Summer Industrial Training Report

Lifelong India Pvt. Ltd. (Dharuhera)

SUBMITTED TO SUBMITTED BY
Mr. Anil Punia Pankaj Kumar

Asst. Prof.mech. dept. Roll No. 14ME65

Department of Mechanical Engineering

RPS GROUP OF INSTITUTIONS, SATNALI ROAD,
MAHENDRAGARH, (HARYANA)
 Safety precautions
Keep this manual where the operator can easily
find them.

Read this manual attentively before starting up the

unit.

For safety reason the operator must read the

following cautions carefully.

This manual classifies precautions into WARNING

and CAUTION. Be sure to follow all precautions
below: they are all important for ensuring safety.

WARNING
In order to avoid fire, explosion or injury, do not
operate the unit when harmful, among which
flammable or corrosive gases, are detected near the
unit.

It is not good for health to expose your body to the

air flow for a long time.
 Do not put a finger, a rod or other objects into the
air outlet or inlet. As the fan is rotating at a high
speed, it will cause injury.

Do not attempt to repair, relocate, modify or

reinstall the air conditioner by yourself. Incorrect
work will cause electric shocks, fire etc.
For repairs and reinstallation, consult your Daikin
dealer for advice and information.

The refrigerant used in the air conditioner is safe.

Although leaks should not occur, if for some reason
any refrigerant happens to leak into the room, make
sure it does not come in contact with any flame as of
gas heaters, kerosene heaters or gas range.

If the air conditioner is not cooling (heating)

properly, the refrigerant may be leaking, so call your
dealer.
When carrying out repairs accompanying adding
refrigerant, check the content of the repairs with our
service staff.

Do not attempt to install the air conditioner by your

self. Incorrect work will result in water leakage,
electric shocks or fire. For installation, consult the
dealer or a qualified technician.
 In order to avoid electric shock, fire or injury, if you
detect any abnormally such as smell of fire, stop the
operation and turn off the breaker. And call your
dealer for instructions.

Depending on the environment, an earth leakage

breaker must be installed. Lack of an earth leakage
breaker may result in electric shocks or fire.

The air conditioner must be earthed. Incomplete

earthing may result in electric shocks. Do not
connect the earth line to a gas pipe, water pipe,
lightning rod, or a telephone earth line.

CAUTION
In order to avoid any quality deterioration, do not
use the unit for cooling precision instruments, food,
plants, animals or works of art.

Never expose little children, plants or animals

directly to the air flow.

Do not place appliances which produce open fire in

places exposed to the air flow from the unit or under
the indoor unit. It may cause incomplete combustion
or deformation of the unit due to the heat.

Process Involved in the Company

1. PLASTIC INJECTION MOLDING PARTS AND

ASSEMBLIES

2. ALUMINUM PRESSURE DIE CASTING PARTS AND

ASSEMBLIES

3. MULTIPLE COMMODITY PARTS AND

ASSEMBLIES

Technology used in the company

1. R & D
2. Tool Room
3. Test Lab
 R&D

Research and development (R&D), also known

in Europe as research and technical (or technological)
development (RTD), is a general term for activities in connection
with corporate or governmental innovation. Research and
development is a component of Innovation and is situated at the
front end of the Innovation life cycle. Innovation builds on R&D
and includescommercialization phases.
The activities that are classified as R&D differ from company to
company, but there are two primary models, with an R&D
department being either staffed by engineers and tasked with
directly developing new products, or staffed with industrial
scientists and tasked with applied research in scientific or
technological fields which may facilitate future product
development. In either case, R&D differs from the vast majority of
corporate activities in that it is not often intended to yield
immediate profit, and generally carries greater risk and an
uncertain return on investment.

