Summer Training Report Mahle
Summer Training Report Mahle
Summer Training Report Mahle
SESSION- 2015-2016
MEDICAPS ISTITUTE OF TECHOLOGY AND
MANAGEMENT
SUBMITTED TO-
SUBMITTED BY-
Mr.Pramendra Dhebena
Pratik Agrawal
(Manager M.S.V.T)
Rajat Sharma
7th semester
PREFACE
The theoretical knowledge can be enhanced effectively if it is
supplemented by practical exposure in an organization. A Proper
solution to an engineering problem can be obtained provided that one
is equipped with theoretical as well as practical skills.
Industrial training gives opportunity to relate theory with practical
applications .Hence over all understanding and application of the
concept improves with the industrial exposure.
CERTIFICATE
-----------------------------Mr.Pramendra Dhebena
(Manager M.S.V.T)
ACKNOWLEDGEMENT
Knowledge is power, for an engineering student this power of knowledge is
unattainable unless an element of practical observation and practical
performance is not added. Mechanical Engineering not only calls for a
theoretical knowledge of the subject but also asks for practical
understanding as well.
This opportunity to work at Mahle (M.S.V.T) was an enriching
experience in itself.
We convey our gratitude and sincere acknowledgement to
Mr.B.V.Reddy (G.M Mahle, Pithampur) & Mrs. Neha Jhalani (H.R Mahle,
Pithampur) for permitting us to undergo this vocational training.
We are grateful to our project guide Mr.Pramendra Dhebena
(Manager M.S.V.T) for his excellent guidance and continuous
encouragement thought the course of the project.
We are also grateful to all the other staff members of M.S.V.T who
stepped up to guide us and to share there valuable knowledge & experience
that helped us for in depth understanding.
Also we are thankful to all the technicians and operators who were
ever ready to give all sort of practical knowledge that was required for the
successful completion of this project.
CONTENT
Introduction
Parts Manufactured
Departments
1-FOUNDRY
2-M.S.V.T
o Nomoco Pre-grinding
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Project Work
Conclusion
INTRODUCTION
Mahle group is a leading developer of engine components all over the
world. Mahle offers unique systems competence in the combustion
engine and engine peripherals, with its three business units Engine
DEPARTMENTS
The plant is divided into two main departments:
1-Foundry
2-Machine Shop
FOUNDARY
Molding Material
Procurement (SHELL SANDRESIN COATED)
PREHEATNI
G
Sand
invest
ment
Four station
moulding
PATTERN
MAKING
CORE MAKING
Bakin
g
Ejection
&
cleaning
INDUCTION FURNACE
CHARGE PREPARATION
Core placement (For Hollow Camshaft Only)
and Mould Closing
CHAPLET PLACEMENT
POURING
ADJUSTMENT
MELTING
NODULARISATIO
N TREATMENT
(FOR SG IRON)
DRESSING OF CORES
SOLIDIFICATION
CORE PREHEATING
KNOCKOUT
SHOT-BLASTING
VISUAL
INSPECTION
FETTLING
INTERNAL SHOT
BLASTING and number
punching
FINAL INSPECTION
(ENDOSCOPY, ULTRASONIC
TESTING)
DISKUS M/C
HARDNESS TEST
LAPPING
LAPPING
HEAT TREATMENT
CRACK TEST
CRACK TEST
TEMPERING
NITRIDING
FINAL GRINDING
LAPPING
FINAL GRINDING
INSPECTION
CRACK TEST
INSPECTION
DISPATCH
DISPATCH
FINAL GRINDING
INSPECTION
PHOSPHATING
FINAL INSPECTION
PACKING
Type of machineProduct
Product/process/Tool
specification
355*254*152.4
Grade- A8ORR
Type of machineProduct
Product/process/Tool
specification
350*60*203ROS260*20
Grade- A80Z1V25/A80RR
400*(60/70)*203ROS260*20
Grade-DA803L5V223/45
Regulating wheel
Type of machineProduct
Mushroom /Cylindrical
tappet
Product/process/Tool
specification
104/68*75*102
Grade-SG36-2818VS3
It is performed to check the hardness of the mushroom tappet head /cylindrical tappet surface.
2 test points are selected which are 120degree apart.
Load of 150kg is applied on the work piece.
Range of hardness lies from 35HRC to 65HRC (depends upon type of tappet).
4. 6- Spindle Turning
a. In this process 6 operations are performed & 6 tools tappets are operated at a
time.
b. This machine is based on Geneva Indexing mechanism.
c. Operations Performed are:
1. Turning: It is the process of removing extra material from workpiece to
generate cylindrical surface.
