Industrial Training Report at Mahindra CIE PDF

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INDUSTRIAL TRAINING REPORT A Training Report At MAHINDRA CIE AUTOMOTIVE LTD MANGAON In partial fulfilment for the requirement of the B.TECH In MECHANICAL ENGINEERING Submitted By: 1. AMBEKAR AKSHAY PRAKASH (10303320171161210044) 2. MANDVADE SACHIN RAJENDRA (10303320171161210024) 3. SONAVALE RAJESH SURESH (10303320171161213010) 4. SALVI ATHARVA RAJKUMAR (10303320171161213002)

MECHANICAL ENGINEERING DR. BABASAHEB AMBEDKAR TECHNOLOGICAL UNIVERSITY, LONERE

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Certificate This is to certify that the project entitled INDUSTRIAL TRAINING Submitted by, 1. AMBEKAR AKSHAY PRAKASH (10303320171161210044) 2. MANDVADE SACHIN RAJENDRA (10303320171161210024) 3. SONAVALE RAJESH SURESH (10303320171161213010) 4. SALVI ATHARVARAJKUMAR (10303320171161213002) is a record of bonafied work carried out by them under my guidance in the fulfilment of the requirement for the Award of B.Tech in Mechanical Engineering Course of Dr. Babasaheb Ambedkar Technological University in the Academic year 2017-18.

Date:-

Mr.

Place: Mahindra composites LTD (mangaon).

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ACKNOWLEDGEMENT We would like to express our sincere thanks to Mr.kharangte, Mr. Sujay Jadhav, Mr.D.S.Shinde, Mr.Navagne, Mr. Kothekar, Mr. avinash Sahasrabuddge, Mr.mukesh Patil, Mr. Sadanand Joshi under whose valuable guidance and light of knowledge, we could complete this project and for his constant encouragement and valuable guidance during the completion of this project work. We take this opportunity to thanks this all staff members for their help whenever required. Finally, we express sincere thanks to all those who helped us directly or indirectly in many ways in completion of this project Work.

1. AMBEKAR AKSHAY PRAKASH (10303320171161210044) 2. MANDVADE SACHIN RAJENDRA (10303320171161210024) 3. SONAVALE RAJESH SURESH (10303320171161213010) 4. SALVI ATHARVARAJKUMAR (10303320171161213002)

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OVERVIEW Founded in 1945 as steel trading company, Mahindra’s group entered automotive manufacturing In 1947.it then brought the iconic Willys jeep on Indian roads. Over the years, it has diversified into many new businesses. The best of entrepreneurial independence and group-wide Synergies. The Mahindra group focuses on enabling people to rise through solutions that power mobility, drive rural prosperity, enhance urban lifestyles and increase business efficiency. A USD 15.9 billion multinational group based in Mumbai, India, Mahindra employs more than1555,000 people in over 100 countries. Mahindra operates in the key industries that drive economic growth, enjoying a leadership position in tractors, utility vehicles, and information technology and vacation ownership. In addition, Mahindra enjoys a strong presence in the agribusiness, aerospace, components, consulting services, defence, energy, financial services, industrial equipment, logistics, real estate, retail, steel and two wheeler industries. In 2012, Mahindra featured on the Forbes global 2000 list, a listing of the biggest and most powerful listed companies in the world.

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VISION

Largest manufacturer of SMC and DMC in India

MISSION Continuously meet the increasing expectations of internal and external customer

HISTORY Page 5 of 34

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A tie-up from 1983-1994 with Menzolit GmbH of Germany, the largest manufacturer of Composites in Europe, brought in advanced technology addressing manufacturing formulations, Manufacturing processes, application engineering and mould design cycles. Today, Mahindra composites prides itself on its capabilities in implementing flexile technology solutions to meet customer requirements through:

 The usage of specific types of reinforcements to service individual demands, such as Chopped glass roving, chopped strand mats, continuous roving, woven roving, synthetic Fibres and other such materials  A judicious choice of matrix materials  Customer-specific manufacturing cycles  A continued search for new applications for the company’s range of products  Committed efforts to develop superior components  Sustaining these

CUSTOMERS Page 6 of 34

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Auto:      

Tata Engineering& Locomotive Co. Ltd Ashok Leyland Ltd. TVS Suzuki Ltd Swarajmazda Ltd. Mahindra Volvo

Electrical:            

L&T Schneider siemens Controls &switchgear’schneider’ Schneider Siemens ABB Legrand, BHEL ABB GE power control Datarswochgear General electric Legrarnd MDS

Others:  GE Medical system India  Philips India

Sheet moulding compound Sheet moulding compound (SMC) or sheet moulding composite is a ready to mould glass-fibre Reinforced polyester material primarily used in compression moulding. The sheet provided in rolls weighing up to 5060 kg.

