Summer Training
Project Report
2011
A
Summer Training Report
taken under
Caparo Maruti Lmt. Gurgaon.
Submitted by :
Sunny
Roll No. 12327
ME (5th Sem.)
Submitted to :
Sh.S.K.Bagga (H.O.D)
Contents
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Acknowledgement
Caparo Group
Caparo History
Caparo Companies
Gurgaon’s Manufacturing Plant
Caparo Products
Product Info
Acknowledgement
I express my deep sense of gratitude to Caparo Maruti Lmt.
for providing me an opurtunity to have my Summer Training in
their company in Production Department. I am highly thankful
to Mr. Rajesh Sharma who was kind enough to familiarize me
to the plants operations.
And I am also very
much thankful from bottom of my heart to My Parents.
Without there kindness it could have never ever be possible.
Caparo Group
“Caparo is more than a successful business enterprise - it is a
story of people, of values and human effort.”
- Lord Paul, Chairmen and Founder.
Caparo Vehicle Products (CVP) is a grouping of innovative well
established Tier 1 and 2 component design, engineering and
manufacturing companies providing advanced solutions to the
automotive, motor sport, commercial and niche vehicle markets
as well as other sectors. Offering design, rapid prototyping and
sample development, as well as series production and line side
delivery, the division is able to provide full vertical integration as
well as component solutions to its customers.
Caparo Maruti History
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In 1968 Lord Paul took out a £5,000 loan and opened
Natural Gas Tubes. The company, based in Huntington
in Cambridgeshire, manufactured spiral weld tubes and
achieved first year sales of £14,000. In 2006 Caparo
group’s sales exceeded £625m.
HISTORY
Companies
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The Caparo group is a collection of over 40 companies
operating on over 60 sites in UK, INDIA, North America,
Spain, Canada and Dubai. With business interest mainly in
manufacturing of steel, automotive and general Engineering
products, the group’s wider activities encompass Material
testing, film distribution and bespoke furniture. In 2006 the
alone the group acquired 22 companies.
Customers
Gurgaon’s Manufacturing Plant
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Operational since
Total area
Build up area
Capacity
Investment
Man power employed
- Feb. 1996
- 12,100 Sq.m.
- 5,600 Sq.m.
- 2.4 mn line stroke p.a.
- INR 100 cr
- 330 employees
PLANTS
PRODUCTS
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Outer Body Panel
Large Inner Panel
Reinforcement
Brackets
Cross Members and Chasis Parts
General Stampings
Introductional Topics
Main topics of discussion of this presentation are here
as :
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General Stampings & their Production Processes
Stampings
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Metal Stamping manufacturing is the process of creating
metal parts by applying extreme pressure to a blank piece
of metal and forming the metal into a desired shape. The
stamping machine includes a specially made form or die
which gives the stamped part shape.
Most metals may manufacture using the stamped process
these include: Aluminium(most alloys) , Brass, Steel,
Galvanized Steel, Titanium, Zinc etc.
Machines used in stamped manufacturing range from a
simple hand press or “Hydraulic Press”, to the much larger
machines referred to as “Drop Hammers”. All stamping
machines incorporate a form or die to give the stamped
metal the desired shape.
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The operations associated with stamping are blanking,
piercing, forming, and drawing.
These operations are done with dedicated tooling also
known as Hard Tooling. This type of tooling is used to make
high volume parts of one configuration of part design. (By
contrast, soft tooling is used in processes such as CNC
turret presses, laser profilers and press brakes). All these
operations can be done either at a single die station or
multiple die stations — performing a progression of
operations, known as a progressive die.
Equipments
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1.
2.
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The equipments of stamping can be categorized to two
types:
Mechanical Presses
Hydraulic Presses
Mechanical Presses: Mechanical presses has a
mechanical flywheel to store the energy, transfer it to
the punch and to the workpiece. They range in size
from 20 tons up to 6000 tons. Strokes range from 5 to
500 mm. and speeds from 20 to 1500 strokes per
minute. Mechanical presses are
well suited for high-speed blanking, shallow drawing and for
making precision parts.
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Hydraulic Presses: Hydraulic Presses use hydraulics to
deliver a controlled force. Tonnage can vary from 20 tons to a
10,000 tons. Strokes can vary from 10 mm to 800 mm
Hydraulic presses can deliver the full power at any point in the
stroke; variable tonnage with overload protection; and
adjustable stroke and speed. Hydraulic presses are suitable
for deep-drawing, compound die action as in blanking with
forming or coining, low speed high tonnage blanking, and
force type of forming rather than displacement type of
forming.