2. Boring: It is used for enlarging a hole produced by drilling, casting etc.
3. Drilling: It is the process of producing cylindrical hole with the help of drill
bit.
4. Chamfering: It is the operation of beveling the extreme end of a workpiece to
remove burs.
Parameters
Spindle RPM
Cutting Oil
Total Cycle
Time
Indexing Time
Turning Time
Specifications
MVT
600-700
ILOCUT 1253
1253
10.5-12.5sec.
22sec.
2sec.
8.5-10.5sec.
CVT
485-540
ILOCUT
202sec.
18-20 sec.
MVT- Mushroom
valve tappet
CVT- Cylindrical
valve tappet
washing with
Gardoclean NC 9809
Quenching in ILO
castrol oil upto 50-60
deg.C temp.
TemperingTempering involves heating steel that has been quenched and hardened for an adequate period
of time so that the metal can be equilibrated. The hardness and strength obtained depend upon
the temperature at which tempering is carried out. Higher temperatures will result into high
ductility, but low strength and hardness. Low tempering temperatures will produce low ductility,
but high strength and hardness. In practice, appropriate tempering temperatures are selected
that will produce the desired level of hardness and strength. This operation is performed on all
carbon steels that have been hardened, in order to reduce their brittleness, so that they can be
used effectively in desired applications.
Furnace temperature from 180-190 degree centigrade(depends on type of tappet).
Tempering is followed by hardening in order to increase toughness and ductility at the
cost of hardness and brittleness.
Capacity-400kg.
Soaking time- 2Hr.
Ambient Cooling is done.
Stress relievingStress relieving is applied to both ferrous and non-ferrous alloys and is intended to remove
internal residual stresses generated by prior manufacturing processes such as machining, cold
rolling and welding. Without it, subsequent processing may give rise to unacceptable distortion
and/or the material can suffer from service problems such as stress corrosion cracking. The
treatment is not intended to produce significant changes in material structures or mechanical
properties, and is therefore normally restricted to relatively low temperatures.
Furnace temperature from 570, 610 degree centigrade (depends on type of tappet).
Stress relieving is followed by either casting or machining according to requirement in
order to increase machinability and removing residual casting stresses.
Capacity-400 kg
Soaking time- 2-3 Hrs.
Up to 350 degree centigrade cooling is done inside furnace then Ambient Cooling is
done.
NitridingIt is one of hardening process that diffuses nitrogen into the surface of a metal to create a casehardened surface. These processes are most commonly used on low-carbon, low-alloy steels.
However, they are also used on medium and high-carbon steels, titanium, aluminum and
molybdenum. Recently, nitriding was used to generate unique duplex microstructure
(Martensite-Austenite, Austenite-ferrite), known to be associated with strongly enhanced
mechanical properties Typical applications include gears, crankshafts, camshafts, cam followers,
valve parts, extruder screws, die-casting tools, forging dies, extrusion dies, firearm components,
injectors and plastic-mold tools.
Gas nitriding- In gas nitriding the donor is a nitrogen rich gas, usually ammonia (NH3),
which is why it is sometimes known as ammonia nitriding. When ammonia comes into
contact with the heated work piece it disassociates into nitrogen and hydrogen. The
nitrogen then diffuses onto the surface of the material creating a nitride layer. The
thickness and phase constitution of the resulting nitriding layers can be selected and the
process optimized for the particular properties required.
Lapping and Chamfering processIt is final chill face grinding process in which we provide convex profile on tappet head in order
to increase its life cycle and chamfering is done in order to provide proper stress distribution.
Cycle time-4 to 8 sec.
Cutting oil-Macron 295 F5.
Lapping roughing wheela) Size- 110*60*94mm / 194*82*175mm.
b) Grade-AA7A 80 H9V3703/AA7A 100 HO 370.
c) Length-15mm.
Lapping finishing wheela) Size- 110*60*94mm / 194*82*175mm.
b) Grade-4A400 N5 BA YOY03/01-EKR-350-LBK.
c) Length-15mm.
Chamfering Wheela) Size- 18.5*26*8 mm.
b) Grade- AA 5021.
c) Length-10 mm.
Convexity 0+0.008.
Chamfer on chill face- 0.4+0.2/-0.0 * 45 degree.
