ARYA COLLEGE OF ENGINEERING & INFORMATION TECHNOLOGY

Industrial Training Report

at

NEEL METAL PRODUTS LIMITED

MANESAR

Submitted To:- Submit By:-

Prof Arun Kumar Arya Hitesh Pathak

(Head of Mechanical Department) 11EARME044

B. Tech Mechanical

4th Year

ACKNOWLEDGEMENT

It is indeed a great pleasure and privilege to present this report on training at

NEEL METAL PRODUCTS LIMITED, JBM GROUP, MANESAR.

I am extremely grateful to my Head of Department and training and placement

officer for issuing a Training letter, which made my training possible at NEEL

METAL PRODUCTS LIMITED, JBM GROUP, MANESAR.

First, I thank The HR Head, MR. Gaurav Saraswat for considering my potential

in doing this training and providing this wonderful opportunity.

I would like to express my gratitude to MR. Rakesh Kumar for his invaluable

suggestions, motivation, guidance and support throughout the training. His

methodology to start from simple ant then deepen through made me to bring

out this project report without anxiety.

Thanks to all other JBM officials, operators and all other members of JBM, yet

uncounted for their help in completing the project and see the light of success.

I am very thankful to friends, colleagues and all other persons who rendered

their assistance directly or indirectly to complete this project work successfully.

Dated- July 2014 Hitesh Pathak

About Company:-

JBM Group began its journey of excellence

in 1983. The organization commenced

operations as a manufacturer of LPG

Cylinders for the Delhi-NCR region of India.

Moving strength to strength, assisted with experience and knowledge, JBM

Group entered into the automotive industry in 1985.

In 1986, the Group signed a joint venture with Maruti Suzuki India Ltd for the

manufacturing of sheet metal components and assemblies. The journey began

with a vision to expand the business in the automotive sector by keeping

abreast with market trends and global technology.

Headquartered at Delhi-NCR, JBM Group is a diversified conglomerate with

presence in automotive, engineering & design services, renewable energy and

education sectors. The organization’s commitment towards all stakeholders

and community has made it a leading manufacturing and engineering player.

The milestones and achievements of JBM Group gave the energy for

diversification and establishment of multiple business units in order to meet

the needs of customers. The organization’s management follow a unique

business model to create empowered companies that enjoy the best of

entrepreneurial independence, assisted with leverage of group-wide synergies.

Overview:-

JBM Group is a focused, dynamic and progressive organization that provides

customers with value added products, services and innovative solutions. The

Group has a diversified portfolio to serve in the field of automotive,

engineering & design services, renewable energy and education sectors and

has an infrastructure of 35 manufacturing plants, 4 engineering & design

centres across 18 locations globally.

With turnover of USD 1.2 billion, JBM Group has broadened its horizons by

focusing on quality delivery, solutions approach, product development

processes, flexible manufacturing systems and contract manufacturing.

JBM Group is primarily a tier- 1 supplier to the automotive OEM industry and

caters services to esteemed clients that include Ashok Leyland, Bajaj Auto Ltd,

Fiat, Ford, General Motors Corporation, Honda, Hero, JCB, Mahindra, Maruti

Suzuki, Renault, Nissan, TATA, Toyota, TVS, Volvo-Eicher, Volkswagen and

many more.

The Group has alliances with more than 20 renowned companies globally and

the associations include Arcelor Mittal, Cornaglia, Dassault Systems, JFE Steel

Corporation, Magnetto (CLN Group), Ogihara, Sumitomo and many more. The

organization’s structure enables each business unit to chart its own future and

simultaneously leverage synergies across its competencies.

Introduction to the Company

Company Profile:-

Name: JAY BHARAT MARUTI LTD.

Division: NEEL METAL PRODUCTS LIMITED, MANESAR

Head Quarters: DELHI

Established: 1983

Turnover: Rs.4500 Crores(overall)

Employees (No.): AROUND 15,000

Introduction:-

The Neel Metal Products Limited, Manesar is a

major vendor company of Honda 2 Wheelers India

Ltd. Neel Metal Products Ltd. (NMPL) is the fastest

growing Company of JBM Group with high-tech plants at various locations in

India. NMPL has earned a leading position in industry with facilities available in

press lines up to 1200 tons, weld lines and ED coating plant- which are not only

limited to auto world but also fitting for white goods industry.

Vision:-

“Expanding leadership in our business through people, keeping pace with

market trends and technology.”

Core Values:-

We believe in...

Simplicity, by keeping a low profile externally and having clear, open and

effective communication within the organization.

Teamwork, with well-defined responsibilities and accountability.

Relationships of trust amongst people, through well-defined job responsibility

and authority.

According top priority to customer focus, through prompt and appropriate

response.

Respect and care for all those dedicated to meeting commitments.

Technology:-

Technology, Innovation and People serve as the 3 key pillars of the JBM

foundation. Core to this philosophy is a constant quest for excellence by

enhancing technology, enabling innovation and empowering people, thereby,

creating consistent value for all stakeholders.

JBM Group has always kept a close watch on the dynamic needs of its

customers and continues the journey of efficiency by enhancing the

technology at every stage. The organization has collaborated with best global

technology partners; possess state-of-the-art manufacturing facilities and

highly automated processes. These advantages have established new

benchmarks that have aided in providing superior quality and flawless

technical perfection to the organization's deliverables.

The continuous commitment towards excellence and consistent efforts to

innovate have brought excellent growth results for the Group. Apart from

incorporating sophisticated technology, JBM Group aims to not only exceed

expectations, but to create value through innovation. The long standing

commitment to nurture research and development has brought the

organization a long way since its commencement 3 decades ago.

Environment, Health & Safety:-

At JBM, sustainability is the way of doing business. The Group aligned its goals

for environment, health and safety, making an impact across its value chain

worldwide. Together with the suppliers, customers and stakeholders, JBM

strives to maintain highest standards to preserve and protect the environment,

as well as enhance the health and safety of the Group’s employees and

communities.

Departments in Neel Metal Products Limited, Manesar:-

1) Paint shop

2) Weld shop

3) Press Shop

4) Quality department

5) Engineering department

6) IT department

7) Finance department

8) Purchase department

9) Maintenance department

Operation and Facilities:-

Facilities to design manufacture and do real time testing of welding and

checking fixtures

Rim rolling line, central anode tri chrome nickel plating and complete wheel

assembly set up

Steel Service Centre - The Company has 4 blanking lines capable of producing

blanks of regular and irregular geometrical shapes and sizes

Tube mills to manufacture Electrical Resistance Welding (ERW) tubes

Vehicle Assembly - Capability to produce complete bodies

Product Range:-

Complete Frame Assembly, Welding and Painting

Tubes for Tubular Components.

Underbody Frames and Parts.

Certifications:-

ISO 9001

ISO/TS 16949

ISO 14001

OHSAS 18001

Production:-

Production is defined by the Webster online as “to make into a product

suitable to use.”

The action of manufacturing from components or raw material or the process

if being so produced.

Production is a process of combining various material inputs and immaterial

inputs in order to make something for consumption. It is the act of creating

output, a good or service which has value and contributes to the utility of

individuals. Economic well-being is created in a production process, meaning of

all economic activities that aim directly or indirectly to satisfy human needs.

The degree to which the needs are satisfied is often accepted as a measure of

economic well-being.

Types of Production Procedure:-

Casting Process:- This type of procedure required liquid material. This is the

only process which uses liquid material. This is oldest procedure of production

in which the molten metal is poured into refractory mould cavity and allowed

to solidify. The object from the cavity removed after the solidification.