New product design and development is more often than not a

crucial factor in the survival of a company. In an industry that is
changing fast, firms must continually revise their design and
range of products. This is necessary due to continuous
technology change and development as well as other competitors
and the changing preference of customers. Without an R&D
program, a firm must rely on strategic alliances, acquisitions, and
networks to tap into the innovations of others.
A system driven by marketing is one that puts the customer needs
first, and only produces goods that are known to sell. Market
research is carried out, which establishes what is needed. If the
development is technology driven then R&D is directed toward
developing products that market research indicates will meet an
unmet need.
In general, research and development activities are conducted by
specialized units or centers belonging to a company, or can
be out-sourced to a contract research organization,universities,
or state agencies. In the context of commerce, "research and
development" normally refers to future-oriented, longer-term
activities in science or technology, using similar techniques
to scientific research but directed toward desired outcomes and
with broad forecasts of commercial yield.
Statistics on organizations devoted to "R&D" may express the
state of an industry, the degree of competition or the lure
of progress. Some common measures include: budgets, numbers
of patents or on rates of peer-reviewed publications. Bank ratios
are one of the best measures, because they are continuously
maintained, public and reflect risk.
In the Unites States, a typical ratio of research and development
for an industrial company is about 3.5% of revenues; this
measure is called "R&D intensity". A high technology company
such as a computer manufacturer might spend 7%.
Although Allergan (a biotech company) tops the spending table
with 43.4% investment, anything over 15% is remarkable and
usually gains a reputation for being a high technology company.
Companies in this category include pharmaceutical
companies such as Merck & Co. (14.1%) orNovartis (15.1%), and
engineering companies like Ericsson (24.9%).[1] Such companies
are often seen as credit risks because their spending ratios are so
unusual.
Generally such firms prosper only in markets whose customers
have extreme needs, such as medicine, scientific instruments,
safety-critical mechanisms (aircraft) or high technology military
armaments. The extreme needs justify the high risk of failure and
consequently high gross margins from 60% to 90% of revenues.
That is, gross profits will be as much as 90% of the sales cost,
with manufacturing costing only 10% of the product price,
because so many individual projects yield no exploitable product.
Most industrial companies get 40% revenues only.
On a technical level, high tech organizations explore ways to re-
purpose and repackage advanced technologies as a way
of amortizing the high overhead. They often reuse advanced
manufacturing processes, expensive safety certifications,
specialized embedded software, computer-aided design software,
electronic designs and mechanical subsystems.
Research has shown that firms with a persistent R&D strategy
outperform those with an irregular or no R&D investment
program.
 Tool Room

1. Lathe Machine
2. Milling Machine
3. Drill Machine
4. Grinding Machine
5. Shaper Machine
6. CNC Lathe Machine
7. VMC Machine

Lathe Machine
Lathe is mother of all the machines

Working Principle:
The lathe is a machine tool which holds the work
piece between two rigid and strong supports called
centers or in a chuck or face plate which revolves.
The cutting tool is rigidly held and supported in a
tool post which is fed against the revolving work.
The normal cutting operations are performed with
the cutting tool fed either parallel or at right angles
to the axis of the work.
1. Bed: The bed is a heavy, rugged casting in which are
mounted the working parts of the lathe. It carries the
headstock and tail stock for supporting the work piece
and provides a base for the movement of carriage
assembly which carries the tool.
2. Legs: The legs carry the entire load of machine and are
firmly secured to floor by foundation bolts.
3. Headstock: The headstock is clamped on the left hand
side of the bed and it serves as housing for the driving
pulleys, back gears, headstock spindle, live centre and
the feed reverse gear. The headstock spindle is a hollow
cylindrical shaft that provides a drive from the motor to
work holding devices.
4. Gear Box: The quick-change gear-box is placed below
the headstock and contains a number of different sized
gears.
5. Carriage: The carriage is located between the
headstock and tailstock and serves the purpose of
supporting, guiding and feeding the tool against the job
during operation. The main parts of carriage are:
6. The saddle: The saddle is an H-shaped casting
mounted on the top of lathe ways. It provides support to
cross-slide, compound rest and tool post.
7. The cross slide : The cross slide is mounted on the top
of saddle, and it provides a mounted or automatic cross
movement for the cutting tool.
8. The compound rest: The compound rest is fitted on
the top of cross slide and is used to support the tool post
and the cutting tool.
9. The tool post: The tool post is mounted on the
compound rest, and it rigidly clamps the cutting tool or
tool holder at the proper height relative to the work
centre line.
10. The apron: The apron is fastened to the saddle and it
houses the gears, clutches and levers required to move
the carriage or cross slide. The engagement of split nut
lever and the automatic feed lever at the same time is
prevented she carriage along the lathe bed.
11. Tailstock: The tailstock is a movable casting located
opposite the headstock on the ways of the bed. The
tailstock can slide along the bed to accommodate
different lengths of work piece between the centres. A
tailstock clamp is provided to lock the tailstock at any
desired position. The tailstock spindle has an internal
taper to hold the dead centre and the tapered shank
tools such as reamers and drills.
 LATHE OPERATIONS
The engine lathe is an accurate and versatile machine on
which many operations can be performed. These
operations are:
1. Plain Turning and Step Turning
2. Facing
3. Parting
4. Drilling
5. Reaming
6. Boring
7. Knurling
8. Grooving
9. Threading
10. Forming
11. Chamfering
12. Filling and Polishing
13. Taper Turning