Surface roughness-Ra 0.07
Crack TestingAs the tappets are subjected to high wear during their opearation. It is not tolerable
to have even a hint of crack on specially chill face to ensure that it may lead to a
major failure.For this, surface of tappets are carefully observed for cracks .In this
process crack which are developed during any of the surface operations are
examined in UV rays by passing it through a particular solution ,so that powder
present in solution gets stuck into the cracks .
Magnetisation of
Tappet
(Generation of
north-south pole)
Passing through
oil+ Magnaflux
fluoroscent powder
solution
Identification of
cracks in UV Rays.
Visual Inspection
under UV rays.
A VOCATIONAL
Examples include; hairline cracks in aircraft landing gear, automotive steering systems and many other
safety critical components on which our lives may depend.
Defects literally jump out at the inspector due to the dramatic contrast between the bright glowing
image of a defect against a dull background
MAHLE ENGINE
Steps to perform:1. Magnetizing the tappet up to min. 3 gauss.
2. Magnetized tappets are to be passed through the test oil mixed with powder.
3. Check the tappets for cracks and foundry defects under the ultra violet light generated
by UV lamp in the dark room.
4. Pass the tappet through demagnetizer to reduce intensity up to 1 gauss.
5. Gauze meter is used to check if the tappet is demagnetized or not.
Ultra Violet lamp intensity- 1500micro watt/cm2.
Test oil- 16gm uniflux powder mixed in make ferro chem. Oil.
COMPON
SESSIO
Phosphating
SUBMITTED TO-
Phosphate coatings are a crystalline conversion coating that is formed on a ferrous metal
substrate. Phosphate coating is employed for the purpose of pretreatment prior to coating or
painting, increasing corrosion protection and improving friction properties of sliding
components. In other instances, phosphate coatings are applied to threaded parts and top
coated with oil (P&O) to add anti-galling and rust inhibiting characteristics.
Process is carried in seven separate tanksManager M.S.V.T )
1) Tank 1- Perform degreasing process.
a) Solution used-water (150 lit.) + gardoclean 4 chemical (750 gm).
b) Working temperature-75-80 degree centigrade.
c) Holding time- 5-6 min.
2) Tank 2- Water rinsing (soft water).
a) Solution used-water
Mr.Pramendra Dhebena
(
Primary+secondary
washing
Gardoclean-104
Surface
conditioning+
water rinsing soft
water.
Surface Conditioning
Gardolene
(VMA+VMC)
PHOSPATING TANK
Phosphating
Gardobond-30 steel
wool+ water rinsing.
Project workSLIDE 1-
Heat Treatment Process thermal expansionCustomer Spec 38.00 0.250 ( VT 8003 ISBe )
Result- Following are the dimensions achieved-
Specification at
Pre Grinding
Before Heat
Treatment Head
Diameter Size
Observed
After Heat
Treatment Head
Diameter Size
Observed
38.00 -05/-0.150
Expansion
Observed after
Heat Treatment
Max 0.42 mm
Conclusion :Trial lot should be pre-grind 0.1 mm under size ( i.e. 38.00 -0.15/-0.25 )
against Specification of Nomoco pre grinding Process. ( Within Customer
Specification )
36% Head Diameter over size found after Heat Treatment Process with Existing
Nomoco Pre grinding Specification ( 2840 Nos over size out off 7706 Nos )
SLIDE 2Total
Aug2013
Pre Grinding Process Study :- Inspect one Dressing Cycle Component 100
Nos , Dressing frequency-50. Status :-Done
Heat Treatment Process Study :- Check 500 Tappets before & after Heat
Treatment Process . Status :- Done.
In
Min-32.84
Max-32.87
Out
Min-32.84
Max-32.87
Variation
0.03
0.03
Conclusion
As per above observations variation(0.03mm) of the process is only 6% of
tolerance under customer specification that is 0.5mm.
As per standard norms the variation should be less than 10% for process to be
correct.
Hence no corrections are required in nomoco pre grinding process.
Specification at
Pre Grinding
Before Heat
Treatment Head
Diameter Size
Observed
After Heat
Treatment Head
Diameter Size
Observed
Expansion
Observed after
Heat Treatment
38.00 -05/-0.150
This tappets Head Diameter grind at Cincinnati Pre Grinding m/c because of
Grinding wheel not available at Nomoco pre Grd. m/c .
Trial lot grind 0.05 mm under size ( i.e. 38.00 -0.2/-0.3 ) against Specification
of Nomoco pre grinding Process. ( Within Customer Specification )
3.68% Head Diameter over size found after Heat Treatment Process with
Existing Nomoco Pre grinding Specification ( 18 Nos over size out off 500 Nos )