SUBMITTED BY:- PANKAJ and SUNITA RANI
MECHANICAL ENGG.
ROLL NO:-12305 &12326
SEM:- 5th
DRONACHARYA COLLEGE OF ENGG;
GURGAON
CERTIFICATE
This is to certify that the project entitled “Brake & Fuel Line” submitted
by Mr. Pankaj & Miss. Sunita Rani is a bonifide record of work carried out
by her under my supervision from 15th June 2011 to 31st July 2011.the
contents of this thesis, in full or in parts have not been submitted to any
other institute or university for the award of any degree.
Mr. Mohan Singh.
Sr.Executive(HR)
INDEX
PROJECT TITTLE
ACKNOELEDGEMENT
COMPANY INTRODUCTION
About TI Automotives World
Organization Structure
Product Overview
Environment & quality
INDUSTRY OVERVIEW
PROJECT INTRODUCTION
Objective Of Training
Objective Of Project
Introduction To Project
ANALYSIS AND FINDINGS
CONCLUSION AND RECOMMENDATIONS
ANNEXURE
ACKNOLEDGEMENT
I am very grateful to all under whom I completed my summer training .I
would like to give my heartiest thanks to Mr. Mohan Singh who give me
opportunities (letter to join as trainee) to do training at Bundy India
Limited.
I would like to express my deep gratitude to Mr. Ravi Verma (project
guide) at Bundy India Limited for their keen interest, valuable guidance
and constant encouragement during the course of my accomplishment of
this project. I am very grateful to them for introducing me to the
technicalities and explaining the subtleties of the project and process
flow of the plant.
COMPANY INTRODUCTION
TI Automotive has maintained the position of a premier supplier to an everchanging global market since 1922, with advances in small diameter steel tube
manufacture, design and fabrication
Technology and innovation have always been our driving force, offering far more
than just tubing expertise to the automotive industry.
Bundy double wall tubing is manufactured from a low carbon, tight tolerance
continuous strip of copper plated cold rolled steel, double wrapped (through 720
degrees) and brazed in a controlled atmosphere to form a double-walled tube.
COMPANY BACKGROUND INFORMATION
TI Automotive is the world's leading
supplier of fluid storage, transfer and delivery systems including
brake, fuel and air conditioning applications.
FOUNDED
TI Automotive Ltd was formed as an independent
company in 2001 in England. Following the merger of TI Group with
Smiths Industries in December 2000, TI Group Automotive Systems
became a division within Smiths Group plc. In July 2001, the
automotive division demerged from Smiths Group.
EMPLOYEES
TI Automotive has more than 16,000 employees in more
than 100 facilities worldwide.
BUSINESS DIVISIONS
TI Automotive is divided into two major divisions. The
Fuel Systems group has approximately 40% of company sales and
the Fluid Carrying Systems group has 60%.
GROWTH CHORONOLGY
TI Automotive's roots are in the remarkable
transformation of TI Group plc from a declining British company in
1986 to a thriving global business by 2000.
TI Group, which originated as Tube Investments Ltd in Birmingham,
England in 1919, grew its automotive business with these major
acquisitions:
PRODUCT OVERVIEW
Our core product offerings focus
on the design, development and manufacture of multilayer blow molded plastic fuel tanks with integrated fuel
delivery module assemblies, including turbine or gerotor
pumps, electronic control modules, sensor units and fill
and vapor control valves.
Complimenting these leading edge complex fuel tank
systems are TI Automotive's rigid and flexible fuel and
brake lines, each available with a comprehensive range of
coating applications and unique connector technology.
Our total systems solutions provide the world's
automotive manufacturers with a filler neck fuel rail
package that is designed to optimize cost, space, weight
and fitment parameters whilst surpassing safety and
emissions requirements.
Additionally, TI Automotive offers world class air
conditioning module assemblies. Steel and aluminum
accumulators and unitized receiver dryers are integrated
with rigid and flexible hose assemblies to provide efficient
and optimum performance in this high temperature
environment.
Fluid Carrying Systems
Our routing expertise comes into its own in the crowded vehicle underbody.