Milling Machine
Milling is the machining process of using rotary cutters to
remove material from a work piece by advancing
(or feeding) in a direction at an angle with the axis of the
tool. It covers a wide variety of different operations and
machines, on scales from small individual parts to large,
heavy-duty gang milling operations. It is one of the most
commonly used processes in industry and machine shops
today for machining parts to precise
 Drilling Machine
Introduction: The drilling machine or drill press is one of
the most common and useful machine employed in
industry for producing forming and finishing holes in a
workpiece. The unit essentially consists of:
1. A spindle which turns the tool (called drill) which can be
advanced in the workpiece either automatically or by
hand.
2. A work table which holds the workpiece rigidly in
position.
Working principle: The rotating edge of the drill exerts a
large force on the workpiece and the hole is generated.
The removal of metal in a drilling operation is by shearing
and extrusion.

Working Principle of Drill machine Sensitive Drill

Machine/Drill Press
Types of Drilling Machines: A wide variety of drilling
machines are available ranging from the simple portable to
highly complex automatic and numerically controlled
machines are as follows:
1. Portable drilling machine: It is a small light weight,
compact and self contained unit that can drill holes upto
12.5 rnrn diameter. The machine is driven by a small
electric motor operating at high speed. The machine is
capable of drilling holes in the workpieces in any position.
2. Sensitive drill machine/press: This is a light weight, high
speed machine designed for drilling small holes in light
jobs. Generally the machine has the capacity to rotate
drills of 1.5 to 15.5 rnrn at high speed of 20,000 rev/min.
Construction: The machine has only a hand feed
mechanism for feeding the tool into the workpiece. This
enables the operator to feel how the drill is cutting and
accordingly he can control the down feed pressure.
Sensitive drill presses are manufactured in bench or floor
models, i.e., the base of machine may be mounted on a
bench or floor.
The main operating parts of a sensitive machine/drill press
are Base, Column, Table, and Drill Head.
1. Base: The base is a heavy casting that supports the
machine structure; it provides rigid mounting for the
column and stability for the machine. The base is usually
provided with holes and slots which help to Bolt the base
to a table or bench and allow the work-holding device or
the workpiece to be fastened to the base.
2. Column: The column is a vertical post that Column
holds the worktable and the head containing the driving
mechanism. The column may be of round or box section.
3. Table: The table, either rectangular or round. Drill
machine/press in shape supports the workpiece and is
carried by the vertical column. The surface of the table is
90-degree to the column and it can be raised, lowered and
swiveled around it. The table can be clamp/hold the
required the workpiece. Slots are provided in most tables
to allow the jigs, fixtures or large workpieces to be
securely fixed directly to the table.
4. Drilling Head: The drilling head, mounted close to the
top of the column, houses the driving arrangement and
variable speed pulleys. These units transmit rotary motion
at different speeds to the drill spindle. The hand feed lever
is used to control the vertical movement of the spindle
sleeve and the cutting tool.
The system is called the sensitive drilling machine/press
as the operator is able to sense the progress of drill with
hand-faced.