Forming Process:- This solid state production process involving minimum

amount of material wastage. In this process the metal may be heated to a

Suppliers

Material

Energy

Capital

Service

Company

(Production)

Customers

Households

Other

Products

temperature, which is slightly below the solidus temperature and then large

force is applied such that material flows and takes the desired shape.

Fabrication Process:- It essentially, involves joining pieces either permanent or

temporarily so that they would perform necessary function. The joining can be

achieved by either or both of heat and pressure or joining through material. It

is secondary manufacturing procedure.

Material Removal Process:- This is also a secondary procedure where the

additional unwanted material is removed in the form of chips from the blank

material by a harder tool so as to obtain the final desired shape.

Production Line:-

A production line is defined as an arrangement in a factory in which a thing

being manufactured is passed through a set linear sequence of mechanical or

manual operations.

A production line is a set of sequential operations established in a factory

whereby materials are put through a refining process to produce an end-

product that is suitable for onward consumption; or components assembled to

make a finished article.

The production line is required to produce products fast. As well the market

demand is getting increase as well we need more products also with more in

quantity. A production of a whole body by a single labour was unable satisfied

this they was also unable fulfil the demand properly then we need some

processes by which we can produce things fast and fulfil the requirement of

market. Due to these the concept of production lines introduced in which

many units work together to produce something. This concept reduces the

production time up to a mark and exponentially increases the profits.

Advantages of Production line:-

One of the biggest advantages of assembly line manufacturing is that it

reduces the skill requirements for line workers. When manufacturing a

doll, a craftsman may have to know how to mould the body, attach hair,

paint the face, and sew the clothing. Assembly manufacturing, however,

isolates one specific task or set of tasks to each worker, meaning that it is

easier to train new workers and mastery of the skill may come faster.

Additionally, automated assembly lines may be easier to create than

craftsman-based versions, because machines may only be able to perform

a limited number of specific tasks.

A benefit of the task-isolation principle is it makes it easier to understand

where breakdowns in efficiency occur. If products are moving along on

schedule until they reach a certain point in the line, it is easy to see that

the speed-reduction in speed occurs at a specific point. This may make

efficiency issues easier to address, since problems may be immediately

apparent and have specific solutions that can be quickly applied.

Increased production and better uniformity are two other advantages of

assembly methods. Since the line is optimized for speed and efficiency, and

tasks are limited, most lines can turn out products much faster than

traditional methods of manufacturing. Since every product is put together

in the same order, at the same speed, by the same technicians, variations

in quality are also less likely. With products that need to be manufactured

in large quantities at a rapid rate, assembly lines may be the most efficient

choice of manufacturing structure.

In terms of wages, there are both advantages and disadvantages to

assembly lines. Since employees on a line are typically less skilled and

educated, their wage range is generally lower than educated craftsmen

with multiple skills. On the other hand, the savings created by efficiency,

fast production, and automation can mean the unskilled or semi-skilled

labourers are paid higher than their counterparts at non-assembly based

manufacturing jobs.

Advantage of an assembly line is the ease of progression from unskilled to

skilled labour. Manufacturing plants may start new workers at jobs that

require the least skills, but as a worker masters his or her particular task,

he or she may get opportunities for more highly-skilled positions that build

directly on basic task abilities. This means that there may be a high chance

for career advancement within an assembly line plant.

Now in the series of reducing production time we are also using automatic

machines and robots to do the work. These are reducing the time of

production with mark able increment in quality too. Robots are single time

investment and also have low maintenance. They don’t demand wedges

after a regular interval of time and factor of risk also low in these case. The

human harm has been reduced up to a mark by using robots.

Disadvantages of Production line:-

The invention of assembly line production resulted in many different

advantages, but there are some significant disadvantages in the method as

well. Most of the benefits have to do with a reduction in cost and an

increased uniformity of the finished products. In addition to creating higher

profit margins, this can also result in products that are more affordable and

easier to repair. Disadvantages that are often associated with this method

of mass production include lower build qualities, rigid or inflexible

production facilities, and a substantially higher initial capital investment.

This type of production is often associated with monotonous or repetitive

jobs as well, which can lead to motivational problems with the workers.

Prior to the advent of the assembly line, the alternatives were less efficient

methods such as cottage industries and craft production. These methods

often allowed for the creation of high quality products, but the cost to

produce them was also high. Each product also tended to be somewhat

unique, which could lead to issues if repairs were needed. Since assembly

line production involves creating highly uniform products at a fast pace,

many of these issues were eradicated. One example is in automobile

manufacturing, where the production method drove down the cost of the

vehicles to the point where the working class could afford to purchase

them.

The disadvantages of the assembly line style of production are the same

qualities described above but looked at from another angle. While several

workers using interchangeable, standardized parts makes for easy repairs

and replacements, it also means each item loses that individualistic flare of

unique craftsmanship. For some products, especially decorative or

luxurious items, it can be very desirable to know that the piece was

uniquely crafted by a single skilled and experienced artisan, who put a lot

of heart and soul into the creation—not just a bunch of disinterested

people on a production line slapping parts together with no personal

investment in the quality of the finished product.

Other disadvantages of assembly line production are based on the worker’s

point of view. Because little training is generally required, wages may not

be very competitive. The work itself can also be extremely repetitive and

monotonous, offering little in the way of mental stimulation and creative

critical thinking.

They required huge capital amount to get established.

Problem in any unit of line stops full production.

Using of robots creating high unemployment in global market.

Production of less quantity increases the cost of product.

Factor can affect the Production Process:-

1. Supplies:- Many manufacturing depends on raw material supplied from

outside sources. Some of the factors that can delay or hamper a regular

delivery schedule include a glitch at the site of a supply source, problem

with transportation or inclement weather. If supplies are not forthcoming

as needed, the potential for shutdown in the manufacturing process can

result. Alternatively a smooth supply operation and well managed

inventory promote production as scheduled.

2. Equipment:- When a manufacturing process involves complex machines to

complete production, a temporary malfunction or a breakdown in an

intricate piece of equipment can affect the production. Identifying means

of improving efficiency of all working parts of production promotes a

continual and more efficient operation. Positioning of equipment and the

personal required to operate machine can also affect production. In a

paper on production cycle times, Mandar M. Chincholkar of Intel

Corporation and several of his academic and research colleagues explain

the concept of “Process Drift” which they describe as a common

occurrence in production where machine fail to function properly due to

lack of cleaning.

3. Factory overhead:- Production depends on utilities to power machines,

cool equipment and light the workspace in their factories. Even a

temporary shutdown of the power supply or lack of a steady water source

can impact production, thus affecting the production process. In addition

management style can have a significant impact on production in both

negative and positive ways.

4. Need of special Parts:- In the textbooks “Operation Management”

professor R Dan Reid of the University of New Hampshire and Nada R.

Sanders of Lehigh University posit “Conformance to specification” as one

definition of quality in production. They cite as an example the situation of

machine parts being built to specs. Here an unforeseen change in made to

order parts can have significant impact on production, especially if the

parts are shipped over long distance from offsite. Disparities in qualities

may require multiple orders for the same inventory, resulting in delays and

temporary slowdowns or shutdowns of the production.

5. People who work at all points:- The workforce especially “touch labour”,

the workers directly involved in the production can affect that process in

many ways. For example: sick days and vacations taken by key personal

must be figured into production to prevent a negative impact on

production. An intangible factor that affects the production process and is

dealt with after the fact is human error. Alternatively, human inside a

production leading to more labour-efficient and cost-effective methods of

production can affect in a positive way.

Object:- Joining procedure of the Chain Case of Honda Unicorn KSPG.

