SUMMER TRAINING REPORT

Motherson Sumi System Limited (MSSL)

SUBMITTED BY ARVIND KUMAR 1009740904 ME B

ACKNOWLEDGEMENT

With profound respect and gratitude, I take the opportunity to convey my thanks to complete the training here. I do extend my heartfelt thanks to NIKHIL BHARADWAJ for providing me this opportunity to be a part of this esteemed organization. I am extremely grateful to all the technical staff of MOTHERSON for their co-operation and guidance that has helped me a lot during the course of training. I have learnt a lot working under them and I will always be indebted of them for this value addition in me. I would also like to thank all the faculty members of Mechanical EngineeringDepartment for their effort of constant co- operation, which have been a significant factor in the accomplishment of my industrial training.

ARVIND KUMAR

CONTENTS
ABOUT MOTHERSON VISION SOME MAJOR SUBGROUP OF COMPANY PRODUCTS BASIC MANUFACTURING PROCESS USED FOR PRODUCTS o INJECTION MOULDING o BLOW MOULDING WELDING PROCESSES o ULTRASONIC WELDING o EXTRUSION WELDING SOME IMPORTANT PRODUCTS OF MOTHERSON o FUEL TANK o EXHAUST SYSTEM

SAMVARDHANA MOTHERSON GROUP

The Samvardhana Motherson Group is a focused, dynamic and progressive group providing customers with value added products, services and innovative solutions. The Group has a diversified product range to serve multiple industries, with automotive industry being the main industry served. The Group business portfolio comprises electrical distribution systems (wiring harnesses), automotive rearview mirrors, polymer processing, injection moulding tools, elastomeric processing, modules and systems, machined metal products, cutting tools, IT services, design engineering, CAE services, sunroofs, vehicle air conditioning systems, lighting systems, cabins for off-highway vehicles, cutting tools and thin film coating metals.

Group Mission Insure customer delight Involve employees as partners in progress Set new standards in good corporate citizenship Enhance shareholder value Group Vision To be a globally preferred solutions provider

Historical milestones of the group

1975

Motherson was founded

1977

First Cable factory started

1983

Technical agreement with Tokai Electric Co. (Now Sumitomo Wiring Systems - Japan) for Wiring Harness

1986

Joint Venture with Wiring Systems Japan

Sumitomo

1989 Injection Moulding

1992 Cutting Tool Manufacturing

1994 Tool Room for small and Medium sized Molds (upto 650 Tons)

1995 Cockpit Assemblies Automotive Mirrors

1997 Blow Moulding

1998 Rubber Injection Moulding

1999 First Overseas (Austria) office established

2ooo

IT and Design Company Representative office at Singapore

2oo1

Liquid Silicon Rubber Injection Moulding Machined Metal Components

2oo2

Wiring Harness manufacturing Sharjah Design Center at Ireland

at

2oo3

Offices in USA & UK established Tool Room at Sharjah Automotive Sunroofs

2oo4

European Headquarters Germany Sheet Metal Die design

at

2oo5

Injection Moulding and Metal Machining in Germany. Joint Venture for:o Environment Management System o Industrial Robots o Automotive Manufacturing Engineering Plastic Moulding and Metal Machining at Germany PVC Tube Manufacturing

2oo6

Wiring Harness Manufacturing in UK Bus Air-conditioned System Auxiliary Equipment for Injection Moulding Machines Cabins for off road vehicles in India

2oo8

JV for Lighting systems, Pedal Box Assembly and Air Intake Manifolds JV for Precision machined metal components

2oo9

Visiocorp becomes a pat of Samvardhana Motherson group and renamed Samvardhana Motherson Reflectes (SMR) Gear Cutting tool manufacturing through a new venture Motherson Advanced tooling solutions. Polymer Compounding

Some major subgroups of the Company AES (India) Engineering Limited AES (India) Engineering Ltd. is a joint venture between Samvardhana Motherson Group and Automotive Engineering Services Co. Ltd. (Japan) (AES) for providing services that include Manufacturing Engineering, Consultation, Project

Management and Turnkey Supplies to the automotive industry. AES is a global player in the automotive engineering field, providing services to major automotive companies worldwide. AES (India) is positioned as an extension of AES global operations in the Indian automotive market. Services are provided in the areas of Plant Layout & Logistics, Prototyping, Process Planning, Simulation, Conceptual & Detail Engineering, Turnkey equipments supply etc. Product/Services Areas of shop coverage Dress/Dies, Body, Paint and assembly shop in vehicle assembly plant. Engine/Transmission machining and assembly line in power train manufacturing plant.