Grinding Machine
A grinding machine, often shortened to grinder, is any of
various power tools or machine tools used for grinding,
which is a type of machining using an abrasive wheel as
the cutting tool. Each grain of abrasive on the wheel's
surface cuts a small chip from the workpiece via shear
deformation.
Grinding is used to finish workpieces that must show high
surface quality (e.g., low surface roughness) and
high accuracy of shape and dimension. As the accuracy in
dimensions in grinding is on the order of 0.000025 mm, in
most applications it tends to be a finishing operation and
removes comparatively little metal, about 0.25 to 0.50 mm
depth. However, there are some roughing applications in
which grinding removes high volumes of metal quite
rapidly. Thus, grinding is a diverse field.

Types of Grinding Machine

 A surface grinder.

A cylindrical grinder.
These machines include the:
Belt grinder, which is usually used as a machining method
to process metals and other materials, with the aid of
coated abrasives. Sanding is the machining of wood;
grinding is the common name for machining metals. Belt
grinding is a versatile process suitable for all kind of
applications like finishing, deburring, and stock removal.
Bench grinder, which usually has two wheels of different
grain sizes for roughing and finishing operations and is
secured to a workbench or floor stand. Its uses include
shaping tool bits or various tools that need to be made or
repaired. Bench grinders are manually operated.
Cylindrical grinder, which includes both the types that
use centers and the centerless types. A cylindrical grinder
may have multiple grinding wheels. The workpiece is
rotated and fed past the wheel(s) to form a cylinder. It is
used to make precision rods, tubes, bearing races,
bushings, and many other parts.
Surface grinder which includes the wash grinder. A
surface grinder has a "head" which is lowered to a
workpiece which is moved back and forth under the
grinding wheel on a table that typically has a controllable
permanent magnet for use with magnetic stock but can
have a vacuum chuck or other fixturing means. The most
common surface grinders have a grinding wheel rotating
on a horizontal axis cutting around the circumference of
the grinding wheel. Rotary surface grinders, commonly
known as "Blanchard" style grinders, have a grinding head
which rotates the grinding wheel on a vertical axis cutting
on the end face of the grinding wheel, while a table rotates
the workpiece in the opposite direction underneath. This
type of machine removes large amounts of material and
grinds flat surfaces with noted spiral grind marks. It can
also be used to make and sharpen metal stamping die
sets, flat shear blades, fixture bases or any flat and
parallel surfaces. Surface grinders can be manually
operated or have CNC controls.
Tool and cutter grinder and the D-bit grinder. These
usually can perform the minor function of the drill
bit grinder, or other specialist tool room grinding
operations.
Jig grinder, which as the name implies, has a variety of
uses when finishing jigs, dies, and fixtures. Its primary
function is in the realm of grinding holes and pins. It can
also be used for complex surface grinding to finish work
started on a mill.
Gear grinder, which is usually employed as the final
machining process when manufacturing a high-precision
gear. The primary function of these machines is to remove
the remaining few thousandths of an inch of material left
by other manufacturing methods (such as gashing or
hobbing).
Die grinder, which is a high-speed hand-held rotary tool
with a small diameter grinding bit. They are typically air
driven (using compressed air), but can be driven with a
small electric motor directly or via a flexible shaft.

