mounted on the arbor or rigidly clampedon the nose of the machine spindle. Face milling cutters are similar to end mills but they are consideraly larger in diameter. They are designed to machine flat surfaces which are perpendicular to the rotational axis of the spindle. The cutters are used on vertical milling, planer type milling and bed type milling machines. 3. END MILLS: End mills have cutting on the teeth on the end as wellas on the periphery. End mills may be made as solid cutters in which the cutter body is part of the shank. End mills are used in tracer-controlled profile milling operations. They are employed for making deep grooves in the base parts, profile recesses, steps, perpendicular planes etc. 4. SIDE MILLING CUTTERS: These cutters have teeth on the periphery and also on one or both sides. These cutters are made in width from about 5mm to 25mm and in diameters from 50 to 200mm. Half-side milling cutters have teeth on only one side and around the circumference. 5. ANGULAR MIILING CUTTERS: These are made as single or double-angle cutters are used to machine angles other than 900. Some of the common cutters are the 450 and 600 single angle cutter nad the 450,600,900 double-angle cutters. 6. According to the purpose or use, we have t-slot milling cutters, woodruff keyslot milling cutters and dove tail cutters for milling dovetail guides.

CUTTER MATERIALS: General purpose solid milling

cutters are made of H.S.S. some cutters are tungsten-carbide

teeth which may be brazed on the tips of the teeth or individually inserted and held in the body of the cutter by some machanical means. Carbide tip cutters are especially adapted to heavy cuts and increased cutting speeds.

CUTTING SPEEDS, FEEDS AND DEPTH OF CUT:

Since the milling cutter is a multi-point cutter, the feed may be given as : Feed per rev., mm/rev, f,=Feed per tooth,mm*number of cutter teeth Feed per min.(table feed),F= Feed per rev*cutter speed(r.p.m) or Where F(mm/rev.)= ft*n*N ft = feed rate per tooth,mm

n=number of cutter teeth The r.p.m of the cutter is obtained as, N=1000*V/3.14D D is cutter diameter in mm. V is the cuting speed in m/min.

STRADDLE MILLING : It is a milling operation in which

a pair of side milling cutters is used for machining two parallel vertical surfaces of a work piece simultaneously.

Parallel facing by two side (single) cutter

ANGULAR MILLING: It is a milling process which is used

for machining flat surfaces at an angle, other than right angle to the axis of the revolving cutter. The cutter used may be a single or double angle cutter depending upon whether a single surface is to be machined or two mutually inclined surfaces simultaneously.

GANG MILLING: It is the name given to the milling

operation which involves the use of a combination of more than two cutters, mounted on a common arbor, for milling a number of flat horizontal and vertical surfaces of a work piece simultaneously. This combination may consist of only side milling.

DRILLING PROCESS

DRILLING PROCESS: The drilling process is extensively

used machining operation by which through or blinf holes are cut or originated in a workpiece. The drilling tool is called a drill is a multi-point cutting tool. The hole is produced by axially feeding the rotating drill into the workpiece which is held on the table of the drilling machine.

DRILLING TOOLS: The most widely employed drilling

tool is a twist drill with two cutting edges or lips. A twist drill consists of the following main parts: the point, the body, the neck and the shank. The point comprises the cutting elements while the body guides the drill in operation. The body of the twist drill has two grooves called flutes cut into its surface. The flutes form cutting surface and also assists in removing the chips out of the drilled hole and making the coolant to get tio the edges. The drill is held and rotated by its shank. The cutting edges are straight and are separated by web thickness of the drill. To help provide adequate strength and rigidity to the drill, the web becomes progressively thicker towards the shank.

DRILLING MACHINES: Drilling machines are classified

into: general purpose, single-purpose and specialized drilling machines.

General Purpose machines: Any hole making operation can

be performed in the general purpose machines. This class includes: 1. Bench type drill press.

