INDUSTRIAL TRAINING REPORT

(SEMESTER VI) (2011) AT

SEBROS GROUP (PLANT III) NOIDA, DEHLI

SUBMITTED IN PARTIAL FULFILLMENT OF BACHELOR OF ENGINEERING (MECHANICAL ENGINEERING)

NAME OF STUDENTS :- Animish Shukhwal

YEAR : III (VI SEM)

UNIVERSITY: SIR PADAMPAT SINGHANIA UNIVERSITY ,UDAIPUR

PLACE OF TRAINING: SPSU CHAMPUS

PERIOD: FROM 02 JUNE TO 23 JUNE 2011

DURATION: 4 Weeks

FIELD OF TRAINING:- MODEL DESIGNING IN PRO-E WILDFIRE 5.0

CERTIFICATE

This is to certify that the project entitled ___________________________ _______________________________________________________ is the bonafide work carried out by Animish Sukhwal , Chandra Shekar Sahu, Patel Parth , Preethish Guha , Suresh Chandra Dangi students of [Link] ,Sir Padampat Singhania University, Udaipur , during the year 2010-2011, in partial fulfillment of the requirements for the award of the Degree of Bhacelor of Mechanical Engineering and that the project has not formed the basis for the award previously of any program, diploma, associateship, fellowship or any other similar title.

Signature of the Guide :

Place: Date:

ACKNOWLEDGEMENT

The languauge of conscience has never been exactly translated into words and we are facing the same dilemma while expressing our feelings. Firstly I would like to express my sincere gratitude indebtness to Mr. Naveen Kumar (Head of Department, Mech. , SPSU), for allowing us to undergo the industrial visit and project . No gratefulness and indebtness would match exposition if endeavored to show my deep sense of respect and reverence to Mr. Anuj Saxena(Director-EXXON Engineering services Pvt. Ltd.) , Ms. Hemlata Bhaskar (Director-EXXON Engineering services Pvt. Ltd.) and Mr. Deepak bal(Aditya Infotech Ltd) who permitted us to have a visit under their able hood. The instrument of acknowledgement will remain off tune if we will not thank the whole team of Sebors Ltd. We are also thankful to the institution for providing us all the facilities as and when required through the congenital atmosphere. We are sincerely thankful to our project guides (Mr. Deepak Paliwal, Mr. Umesh Mishra , Mr. Ranjan Basak and Mr. Tingarkar Goverdhan) for providing us necessary guidance as per project requirements. At last we express my thanks to EXXON Engineering services Pvt. Ltd , Aditya Infotech Ltd. and Sebros Ltd for cooperating us during training period and also for giving the most valuable and practical lessons , dedication and sincerity .We also want to thanks our classmates who also helped us for the completion of the project.

Animish Sukhwal Chandra Shakher Sahu Parth Patel Kumar Preethish Guha Suresh Chandra Dangi

TABLE OF CONTENT

PART 1 (INDUSTRIAL VISIT)

PART 2 (PROJECT)
1. INTRODUCTION :
2. OBJECTIVE

3. SCOPE AND LIMITATIONS OF PROJECT

5. PROJECT DESIGN AND ASSEMBLY 6. CONCLUSION

INDUSTRIAL VISIT
Industrial visit is a part of the engineering course, during which students visit companies and get insight of on the internal working environment of the company. The industrial visit also provides an insight on how companies work and also useful information related to the practical aspects of the course which cannot be visualized in lectures. 1. INTRODUCTION Date of visit : 3-4 June , 2011 Visit to: Aditya Infotech Ltd. ,Sebros Group ( Noida , Plant III) 1.1 The Background

ADITYA INFOTECH LTD. Aditya Group is a 100% Family Owned Group and has over 100 year of business experience in Newsprint (Paper & Pulp), Computer Hardware / Software, Media & Entertainment Products, Household Products, Textiles & Real Estate Business. The group comprises of following group companies to handle its varied businesses. Group companies 1. Newsprint Sales Corporation Newsprint, Paper & Pulp. 2. Aditya Promoters Ltd House Hold Products & Crystal Glassware Products. 3. Aditya Infotech Ltd Computer Hardware / Software, Media & Entertainment, Audio/Video, Broadcast, Post Production solutions, etc. EXXON ENGINEERING SERVICES PVT. LTD. Exxon is a dynamic global technology services company delivering strategic end-to-end engineering & documentation solutions. Exxon has established a State-of-the-art Engineering Center in India for executing projects on the QCD (Quality, Cost effectiveness & Delivery) model that boasts of expert groups, engineering domains combined synergistically with

collaboration project management & quality processes. Exxon has team of design engineers working for our customer base spread across USA, UK & India belonging to the Industrial Machinery, Machine Tools, General Engineering, Material Handling, Mining & Yellow line Equipment manufacturing, Transportation, Aerospace, Automotive segments. They offer their customers a host of Engineering / CAD / CAM / CAE and TCT services. They offer:-