VMC Machine
CNC vertical machining centers (VMCs) remain machine
shop staples. These milling machines have vertically
oriented spindles that approach workpieces mounted on
their table from above and commonly perform 2.5- or 3-
axis machining operations. They are less costly than
horizontal machining centers (HMCs), which makes them
attractive to small job shops as well as larger machining
operations. In addition, the performance of these
machines has increased over the years, leveraging
technologies such as high-speed spindles and advanced
CNC capabilities (including conversational control
programming). Ancillary equipment is also available to
increase the flexibility and capability of these machines,
including spindle speeders, angle heads, tool- and part-
probes, quick-change workholding devices, and rotary
indexers to enable four- or five-axis machining work.
 Die Casting
Die casting is a metal casting process that is characterized
by forcing molten metal under high pressure into a mould
cavity. The mould cavity is created using two
hardened tool steel dies which have been machined into
shape and work similarly to an injection mould during the
process. Most die castings are made from non-
ferrous metals,
specifically zinc, copper, aluminium, magnesium, lead, pe
wter and tin-based alloys. Depending on the type of metal
being cast, a hot- or cold-chamber machine is used.
The casting equipment and the metal dies represent large
capital costs and this tends to limit the process to high-
volume production. Manufacture of parts using die casting
is relatively simple, involving only four main steps, which
keeps the incremental cost per item low. It is especially
suited for a large quantity of small- to medium-sized
castings, which is why die casting produces more castings
than any other casting process. Die castings are
characterized by a very good surface finish (by casting
standards) and dimensional consistency.
Two variants are pore-free die casting, which is used to
eliminate gas porosity defects; and direct injection die
casting, which is used with zinc castings to reduce scrap
and increase yield.
Aluminium casting processes are classified as Ingot
casting or Mould casting. During the first process, primary
or secondary aluminium is cast into rolling ingot (slab),
extrusion ingot (billet) and wire bar ingot which are
subsequently transformed in semi- and finished products.

The second process is used in the foundries for producing

cast products. This is the oldest and simplest (in theory
but not in practice) means of manufacturing shaped
components.

This section describes exclusively Mould casting which

can be divided into two main groups :

Sand casting

Die casting

Other techniques such as "lost foam" or "wax pattern"

processes are also used but their economical importance
is considerably lower than both listed techniques.

Sand Casting
In sand casting, re-usable, permanent patterns are used to
make the sand moulds. The preparation and the bonding
of this sand mould are the critical step and very often are
the rate-controlling step of this process. Two main routes
are used for bonding the sand moulds:
The "green sand" consists of mixtures of sand, clay
and moisture.

The "dry sand" consists of sand and synthetic

binders cured thermally or chemically.
The sand cores used for forming the inside shape of
hollow parts of the casting are made using dry sand
components.

This versatile technique is generally used for high-volume

production.

Normally, such moulds are filled by pouring the melted

metal in the filling system. Mould designing is a particularly
complex art and is based on the same principle as gravity
die casting illustrated in Figure 4.

In the "low pressure" sand casting technique, the melted

metal is forced to enter the mould by low pressure
difference. This more complicated process allows the
production of cast products with thinner wall thickness.

Die Casting
In this technique, the mould is generally not destroyed at
each cast but is permanent, being made of a metal such
as cast iron or steel. There are a number of die casting
processes, as summarised in Figure 2. High pressure die
casting is the most widely used, representing about 50%
of all light alloy casting production. Low pressure die
casting currently accounts for about 20% of production
and its use is increasing. Gravity die casting accounts for
the rest, with the exception of a small but growing
contribution from the recently introduced vacuum die
casting and squeeze casting process.

High Pressure Die Casting

In this process, the liquid metal is injected at high speed
and high pressure into a metal mould.

This equipment consists of two vertical platens on which

bolsters are located which hold the die halves. One platen
is fixed and the other can move so that the die can be
opened and closed. A measured amount of metal is
poured into the shot sleeve and then introduced into the
mould cavity using a hydraulically-driven piston. Once the
metal has solidified, the die is opened and the casting
removed.

In this process, special precautions must be taken to avoid

too many gas inclusions which cause blistering during
subsequent heat-treatment or welding of the casting
product.

Both the machine and its dies are very expensive, and for
this reason pressure die casting is economical only for
high-volume production.