Abstract:- The chain case is a most important part of two wheeler. It prevents

chain from the dirt and mud. As the two wheelers have an open type of body

and chain drives in free environment so there a definite chance of rusting and

corrosion occurs. So chain case prevents the chain from above factors. In India,

the Women wear their traditional dresses like Sari, Ghaghara and many other

dresses which consists a huge round of cloth covering their legs. So when they

sit on back side of two wheelers by wearing these dresses it creates definite

chances of tear of cloth by contacting with driven chain. It makes the condition

of accident many times women also get dead in this case. In other cases of

developing countries like India, Pakistan, African Countries traffic rules are not

so effective. On a single two wheeler more than allowed person travel. It also

creates definite chances of accident by contact with driving chain and chain

can also tear their dress or contact of clothes can make them snagged. So the

chain case is highly essential in two wheelers of India. It works like chain case

and dress guard both. It completely encloses chain and protects it from

contamination.

Theory:- Here the work done on the Honda Unicorn KSPG bike chain case. In

the joining of chain case 5 steps are involved. Pre discharge inspection of this

involves 2 steps. The parts of this chain case are jointed with the spot welding.

This spot welding consist two copper electrodes which transfer a higher

voltage through part this generates high heat at transfer spot and this heat

joint part by a spot. Sheet metal is used to make chain case. The chain case

consists 7 parts which make one side case. It is differentiated in two Left and

Right part in this L part is engaged with Dust cover. Due to the high strength

and low in weight Aluminium is used to make Unicorn chain case.

Spot Welding:-

Spot welding is one of the oldest welding processes. It is used in a wide range

of industries but notably for the assembly of sheet steel vehicle bodies. This is

a type of resistance welding where the spot welds are made at regular

intervals on overlapping sheets of metal. Spot welding is primarily used for

joining parts that are normally up to 3 mm in thickness. Thickness of the parts

to be welded should be equal or the ratio of thickness should be less than 3:1.

The strength of the joint depends on the number and size of the welds. Spot-

weld diameters range from 3 mm to 12.5 mm.

Working of Spot Welding:-

Spot welding is one form of

resistance welding, which is a

method of welding two or more

metal sheets together without using

any filler material by applying

pressure and heat to the area to be

welded. The process is used for

joining sheet materials and uses

shaped copper alloy electrodes to

apply pressure and convey the electrical current through the work pieces. In all

forms of resistance welding, the parts are locally heated. The material between

the electrodes yields and is squeezed together. It then melts, destroying the

interface between the parts. The current is switched off and the "nugget" of

molten materials solidifies forming the joint.

To create heat, copper electrodes pass an electric current through the work

pieces. The heat generated depends on the electrical resistance and thermal

conductivity of the metal, and the time that the current is applied. The heat

generated is expressed by the equation:

E=I2*R*t

Where E is the heat energy, I is the current, R is the electrical resistance and t

is the time that the current is applied.

Copper is used for electrodes because it has a low resistance and high thermal

conductivity compared to most metals. This ensures that the heat is generated

in the work pieces instead of the electrodes.

Materials suitable for spot welding:-

Steel has a higher electrical resistivity and

lower thermal conductivity than the copper

electrodes, making welding relatively easy. Low

carbon steel is most suitable for spot welding.

Higher carbon content or alloy steel tends to

form hard welds that are brittle and could crack. Aluminium has an electrical

resistivity and thermal conductivity that is closer to that of copper. However,

aluminium's melting point is much lower than that of copper, making welding

possible. Higher levels of current must be used for welding aluminium because

of its low resistivity.

Galvanized steel (i.e. steel coated with zinc to prevent corrosion) requires a

different welding approach than uncoated steel. The zinc coating must first be

melted off before the steel is joined. Zinc has a low melting point, so a pulse of

current before welding will accomplish this. During the weld, the zinc can

combine with the steel and lower its resistivity. Therefore, higher levels of

current are required to weld galvanized steel.

Electrode force:-

The purpose of the electrode

force is to squeeze the metal

sheets to be joined together. This

requires a large electrode force

because else the weld quality will

not be good enough. However,

the force must not be to large as

it might cause other problems.

When the electrode force is

increased the heat energy will

decrease. This means that the

higher electrode force requires a

higher weld current. When weld

current becomes too high spatter will occur between electrodes and sheets.

This will cause the electrodes to get stuck to the sheet.

An adequate target value for the electrode force is 90 N per mm2. One

problem, though, is that the size of the contact surface will increase during

welding. To keep the same conditions during the whole welding process, the

electrode force needs to be gradually increased. As it is rather difficult to

change the electrode force in the same rate as the electrodes are

"mushroomed", usually an average value is chosen.

Diameter of the electrode contact surface:-

One general criterion of resistance spot-welding is that the weld shall have a

nugget diameter of 5*t1/2, “t” being the thickness of the steel sheet. Thus, a

spot weld made in two sheets, each 1 mm in thickness, would generate a

nugget 5 mm in diameter according to the 5*t½-rule. Diameter of the electrode

contact surface should be slightly larger than the nugget diameter. For

example, spot welding two sheets of 1 mm thickness would require an

electrode with a contact diameter of 6 mm. In practice, an electrode with a

contact diameter of 6 mm is standard for sheet thickness of 0.5 to 1.25 mm.

This contact diameter of 6 mm conforms to the ISO standard for new

electrodes.

Squeeze time:-

Squeeze Time is the time interval between the initial application of the

electrode force on the work and the first application of current. Squeeze time

is necessary to delay the weld current until the electrode force has attained

the desired level.

Weld time:-

Weld time is the time during which welding current is applied to the metal

sheets. The weld time is measured and adjusted in cycles of line voltage as are

all timing functions. One cycle is 1/50 of a second in a 50 Hz power system.

(When the weld time is taken from American literature, the number of cycles

has to be reduced due to the higher frequency (60Hz) that is used in the USA.)

As the weld time is, more or less, related to what is required for the weld spot,

it is difficult to give an exact value of the optimum weld time. For instance:

Weld time should be as short as possible.

The weld current should give the best weld quality as possible.

The weld parameters should be chosen to give as little wearing of the

electrodes as possible. (Often this means a short weld time.)

The weld time shall cause the nugget diameter to be big when welding thick

sheets.

The weld time might have to be adjusted to fit the welding equipment in case

it does not fulfil the requirements for the weld current and the electrode force.

(This means that a longer weld time may be needed.)

The weld time shall cause the indentation due to the electrode to be as small

as possible. (This is achieved by using a short weld time.) The weld time shall

be adjusted to welding with automatic tip-dressing, where the size of the

electrode contact surface can be kept at a constant value. (This means a

shorter welding time.) When welding sheets with a thickness greater than 2

mm it might be appropriate to divide the weld time into a number of impulses

to avoid the heat energy to increase. This method will give good-looking spot

welds but the strength of the weld might be poor. By multiplying the thickness

of the sheet by ten, a good target value for the weld time can be reached.

When welding two sheets with the thickness 1 mm each, an appropriate weld

time is 10 periods (50Hz).

Hold time (cooling-time):-

Hold time is the time, after the welding, when the electrodes are still applied

to the sheet to chill the weld. Considered from a welding technical point of

view, the hold time is the most interesting welding parameter. Hold time is

necessary to allow the weld nugget to solidify before releasing the welded

parts, but it must not be to long as this may cause the heat in the weld spot to

spread to the electrode and heat it. The electrode will then get more exposed

to wear. Further, if the hold time is too long and the carbon content of the

material is high (more than 0.1%), there is a risk the weld will become brittle.

When weld galvanized carbon steel a longer hold time is recommended.