2. Single and multiple spindle upright drill press. 3. Radial drilling machines and others.

Single purpose machines: This class includes:

1. Centre-drilling and deep holing machines 2. Semi-automatic and automatic drilling machines.

BROACHING PROCESS

BROACHING: Broaching is a process of machining a

surface with a special multipoint tool called a broach whose teeth remove the whole machining allowance in a single stroke. The process differs from other machining processes in that the only motion is the primary cutting motion of the tool. The feed is obtained by placing the teeth progressively deeper with in the tool, thus, each tool edge takes off a successive layer of the material. The primary cutting motion is translational along the broach axis. Broaching is used for machining through holes of any cross sectional shape, straight and helical slots, external surfaces of various shapes, external and internal toothed gears, splines, keyways and rifling. Broaching of inside surfaces is called internal or hole broaching and that of the outside surfaces as Surface broaching. Typical internal broaching operations are : the sizing of holes, cutting of serrations, straight or helical splines, keyways and gun rifling. Although the cutting speeds used in broach are relatively low(2 to 5 m per min.) , the production rate is very high since the total length of the cutting edges that are simaltaneously in operation is very great.

Material: High speed steel (H.S.S) is by far the most widely

used material for the broaches. Carbide tools are also used to an advantage on steel casting to offset the damaging effect of local hard spots.

Types of broaching machines:

1. Internal broaching machines: a) Vertical pull down broaching machines: In these machines, the broach, instead of being pushed, is pulled through the job. The pulling mechanism is in the base of the machine. The broach is suspended above the work-table by an upper carriage. To start the broaching operation, the broach is lowered through the workpiece held in a fixture on the worktable. The broach is automatically engaged by the pullingmechanism and is pulled down through the job. After the completion of operation, the broach returns to its starting position. b) Vertical pull up broaching machines: Here, the pushing mechanism is above the worktable and the broach is I the base of the machine. The broach enters the job held against the underside of the table and is pull upward. At the end of the operation, the work is free and falls down into a container.

REAMING
REAMING: It is an operation to finishing the hole to bring it
to accurate size and have a fine surface finish. The operation is performed by a multitooth tool called reamer. The operation serves to produce a straight, smooth and accurate hole. The accuracy is expected is within plus-minus 0.005mm

TAPPING
TAPPING: It is the operation done for forming internal threads by means of the tool called tap. To perform this operation the machine should be equipped with a reversible motor or some other reversing mechanism.

TAP DRILL SIZE: For tapping, the size of the hole to be

made through drilling has to be smaller than the size of the tap. It is because the tap size is equal to the outside diameter of the threads whereas the size of the drill o be used before tapping should be equal to the core diameter of the threads. For common usage approximate tap-drill size given by a rule: Drill size= 0.8*tap size ng cutters or of side and plain milling cutters.

INDUCTION HARDENING
INDUCTION HARDENING: It is a form of heat treatment in
which a metalpart is heated by induction heating and then quenched. The quenched metal undergoes a martensitic transformation, increasing the hardness and brittleness of the part. Induction hardening is used to selectively harden areas of a part or assembly without affecting the properties of the part as a whole . Induction heating is a non contact heating process which utilises the principle of electromagnetic induction to produce heat inside the surface layer of a work-piece. By placing a conductive material into a strong alternating magnetic field electrical current can be made to flow in the steel thereby creating heat due to the I2R losses in the material. In magnetic materials, further heat is

generated below the curie point due to hysteresis losses. The current generated flows predominantly in the surface layer, the depth of this layer being dictated by the frequency of the alternating field, the surface power density, the permeability of the material, the heat time and the diameter of the bar or material thickness. By quenching this heated layer in water, oil or a polymer based quench the surface layer is altered to form a martensitic structure which is harder than the base metal.

BURNISHING
BURNISHING: Burnishing operation is the process of getting a
smooth and shiny surface by contact and rubbing of the surface against the walls of a hard tool. It is a finish and strengthening process.

TOOL ROOM
JIGS AND FIXTURES: Jigs and fixtures are the devices
which help in increasing the rate of production of identical parts and simaltaneously reducing the human efforts required for producing these parts. Suitable devices has to be used for holding and locating purposes so that the repition of work can be done economically. These devices are called jigs and fixtures.