Low Pressure Die Casting

The die is filled from a pressurised crucible below, and
pressures of up to 0.7 bar are usual. Low-pressure die
casting is especially suited to the production of
components that are symmetric about an axis of rotation.
Light automotive wheels are normally manufactured by
this technique.

Vacuum Die Casting

The principle is the same as low-pressure die casting. The
pressure inside the die is decreased by a vacuum pump
and the difference of pressure forces the liquid metal to
enter the die. This transfer is less turbulent than by other
casting techniques so that gas inclusions can be very
limited. As a consequence, this new technique is specially
aimed to components which can subsequently be heat-
treated.

Squeeze Casting or Squeeze Forming

Liquid metal is introduced into an open die, just as in a
closed die forging process. The dies are then closed.
During the final stages of closure, the liquid is displaced
into the further parts of the die. No great fluidity
requirements are demanded of the liquid, since the
displacements are small. Thus forging alloys, which
generally have poor fluidities which normally precludes the
casting route, can be cast by this process.

This technique is especially suited for making fibre-

reinforced castings from fibre cake preform. Squeeze
casting forces liquid aluminium to infiltrate the preform. In
comparison with non-reinforced aluminium alloy,
aluminium alloy matrix composites manufactured by this
technique can double the fatigue strength at 300C.
Hence, such reinforcements are commonly used at the
edges of the piston head of a diesel engine where
solicitations are particularly high.

Conclusions
Aluminium castings are very powerful and versatile
techniques for manufacturing semi- or finished products
with intricate shapes. Those techniques are continuously
improved and developed to satisfy the user needs and to
penetrate new markets.

Innovations are mainly oriented to the automobile

sector which is the most important market for castings.
This continual improvement and development will ensure
that aluminium castings continue to play a vital role in this
field.

Injection Moulding
Injection moulding along with extrusion ranks as one of the
prime processes for producing plastic articles. It is a fast
process and is used to produce large numbers of identical
items from high precision engineering components to
disposable consumer goods.Material granules for the part
is fed via a hopper into a heated barrel, melted using
heater bands and the frictional action of a reciprocating
screw barrel. The plastic is then injection through a nozzle
into a mould cavity where it cools and hardens to the
configuration of the cavity. The mould tool is mounted on a
moveable platen when the part has solidified, the platen
opens and the part is ejected out using ejector pins.

Types of Injection Moulding

Reaction injection molding

Process for molding polyurethane, epoxy, and other liquid
chemical systems. A mixture of two to four components in
the proper chemical ratio is accomplished by a high-
pressure impingement-type mixing head, from which the
mixed material is delivered into the mold at low pressure,
where it reacts (cures).
Liquid injection molding
Process that involves an integrated system for
proportioning, mixing, and dispensing dual-component
liquid resin formulations and directly injecting the resultant
mix into a mold which is clamped under pressure. See
Injection molding.
Gas assist injection molding
Plastic molding process in which a high-pressure gas is
co-injected along with the plastic part to produce discrete
internal hollow sections. It differs from blow molding in that
one large hollow product is not created; rather, a solid
piece with hollow sections is produced.
Co-injection molding
This is a process that creates a skin and core material
arrangement in a molded part. The skin material is
injected first into the mold cavity, and is immediately
followed by a core material. As the skin material flows into
the cavity, the material next to the cavity walls freezes and
material flows down a center channel. When the core
material enters it displaces the skin material in the center
of the channel by pushing the skin ahead. As it flows
ahead it continues to freeze on the walls producing the
skin layer
2-Shot Injection Molding
This technology produces a part with two different raw
materials or colors in a single operation. The machine has
two injection units: one vertical and one horizontal. By
using a rotating mold, the machine automatically produces
a substrate of one resin or color and overmolds the part
with the second resin or color.
Fusible core injection molding
It is used in the manufacture of molded components with
cavities or undercuts, which would not be possible with
tools having demoldable cores.
Rapid injection molding
Rapid Injection Molding allows us to make prototype
injection molded parts in a production thermoplastic resin
in 2-5 weeks. These parts may be used for full functional
and fit testing as well as test marketing.