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INDUSTRIAL TRAINING REPORT SMC is both a process and reinforced composite material. This is manufactured by dispersing long strands (>l”) of chopped glass fibres on a bath of polyester resin. The longer glass fibres in SMC result in better strength properties than standard bulk moulding compound (BMC) products.

Process: Paste reservoir dispenses a measured amount of specified resin paste onto paste carrier film. This carrier film passes underneath a copper, which cuts the glass roving onto the surface. Once these have drifted through the depth of resin paste, another sheet is added on top, which sandwiches the glass. The sheet are compacted and then enter onto a takeup roll, which is used to store the product whilst to matures. The carrier film is then later removed and the material is cut into charges. Depending on what shape is required determines the shape of the charge and steel die which it is then added to. Heat and pressure act on the charge and once fully cured, this is then removed from the mould as the finished product.

Advantages 1. Compares to similar methods, 2. SMC benefits from a very high volume production ability. 3. excellent part reproducibility, Page 8 of 34

INDUSTRIAL TRAINING REPORT 4. It is cost effective as low labour requirements per production level in component shop is very good and industry scrap is reduced substantially. 5. Weight reduction, 6. Due to more dimensional and the ability to consolidate many parts into one, is advantageous. 7. The level of flexibility also exceeds many counterpart processes

Dough moulding compound Dough moulding compound (DMC) or bulk moulding composite is a ready to mould, glass-fibre reinforced polyester material primarily used in injection moulding and compression moulding. The material is provided in or logs. DMC is manufactured by mixing strands (>l”) of chopped glass fibre in a mixer with polyester resin. The glass fibre in DMC result in better strength properties Page 9 of 34

INDUSTRIAL TRAINING REPORT than standard thermoplastic products. Typical appliance, automotive, and transit

Hand lay- up process It is the basic form of moulding process and it is most economical. A pattern of product to be manufactured is made to exact dimension. Using this mould is made. It is generally made by hand lay-up process. Jell coat is applied on required finished surface of mould. Glass made is laid over it. A homogeneous mixture of risen and binder applied over the matt with the brush.

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Advantages 1. Cooling cost is less 2. It is most economical process for low cost moulding 3. Best low volume of production

Compression Moulding Compression moulding process is one of the low cost moulding methods as compared to injection moulding and transfer moulding. It is a high pressure forming process in which the molten plastic material is squeezed directly into a mould cavity by the application of heat and pressure to conform to the shape of the mould. The schematic of compression moulding process is shown in figure

Working Principle:In this process, the predetermined amount of charge of plastic material is placed in the lower half of a heated mould cavity. The plastic material is preheated before inserting into the mould cavity to reduce the temperature difference between the material and the mould cavity. The mould cavity is closed with upper movable half mould and pressure is applied to compress the material in to the mould cavity. This causes the raw material to be squeezed out to take the shape of the mould cavity. The application of the heat and pressure increases the polymerization process. Hence, plastic material is cured. The temperature of the mould cavity is usually in the range of 130Page 11 of 34

INDUSTRIAL TRAINING REPORT 200°C. Generally, the hydraulic pressure is required in the range of 725 MPa to squeeze the plastic material. The mould cavity is then cooled for sometimes so that moulded plastic part gets solidified. The mould cavity is then opened and the final product is taken out with the help of ejector pin. The moulded part may require the finishing operation. In compression moulding, the charge of plastic material may be inserted into the mould cavity either as a powder, granules or as a preformed. The manufacturing cycle time (heating, cooling, and part ejection) may be long (about 1-6 minutes). For high production rate, it is desirable to have multi cavity moulds. Compression mould cavity can also be available in a wide variety of shapes and sizes; therefore plastic products can be manufactured into different shapes and sizes. There are four important factors to be considered before compression moulding process: 1. 2. 3. 4.