Weld current:-

The weld current is the current in the welding circuit during the making of a

weld. The amount of weld current is controlled by two things; first, the setting

of the transformer tap switch determines the maximum amount of weld

current available; second the percent of current control determines the

percent of the available current to be used for making the weld. Low percent

current settings are not normally recommended as this may impair the quality

of the weld. Adjust the tap switch so that proper welding current can be

obtained with the percent current set between seventy and ninety percent.

The weld current should be kept as low as possible. When determining the

current to be used, the current is gradually increased until weld spatter occurs

between the metal sheets. This indicates that the correct weld current has

been reached.

Methodology:-

1. First step all the sheets of metal is procured from the vendor

2. The grade of the material is checked by the inspection department. In

inspection these three things are checked. Wrong size of the metal sheet,

grade of the metal sheet and the visual defects of the metal sheet.

3. Then in the series of making Right side of case first operation is performed

in this step we joint upper R body to Patch A and Patch B.

4. Patch A has two spots points and Patch B has four spot points.

5. One point of Patch A also will be jointed with bolt support to body

6. One corner point of Patch B also will be jointed with bolt support to body.

7. Right Side of Chain case is final now.

8. Then in the series of making Left side of case first operation is performed in

this step we joint upper L body to Plate A, Plate B and Plate C.

9. Plate A has two spot points Plate B has four spot points and Plate C has

four spot points too.

10. Swing arm patch also will be attached with Plate B at Corner.

11. These Plates A, B, C will further used for fitment of case with body.

12. Then we joint Dust Guard on L body. Dust Guard has seven spot points.

13. In last Plate D will attach with both sides and then chain case will go for

PDI.

PDI of Chain Case:-

1. In first step of PDI we measure the holes via gauge and inspect the position

of hole and joints.

2. In second step of PDI we test the strength of joint via performing stretch

test. Scratch and Roundness of edges and corner also perform again here.

3. Then Chain case will send for Painting.

The whole procedure of making Chain Case will take 20 seconds to complete

with PDI. Making process of Right and Left Part has been done parallel. The

annual defects of the pieces are 2% of total.

Precaution to take in Joining:-

1. Do not stop the part at a same place.

2. Do not perform welding without wearing gloves.

3. Do the work at same rate as guided.

4. Always wear an apron before start working.

5. Always follow the rules of workshop.

6. In case of any hazard contact to supervisor and medical officer.

Conclusion of Project:-

Joining procedure of Chain Case of Honda Unicorn has been completed. The

total find error is 5% on my work.

Object:- Painting Procedure of Chain Case of Honda Unicorn KSPG, Connecting

Rod of Honda Unicorn KSPG and Honda Activa KWPG.

Abstract:- A primer or undercoat is a preparatory coating put on materials

before painting. Priming ensures better adhesion of paint to the surface,

increases paint durability, and provides additional protection for the material

being painted

Primer is a paint product that allows finishing paint to adhere much better

than if it was used alone. For this purpose, primer is designed to adhere to

surfaces and to form a binding layer that is better prepared to receive the

paint. Because primers do not need to be engineered to have durable, finished

surfaces, they can instead be engineered to have improved filling and binding

properties with the material underneath. Sometimes, this is achieved with

specific chemistry, as in the case of aluminium primer, but more often, this is

achieved through controlling the primer's physical properties such as porosity,

tackiness, and hygroscope.

In practice, primer is often used when painting many kinds of porous materials,

such as concrete and especially wood (see detailed description below). Priming

is mandatory if the material is not water resistant and will be exposed to the

elements. Priming gypsum board (drywall) is also standard practice with new

construction because it seals the wall and aids in preventing mould. Primers

can also be used for dirty surfaces that, for some reason, cannot be cleaned, or

before painting light colours over existing dark colours.

Primers can usually be tinted to a close match with the colour of the finishing

paint. If the finishing paint is a deep colour, tinting the primer can reduce the

number of layers of finishing paint that are necessary for good uniformity

across the painted surface.

There may be a maximum time frame within which a topcoat should be

applied over the primer after the primer dries, in order to achieve maximum

performance. Depending on the primer, the next coat of paint should be

applied as quickly as 24 hours or you may have as long as 2 weeks. Painting

after the suggested timeframe may cause performance issues depending on

the specific situation. Supposedly, you want to apply the finish coat of paint

before the primer fully cures on a molecular level. Doing this allows maximum

adhesion/bonding of the topcoat to the primer. If top coating after the

suggested timeframe, consider using a "self priming" topcoat. For definitive

answers on recommended repainting timeframe, check the primer

label/website, or contact the manufacturer directly. Recoat timeframe is most

likely a more critical factor in exterior application because of the more extreme

climatic exposure.

A primer designed for metal is still highly recommended if a part is to be

exposed to moisture. Once water seeps through to the bare

metal, oxidation will begin (plain steel will simply rust). Metal primers might

contain additional materials to protect against corrosion, such as sacrificial

zinc.

Metal hydroxides/oxides do not provide a solid surface for the paint to adhere

to, and paint will come off in large flakes. Using a primer will provide extra

insurance against such a scenario. An additional reason for using a primer on

metal could be the poor condition of the surface. A steel part can be rusty, for

example. Of course, the best solution is to thoroughly clean the metal

(blasting), but when this is not a viable option, special kinds of primers can be

used that chemically convert rust to the solid metal salts. And even though

such surface is still lacking in comparison to the shiny clean metal, it is yet

much better than weak, porous rust.

Methodology:-

Process Flow Chart (Paint Shop)

Loading

Hot Water Rinse

Knock of Degreasing

Degreasing

Industrial Water Rinse 1

Industrial Water Rinse 2

Surface Activation

Phosphatising

DM Water Rinse 1

DM Water Rinse 2

Water Dry Oven

Tag Rag

Primer Coat

Base Coat

Top Coat

Paint Baking Oven

Unloading

Preparations for the Painting Procedure:-

1. For the Hot Water Rinse: Here we take a sump tank for containing of water

than we heat that up to 40 to 60˚C with maintaining of 0.5 to 1.2 Kg/cm2

pressure. Here we take normal water which is usually available.

2. For Knock of Degreasing: Here we take a cleaning chemical in a tank and

maintain 40 to 60˚C temperature, 0.5 to 1.2 Kg/cm2 pressure and alkalinity

30 to 35 ml.

3. For Degreasing: Here we again maintain the cleaning chemical condition as

Knock of Degreasing.

4. For Water Rinse 1: Here we take water in a tank and maintain pressure at

0.5 to 1.0 Kg/cm2 and pH value at 8.0 to 10.0.

5. For Water Rinse 2: Here we again take water in tank and maintain pressure

at 0.5 to 1.0 Kg/cm2 and pH value at 8.0 to 9.0.

6. For Surface Activation: Here we take a special chemical in tank for that

maintains pressure at 0.5 to 1.0 Kg/cm2 and pH value at 8.0 to 10.0.

7. For Phosphatising: We take a coat of phosphate for that maintain pressure

at 0.8 to 1.0 Kg/cm2, Temperature at 40 to 50˚C, Total Acidity 20 to 24 ml,

Free Acidity 0.6 to 0.8 ml and Tonner Value at 2 to 4 ml.

8. For DM Rinse 1: We take water in tank and maintain pressure at 0.5 to 1.0

Kg/cm2 and pH value at 5 to 6.

9. For DM Rinse 2: We take water in tank and maintain pressure at 0.5 to 1.0

Kg/cm2 and pH value at 6.5 to 7.0.

10. For Dry off Oven: Maintain Temperature at 90 to 100˚C.

11. For Coating: A spray paint equipment is required and Water-Grease

Solution to prevent walls from Coat.

