SIX MONTH INDUSTRIAL TRAINING REPORT

ON

Studied everything in brief about production of

various products in cold forging shop
COMPLETED AT

MICROTURNERS-6 BADDI
SUBMITTED IN PARTIAL FULFILLMENT FOR AWARD OF DEGREE OF

BACHELOR OF TECHNOLOGY
IN

MECHANICAL ENGINEERING
BY

YOGESH KUMAR
2011UGME122

DEPARTMENT OF MECHANICAL ENGINEERING OF BAHRA UNIVERSITY

SHIMLA HILLS (Waknaghat distt. Solan).

DECLARATION
I hereby declare that the Industrial Training Report entitled ("Study everything in brief about
production of various Products in Cold Forging Shop") is an authentic record of my own work as
requirements of 6-months Industrial Training during the period from 16 july 2014 to 16 jan
2015for the award of degree of B.Tech. (Mechanical Engineering), BAHRA UNIVERSITY
SHIMLA HILLS (WaknaghatDistt. Solan) under the guidance of

Yogesh kumar
2011UGME122

Date: 10 December 2014

Certified that the above statement made by the student is correct to the best of our knowledge
and belief.
Signatures
Examined by:HOD/DEAN
(Signature and Seal)

II

Acknowledgement
I have taken efforts in this project. However, it would not have been possible without the
kind support and help of many individuals and organisations. I would like to extend my
sincere thanks to all of them
Iam highly indebted to Sanjeev doogle for their guidance and constant supervision as
well as for providing necessary information regarding the project & also for their support
in completing the project.
I would like to express my gratitude towards my parents & member of Micro Turners
Company for their kind co-operation and encouragement which help in completion of
the project.
I would like to express my special gratitude and thanks to industry persons for giving me
such intentions and time.
My thanks and appreciations in completing the project also go to the people who have
willingly helped me out with their abilities.

PROFILE
III

The core strength of our organization is the latest machining facility and the dedicated
man power of approx. 300 numbers which comprises of qualified engineers , skilled
machinist and competent administrative work force.

We have designed S.P.M s for doing the critical operations which are otherwise difficult
to do in conventional machining. For effective measurement we have design gauges for
every operation even if the operation is small.

With such an infrastructure strength, we have been identified as single source supplier
for many components of TVS motor company, Honda and many other company.

ABOUT COMPANY
IV

Microturners group , founded in 1969 (started with name A.K Automatics) is one of the
largest integrated component manufactures in INDIA .It has 12 world class manufacture
facility mainly located in the north and west INDIA.With the infrastructure and
technology platform development over 25 years , the group is well positioned in INDIA
auto and non- auto component markets.

With over 1400 component , microturner is mainly into the manufacturing of kick start
mechanism , transmission gear train assembly , gear shifting towers and forks ,
chain/timing sprocket , ratchets , pinion , special engines fastener , clutch shafts ,
armature shafts , bearing races and rings , 2-WHD chassis , frames , silencers and
special turned component.

Microturners mainly aims at expanding their business across the globes through
technological excellence.We significantly features-HIGH QUALITY-HIGH VOLIME-LOW
COST.

VISION
V

To be a leader amongst the original equipment manufactures by constantly evolving,

continuously absorbing and implementing latest techniques.

MISSION
To work efficiently and meeting total satisfaction of our valued customer and for the
prosperity and growth of our associates and people with us.

QUALITY POLICY
We will endeavour to be world class organisation and satisfy our customerneeds
towards reliable performance in all our products .We shall be committedto continuous
improvement through. Quality Management System in order to meet customer needs
and expectation with increased morale of our personnel .For this we shall create an
environment to encourage all our employee and suppliers to prevent defects and strive
for excellence.

QUALITY AWARDS
VI

Quality award 2005Hero Honda

Quality award-Bronze 2009Bajaj Auto
Quality award-Gold 2011Bajaj Auto
Best Machining Award 2010Honda
Quality Award 2011Mahindra
DOL Award 2007Hero Honda
TPM Award 2011Bajaj Auto
Delivery Award 2003Honda
Quality Award 2002Yamaha
MICROTURNERS PLANTS
VII

HIMACHAL PRADESH:
MICROTURNERS-II BAROTIWALA
MICROTURNERS-IV NALAGARH
MICROTURNERS-PARVANU

HARYANA:
A.K AUTOMATICS-I ROHTAK
A.K AUTOMATICS-III ROHTAK
KHM Drive SYSTEM PVT MANESAR GURGAON
MICROTURNERS-III BINOLA GURGAON
MICROTURNERS-I ROHTAK

MAHARASHTRA:
MICROTURNERS-IV CHAKAN

UTRAKHAND:
MICROTURNERS-VII HARIDWAR
MICROTURNERS-V PANTNAGAR
MICROTURNERS METAL MAN PANTNAGAR

FACT SHEET
VIII

Year of establishment-1969
Nature of business-supplier manufacture
India mart member since-2010

Aim / Vision / Mission

Cost effective solutions

World class quality
Value added products to customers
Team work
Continual improvement
Zero defects
TPM
To provide best price at competitive price

Memberships / affiliations
AnTS- 16949:2009 AND TS-16949:2002 certified company.