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Services Simultaneous Engineering Logistics Planning Procurement of Machinery and Equipment Installation of equipment Launching support Quality build up activities Coaching of manufacturing staffs/operators Continuous Improvement Kaizen (Covering parts) Program management

Magneti Marelli Motherson Auto System Ltd. Magneti Marelli Motherson Auto System Limited is a joint Venture between Samvardhana Motherson Group and Magneti Marelli, Italy.

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Product range includes: Automotive Lighting Head Lamps o Xenon o Projection/Reflection Halogen o Advanced front lighting system o LED-technology o Infrared Emitters Rear Lamps o CHMSL o LED-technology o Rear reflectors o License plate combi Auxiliary Lamps, other products o Fog lamps o Turn signals o Door reflectors o Side markers

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POWERTRAIN Air Intake Module including o Air Intake Manifold o Throttle body o Fuel rail o Injectors LPG/CNG Intake Module including o Air intake manifold o Fuel rail o LPG/CNG injectors o Pressure regulator PEDAL BOX MODULE Main features: o Brake and Clutch Pedal with release device o Quick Fit device for connecting Brake Pedal to Servo Brake Push Rod o CMC assembled on Pedal Box o Pedal Box with Electronic Throttle Control (ETC) ETC Pedal program o Integrated sensor and pedal unit o Individual adaptation of pedal forces o Dual output signal for redundant operation o Non-contacting sensor technology o Optional kick down feature
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Motherson Sumi System Limited (MSSL) Motherson Sumi Systems Limited (MSSL) is the flagship company of the Samvardhana Motherson Group and was established in 1986. It is a joint venture between Samvardhan`a Motherson Group and Sumitomo Wiring Systems (Japan). MSSL is a focused, dynamic and progressive company providing customers with innovative and value-added products, services and solutions. The Company is listed at the stock exchanges since 1993. The recent acquisition of mirror business from Visiocorp (now renamed as Samvardhana Motherson Reflectec) has helped MSSL evolve as one of the worlds leading automotive mirror manufacturer. The Company is Indias largest manufacturer of automotive wiring harnesses and mirrors for passenger cars. It is also a leading supplier of plastic components and modules to the automotive industry.

MSSL facility in Noida

MSSL Bangalore

facility

in

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Over the years MSSL has collaborated with global technology leaders and has further leveraged its competency in existing areas to create products fulfilling the technical needs of its customers. MSSL and its joint ventures have invested in state-of-the-art technologies and infrastructure to ensure superior efficiencies & total customer satisfaction. MSSL is strengthening its position as a globally preferred solution provider by offering end-to-end solutions encompassing designing from basic data to prototyping, tooling, molding, assembly and integrated modules. The ability to provide this end-to-end solution in each product category and combine these solutions in the form of full system solutions has enabled the Company to evolve as a preferred supplier. These solutions are supported by the flexibility to supply from any of the alternative manufacturing bases and logistic models best suited to customer requirements. MSSL has developed a network of manufacturing bases, design centers, logistics centers, marketing support and sourcing hubs across a diversified geographical base. MSSL has presence in 21 countries which includes India (Noida , Gurgaon, Manesar, Faridabad , Pune, Bengaluru, Chennai, Kandla, Lucknow & Puducherry), UAE., Sri Lanka, Singapore, China, South Korea, Japan, Germany, UK., Czech Republic, Austria, Hungary, Italy, Spain, France, Ireland, U.S.A, Mexico, South Africa, Australia & Mauritius to provide timely and quality delivery its customers worldwide. MSSL has manufacturing bases across five continents - Asia, Europe,

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North America, Africa and Australia to support its customers. MSSLs diverse global customer base comprises of almost all leading automobile manufacturers globally. Product Range It has been MSSLs Endeavour to constantly add new products in its product line with the objective of emerging as a single-service interface for multiple customer needs. MSSL has 9 JV partners with over 14 collaborations. The Company has collaborated with technology leaders in their respective fields to bring relevant technologies for the products required by its customers. MSSLs diversity of product range coupled with the depth within each product portfolio, has helped the company garner leadership in its area of operations.

