KUMARAGURU COLLEGE OF TECHNOLOGY

Summer Internship Report

SUMMER INTERNSHIP PROJECT REPORT

Submitted by

[Link]

in partial fulfilment for the award of the degree of

BACHELOR OF ENGINEERING

in

ELECTRONICS AND COMMUNICATION ENGINEERING

KUMARAGURU COLLEGE OF TECHNOLOGY

(An Autonomous Institution affiliated to Anna University, Chennai)

Post Box No: 2034, Coimbatore - 641049

AUGUST 2025
 KUMARAGURU COLLEGE OF TECHNOLOGY,

COIMBATORE – 641 049

Department of ECE

BONAFIDE CERTIFICATE

INTERNSHIP

<24ECJ204>

Name : [Link]

Roll No : 24BEC142

Year : II Year

Branch : B. E – ECE

HoD / ECE

Submitted for the Examination held on 30.08.2025.

Expert Member 1 Expert Member 2

Declaration by the student
I, [Link], a student of at Kumaraguru College of Technology,Coimbatore, hereby declare that the
internship report entitled “Industrial Exposure in degating and fettling solutions” is an original work
conducted and prepared by me under the guidance of Mr. Chandrasekaran,Managing director, at Sri
vivegha engineering pvt Ltd,during June 2025 internship period. This document is submitted in
partial fulfillment of the requirements for the degree of Electronics and communication engineering
at kumaraguru college of technology.

I hereby certify that the information presented in this report is true and accurate to the best of my
knowledge and belief.

Date: 30.08.2025
Place: coimbatore

Signature: _____________________

[Link]
About Company/Industry

Sri Vivegha Engineering Pvt. Ltd., which is headquartered in Coimbatore, deals with
automation and engineering solutions for foundries. With the motto of offering safe,
efficient, and reliable degating and fettling systems, the company has emerged as a reliable
partner for many foundries in India.

The company deals mainly with:

Degating solutions - taking out excess metal and gates from castings via automated cutting
systems.

Fettling solutions - grinding, deburring, and finishing processes for cast pieces.

Robotics and Automation - robotic arms mounted with grinding equipment to eliminate
manual fettling.

Quality assurance achievement of defect-free castings with sophisticated inspection

techniques.

Their solutions have minimized manual effort, ensured uniformity, and improved worker
safety, which are significant issues in traditional foundry operations.

Table of Contents

Introduction

Formal Training Provided

Industrial Training

Objectives

Tools & Technology Used

Techniques Studied

Software and Tools

Daily Internship Work Summary

Problem Identification / Case Study

Learnings and Outcomes

References

Appendices:

Chapter 1. Introduction

Foundry is one of the oldest and most important manufacturing sectors, producing metal
castings for automotive, aerospace, defense, and heavy engineering industries. Two of the
key processes in foundries are degating, which involves removing runners, risers, and excess
material, and fettling, which includes finishing operations like grinding, deburring, and
polishing.

Traditionally, workers performed these tasks by hand using hammers, chisels, and portable
grinders. While effective, this method had several drawbacks:

Inconsistent quality depending on the skill of the operator.

High safety risks such as dust inhalation, injuries, and burns.

Low productivity compared to modern industry standards.

Sri Vivegha Engineering Pvt. Ltd. in Coimbatore has pioneered automation and robotic
solutions to tackle these issues. Their machines combine mechanical equipment, robotics,
sensors, and control systems to achieve:

Greater accuracy and finishing standards.

Reduced fatigue and injuries for operators.

Faster production speeds.

Implementation of Industry 4.0 principles.

My internship focused on learning about these industrial practices, examining the use of
electronics, automation, and robotics in modern fettling solutions, and connecting the
theoretical knowledge of ECE concepts like PLC, sensors, and control systems with practical
industrial applications.

Chapter 2. Formal Training Provided

Before gaining hands-on experience, I completed a formal induction program during the
first week. The training included classroom sessions as well as floor visits.