Achievements
1969
IX

Start of AK Automatics, Rohtak:equipped with single spindle automats (traubs)

for manufacture of precision turned components
1981
Establishment of micro turners, Rohatk: equipped with hot / warm forging
presses coupled with induction heaters, resistance heating and metal gathering
machines.
1983
1983 establishment of micro turners, parwanoo (HP):a dedicated unit to Maruti
Udyog limited for manufactures and supplies of gear shifting rods.
1984
1983approval received from hero Honda as a vendor to start supply of engine /
chasis components of motor cycles.
1993
Approval received from Bajaj auto ltd to start supplies for cold forged axles /
cylinder heads bolts and other fasteners and precision machined components
followed by supply of kick shaft assembly in subsequent years.
1994
Addition of better heat treatment facilities including gas carburising and LCN
treatment facilities.
1996
Addition of gear shapers and gar hobbing machines to finish complete gears.
1998
Addition of facilities for bearing races manufacturing including track grinding
2002
X

Establishment of micro turners, BROTIVALA (HP)-equipped with 4 die 5 station

part formers, k knuckle joint presses, hydraulic presses, long stroke headers,
CNC machine, CNC grinders, gear hobbing of manufacturing of kick shafts ,
transmission gears,bearing races, cam chain sprockets, ratchets and gear/pinion
kick starter
2005
Establishment of microturners, Gurgaon (HR)- A unit equipped with knuckle joints
presses, hydraulic presses, CNC machine, grinding machine e, gear hobbing
machines for manufacturing of transmission shafts and gears, cam chain
sprocket chain, gear kick starter etc.sealed quench furnaces.
2006
In process to establish micro turners, PANTNAGAR (UK)-A dedicated unit for
BAL PANTNAGAR (UTTRANCHAL)
2009
Establishment of microturner, HARIDWAR (UK)-A dedicated unit for HERO
HONDA motor LTD. HARIDWAR (UK) for suppliers of precision machine and
forged components.
2010
In process-a new unit of microturners is in process at Nalagarh (HP) Micro
turners, Gurgaon gets TS-16949:2002 certification

MICROTURNERS CUSTOMERS
Yamaha
TVS
Tata
Suzuki
Sona
XI

Piaggio
Nissan
Maruti Suzuki
Mahindra Two Wheeler
Mahindra
Kirloskr
Honda
Hero Bajaj
Ashok Leyland

TABLE OF CONTENTS
1. Introduction to organisation

2 No. of departments and shops

2.1 Production shop

2.1.1 Cold forging shop

2.1.2 Machine shop

2.1.3 Heat treatment shop

2.1.4 Plating shop

11

2.1.5 Material testing lab

14
XII

2.2 Product services

15

2.2.1 Tool room

15

2.2.2 Tool control cell

15

2.2.3 Production planning & control

15

2.2.4 Material Management & control

15

2.2.5 Quality Engineering

15

2.2.6 Maintenance

15

3. Project details

15

3.1 Introduction

15

3.1.1 Background

16

3.1.2 Cold forging process

17

3.1.3 Cold Extrusion

19

3.1.4 Design Consideration for Cold Forging

20

3.1.5 Thread rolling

24

3.2 Raw Material selection

30

3.2.1 Introduction

30

3.2.2 Material used

31

3.3 Selection of Die Material

33

3.3.1 Introduction

33

3.3.2 Die Blocks

34

3.3.3 Die Analysis

35

3.4 Lubricants

36

3.4.1 Introduction to Lubrication

36

3.4.2 Classification of Lubrication Mechanism

36

3.4.3 Characterstics of Ideal Lubricants

37

3.4.4 Selection Criteria for Industrial Lubricants

39

3.4.5 Lubrication used in Microturner

39

3.3 Study of Machine (NBM)

41

3.3.1 Specification & features

41

3.3.2 Product formed

42

3.3.3 Die & punches used

43
XIII

3.3.4 Instruments & Gauges

46

3.3.5 Tools used

46

3.4 Results

50

3.5 Conclusion

51

LIST OF TABLES
Table No.

Table Caption

Page Number

Table 2.1.4 Chemicals showing resistance against corrosion

14

Table 3.2.2 Chemical composition of typical cold forging grades

31

Table 3.3.1 Recommended Die Block Material for Forging Various

34

Material
Table 3.5.3 Specification of Cam Brake

45

Table 3.5.5 Specification of Front Axle

49

XIV

LIST OF FIGURE
Fig No.

Fig Caption

Page Number

Fig 2.1.1

Layout of Cold Forging Shop

Fig 2.1.2

CNC Products

Fig 3.1.2(a)

Cold Heading

18

Fig 3.1.2(b)

Trimming

18

Fig 3.1.2(c)

Piercing

18

Fig 3.1.2(d)

Extrusion

19

Fig 3.1.4(a)

Machine Drawing of the Component

21

Fig 3.1.4(b)

Single Blow Header

23
XV

Fig 3.1.4(c)

Double Blow Header

23

Fig 3.1.4(d)

Multiple Die Machine

24

Fig 3.1.5(a)

Thread Rolling

24

Fig 3.1.5(b)

Rolling of External Threads by Flat Die

26

Fig 3.1.5(c)

Principle of Thread Rolling by Flat Dies

27

Fig 3.5.2

Cam Front Brake

42

Fig 3.5.3

Types of Dies used in Bolt Maker Machine

44

XVI