Amount of plastic material (charge) Heating time and melting temperature of plastic material Pressure required to squeeze the material in to the mould cavity Cooling time

Two different types of moulding compounds i.e. bulk moulding compound (BMC) and sheet moulding compound (SMC) are commonly used in compression moulding process. In bulk moulding compound, the plastic materials are blended with fillers and short fibres and placed into the mould cavity. In SMC, the long fibre sheet is usually cut according to the mould cavity and placed into the mould surface. The resin is placed on the fibre sheet. It is a layer-by-layer making process. The process is completed until desired thickness is obtained. The long fibre sheet results in better mechanical properties as compared with the bulk moulding compound products. In both the moulding compounds (BMC and SMC), the plastic materials are conformed to the mould cavity, with the application of heat and pressure.

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Compression moulding setup

Materials Used Different types of thermosets and thermoplastics materials can be used for compression moulding process. For example: Epoxies, Urea formaldehyde (UF), Melamine formaldehyde (MF), Phenolics (PF), Polyester, Polyamide (PI), Polyamide-imide (PAI), Polyphenylenesulfide(PPS), Polyether-etherketone (PEEK), Torlon, and Vespel.

Applications Compression moulding process is used for manufacturing electrical and electronic equipments (electrical wall receptacles, circuit breakers, television cabinets, radio cases, electric plugs and Page 13 of 34

INDUSTRIAL TRAINING REPORT sockets, electrical switch, fuse box, electricity meter housing), brush and mirror handles, trays, cookware knobs, clothes dryer blower fan blade, cooking utensils, milling machine adjustment wheel, water testing equipment buttons, dinnerware, appliance housings, aircraft main power terminal housing, pot handles, dinnerware plates, automotive parts (such as hoods, fenders, scoops, spoilers, gears), flatware, buttons, buckles, and large container. Compression moulding is also suitable for heavy moulding applications.

Advantages The advantages of the compression moulding process are as following: 1. 2. 3. 4. 5. 6.

Low initial setup costs and fast setup time Heavy plastic parts can be moulded Complex intricate parts can be made Good surface finish of the moulded parts Wastes relatively little material as compared with other methods The moulding process is cheaper as compared to injection moulding

Disadvantages The disadvantages of the compression moulding process are as following: 1. Low production rate 2. Limited largely to flat or moderately curved parts with no undercuts

Resin transfer moulding Resin transfer moulding is a closed moulding process. In this technique, as the name indicates, resin is transferred over the already placed reinforcement. Reinforcement in terms of either woven mat or strand mat form is placed on the surface of lower half mould. A

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INDUSTRIAL TRAINING REPORT release gel is applied on the mould surface for easy removal of the composite. The mould is properly closed and clamped. The clamping can be done either perimeter clamping or press clamping mechanism. The resin is pumped into the mould through ports and air is displaced through other vents. The uniformity of resin flow can be enhanced by using a catalyst as an accelerator and vacuum application. After curing, the mould is opened and composite product is taken out. The schematic of resin transfer moulding process is shown in figure 1. Resin transfer moulding can incorporate soft or hard mould depending upon the expected duration of run. For soft mould, thermosetting polymers like epoxy and polyester can be used for moulding material. For hard mould, materials like steel and aluminium can be used. The cost of mould varies from very low to high cost mould with short to long life moulds. The process can be automated to reduce cycle time. For complex shapes to be produced, preformed fibre reinforcements are used. The viscosity of the resin plays an important role in resin transfer moulding process because injection time depends upon viscosity of the resin. If viscosity of resin is high, high pressure is required which may cause displacement of fibres, known as fibre wash.

Resin transfer moulding.