12. For Paint Baking Oven: Maintain Temperature at 130 to 140˚C.

*Cleaning chemical for KOD and chemical for Surface Activation are patented

products of company. They don’t disclose composition and name of these.

These chemicals are only known by their work.

Process:-

1. In first step chain case, connecting rod loaded on Hangers. This hanger is

attached with the 249 meter long belt. On the whole length of belt 416

hangers are attached.

2. Then these loaded parts went to first chamber which is Hot Water Rinse

chamber. In this chamber hot water rain dropped on the parts which cleans

all the dirt and all other things.

3. Then these loaded parts went to next chamber which is KOD (Knock of

Degreasing) chamber. In this chamber a cleaning chemical dropped on the

parts which remove water from surface, other dirt which cannot be

cleaned by water and extra material.

4. Then these parts went to next chamber degreasing chamber which again

perform KOD action. This is for precautions that if any impurity is left that

will definitely clear here.

5. Then it went to Industrial Water Rinse 1 chamber where distilled water

clears the cleaning chemical.

6. In next chamber industrial Water Rinse 2 again distilled water rain over

parts and clean them.

7. Then they sanded to Surface Activation chamber where a chemical

dropped on parts and this rain activates surface of parts for next step.

8. Then parts went into Phosphatising chamber here rain of phosphate occurs

over parts which creates a layer of phosphate over them. This coat of

phosphate makes paint properly bind with part.

9. Then in DM Rinse Water 1 chamber these parts again cleans. This cleans

the unwanted phosphate coating and impurity (if left).

10. Then in DM Rinse Water 2 chamber these parts again cleans. This again

cleans impurity (if left).

11. In next step it sanded to air blower chamber which dries water from parts.

12. After air blowing it went to Water Dry Oven chamber here it heats up to 90

to 100˚C which definitely removes water from parts.

13. After these pre treatment processes now Parts come into TAG RAG

chamber. Here workman manually check all parts and put some another

parts (which have some error in painting in previous cycle).

14. Now after manually checking parts sanded to Primer Coat chamber here a

medium viscous paint has been painted manually via spray paint gun. Here

a gel mixture of Water-Grease continuous flow on chamber wall to prevent

walls from Paint.

15. Then parts sanded to Base Coat chamber here a high viscous paint has

been panted manually over Primer Coated part. This creates a second layer

of paint on Parts.

16. Then parts sanded to Top Coat chamber (if required) here a low viscous

paint has been painted manually via spray paint gun on Base Coated Parts.

This process is only necessary for some parts. Usually this is not required.

17. Then at last parts sanded to Paint Bake Oven here they left for the Baking

at temperature of 130 to 140˚C for 20 minutes. This makes paint

permanently bind with part.

18. After the baking process parts unloaded from Hangers for PDI

19. The whole process runs at 1.6m/min speed of belt.

Chemical Tests:-

For Knock of Degreasing: Alkalinity Test:

1. Take 10 ml sample in a beaker.

2. Then add 4-6 ml of phenolphthalein (indicator)(red).

3. Then add 16-14 ml H2SO4 in beaker.

4. Now titrate them this titration make red colour invisible this value should

be in given range of 30 to 35 ml.

5. If the value is not in range then change the chemical in tank.

Water Rinse:

Perform pH test via litmus paper and litmus scale.

Phosphatising: Total Acidity:

1. Take 10 ml sample in beaker.

2. Then add 4-6 ml of phenolphthalein this will make sample colourless.

3. Then add NaOH in Sample and on which point this sample show Light Pink

colour will be the last point and this should be in given range of 20 to 24

ml.

4. If the value is not in range then change the chemical in tank.

Free Acidity:

1. Take 10 ml of sample in beaker.

2. Then add chromo phenol blue indicator in sample which make sample

yellow.

3. Then by the help of NaOH titrate this mixture when it show Light Blue

colour that will be the end point of reaction and this should be in given

range of 0.6 to 0.8 ml.

Chemical Tests must be performed after every 4 hours.

Viscosity Tests:-

The viscosity of a fluid is a measure of its resistance to gradual deformation

by shear stress or tensile stress. For liquids, it corresponds to the informal

notion of "thickness".

Viscosity is due to the friction between neighbouring particles in a fluid that

are moving at different velocities. When the fluid is forced through a tube, the

fluid generally moves faster near the axis and very slowly near the walls;

therefore, some stress (such as a pressure difference between the two ends of

the tube) is needed to overcome the friction between layers and keep the fluid

moving. For the same velocity pattern, the stress required is proportional to

the fluid's viscosity. A liquid's viscosity depends on the size and shape of its

particles and the attractions between the particles.

A fluid that has no resistance to shear stress is known as an ideal fluid or in

viscid fluid. Zero viscosity is observed only at very low temperatures, in super

fluids. Otherwise all fluids have positive viscosity. If the viscosity is very high,

for instance in pitch, the fluid will appear to be a solid in the short term. A

liquid whose viscosity is less than that of water is sometimes known as

a mobile liquid, while a substance with a viscosity substantially greater than

water is called a viscous liquid

Viscosity is measured with various types of viscometers and rheometers. A

rheometer is used for those fluids that cannot be defined by a single value of

viscosity and therefore require more parameters to be set and measured than

is the case for a viscometer. Close temperature control of the fluid is essential

to acquire accurate measurements, particularly in materials like lubricants,

whose viscosity can double with a change of only 5 °C.

For some fluids, viscosity is a constant over a wide range of shear rates

(Newtonian fluids). The fluids without a constant viscosity (non-Newtonian

fluids) cannot be described by a single number. Non-Newtonian fluids exhibit a

variety of different correlations between shear stress and shear rate.

One of the most common instruments for measuring kinematic viscosity is the

glass capillary viscometer.

In coating industries, viscosity may be measured with a cup in which the efflux

time is measured. There are several sorts of cup- e.g. Zahn cup, Ford viscosity

cup- with usage of each type varying mainly according to the industry. The

efflux time can also be converted to kinematic viscosities (centistokes, cSt)

through the conversion equations.

Also used in coatings, a Stormier viscometer uses load-based rotation in order

to determine viscosity. The viscosity is reported in Krebs units (KU), which are

unique to Stormier viscometers.

Vibrating viscometers can also be used to measure viscosity. These models

such as the Dynatron use vibration rather than rotation to measure viscosity.

Extensional viscosity can be measured with various rheometers that

apply extensional stress.

Volume viscosity can be measured with an acoustic rheometer.

Apparent viscosity is a calculation derived from tests performed on drilling

fluid used in oil or gas well development. These calculations and tests help

engineers develop and maintain the properties of the drilling fluid to the

specifications required.

Ford Cup:

The Ford viscosity cup is a simple gravity device that permits the timed flow of

a known volume of liquid passing through an orifice located at the bottom.

Under ideal conditions, this rate of flow would be proportional to

the kinematic viscosity (expressed in stokes and centistokes) that is dependent

upon the specific gravity of the

draining liquid. However, the

conditions in a simple flow cup are

seldom ideal for making true

measurements of viscosity. It is

important when using a Ford Cup and

when retesting liquids that the

temperature of the cup and the liquid

is maintained, as ambient temperature

makes a significant difference to

viscosity and thus flow rate.

The original Ford Cup was based on Imperial (US) measurement of the

aperture.

Din Cup 4 mm., standard DIN 53211 (cancelled) ISO Cup 2, 3, 4, 5, 6, 8 mm.

standard ISO 2431 AFNOR Cup 2,5, 4, 6, 8 mm. standard NF T30-014 ASTM Cup

1,2,3,4,5 standard ASTM D1200

Here Paint used for Painting Chain Case, Connecting Rod is Nerolec Paint.