Software Solutions

Engineering Services

Training

Placement Services

SEBROS GROUP LTD. Beginning with the manufacturing of LP Gas Pipe Assemblies for domestic gas stove in 1983, Sebros today is a conglomerate of seven plants manufacturing over 2000 different tubular components and fabrication assemblies for leading automotive manufacturers in the country. They also have strong Customer base overseas and the products are exported to leading OEMS in Europe, North America & South America. Founded in 1983 by Mr.S. L. Sethi, a self-made industrialist, Sebros, as one of the Leading names in the Automotive Tubing Components today, employs the best brains in the field. The company gives special focus to human resource development and has fostered a work culture wherein the individuality of people is respected. Sebros has built stateof-theart facilities to design the products and their tooling using the latest CAD techniques including 3D modelling. Our modern manufacturing facilities ensure that the production process is speedy and the time taken to launch new products is minimum.

1.2 The company and its product line

Aditya Group
One of the largest Indenters of all types of publication papers catering to the needs of most leading newspapers and magazines all over India & Nepal. Manufacturers & Exporters of Vacuum Flasks, Thermo wares & Household Products under Aditya Brand. The company is regularly importing Glassware products from PASABAHCE (Sisecam Group) Turkey and Saint Gobain, Brazil and are distributing them across India. Aditya Infotech Ltd. is a pioneer in introducing future technologies to the Indian market and is considered one of the best value-added distribution house with 25 own branch offices across the country.

SEBROS GROUP LTD

the demands of Automobile and Tractor industry. Accredited with ISO/TS 16949, this plant has ultra modern manufacturing facilities including fully computerized Induction Hardening Machines, CNC Pipe bending Machines MIG Welding Machines, Hydraulic Presses, Welding SPM and Leakage Testing Equipments. Main Products Side Impact Safety Beams Oil Strainers Radiator Pipes Guide Oil Level Gauge (Dip Stick Housing) Fuel Pipes Neck Components Fuel Filler Hydraulic Pipes

Plant-II

Started in 1994, this plant produces Tubular Seat Frame assemblies for

all major seating system manufacturers in India. Plant-II is accredited with ISO9002 and employs 100 people State-of-the-art facilities here include CNC Pipe Bending Machines, Twin Head pipe bending machines, MIG Welding, Projection welding Machines and Power Presses. Main Products Tubular Car Seat Frames Entertainment Seat Frames Plant-III an exclusive unit set up in 1998 for manufacturing of AC Pipes &

Hose Assemblies. A ISO/TS16949 certified unit, Sebros Plant-III has employee strength of 250. Today they manufacture a complete range of HVAC Pipes for automotive application. They also produce EGR component which are used in new generation diesel engines. Approximately 40% of sales revenues for this unit are generated through exports to global markets. Main Products AC Hose Assembly (Suction & Discharge Hose) End Connector for Hose Assembly Liquid Pipes EGR Components Hydro formed Tubular Parts

SD Auto Engineering 1 Till 1994, Sebros was known in automotive industry as a company manufacturing tubular components only. Diversification into new a machining, a key factor to achieve customer satisfaction and sustain growth, changed this [Link] Auto Engineering is ISO certified unit with employee strength of 250 peoples.

Main Products Housing Steering Rack Rack Steering Steering Locks Pitman Arms Column Assembly Collapsible shafts Collapsible Shaft Tubes

SD Auto Engineering 2 As a part of our diversification , SD engineering II was established in 2004, to manufacture Stamped & Tublar Assemblies for Fuel filters .This Unit produces Filter Cover assemblies & Supply to all major Filter Manufacturing units in India & Overseas. SD Engineering- II is a futuristic facility with equipments like Converiased Brazing Furnace, Vibro cleaning Machine, Pipe End forming Machine, Ultrasonic Cleaners & Differential Leak Testing Machines besides modern measuring equipments such as surface roughness Tester. SD Engineering- II is ISO/TS 16949 certified unit and has employee strength of 50. Main Products Fuel Filter Cover Fuel Filter Body With the intention of serving our esteemed customers more

Sebros Auto, Pune

efficiently and making our services available for other OEMS in western part of India, A new unit , Sebros Auto Pvt. Ltd was started in Pune in year 2006. Sebros Auto, Pune is an extension of Sebros Unit III where air conditioning pipes for automotive application are produced Sebros Auto Pune is ISO/TS 16949 certified unit the total

manpower of [Link] equipments at Sebros Auto, Pune include CNC Pipe Bending Machines, Pipe End Forming Machines, O Ring Groove Forming Machines, Hose Crimping Machines etc. SOME PRODUCTS

CLIENTS

[Link]
To help students fulfil certain curriculum requirements To provide a unique opportunity for students to gain an insight into a working environment related to a subject area. To help students develop their communication and inter-personal skills in the context of work. To help businesses promote their line of work.