Important components of resin transfer moulding process: There are mainly five components in the resin transfer moulding system, which govern the processing of composites. These components are: 1. Resin and catalyst container Page 15 of 34

INDUSTRIAL TRAINING REPORT 2. Pumping unit 3. Mixing chamber 4. Resin injector 5. Moulding unit There are two separate containers for resin and catalyst. Resin container is larger than the catalyst container. Both the containers have separate outlets that pass through pumping unit and opens in mixing chamber. Pumping unit transfers the resin and catalyst to the mixing chamber. Resin and catalyst is mixed thoroughly in the mixing chamber. Resin injector is used to inject the mixture to the mould cavity. Moulding unit has two halves namely upper half mould and lower half mould. Heating arrangement is integrated with moulding unit. Vents are provided to release the gases in the mould cavity during clamping.

Applications:1. Hollow shapes and complex structure can be produced. 2. Automotive body parts, big containers, bathtubs are commonly

processed through resin transfer moulding technique.

Advantages: 1. Composite part produced with this method has good surface finish on both side surface of the product. 2. Any combination of reinforced materials (including 3D) in any orientation can be achieved. 3. Fast cycle time can be achieved through temperature control tooling device. 4. Process can be manual control, semi-automated or highly automated.

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INDUSTRIAL TRAINING REPORT 5. Composite part thickness is uniform which is determined by the mould cavity. 6. There is low emission during composite processing. 7. Strict dimensional tolerances are possible to achieve. 8. Ability to incorporate inserts and other attachments into mould. 9. The process does not require high injection pressure. 10. Material wastage is reduced as near net shape parts are produced. 11. Higher production rate is associated with process automation.

Disadvantages: 1. Mould cavity limits the size of the composite. 2. High tooling cost. 3. There is limitation on reinforcing materials due to the flow and resin saturation.

A) Barcol hardness test The Barcol test hardnessCharacterizes the indentation hardness of materials through the depth of penetration of an indentor, loaded on a material sample and compared to penetration in a reference material. The method most often used for composite materials such as reinforced thermosetting resins or to determine how much resin or plastic has cured. The test complements the measurement of glass transition temp. as an indirect measure of degree of cure of composite. It is inexpensive and quick, and provides information on the cure throughout a part

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B) Charpy impact test The charpy impact test, also known as the charpy V- notch test, so a standardized high strain rate test which determine the amount of energy absorbed by a material during fracture .this absorbed energy is measure of a lot a given material’ notch toughness and acts an tool to study temperaturedependent ductile transition . It is widely applied in industry, since it is easy to prepare and conduct and results can be obtained quickly and charpy. A disadvantage is that some result are only comparative. The test was developed around 1900 by S.B.RUSSEL (1898, American) and G charpy (1901,French). The test become now as the charpy test in the early 1900s Page 18 of 34

INDUSTRIAL TRAINING REPORT due to the technical contribution and standardization efforts by Georges charpy. The test was pivotal in understanding the fracture problems of sheets during WW II .today it is used In many industries for testing materials used in the construction or pressure vessels and bridge and to determine how storms will affect materials use in them.

C) Heat deflection temperature The heat deflection temperature or heat distortion temperature (HDT, HDTUL,or DTUL) is the temperature at which a polymer or plastic sample deforms under a specified load.

DETERMINATION The heat distortion temperature is determined by the following test procedure outline in ASTM D684. The test specimen is loaded in three – point bending in edgewise direction. The outer fibre stress used for testing is either 0.455Mpa, and the temperature is increased at 20C/min until the

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INDUSTRIAL TRAINING REPORT specimen deflects 0.25mm .This is similar to the test procedure defined in the ISO 5 standard.

D) Dry Arc resistance Testing Machine This machine is designed to with ASTM D495 standard for Dry Arc Resistance Testing of electrical insulating materials. All the seven cycles mentioned in the above ASTM standard are implemented in the machine it also has an additional feature to turn OFF the test automatically after a conducting path is formed. This feature can be used while testing insulating materials that fail by forming a conducting path,

A Brief Description of the test: Page 20 of 34

INDUSTRIAL TRAINING REPORT This test the electrical insulating material by exposing it to Arcing under high voltage the test specimen is placed under electrodes that are spaced at a specified distance (6.35mm or ¼ inch). In addition, an Arc is generated between these electrodes. The test consists of 7 cycles starting from cycle 1. As the cycles progress the test becomes progressively harsher. The test specimen that have lower insulating strength fail earlier in the first few cycles while those with higher insulating strengths endu...