The Ford Viscosity Cup which is used in Company has volume of 100-106 ml.

Viscosity test must repeat after every 4 hours.

Total Time is 30 min. in Painting Procedure of Chain Case & Connecting Rod.

Coat Type Ford Viscosity Cup Value

Primer Coat 15-18 sec

Base Coat 17-20 sec

Top Coat 15 sec

Pre Discharge Inspection of Painted Parts:-

This PDI involves two steps of inspection:-

1. First check every side that should be painted uniformly.

2. Check every side carefully no scratch should be there.

3. If any problem occurs then part should be again hanging in TAG RAG.

Precaution to take in Painting:-

1. Hang parts on hanger carefully.

2. All the tests must be performed after regular time interval.

3. Carefully check every part in TAG RAG chamber

4. Every Part should be unloaded carefully

5. Every movement must be like the last movement of spray gun in the

coating chamber.

6. Heating Chambers should be clean by HNO3 after every rest of machine.

Total annual error in painting of Chain Case and Connecting Rod is 0.2%.

Conclusion of Project:-

Painting procedure of the Chain Case of Honda Unicorn and Connecting Rod of

Honda Unicorn and Honda Activa is completed. No error was found in working

procedure.

Object:- Making process of Step Pillion of Honda Activa.

Abstract:- Step Pillion or Foot Rest is provided for the relaxation of back sitter

foot. This is made of Mild Steel and attached with the frame. Honda Activa has

two foot rest Left Side and Right Side. This step pillion is jointed via Mig

Welding Process and it is jointed to frame via Electric Arc Welding.

MIG Welding:-

Metal Inert Gas (MIG) welding, sometimes referred to by Gas metal arc

welding (GMAW) welding or metal active gas (MAG)welding, is a welding

process in which an electric arc forms between a

consumable wire electrode and the work piece metal(s), which heats the work

piece metal(s), causing them to melt, and join. Along with the wire electrode,

a shielding gas feeds through the welding gun, which shields the process from

contaminants in the air. The process can be semi-automatic or automatic. A

constant voltage, direct current power source is most commonly used with

GMAW, but constant current systems, as well as alternating current, can be

used. There are four primary methods of metal transfer in GMAW, called

globular, short-circuiting, spray, and pulsed-spray, each of which has distinct

properties and corresponding advantages and limitations.

Originally developed for welding aluminium and other non-ferrous materials in

the 1940s, GMAW was soon applied to steels because it provided faster

welding time compared to other welding processes. The cost of inert gas

limited its use in steels until several years later, when the use of semi-inert

gases such as carbon dioxide became common. Further developments during

the 1950s and 1960s gave the process more versatility and as a result, it

became a highly used industrial process. Today, GMAW is the most common

industrial welding process, preferred for its versatility, speed and the relative

ease of adapting the process to robotic automation. Unlike welding processes

that do not employ a shielding gas, such as shielded metal arc welding, it is

rarely used outdoors or in other areas of air volatility. A related process, flux

cored arc welding, often does not use a shielding gas, but instead employs an

electrode wire that is hollow and filled with flux.

Equipment of MIG:-

To perform gas metal arc welding, the basic necessary equipment is a welding

gun, a wire feed unit, a welding power supply, an electrode wire, and

a shielding gas supply.

Welding Gun:-

The typical GMAW welding gun has a number of key parts—a control switch, a

contact tip, a power cable, a gas nozzle, an electrode conduit and liner, and a

gas hose. The control switch, or trigger, when pressed by the operator, initiates

the wire feed, electric power, and the shielding gas flow, causing an electric arc

to be struck. The contact tip, normally made of copper and sometimes

chemically treated to reduce spatter, is connected to the welding power

source through the power cable and transmits the electrical energy to the

electrode while directing it to the weld area. It must be firmly secured and

properly sized, since it must allow the electrode to pass while maintaining

electrical contact. On the way to the contact tip, the wire is protected and

guided by the electrode conduit and liner, which help prevent buckling and

maintain an uninterrupted wire feed. The gas nozzle directs the shielding gas

evenly into the welding zone. Inconsistent flow may not adequately protect

the weld area. Larger nozzles provide greater shielding gas flow, which is useful

for high current welding operations that develop a larger molten weld pool. A

gas hose from the tanks of shielding gas supplies the gas to the nozzle.

Sometimes, a water hose is also built into the welding gun, cooling the gun in

high heat operations.

The wire feed unit supplies the electrode to the work, driving it through the

conduit and on to the contact tip. Most models provide the wire at a constant

feed rate, but more advanced machines can vary the feed rate in response to

the arc length and voltage. Some wire feeders can reach feed rates as high as

30.5 m/min (1200 in/min), but feed rates for semiautomatic GMAW typically

range from 2 to 10 m/min (75–400 in/min)

Tool style:-

The top electrode holder is a semiautomatic air-cooled holder. Compressed air

circulates through it to maintain moderate temperatures. It is used with lower

current levels for welding lap or butt joints. The second most common type of

electrode holder is semiautomatic water-cooled; where the only difference is

that water takes the place of air. It uses higher current levels for welding T or

corner joints. The third typical holder type is a water cooled automatic

electrode holder—which is typically used with automated equipment.

Power Supply:-

Most applications of gas metal arc welding use a constant voltage power

supply. As a result, any change in arc length (which is directly related to

voltage) results in a large change in heat input and current. A shorter arc

length causes a much greater heat input, which makes the wire electrode melt

more quickly and thereby restore the original arc length. This helps operators

keep the arc length consistent even when manually welding with hand-held

welding guns. To achieve a similar effect, sometimes a constant current power

source is used in combination with an arc voltage-controlled wire feed unit. In

this case, a change in arc length makes the wire feed rate adjust to maintain a

relatively constant arc length. In rare circumstances, a constant current power

source and a constant wire feed rate unit might be coupled, especially for the

welding of metals with high thermal conductivities, such as aluminium. This

grants the operator additional control over the heat input into the weld, but

requires significant skill to perform successfully.

Alternating current is rarely used with GMAW; instead, direct current is

employed and the electrode is generally positively charged. Since

the anode tends to have a greater heat concentration, this results in faster

melting of the feed wire, which increases weld penetration and welding speed.

The polarity can be reversed only when special emissive-coated electrode

wires are used, but since these are not popular, a negatively charged electrode

is rarely employed.

Electrode:-

Electrode selection is based primarily on the composition of the metal being

welded, the process variation being used, joint design and the material surface

conditions. Electrode selection greatly influences the mechanical properties of

the weld and is a key factor of weld quality. In general the finished weld metal

should have mechanical properties similar to those of the base material with

no defects such as discontinuities, entrained contaminants or porosity within

the weld. To achieve these goals a wide variety of electrodes exist. All

commercially available electrodes contain deoxidizing metals such

as silicon, manganese, titanium and aluminium in small percentages to help

prevent oxygen porosity. Some contain denaturising metals such as titanium

and zirconium to avoid nitrogen porosity. Depending on the process variation

and base material being welded the diameters of the electrodes used in

GMAW typically range from 0.7 to 2.4 mm (0.028–0.095 in) but can be as large

as 4 mm (0.16 in). The smallest electrodes, generally up to 1.14 mm

(0.045 in) are associated with the short-circuiting metal transfer process, while

the most common spray-transfer process mode electrodes are usually at least

0.9 mm (0.035 in).