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Introduction to company

Motherson Automotive Technologies & Engineering (MATE), a division of Motherson Sumi Systems Ltd (MSSL), specializes in large size injection moulding, blow moulding, compression moulding and vacuum forming, which are supported by post moulding operations. MATE manufactures a wide range of plastic components for the automotive and the non-automotive industry.

Manufacturing Capabilities Injection Moulding machines from 40 ton to 3200 ton capacity. Gas Injection Moulding facility. State-of-the-art Blow Moulding machines Compression Moulding facility Post moulding Operations o Product Finishing with fabric Upholstery and Vinyl Lamination o Robotic Trimming Operations o Ultrasonic Welding o Hot plate welding o Painting o Silk screen printing o Auto screen printing o Pad printing
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Product Range

Blow Molded Components Heating, Ventilation and Air Conditioning Engine and Air Intake Ducts Wind Shield Washer Bottles Radiator Reservoir Tanks Plastic Fuel Tanks (2-Wheelers) Resonator/Pipe Air Intake Arm Rests Bellows Body styling kit-spoilers Ducts

Injection molded components Interior/Exterior Trims and parts Scuff plates Auto A.C components Mirror housings Under bonnet parts Structured plastic components Inside handles Body colored painted parts

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Modules IP Module Door Trims Floor console Module Bumper Modules Air Cleaners

Products and services Wire harness MATE is the largest manufacturer of integrated wiring harness in India, the Samvardhana Motherson group holds over 65% share of the Indian passenger car wiring harness market. The group manufactures wiring harnesses for the entire cross-section of the automotive industry-from passenger cars to commercial vehicles, two wheelers and three wheelers, multi utility vehicles, farm, material handling equipment and offthe-road vehicles. The group also manufactures specialized wiring harnesses for white goods, office automation, medical diagnostic equipment, electrical and electronic equipment. Designing and developing wiring harnesses from first principle concepts on latest design software, the group provides total solutions in wiring harness manufacturing .
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The group has complete backward integration for manufacturing critical wiring harness components. In-house capability for design and manufacturing of applicators, jigs, assembly boards and circuit checking boards enable process design control and flexibility The Engineering Capabilities for Wiring Harness Process Design & Development o In-house capability of process design and validation o Applicator design & manufacturing Design & manufacturing of circuit checking & assembly boards Tooling design for wiring harness process equipment, testing and assembly equipment. Electrical Distribution System Products Cable & Harness o Wiring harness o Lead wire o Battery cable o Flat cable harness o High tension cords (Engine cables)

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Wiring harness components o Wired o Terminals o Connectors o Caps and sleeves o Clamps and binders o Fuse boxes Modules with integrated wiring harnesses

Injection Moulding Tool design & manufacturing capabilities of the group is a key to its ability to provide full system solutions. The group has collaborations with Sumitomo Wiring Systems, Japan and Center Tooling, Australia for tool design & manufacturing.

The tool rooms specialize in high precision, multi cavity, small, medium and large size tools capable of running on injection moulding machines upto 3200 tones.

Tool manufacturing is done on state-of-the-art CNC machines. In-house proving & tryout facilities on injection moulding machines are in tandem with tool manufacturing facilities.

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Precision Metal Machining The Samvardhana Motherson Group Specializes in high precision machined metal components and assemblies mainly for Automotive and IT Hardware industries, Microscopes and engineering applications. The group has manufacturing bases in India and Germany. The facilities include state-of-the-art CNC machines coupled with highly customized special purpose machines for intricate machining requirements. The machined metal components are supplied to customers across the world, especially to Europe and USA. Product range Fuel pump parts Plastic and metal combined parts Capstone working turning, milling parts Cubic parts Sub assemblies with plastics and coatings Machined extruded aluminum shapes Docking plates Parts for microscopes Heat sinks for computer processors

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Plastic Moulding Plastic Injection Moulding The group manufactures a wide range of injection molded plastic components and assemblies for automotive, electrical, electronics, medial diagnostics and other industries. The group specializes in high precision, surface critical, assembly-oriented

components and assemblies. Injection moulding operations are augmented by complete post moulding processes and special customized lines for plastic-plastic, plastic-rubber and plastic-metal assemblies. The moulding technologies include: Plastic injection moulding Gas assisted injection moulding 2k moulding Insert moulding Inmold lamination

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Blow moulding Blow moulding products cover a wide range of components & assemblies for the automotive industry, which include heating, ventilation and air conditioning ducts, bottles & reservoirs, spoilers and 2-wheeler fuel tanks. The range also extends to components for office automation and other industries. the facilities are supported by robotic trimming and assembly operations.