As we are undergoing pro-e training the industrial visit will help us to relate the application of this software in the real world with a better [Link] will also help us to indentify , how different organizations are inter-related .

3. ACTIVITIES :-CNC Pipe Bending Machines, Pipe End Forming, O Ring Groove
Forming Machines, Hose Crimping, Hydro Forming Machines, Brazing Furnace & Differential Leak Testing Machines besides modern measuring equipments such as CMM/Profile Projector etc.

[Link]
From the visit we came to know different processes in the manufacturing of piping system in a automobile, one of the most fascinating is the hydro forming process. The use of CNCs also enriched our knowledge. We also came to know that how in a small area a lot of processes can be adopted.

PROJECT
1. INTRODUCTION Drafting or technical drawing is the means by which mechanical engineers design products and create instructions for manufacturing parts. A technical drawing can be a computer model or hand-drawn schematic showing all the dimensions necessary to manufacture a part, as well as assembly notes, a list of required materials, and other pertinent information. A mechanical engineer or skilled worker who creates technical drawings may be referred to as a drafter or draftsman. Drafting has historically been a two-dimensional process, but computer-aided design (CAD) programs now allow the designer to create in three dimensions. Creo Elements/Pro, a product formerly known as Pro/ENGINEER is a parametric, integrated 3D CAD/CAM/CAE solution created by Parametric Technology Corporation (PTC). It was the first to market with parametric, feature-based, associative solid modeling software. The application runs on Microsoft Windows and Unix platforms, and provides solid modeling, assembly modeling and drafting, finite element analysis, and NC and tooling functionality for mechanical engineers.

2.

PURPOSE

Aim:- To design a mechanical fixture for a tapping operation of the given tool. A fixture is a workholding or support device used in the manufacturing industry. What makes a fixture unique is that each one is built to fit a particular part or shape. The main purpose of a fixture is to locate and in some cases hold a workpiece during either a machining operation or some other industrial process. A jig differs from a fixture in that it guides the tool to its correct position in addition to locating and supporting the workpiece. The primary purposes of jigs and fixtures is to:

Reduce the cost of production Maintain consistent quality

Maximize efficiency Enable a variety of parts to be made to correct specifications Reduce operator errors

Types of Fixtures: General Purpose - They are usually relatively inexpensive and can be used to hold a variety and range of sizes of workpieces (examples: Vises, chucks, split collets). Special Purpose - They are designed and built to hold a particular workpiece for a specific operation on a specific machine or process. The fixture provided to us is a Special Purpose fixture which is used to hold the tapping fixture. Given workpiece:-

3. SCOPE AND LIMITATIONS OF PROJECT

The fixture to be designed, comes under Special purpose type of fixture, means a particular type of product can be produced in this fixture. Computer-Aided Design (CAD) is the use of wide range of computer-based tools that assist engineers in their design activities. It involves both software and special-purpose hardware. The capabilities of modern CAD systems include reuse of design components, ease of design modification and versioning, automatic generation of standard components of the design ,validation/verification of designs against

specifications and design rules, simulation of designs, finite element analysis and automated design of assemblies etc. Development in CAD results in real- time process simulation and Computer Numerically Controlled manufacturing. Integrating Computer-Aided

Manufacturing (CAM) with Computer-Aided Design systems which are the part of the CIM produces quicker and more efficient manufacturing processes. The design of the fixture can be modified according to the needs of the workpiece to be worked but with a limitation that it will remain Special purpose type of fixture. This fixture which is articulated ,similar kinds of fixture are being used industries. With the limitation of the size of the workpiece the size of the fixture also limits.

4. METHODOLOGY
Initially the dimensions of the workpiece are taken with the help of vernier calipers.

Then the fixture is designed with taking the dimensions into consideration.

THEN THE SLIDERS ARE DESIGNED FOR BOTH THE ENDS OF THE FIXTURE.

 THEN THE GUIDE IS DESIGNED FOR THE DRILL TO TAP IN.

THE BASE IS DESIGNED ON WHICH THE FIXTURE WILL REST.

THEN THE BOLTS ARE DESIGNED TO CLAMP UP THE FIXTURE ON BASE .

5. PROJECT DESIGN AND ASSEMBLY THE EXPLODED AND UNEXPLODED ASSEMBLY IS SHOWN BELOW.

6. CONCLUSION After designing the whole assembly we came to know the practical application of PRO-E in industry, and how it is being used in different manufacturing processes. We also came to know how theory and practical knowledge are interrelated .