Shielding Gas:-

Shielding gases are necessary for gas metal arc welding to protect the welding

area from atmospheric gases such as nitrogen and oxygen, which can cause

fusion defects, porosity, and weld metal embrittlement if they come in contact

with the electrode, the arc, or the welding metal. This problem is common to

all arc welding processes; for example, in the older Shielded-Metal Arc Welding

process (SMAW), the electrode is coated with a solid flux which evolves a

protective cloud of carbon dioxide when melted by the arc. In GMAW,

however, the electrode wire does not have a flux coating, and a separate

shielding gas is employed to protect the weld. This eliminates slag, the hard

residue from the flux that builds up after welding and must be chipped off to

reveal the completed weld.

The choice of a shielding gas depends on several factors, most importantly the

type of material being welded and the process variation being used. Pure inert

gases such as argon and helium are only used for nonferrous welding; with

steel they do not provide adequate weld penetration (argon) or cause an

erratic arc and encourage spatter (with helium). Pure carbon dioxide, on the

other hand, allows for deep penetration welds but encourages oxide

formation, which adversely affect the mechanical properties of the weld. lts

low cost makes it an attractive choice, but because of the reactivity of the arc

plasma, spatter is unavoidable and welding thin materials is difficult. As a

result, argon and carbon dioxide are frequently mixed in a 75%/25% to

90%/10% mixture. Generally, in short circuit GMAW, higher carbon dioxide

content increases the weld heat and energy when all other weld parameters

(volts, current, electrode type and diameter) are held the same. As the carbon

dioxide content increases over 20%, spray transfer GMAW becomes

increasingly problematic, especially with smaller electrode diameters.

Argon is also commonly mixed with other gases, oxygen, helium, hydrogen,

and nitrogen. The addition of up to 5% oxygen (like the higher concentrations

of carbon dioxide mentioned above) can be helpful in welding stainless steel,

however, in most applications carbon dioxide is preferred. Increased oxygen

makes the shielding gas oxidize the electrode, which can lead to porosity in the

deposit if the electrode does not contain sufficient deoxidizers. Excessive

oxygen, especially when used in application for which it is not prescribed, can

lead to brittleness in the heat affected zone. Argon-helium mixtures are

extremely inert, and can be used on nonferrous materials. A helium

concentration of 50%–75% raises the required voltage and increases the heat

in the arc, due to helium's higher ionization temperature. Hydrogen is

sometimes added to argon in small concentrations (up to about 5%) for

welding nickel and thick stainless steel work pieces. In higher concentrations

(up to 25% hydrogen), it may be used for welding conductive materials such as

copper. However, it should not be used on steel, aluminium or magnesium

because it can cause porosity and hydrogen embrittlement.

Operation:-

For most of its applications gas metal arc welding is a fairly simple welding

process to learn requiring no more than a week or two to master basic welding

technique. Even when welding is performed by well-trained operators weld

quality can fluctuate since it depends on a number of external factors. All

GMAW is dangerous, though perhaps less so than some other welding

methods, such as shielded metal arc welding. The basic technique for GMAW is

quite simple, since the electrode is fed automatically through the torch (head

of tip). By contrast, in gas tungsten arc welding, the welder must handle a

welding torch in one hand and a separate filler wire in the other, and in

shielded metal arc welding, the operator must frequently chip off slag and

change welding electrodes. GMAW requires only that the operator guide the

welding gun with proper position and orientation along the area being welded.

Keeping a consistent contact tip-to-work distance (the stick out distance) is

important, because a long stick out distance can cause the electrode to

overheat and also wastes shielding gas. Stick out distance varies for different

GMAW weld processes and applications. The orientation of the gun is also

important—it should be held so as to bisect the angle between the work

pieces; that is, at 45 degrees for a fillet weld and 90 degrees for welding a flat

surface. The travel angle, or lead angle, is the angle of the torch with respect to

the direction of travel, and it should generally remain approximately vertical.

However, the desirable angle changes somewhat depending on the type of

shielding gas used—with pure inert gases; the bottom of the torch is often

slightly in front of the upper section, while the opposite is true when the

welding atmosphere is carbon dioxide.

Advantages of MIG welding:-

The ability to join a wide range of metals and thicknesses

All-position welding capability

A good weld bead

A minimum of weld splatter

Easy to learn

Disadvantages of MIG welding:-

MIG welding can only be used on thin to medium thick metals

The use of an inert gas makes this type of welding less portable than arc

welding which requires no external source of shielding gas

Produces a somewhat sloppier and less controlled weld as compared to TIG

(Tungsten Inert Gas Welding)

Parts:-

1. Holder

2. Cable Tie

3. R Pipe

4. Straight Pipe

5. Stay

6. Patgn (Thick and Thin)

7. Gusset Stay

8. MIG Welding

Methodology:-

1. First step all the sheets of metal is procured from the vendor

2. The grade of the material is checked by the inspection department. In

inspection these three things are checked. Wrong size of the metal sheet,

grade of the metal sheet and the visual defects of the metal sheet.

3. After this all inspection Gusset Holder will join with R Pipe and Straight

Pipe.

4. In next step Patgn will join with upper made assembly.

5. Further Stay will join with made assembly.

6. Then Cable Tie and Gusset Stay will join with assembly in left side assembly

of pillion whole process is same but cable tie will not be jointed. Then it will

send to PDI.

Pre Discharge Inspection of Step Pillion:-

1. First we check all the part by pillion gauge.

2. Then we check the welding and overlapping of metal at joints.

3. In last all hole consisting part will check.

Total Annual defect is 5% in the production of step pillion of Honda Activa.

Total time for the making of step pillion of Honda Activa is 20 second.

Precaution for production of Step Pillion:-

1. Always use a black glass eye protective film in welding procedure.

2. Always wear gloves in welding procedure.

3. Always wear an apron before start welding.

4. Always wear long boots to prevent skin from spark.

5. Always check gas nozzle before start.

Conclusion of Project:-

Production procedure of Step Pillion of Honda Activa is completed. The total

error find is 10% in my work.

Object:- Production procedure of Frame of Honda Activa KWPG.

Abstract:- A frame is the main structure of the chassis of a motor vehicle. All

other components fasten to it; a term for this design is body-on-frame

construction.

The main functions of a frame in motor vehicles are:-

To support the vehicle's chassis components and body

To deal with static and dynamic loads, without undue deflection or

distortion.

These include:

Weight of the body, passengers, and cargo loads.

Vertical and torsion twisting transmitted by going over uneven surfaces.

Transverse lateral forces caused by road conditions, side wind, and

steering the vehicle.

Torque from the engine and transmission.

Longitudinal tensile forces from starting and acceleration, as well as

compression from braking.

Sudden impacts from collisions.

A motorcycle frame includes the head tube that holds the front fork and allows

it to pivot. Some motorcycles include the engine as a load-bearing, stressed

member. The rear suspension is an integral component in the design.

Traditionally frames were steel, but titanium, aluminium, magnesium,

and carbon-fibre, along with composites of these materials, are now used.

Because of different motorcycles' varying needs of cost, complexity, weight

distribution, stiffness, power output and speed, there is no single ideal frame

design.

Material used for Frame:-

Steel

Aluminium

Carbon Fibre

Titanium

Magnesium

Composite

Type of Two Wheeler Frame:-

Spine or Backbone

Single Cradle

Half-Duplex Cradle

Full Duplex Cradle

Perimeter

Beam

Pressed

Monocoque

Trellis

Underbone

The frame is welded via electric arc welding.

Electric Arc Welding:-

Arc welding is a type of welding that uses a welding power supply to create

an electric arc between an electrode and the base material to melt the metals

at the welding point. They can use either direct (DC) or alternating (AC)

current, and consumable or non-consumable electrodes. The welding region is

usually protected by some type of shielding gas, vapor, or slag. Arc welding

processes may be manual, semi-automatic, or fully automated. First developed

in the late part of the 19th century, arc welding became commercially

important in shipbuilding during the Second World War. Today it remains an

important process for the fabrication of steel structures and vehicles.