Hydraulic Press
Mechanical Press
Sheet Metal Stamping
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Stamping presses and stamping dies are tools used to
produce high volume sheet metal parts. These parts
achieve their shape through the effects of the die
tooling.
Production stamping is generally performed on
materials .020” to .080” thick, but the process also can
be applied to foils as thin as .001” or to plate stock with
thickness' approaching 1.000”
Formability is the primary attribute of sheet metal
material. Formability is further defined as the materials
ability to be:
1. Bending
2. Stretching
3. Drawing
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The metallurgical term for these qualities is “ductility”.
Ductility is the materials ability to deform and elongate
without fracture. The extent to which a stamping is
subjected to such deformation is directly related to the
part’s overall shape and geometry. Other factors also
influence the material’s formability. They include:
1.
2.
3.
4.
5.
6.
The die design
The press
The press speed
Lubrication
Sheet metal feeding mechanisms
Monitoring and control systems
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The stamping manufacturing process in very capable of
high production runs. Depending on the complexity of the
part, and additional manufacturing steps ( progressive
stamping ) required for the final part, will drive the effective
cost-per-part of stamping manufacturing. Typical stamping
speeds do vary, however many high production stamping
manufacturers are capable of 30 to 80 stamping stokes
per minute. The main process followed in stamping
production are as :
1. Blanking
2. Drawing
3. Forming
4. Machining
5. Piercing
Blanking
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Blanking is cutting up a large sheet of stock into smaller
pieces suitable for the next operation in stamping, such
as drawing and forming. Often this is combined with
piercing.
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Blanking can be as simple as a cookie cutter type die to
produce prototype parts, or high speed dies that run at
1000+ strokes per minute, running coil stock which has
been slit to a specified width.
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For production parts, the final configuration of the drawn
or formed shape needs to be established before the
blank die can be built-since the blank size and the slit
width size needs to be established precisely.
Blanking
Drawing
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In drawing, a blank piece of sheet metal is restrained at
the edges, and the middle section is forced by a punch
into a die to stretch the metal into a cup shaped drawn
part. This drawn part can be circular, rectangular or just
about any cross-section.
Drawing can be either shallow or deep depending on the
amount of deformation. Shallow drawing is used to
describe the process where the depth of draw is less than
the smallest dimension of the opening; otherwise, it is
considered deep drawing.
Drawing leads to wrinkling and puckering at the edge
where the sheet metal is clamped. This is usually removed
by a separate trimming operation.
Drawing
Forming
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Forming is similar to bending. Complex parts such as Usections, channel sections of different profiles can be
produced by doing multiple bends.
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There is no change in thickness. Good dimensional
repeatability as well as close tolerances is possible with
this process.
Forming
Machining
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Machining is consisting of many different processes such
as Drilling, tapping, counterboring, and countersinking.
They are as following :
Drilling: Drilling is done in sheet metal only when piercing
cannot deliver the accuracy required. For example, on a
formed part, when holes on different features need to be
coaxial, the accuracy obtained by machining may be
required.
Tapping: Tapping can be done using cut threads or
formed threads. Formed threads (thread rolling) is
preferable for the following reasons :
Thread rolling is faster than cutting.
2. Fewer burrs are generated, so no clean up is required or
risk of future hazards such as shorting with electronic
components.
3. Larger sized holes are required for thread rolling vs.
tapping, resulting in improved tap life.
4. Rolled threads are stronger due to cold working.
Typically, rolled threads are 20% stronger than cut
threads.
5. For very thin stock, either threaded fasteners such as
clinch nuts, or forming thread in extruded holes is
recommended.
OR
1. The material is upset in the sheet metal hole to form one
thread pitch.
1.
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Counterboring: Counterboring is often done to provide
clearance and a bearing surface for the fastener's head.
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Countersinking: Countersinking allows for flush
mounting of flat head fasteners. Countersinking cannot
always be done for very thin stock or for very large
fasteners.
Piercing
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Piercing is the operation of cutting internal features (holes or slots) in
stock. Piercing can also be combined with other operations such as
lance and form (to make a small feature such as tab), pierce and
extrude (to make an extruded hole). All these operations can be
combined with blanking.
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Piercing of all the holes is best done together to ensure good hole-tohole tolerance and part repeatability. However if the material distorts,
the method described below can be done.
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When there are large numbers of holes, in a tight pitch, there could be
distortions, due to the high amount of tension on the upper surface due
to stretching and compression on the bottom surface. This causes the
material not to lay flat. This can be avoided/lessened by staggering the
piercing of the holes. Holes are punched in a staggered pattern; then
the other holes are punched in the alternate staggered pattern.
Piercing
Thank You !!!