Post moulding operations Ultrasonic welding Vibration welding Screen printing Curve printing Hot plate welding Body color matched painting Robotic welding

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Rubber Moulding and Extrusion The group manufactures extruded rubber components and has in-house rubber mixing facilities. It has the largest non-tire related rubber mixing plant in Australia currently having 1900 material formulations which include 15 different polymers.

Injection molded rubber components The rubber injection moulding facilities of the group support the automotive and other industries with a wide range of rubber components such as: grommets, boots, bellows, gaskets, seals, water strike back valves, damper rings, nozzles, rubber to plastic & rubber to metal products. The facilities are supported with cryogenic de-flashing, in-house tool maintenance and complete in-house testing facilities.

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Liquid Silicon Rubber Components Liquid silicon rubber injection moulding operations manufacture components for an extensive range of applications which include: Automotive Frame and plug sealing, anode caps, keypads, switch covers, central locking system membranes. Kitchen Appliances Measuring & Control Technology Steam iron seals, diffuser heads, dishwasher seals, vacuum cleaner flaps. Medical Equipment Seals, injection plungers, wart caps, soother nipples, oxygen bellows, catheters and catheter holders. Injection & Compression Molded Products Silent bloc Industrial Mountings and couplings. Auto & Truck Suspension Components. Wheel Chocks. High Precision Molded Products. Molded Rubber Brake Components. Rolling Stock Bogie Rubber & Metal Component

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Bonded Components Suspension bushes Engine and transmission variants Bump stops Large engine gaskets

Extruded rubber Profiles Weather strips Glass run Boot and hood seals Tank Flares

SKH Metals LTD. SKH Metals, formerly known as Mark Auto Industries, was established in 1986 as a joint venture company setup by Maruti Suzuki India Limited, the largest car manufacturer in India, to cater to its requirements of Fuel tanks and other sheet Metals parts. In 2005, the company was taken over by the Krishna Maruti Group and renamed S.K.H Metals Ltd. Since then under the leadership of its new Managing Directors Mr. Sunandan Kapur, the company has broadened its horizons to become a reckoning force within the industry.

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Krishna has two brands in the groups i.e. Krishna representing Auto Interiors and S.K.H Metals representing metal parts. Krishna has a total 10 manufacturing facilities (product specific) in the National Capital Region (Gurgaon). All the manufacturing facilities are TS-16949 certified and they have won the coveted Deming Prize (Total Quality Management) at their seating Division (the youngest and the first seating company in the world to receive this prestigious prize). There consolidated Group Turnover for the current financial year is $191 Million and they are targeting $ 261 Million for Financial year 2007-2008. S.K.H Metals Ltd. Started as Mark Auto Industries as a joint venture between Maruti and three promoters after that in 1987 Plant one Commissioned and 1995 plant second commissioned. Maruti takeover of mark auto industries in 2001 and In February 2005 Mark Auto acpuired by Krishna Group and In 2006 Company renamed as S.K.H Metals after that 2007-08 it growth was increasing day by day it revenue in 2007-08 reachs to Euro 60 Mio and in 2008-09 it is Euro 85 Mio it is expected that it will give revenue of Euro 185 Mio in 2011-2012. It is planning to extend it product Fuel Tanks Exhaust Assembly (Cold End) (JV with Magnetic Marelli) Gear shifter assembly (JV with Sila) A Diverse range of Stampings and Welded assemblies. Rear Axle & Suspension Parts (Subject to Business award)

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S.K.H METALS Ltd. PRODUCT PARTICULLAR

Fuel tank

Exhaust system

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Stampings and Assemblies

Welded Assemblies

Axle Housings

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INJECTION MOULDING
Injection molding is a manufacturing process for producing parts from both thermoplastic and thermosetting plasticmaterials. Material is fed into a heated barrel, mixed, and forced into a mold cavity where it cools and hardens to the configuration of the cavity.[1] After a product is designed, usually by an industrial designer or an engineer, molds are made by a moldmaker (or toolmaker) from metal, usually either steel oraluminum, and precision-machined to form the features of the desired part. Injection molding is widely used for manufacturing a variety of parts, from the smallest component to entire body panels of cars. The complete range of services from tool design to tool manufacturing and injection moulding under one roof make the group a Total Tooling Solutions provider.