Power Supply:-

To supply the electrical energy necessary for arc welding processes, a number

of different power supplies can be used. The most common classification is

constant current power supplies and constant voltage power supplies. In arc

welding, the voltage is directly related to the length of the arc, and the current

is related to the amount of heat input. Constant current power supplies are

most often used for manual welding processes such as gas tungsten arc

welding and shielded metal arc welding, because they maintain a relatively

constant current even as the voltage varies. This is important because in

manual welding, it can be difficult to hold the electrode perfectly steady, and

as a result, the arc length and thus voltage tend to fluctuate. Constant voltage

power supplies hold the voltage constant and vary the current, and as a result,

are most often used for automated welding processes such as gas metal arc

welding, flux cored arc welding, and submerged arc welding. In these

processes, arc length is kept constant, since any fluctuation in the distance

between the wire and the base material is quickly rectified by a large change in

current. For example, if the wire and the base material get too close, the

current will rapidly increase, which in turn causes the heat to increase and the

tip of the wire to melt, returning it to its original separation distance.

The direction of current used in arc welding also plays an important role in

welding. Consumable electrode processes such as shielded metal arc welding

and gas metal arc welding generally use direct current, but the electrode can

be charged either positively or negatively. In welding, the positively

charged anode will have a greater heat concentration and, as a result,

changing the polarity of the electrode has an impact on weld properties. If the

electrode is positively charged, it will melt more quickly, increasing weld

penetration and welding speed. Alternatively, a negatively charged electrode

results in more shallow welds. Non-consumable electrode processes, such as

gas tungsten arc welding, can use either type of direct current (DC), as well as

alternating current (AC). With direct current however, because the electrode

only creates the arc and does not provide filler material, a positively charged

electrode causes shallow welds, while a negatively charged electrode makes

deeper welds. Alternating current rapidly moves between these two, resulting

in medium-penetration welds. One disadvantage of AC, the fact that the arc

must be re-ignited after every zero crossing, has been addressed with the

invention of special power units that produce a square wave pattern instead of

the normal sine wave, eliminating low-voltage time after the zero crossings

and minimizing the effects of the problem.

Duty cycle is a welding equipment specification which defines the number of

minutes, within a 10 minute period, during which a given arc welder can safely

be used. For example, an 80 A welder with a 60% duty cycle must be "rested"

for at least 4 minutes after 6 minutes of continuous welding. Failure to observe

duty cycle limitations could damage the welder. Commercial- or professional-

grade welders typically have a 100% duty cycle.

The pros of ARC welding are:-

The equipment that is used for welding purposes is not very expensive and

can be afforded by all. It is also easy to use. This makes it very convenient

for people who want to weld using ARC welding.

You will generally think of welding equipment as being unwieldy and

heavy. The equipment used in ARC welding is portable making it very easy

for use in all places. It can be taken to any place and can also be inside a

confined place.

It is not necessary to have auxiliary gas shielding.

The reason that it is most used is that it is suitable for welding most metals

and alloys. So, you need not go in for different types of welding and can do

with ARC welding.

The cons of Arc welding are:-

There is need to replace the weld electrode in ARC welding frequently. So,

care should be taken to do it whenever necessary.

The rate of deposition is lower than continuous electrode process.

It is necessary to remove the slag from the weld.

When welding, very bright is produced. The welding operator should be

very careful and wear protective glasses. The welder should also wear

protective gear, so that he is protected from electric shock, burns and

other problems that might arise while welding due to the high intensity of

heat.

Welding is an essential process for joining two metals and arc welding is

most commonly used because of the minimum equipment used and a

person with minimum training. So, you should consider the pros and cons

before starting to arc weld. Since the cons can all be taken care of and arc

welding is a very useful and simple process for welding, people should use

it for welding purposes.

Methodology:-

ERW Steel 2 is used to make frame which has

Thickness = 2.60 mm, 1.60 mm

Diameter = 38.10 mm

Length = 929 mm

1. First step all the sheets of metal is procured from the vendor.

2. The grade of the material is checked by the inspection department. In

inspection these three things are checked. Wrong size of the metal pipe,

grade of the metal pipe and the visual defects of the metal pipe.

3. In after inspection step pipe is bended via Bending Machine which is made

by YLM Taiwan. It is a computer operated system. This machine used

Hydraulic energy for Clamping, Holding and Pressing. The pressure is used

to bend this pipe is 110 Kg/cm2 with maximum tolerance of 1 mm. Here

pipe is bended to a pre defined shape. Honda Avtiva has underbone type of

frame.

4. After bending the pipe sanded to Milling Section. In this section milling

section Drill holes in it during the drill operation water is used as coolant.

5. Than operation performed pipe sanded for Grinding Operation. In this

section Grinder wheel is used to finish surface and remove extra material

from pipe.

6. In next step of assembly a Rod opener and centre cross welding has to be

done.

7. Then this prepared pipe sanded for the assembly. In first step of assembly

pipe is pivoted and under covered.

8. In next step L shape bended pipe welded with Seat Lock, Duet Pipe and join

with 3 rubber clips.

9. Then a robot do Round welding of duet pipe. Rear frame is prepared by

going through these steps.

10. In the assembly of front frame first bended pipe join with Lower Cross via

Patch Welding

11. Then main pipe joint with Lower Cross via welding.

12. Then at next assembly main pipe head pipe, gusset pipe, step bar join via

welding and a wise harshness has clipped with it.

13. Then to make these permanent joint an open final welding has to be done.

14. Then an open final welding and round welding joint both side of frames.

15. Then main pipe gusset is jointed with round welding.

16. Then guide cable, RR break cable, guide throsed cable jointed and sand for

quality check.

Quality Check of Honda Activa Frame:-

In first step of quality check the completed frame grinded and reworked.

The fine boring operation has to be done where required.

Then tapping operation performed and Frame sand to PDI.

Pre Discharge Inspection of Frame:-

1. In first step of PDI a hand jig gauge is used to inspect.

2. Then final gauge is used to inspect

3. Then all welded joints and curves has inspected.

The total process of assembling of both frames is completed in 30 seconds.

The total annual defects are 0.20% of total production.

Problems occur with production of Honda Activa Frame:-

Problems with bending operation:

1. Due to the uneven grains many times wrinkle occur during bending. This

problem cannot be solved. This makes pipe waste.

2. Due to uneven force many times bending variation occurs. This is also a

insolvable problem and makes pipe waste.

Problem with milling operations:

1. Due to uneven grains notching problem occurs and this is also insolvable

problem and makes pipe waste.

2. Due to wear of drill jig many times holes drilling get uneven. This problem

can be solved via drilling with new jig.

Problem with grinding operation:

1. Due to problem in pipe shape and grinding wheel more chip get removed

from pipe. This may make pipe waste.

2. Surface Finish

Conclusion of Project:

The production procedure of Honda Activa Frame completed. This procedure

makes me able to work in hard environment. The error in my work of

production procedure is 10%.

Conclusion

It’s always a great opportunity to experience the valuable exposure of an

industry. There is lot of difference between the Theories and Practices. This

Training enables me to understand the aspects of professional life. I like the

working environment followed at NEEL METAL PRODUCTS LTD. and come to

know how to deal with our colleagues. The company’s members are well

cultured & well mannered.

An effective process is followed at NEEL METAL PRODUCTS LTD. but it would

become more valuable and impressive by implementing certain efficient

measures. The company is constantly focusing on providing better services,

quality and reliability to customers, and running successfully in this era of

competition.