ADVANTAGES OF JIGS AND FIXTURE

1. They enable easy means for manufacturing of interchangeable parts and thus facilitate easy and qiuck work. 2. Pre-machining operations, like marking, measuring, lay-out, etc. required in case of individual parts, are totally eliminated with the use of jigs and fixtures. 3. Once a properly designed jig or fixture is set up in position, any number of identical parts can be produced without any additional setup. 4. Production capacity is increased with their use because of single set up. 5. Reduce the work handling time 6. They offer a high clamping rigidity. Therefore, higher speed, feed and depth of cut can be used for machining.

7. Machining accuracy is increased because of the automatic location of the work. 8. The parts produced with their use are very accurate. As such, the expenditure due to inspection and control of finished components is considerably reduced. 9. There is large reduction in fatique to the operator. Enables machining of complex and heavy components. 10. Needs less skilled labour, and effecting in reducing labour cost.

INSPECTION & QUALITY CONTROL

It is an essential component of production control through which the necessary control over the quality of a product is maintained right from the raw material stage to the final finished stage. It is , thus, a tool for controlling the quality of a product and assess its acceptability.

OBJECTIVES OF INSPECTION
THE MAIN OBJECTIVES OF INSPECTION ARE:
1. To separate the defective products from the acceptable ones and, thus, ensure proper quality standards of the products. 2. By doing so, to prevent the defective or sub-quality products from reaching the assembly stage and hence, the customer. 3. Thus, to prevent the chances of lowering of image and reputation of an industry and at the same time protecting the interests of the customers. 4. To find out defects in raw material and errors in workmanship to prevent use of defective materials and further processing of defective parts. 5. To find out errors in processing, feedback this information to the concerned people to enable them to take corrective steps to prevent manufacture of poor quality products.

6. To collect and compile information about the performance of the product, which is used by several departments like engineering, design, production, purchase, quality control, etc

MAIN FUNCTIONS OF INSPECTION DEPARTMENT ARE:

1. To inspect the incoming raw material. 2. To carry out metallurgical operations. 3. To carry out tests for determining mechanical and physical properties. 4. To inspect the parts made from outside on sub-contract basis. 5. To inspect standard components purchased from outside. 6. To carry out in-process inspection. 7. To inspect cuttingand other tools purchase from outside. 8. To inspect reground tools, jigs and fixtures before they are issued for use. 9. To periodically check the gauging equipment and measuring instruments for their accuracy. 10. To inspect finished products. 11. To detect errors in production methods and design of products and report them to appropriate authorities for remedial measures. 12. To segregate products which can be salvaged through reworking, those which can be used and those which are to be totally rejected.

MEASURING INSTRUMENTS

MICROMETER: The micrometer is a precision measuring

instrument, used by engineers. Each revolution of the rachet moves the spindle face 0.5mm towards the anvil face. The object to be measured is placed between the anvil face and the spindle face. The rachet is turned clockwise until the object is trapped between these two surfaces and the rachet makes a clicking noise. This means that the rachet cannot be tightened any more and the measurement can be read. Least count=0.01

Vernier caliper: The Vernier Caliper is a precision instrument

that can be used to measure internal and external distances extremely accurately. The example shown below is a manual caliper. Measurements are interpreted from the scale by the user. This is more difficult than using a digital vernier caliper which has an LCD digital display on which the reading appears. The manual version has both an imperial and metric scale. Manually operated vernier calipers can still be bought and remain popular because they are much cheaper than the digital version. Also, the digital version requires a small battery whereas the manual version does not need any power source. Least count= 0.02

FORK SECTION COMPONENTS

1-2, water cool 3-4 water cool 5-6 jaw 4-5 GT-51 Shifter fork Implus draft river Differential lock

PROCESSES/OPERATION
Fork 2nd gear shifter
Raw material inspection Drilling Reference facing Total length Chamfer Broaching Reference face grinding Pad milling Gap milling Angle milling Slot milling Spot milling Drilling

Chamfer Tapping Burring Pad height Pad finish De burring Induction hardening Final inspection

CNC SECTION COMPONENTS

Crank Sensor Spindle Brake Drum Guide Bush 3-Star Hydraulic Arm Lifter

PROCESS/OPERATION
CNC facing CNC turning CNC grooving Drilling Boring Reaming

Chamfering Broaching

Hydraulic arm lifter

Crank