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Process characteristics

Utilizes a ram or screw-type plunger to force molten plastic material into a mold cavity Produces a solid or open-ended shape that has conformed to the contour of the mold Used to process both thermoplastic and thermosetting polymers, with the former being considerably more prolific in terms of annual material volumes processed. The prevalence of thermoplastics is a result of many factors including:

simultaneous economic, engineering, and manufacturing feasibility unique and diverse material properties, well suited for a larger proportion of consumer and engineering applications the ability to soften and flow upon heating facilitates recycling post consumer waste, reject parts, and the melt delivery system reduces manufacturing risks associated with the injection unit. Thermosets, which cannot flow after the chemical crosslinking occurs, are susceptible to crosslinking in the injection barrel and encapsulating the screw and check valves leading to flow obstructions, mechanical seizures, damage to expensive components, and timely/costly down-times during the mechanical removal of thermosetting polymer from the injection components. reduces manufacturing time per part produced in many scenarios because the thermal solidification of thermoplastics be achieved in a shorter time duration than the chemical solidification of thermosets

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cavity can be identical and form the same parts or can be unique and form multiple different geometries during a single cycle. Molds are generally made from tool steels but stainless steels and aluminum molds are suitable for certain applications. Aluminum molds typically are ill-suited for high volume production or parts with narrow dimensional tolerances as they have inferior mechanical properties and are more prone to wear and damage and deformation during the injection and clamping cycles, but are cost effective in low volume applications as mold fabrication costs and time are considerably reduced. Many steel molds are

designed to process well over a million parts during their lifetime and can cost hundreds of thousands of dollars to fabricate.

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BLOW MOULDING Blow molding (also known as blow moulding or blow forming) is a manufacturing process by which hollow plasticparts are formed. In general, there are three main types of blow molding: extrusion blow molding, injection blow molding, and stretch blow molding. The blow molding process begins with melting down the plastic and forming it into a parison or preform. The parison is a tubelike piece of plastic with a hole in one end in which compressed air can pass through. The parison is then clamped into a mold and air is pumped into it. The air pressure then pushes the plastic out to match the mold. Once the plastic has cooled and hardened the mold opens up and the part is ejected. Typologies of blow molding Extrusion blow molding

Extrusion blow molding

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In extrusion blow molding (EBM), plastic is melted and extruded into a hollow tube (a parison). This parison is then captured by closing it into a cooled metal mold. Air is then blown into the parison, inflating it into the shape of the hollow bottle, container, or part. After the plastic has cooled sufficiently, the mold is opened and the part is ejected.[2] Continuous and Intermittent are two variations of Extrusion Blow Molding. In Continuous Extrusion Blow Molding the parison is extruded continuously and the individual parts are cut off by a suitable knife. In Intermittent blow molding there are two processes: straight intermittent is similar to injection molding whereby the screw turns, then stops and pushes the melt out. With the accumulator method, an accumulator gathers melted plastic and when the previous mold has cooled and enough plastic has accumulated, a rod pushes the melted plastic and forms the parison. In this case the screw may turn continuously or intermittently.[3] EBM processes may be either continuous (constant extrusion of the parison) or intermittent. Types of EBM equipment may be categorized as follows: Continuous extrusion equipment

rotary wheel blow molding systems shuttle machinery

Intermittent extrusion machinery reciprocating screw machinery accumulator head machinery Examples of parts made by the EBM process include dairy containers, shampoo bottles, hoses/pipes, and hollow industrial parts such as drums.

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Injection blow molding The process of injection blow molding (IBM) is used for the production of hollow glass and plastic objects in large quantities. In the IBM process, the polymer is injection molded onto a core pin; then the core pin is rotated to a blow molding station to be inflated and cooled. This is the least-used of the three blow molding processes, and is typically used to make small medical and single serve bottles. The process is divided into three steps: injection, blowing and ejection.[4] The injection blow molding machine is based on an extruder barrel and screw assembly which melts the polymer. The molten polymer is fed into a manifold[disambiguation needed] where it is injected through nozzles into a hollow, heated preform mold. The preform mold forms the external shape and is clamped around a mandrel (the core rod) which forms the internal shape of the preform. The preform consists of a fully formed bottle/jar neck with a thick tube of polymer attached, which will form the body. The preform mold opens and the core rod is rotated and clamped into the hollow, chilled blow mold. The core rod opens and allows compressed air into the preform, which inflates it to the finished article shape. After a cooling period the blow mold opens and the core rod is rotated to the ejection position. The finished article is stripped off the core rod and leak-tested prior to packing. The preform and blow mold can have many cavities, typically three to sixteen depending on the article size and the required output. There are three sets of core rods, which allow concurrent preform injection, blow molding and ejection. Stretch blow molding process In the stretch blow molding (SBM) process, the plastic is first molded into a "preform" using the injection molding process. These preforms are produced with the necks of the bottles, including threads (the "finish") on one end. These preforms are packaged, and fed later (after cooling) into a reheat stretch blow molding machine. In the SBM process, the preforms are heated (typically using infrared heaters) above their glass transition temperature, then blown using high pressure air into bottles using metal blow molds. The preform is always stretched with a core rod as part of the process.