2.1 Safety Training

The importance of PPE (Personal Protective Equipment): helmets, gloves, masks, and ear
protection.

Operation of CNC and robotic machinery.

Emergency procedures for fire, electrical failure, and mechanical hazards.

2.2 Foundry Process Orientation

Casting Fundamentals: preparing the mold, pouring molten metal, cooling, and
solidification.

Degating: techniques for removing unwanted gates and risers.

Fettling: operations including grinding, trimming, polishing, and deburring.

2.3 Introduction to Automation Tools

Robot arms for grinding and trimming.

CNC-controlled grinding machines.

PLC-based automation systems for sequence control.

Sensors used to detect defects and ensure quality.

2.4 Advantages of the Training

This training gave me a solid understanding of industrial workflow, hazard management,
and how automation fits into manufacturing.

Chapter 3. Industrial Training

This phase was the core of my internship. I gained hands-on experience with degating and
fettling machinery, tools, and technologies.

3.1 Training Objectives

To learn about automation as a replacement for manual fettling.
To understand the integration of mechanical and electronic systems in industrial equipment.

To experience real-time quality control processes.

To connect ECE principles such as PLCs, control systems, and sensors to industrial
applications.

3.2 Tools & Technology Used

Robotic Arms: six-axis robots programmed for cutting, grinding, and polishing.

CNC Machines: for precise and repeatable fettling operations.

Pneumatic Tools: for high-speed degating.

Vision Sensors: for measuring casting dimensions and alignment.

PLC Controllers: used for automation sequences and machine integration.

3.3 Department-Wise Training

Design Department
I became familiar with AutoCAD and SolidWorks models of fettling machines.
I learned how customized designs are created based on the size and type of casting.
I viewed 3D models of robotic work cells.

Production Department

I studied various fettling techniques: grinding, trimming, deburring, and polishing.

I understood the workflow of degating machines.

I observed the differences between manual and robotic fettling.

Automation Department
I learned the basics of PLC ladder logic programming.

I learned how to program robot arms for individual operations.

I grasped the role of sensors and actuators in achieving precision.

Quality Assurance Department

I checked the dimensions of castings using gauges.

I examined visual and surface flaws.

I learned how automated systems can minimize defects.

Chapter 4. Summary of Daily Internship Work

Week 1. Induction & Observation

I was introduced to the company and went through a safety induction.

I familiarized myself with casting, degating, and fettling operations.

I observed the differences between manual and automated fettling.

Week 2. Tools and Machines for Learning

I was introduced to CNC fettling machines.
I observed the pneumatic cutters for degating.

I had a practical demonstration of operating a PLC-controlled machine.

Chapter 5. Problem Identification / Case Study

Problem Statement

Hand fettling is unsafe, inconsistent, and time-consuming. The goal was to evaluate how
robotic fettling could resolve these issues.

Observation

Hand fettling takes around 15-20 minutes per component.

Robotic fettling reduces the cycle time to about 8-10 minutes per component.

Defect rejection rates decreased by 30% with robotic fettling.

Solution Proposed
Use of six-axis robotic arms for consistent grinding.

Incorporation of vision sensors for autonomous defect detection.

Addition of dust collection and safety enclosures to improve operator safety.

Impact

Productivity increased by 40%.

Safety risks were significantly reduced.

Surface finish quality improved noticeably.

Chapter 6. Learnings and Outcomes

Technical Learnings
I learned the fundamentals of PLC ladder logic programming.

I explored the use of sensors in automation, including proximity, vision, and vibration
sensors.

I understood how to integrate mechanical and electronic systems.

I applied robotics in heavy industries.

Industrial Awareness

I recognized the importance of safety and quality standards.

I experienced Industry 4.0 automation in real time.

I learned about the design, production, and inspection processes.

Personal Growth

I improved my communication skills through interaction within the industry.

I developed the ability to apply theoretical knowledge to practical settings.

I built confidence in a professional work environment.