Brake and fuel line bundles, designed to optimize space and maximize fitment speed,
save valuable assembly time. Supplied on a “just-in-time” or sequence-delivery basis,
we provide simple inventory. Control and reduced assembly-line congestion.
Brake & Fuel Products :TI Automotive provides a brake and fuel solution for each
customer application. Our tubular products include rigid brake and fuel
lines, flexible fuel lines, and high-pressure diesel products designed to
meet a variety of customer needs. Corrugated monoand multi-layer tubes
and assemblies complete the portfolio for fuel-vapor systems. A
comprehensive range of coatings, which exceed corrosion and abrasion
protection standards, enhances product quality and durability
Air Conditioning Tube & Hose Assemblies:Ever-changing emission, fuel efficiency,
and cost requirements demand enhancement of current
air-conditioning systems as well as innovation in alternate
refrigerant technology. As a driving force for cost-effective
materials, design, and processes for the mobile air
conditioning “loop,” TI Automotive continues to set
standards within the industry. Our combination of coupling,
bending, and connection technology enables us to meet
our customers’ unique needs for quick connectors, in-line
heat exchangers, and high-pressure couplings.
Heater & Radiator Hose Systems
We offer a wide range of
hose constructions and diameters to match our
customers’ needs, including high-temperature
requirements. Manufacturing capabilities
include formed, coupled hoses with tube or
quick connectors and pre-positioned clamps
(mechanical/adhesive).
Other Automotive Products
Our commitment to lean manufacturing has pushed our connector
technology to the forefront of the automotive industry, and TI Automotive produces more quick connects
than anyone else in the world. From high-pressure quick connects to spin-welding joints between a quick
connector and flexible tube line, we provide solutions for every manufacturing need. In addition to
meeting the automotive industry’s low-permeation standards, our connectors make for easy installation
at the assembly line. TI Automotive also manufactures air bag tubes and other formed tubular products in
a variety of intricate shapes to meet our customers’ specifications. These products are supplied to all
tiers of the automotive supply cha
Product Quality:Copper Plated Double Wall Steel Tubing
specifications SAE J527, ASTM A254.
Meets automotive brake tube specifications worldwide
Available in coils, straight boom lengths, cut-to-length, or fabricated assemblies
Available annealed
Some common applications include brake lines, high-pressure fuel injection lines, hydraulic line and compressor lines
Product Features
Product Benefits
Double wall construction
Designed to withstand high internal pressures and combat vibration fatigue
Bead free no weld flash inside or outside the tube
Smooth, clean, precise I.D.
Copper finish on inside and outside of tubing
Facilitates brazing tubing to fittings, stampings and other parts
Available in a wide variety of coatings.
Extended corrosion protection
Single Wall Low Carbon
Steel Tubing
Meets or exceeds specifications SAE J525, SAE
J526, SAE J356A, ASTM A269, and ASTM A268.
Meets all automotive industry standards.
Some common applications include:
o fuel supply and return lines
o vent and vacuum lines
o fuel rails
o power steering
o engine/oil coolers
o HVAC components
o Fuel filler necks
o refrigeration
Product Features
Product Benefits
High grade single wall strip materials are utilized
to ensure optimized physical properties
Provides ease of fabrication and can be expanded, compressed,
flattened, cut formed or bent into almost any shape
Most sizes available as welded, cold drawn, or
annealed
Enables low-cost material substitution
Available in a wide variety of coatings &
stainless alloys
Provides a variety of low cost corrosion protection options to
meet every application
Conductive Nylon O.D. coated tube, with or
without nickel I.D., available
Offers a replacement for many stainless steel and aluminum
tubing applications
Fluid and gas carrying capabilities at medium to
high pressure
Provides a wide range of product capabilities
Coatings
Inner Sacrificial Layer
Hot Dipped Alloy Layer consisting
of 95% Zinc and 5% Aluminum
Outer
Barrier
Layer
None
Other Info.
Coating may be soldered. Contact TI
Automotive for method description.