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In the single-stage process both preform manufacture and bottle blowing are performed in the same machine. The stretching of some polymers, such as PET (polyethylene terephthalate) results in strain hardening of the resin, allowing the bottles to resist deforming under the pressures formed by carbonated beverages, which typically approach 60 psi.The main applications are bottles, jars and other containers. Advantages of blow molding include: low tool and die cost; fast production rates; ability to mold complex part; produces recyclable parts Disadvantages of blow molding include: limited to hollow parts, wall thickness is hard to control. [edit]Spin trimming Containers such as jars often have an excess of material due to the molding process. This is trimmed off by spinning the container while a blade cuts the material away. This excess plastic is then recycled to create new moldings. Spin Trimmers are used on a number of materials, such as PC, PET, PVC, HDPE, PE+LDPE and LLDPE. Different types of the materials have their own physical characteristics affecting trimming. For example, moldings produced from amorphous materials are much more difficult to trim than crystalline materials. Titanium coated blades are often used rather than standard steel to increase life by a factor of 30 times.[5]

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ULTRASONIC WELDING Ultrasonic welding is an industrial technique whereby highfrequency ultrasonic acoustic vibrations are locally applied to workpieces being held together under pressure to create a solid-state weld. It is commonly used for plastics, and especially for joining dissimilar materials. In ultrasonic welding, there are no connective bolts, nails, soldering materials, or adhesives necessary to bind the materials together

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Process
For joining complex injection molded thermoplastic parts, ultrasonic welding equipment can be easily customized to fit the exact specifications of the parts being welded. The parts are sandwiched between a fixed shaped nest (anvil) and a sonotrode (horn) connected to a transducer, and a ~20 kHz low-amplitude acoustic vibration is emitted. (Note: Common frequencies used in ultrasonic welding of thermoplastics are 15 kHz, 20 kHz, 30 kHz, 35 kHz, 40 kHz and 70 kHz). When welding plastics, the interface of the two parts is specially designed to concentrate the melting prcess. One of the materials usually has a spiked energy director which contacts the second plastic part. The ultrasonic energy melts the point contact between the parts, creating a joint. This process is a good automated alternative to glue, screws or snap-fit designs.

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It is typically used with small parts (e.g. cell phones, consumer electronics, disposable medical tools, toys, etc.) but it can be used on parts as large as a small automotive instrument cluster. Ultrasonics can also be used to weld metals, but are typically limited to small welds of thin, malleable metals, e.g. aluminum, copper, nickel. Ultrasonics would not be used in welding the chassis of an automobile or in welding pieces of a bicycle together, due to the power levels required. Applications The applications of ultrasonic welding are extensive and are found in many industries including electrical and computer, automotive and aerospace, medical, and packaging. Whether two items can be ultrasonically welded is determined by their thickness. If they are too thick this process will not join them. This is the main obstacle in the welding of metals. However, wires, microcircuit connections, sheet metal, foils, ribbons and meshes are often joined using ultrasonic welding. Ultrasonic welding is a very popular technique for bonding thermoplastics. It is fast and easily automated with weld times often below one second and there is no ventilation system required to remove heat or exhaust. This type of welding is often used to build assemblies that are too small, too complex, or too delicate for more common welding techniques.

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WELDING TECHNIQUES FOR PRODUCTS A number of techniques are used for welding plastics. 1.Hot gas welding Hot gas welding, also known as hot air welding, is a plastic welding technique using heat. A specially designed heat gun, called a hot air welder, produces a jet of hot air that softens both the parts to be joined and a plastic filler rod, all of which must be of the same or a very similar plastic. Welding PVC to acrylic is an exception to this rule. Hot air/gas welding is a common fabrication technique for manufacturing smaller items such as chemical tanks, water tanks, heat exchangers, and plumbing fittings. In the case of webs and films a filler rod may not be used. Two sheets of plastic are heated via a hot gas (or a heating element) and then rolled together. This is a quick welding process and can be performed continuously. Heat seal A variety of heat sealers are available to join thermoplastic materials such as plastic films: Hot bar sealer, Impulse sealer, etc. [edit]Freehand welding With freehand welding, the jet of hot air (or inert gas) from the welder is played on the weld area and the tip of the weld rod at the same time. As the rod softens, it is pushed into the joint and fuses to the parts. This process is slower than most others, but it can be used in almost any situation. Speed tip welding With speed welding, the plastic welder, similar to a soldering iron in appearance and wattage, is fitted with a feed tube for the plastic weld rod. The speed tip heats the rod and the substrate, while at the same time it presses the molten weld rod into position. A bead of softened plastic is laid into the joint, and the parts and weld rod fuse. With some types of plastic such as polypropylene, the melted welding rod must be "mixed" with the semi-melted base material being fabricated or repaired.

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These welding techniques have been perfected over time and have been utilised for over 50 years by professional plastic fabricators and repairers internationally. Speed tip welding method is a much faster welding technique and with practice can be used in tight corners. A version of the speed tip "gun" is essentially a soldering iron with a broad, flat tip that can be used to melt the weld joint and filler materiel to create a bond.

Extrusion welding
Extrusion welding allows the application of bigger welds in a single weld pass. It is the preferred technique for joining material over 6 mm thick. Welding rod is drawn into a miniature hand held plastic extruder, plasticized, and forced out of the extruder against the parts being joined, which are softened with a jet of hot air to allow bonding to take place.

Contact welding
This is the same as spot welding except that heat is supplied with conduction of the pincher tips instead of electrical conduction. Two plastic parts are brought together where heated tips pinch them, melting and joining the parts in the process.

Hot plate welding

Related to contact welding, this technique is used to weld larger parts, or parts that have a complex weld joint geometry. The two parts to be welded are placed in the tooling attached to the two opposing platens of a press. A hot plate, with a shape that matches the weld joint geometry of the parts to be welded, is moved in position between the two parts. The two opposing platens move the parts into contact with the hot plate until the heat softens the interfaces to the melting point of the plastic. When this condition is achieved the hot plate is removed, and the parts are pressed together and held until the weld joint cools and re-solidifies to create a permanent bond.

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High frequency welding

Certain plastics with chemical dipoles, such as PVC, polyamides (PA) and acetates can be heated with high frequency electromagnetic waves. High frequency welding uses this property to soften the plastics for joining. The heating can be localized, and the process can be continuous. Also known as Dielectric Sealing, R.F. (Radio Frequency) Heat Sealing. In a ferromagnetic work piece, plastics can be induction-welded by formulating them with metallic or ferromagnetic compounds, called susceptors. These susceptors absorb electromagnetic energy from an induction coil, become hot, and lose their heat energy to the surrounding material by thermal conduction. Radio frequency welding is a very mature technology that has been around since the 1940s. Two pieces of material are placed on a table press that applies pressure to both surface areas. Dies are used to direct the welding process. When the press comes together, high frequency waves (usually 27.12 MHz) are passed through the small area between the die and the table where the weld takes place. This high frequency (radio frequency) field causes the molecules in certain materials to move and get hot, and the combination of this heat under pressure causes the weld to take the shape of the die. RF welding is fast. This type of welding is used to connect polymer films used in a variety of industries where a strong consistent leak-proof seal is required. In the fabrics industry, RF is most often used to weld PVC and polyurethane (PU) coated fabrics. This is a very consistent method of welding. The most common materials used in RF welding are PVC and polyurethane. It is also possible to weld other polymers such as nylon, PET, EVA and some ABS plastics.

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SOME IMPORTANT PRODUCTS OF MOTHERSON

1.FUEL TANK A petrol fuel tank is a safe container for flammable fluids. Though any storage tank for fuel may be so called, the term is typically applied to part of an engine system in which the fuel is stored and propelled (fuel pump) or released (pressurized gas) into an engine. Fuel tanks range in size and complexity from the small plastic tank of a butane lighter to the multi-chambered cryogenicSpace Shuttle external tank.