Meets OEM
Customer
Specifications
Daimler Chrysler
PS-8688 Code NZ
Ford Motor
Company
ESA-M1A270-A
General Motors
Corp.
GM123M
GM124M Code AG
PVF COATING
Inner Sacrificial Layer
Electroplated Zinc Layer
Outer Barrier Layer
PVF ( Polyvinyl Fluoride ) Paint Layer
Other Info.
Meets OEM Customer Specifications
Daimler Chrysler
PS-8688 Code PE
Ford Motor Company
WSK-M2P139-AESA-M21P20A
Process Of Production:1. Material receipt
2 .Tube Cutting
3 .Deburring +Air blow
4 .Swaging
5 .1st End Forming
6 .Sleeve Cutting
7 .Nut/Sleeve Insertion
8 .2nd End Forming
9 .Marking/Sleeve Location
10 .Sleeve Shrinkage
11 .Inspection/Final Air Blow
12 .CNC/Power Bending
13 .Manual Bending
14 .Leak Testing
15 .Final Inspection
16 .Packing/Storage
17 .Dispatch
1 .Material Receipt
2 .Tube Cutting:Cut the tube with the help of power cutter according their length
3 .Deburring+Air Blow
During they cutting process the sharp edges are formed in the end so we remove
the sharp edges .We use deburring process & air blow for remove dart particle in
tube.
4 .Swaging :During the deburring process the diameter of tube increases so we
want to actual size of the diameter of the tube we use swaging process.
5 .1st End Forming :After the swaging operation we form the first and of the tube using pressure punching
machine .pressure which is use is 70kgf/cm2
6.Sleeve Cutting
Some time we avoid the fuel pipe and break pipe from heat and
corrosion we use sleeve pipe insert in the sleeve
7 .Nut/Sleeve Insertion:After forming the 1st end insert the nut and sleeve. This operation is held manually
9 .Marking/Sleeve Location
Marking the position of the sleeve in the pipe and inert the sleeve
10 .Sleeve Shrinkage
about 140
C.
After insertion of the sleeve .The pipe is passes over the temperature
and then sleeve shrink
11 .Inspection/Final Air Blow
Inspection for the cut and other fault like leakage
12 .CNC/Power Bending
The pipe is bend with the help of the CNC/Power bending according to their
PLANE,FEED,BEND.Pressure is required for this is 6 bar
13 .Manual Bending
This operation is also done with the help of manual bending
14 .Leak Testing
This is for the test for leakage in the pipe. Fill the air in the pipe then pipe deepwater tank
15 .Final Inspection
16 .Packing/Storage
17 .Despatch
Environment & Quality
Environmental Responsibility
In order to minimize its own impact on the environment, TI Automotive is
seeking ISO 14001 certification on a global basis. This international
standard sets criteria to ensure that an effective environmental
management system is in place at each facility. We monitor our
environmental performance closely and third party verification audits are
conducted annually. With these aids we can assess our achievements and
review our targets on a regular basis. Our aim is ongoing improvement so
further developments are constantly being implemented.
All eligible TI Automotive sites are ISO 14001 certified or working toward
certification.
Many of TI Automotive's products have positive environmental impacts in
terms of emissions and noise reduction. We constantly monitor emissions
legislation on a global basis. California's upcoming LEV II and PZEV
standards are the current driver for evaporative emissions regulations,
worldwide. These stringent standards are likely to serve as the model,
with modifications, for future standards throughout the world.
TI Automotive is committed to helping its customers meet LEV II, PZEV
and other future standards with innovative, cost-effective, fuel system
products.
Global Customer Base
TI Automotive has a supplier partnership with
every major Original Equipment Manufacturer (OEM) in the world. TI
Automotive is able to maintain these relationships by continually adapting as
the automotive industry's boundaries expand across the globe. Our global
customer base includes the following companies:
BMW
Honda
Fiat
Isuzu
Hyundai
Daewoo
Ned car
Ford
PSA
General Motors
Renault
Toyota
BIBLIOGRAPHY:www.Tiautomotive.com
Thanks….
No questions plzzz….