Uses Typically, a fuel tank must allow or provide the following:

Storage of fuel: the system must contain a given quantity of fuel and must avoid leakage and limit evaporative emissions Filling: the fuel tank must be filled in a secure way, without sparks Provide a method for determining level of fuel in tank, gauging (the remaining quantity of fuel in the tank must be measured or evaluated) Venting (if over-pressure is not allowed, the fuel vapors must be managed through valves) Feeding of the engine (through a pump) Anticipate potentials for damage and provide safe survival potential.

Plastic (high-density polyethylene HDPE) as a fuel tank material of construction, while functionally viable in the short term, has a long term potential to become saturated as fuels such as diesel and gasoline permeate the HDPE material.

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Considering the inertia and kinetic energy of fuel in a plastic tank being transported by a vehicle, environmental stress cracking is a definite potential. The flammability of fuel makes stress cracking a possible cause of catastrophic failure. Emergencies aside, HDPE plastic is suitable for short term storage of diesel and gasoline. In the U.S., Underwriters Laboratories approved (UL 142) tanks would be a minimum design consideration. [edit]Fuel tank construction

Fuel tank for the Apollo Lunar Module, 1960s

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While most tanks are manufactured, some fuel tanks are still fabricated by metal craftsmen or hand-made in the case of bladder-style tanks. These include custom and restoration tanks for automotive,aircraft, motorcycles, and even tractors. Construction of fuel tanks follows a series of specific steps. The craftsman generally creates a mockup to determine the accurate size and shape of the tank, usually out of foam board. Next, design issues that affect the structure of the tank are addressed - such as where the outlet, drain, fluid level indicator, seams, and baffles go. Then the craftsmen must determine the thickness, temper and alloy of the sheet he will use to make the tank. After the sheet is cut to the shapes needed, various pieces are bent to create the basic shell and/or ends and baffles for the tank. Many fuel tanks' baffles (particularly in aircraft and racecars) contain lightening holes. These flanged holes serve two purposes, they reduce the weight of the tank while adding strength to the baffles. Toward the ends of construction openings are added for the filler neck, fuel pickup, drain, and fuel-level sending unit. Sometimes these holes are created on the flat shell, other times they are added at the end of the fabrication process. Baffles and ends can be riveted into place. The heads of the rivets are frequently brazed or soldered to prevent tank leaks. Ends can then be hemmed in and soldered, or flanged and brazed (and/or sealed with an epoxy-type sealant) or the ends can be flanged and then welded. Once the soldering, brazing or welding is complete, the fuel tank is leak-tested.[1] 2.EXHAUST SYSTEM An exhaust system is usually piping used to guide reaction exhaust gases away from a controlled combustion inside an engine or stove. The entire system conveys burnt gases from the engine and includes one or more exhaust pipes. Depending on the overall system design, the exhaust gas may flow through one or more of: Cylinder head and exhaust manifold

A turbocharger to increase engine power. A catalytic converter to reduce air pollution. A muffler (North America) / silencer (Europe), to reduce noise

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In a motor vehicle, the term powertrain or powerplant refers to the group of components that generate power and deliver it to the road surface, water, or air. This includes the engine, transmission, drive shafts, differentials, and the final drive (drive wheels, continuous track as in tanks or Caterpillar tractors, propeller, etc.). Sometimes "powertrain" is used to refer to simply the engine and transmission, including the other components only if they are integral to the transmission. In a carriage or wagon, running gear designates the wheels and axles in distinction from the body. A motor vehicle's driveline consists of the parts of the powertrain excluding the engine and transmission. It is the portion of a vehicle, after the transmission, that changes depending on whether a vehicle is front-wheel, rear-wheel, or four-wheel drive, or less-common six-wheel or eight-wheel drive. In a wider sense, the power-train includes all of its components used to transform stored (chemical, solar, nuclear, kinetic, potential, etc.) energy into kinetic energy for propulsion purposes. This includes the utilization of multiple power sources and nonwheel-based vehicles.

Manufacturing
The manufacturing of powertrain components and systems is important to industry, including the automotive and other vehicle sectors. Competitiveness drives companies to engineer and produce powertrain systems that over time are more economical to manufacture, higher in product quality and reliability, higher in performance, more fuel efficient, less polluting, and longer in life expectancy. In turn these requirements have led to designs involving higher internal pressures, greater instantaneous forces, and increased complexity of design and mechanical operation. The resulting designs in turn impose significantly more severe requirements on parts shape and dimension; and material surface flatness, waviness, roughness, and porosity. Quality control over these parameters is achieved through metrology technology applied to all of the steps in powertrain manufacturing processes.

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