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First, I thank The HR Head, MR. Gaurav Saraswat for considering my potential
in doing this training and providing this wonderful opportunity.
I would like to express my gratitude to MR. Rakesh Kumar for his invaluable
suggestions, motivation, guidance and support throughout the training. His
methodology to start from simple ant then deepen through made me to bring
out this project report without anxiety.
Thanks to all other JBM officials, operators and all other members of JBM, yet
uncounted for their help in completing the project and see the light of success.
I am very thankful to friends, colleagues and all other persons who rendered
their assistance directly or indirectly to complete this project work successfully.
In 1986, the Group signed a joint venture with Maruti Suzuki India Ltd for the
manufacturing of sheet metal components and assemblies. The journey began
with a vision to expand the business in the automotive sector by keeping
abreast with market trends and global technology.
The milestones and achievements of JBM Group gave the energy for
diversification and establishment of multiple business units in order to meet
the needs of customers. The organization’s management follow a unique
business model to create empowered companies that enjoy the best of
entrepreneurial independence, assisted with leverage of group-wide synergies.
Overview:-
With turnover of USD 1.2 billion, JBM Group has broadened its horizons by
focusing on quality delivery, solutions approach, product development
processes, flexible manufacturing systems and contract manufacturing.
JBM Group is primarily a tier- 1 supplier to the automotive OEM industry and
caters services to esteemed clients that include Ashok Leyland, Bajaj Auto Ltd,
Fiat, Ford, General Motors Corporation, Honda, Hero, JCB, Mahindra, Maruti
Suzuki, Renault, Nissan, TATA, Toyota, TVS, Volvo-Eicher, Volkswagen and
many more.
The Group has alliances with more than 20 renowned companies globally and
the associations include Arcelor Mittal, Cornaglia, Dassault Systems, JFE Steel
Corporation, Magnetto (CLN Group), Ogihara, Sumitomo and many more. The
organization’s structure enables each business unit to chart its own future and
simultaneously leverage synergies across its competencies.
Introduction to the Company
Company Profile:-
Vision:-
Core Values:-
We believe in...
Simplicity, by keeping a low profile externally and having clear, open and
effective communication within the organization.
Technology:-
Technology, Innovation and People serve as the 3 key pillars of the JBM
foundation. Core to this philosophy is a constant quest for excellence by
enhancing technology, enabling innovation and empowering people, thereby,
creating consistent value for all stakeholders.
JBM Group has always kept a close watch on the dynamic needs of its
customers and continues the journey of efficiency by enhancing the
technology at every stage. The organization has collaborated with best global
technology partners; possess state-of-the-art manufacturing facilities and
highly automated processes. These advantages have established new
benchmarks that have aided in providing superior quality and flawless
technical perfection to the organization's deliverables.
At JBM, sustainability is the way of doing business. The Group aligned its goals
for environment, health and safety, making an impact across its value chain
worldwide. Together with the suppliers, customers and stakeholders, JBM
strives to maintain highest standards to preserve and protect the environment,
as well as enhance the health and safety of the Group’s employees and
communities.
1) Paint shop
2) Weld shop
3) Press Shop
4) Quality department
5) Engineering department
6) IT department
7) Finance department
8) Purchase department
9) Maintenance department
Rim rolling line, central anode tri chrome nickel plating and complete wheel
assembly set up
Steel Service Centre - The Company has 4 blanking lines capable of producing
blanks of regular and irregular geometrical shapes and sizes
Product Range:-
Certifications:-
ISO 9001
ISO/TS 16949
ISO 14001
OHSAS 18001
Production:-
Casting Process:- This type of procedure required liquid material. This is the
only process which uses liquid material. This is oldest procedure of production
in which the molten metal is poured into refractory mould cavity and allowed
to solidify. The object from the cavity removed after the solidification.
Production Line:-
The production line is required to produce products fast. As well the market
demand is getting increase as well we need more products also with more in
quantity. A production of a whole body by a single labour was unable satisfied
this they was also unable fulfil the demand properly then we need some
processes by which we can produce things fast and fulfil the requirement of
market. Due to these the concept of production lines introduced in which
many units work together to produce something. This concept reduces the
production time up to a mark and exponentially increases the profits.
Advantages of Production line:-
Abstract:- The chain case is a most important part of two wheeler. It prevents
chain from the dirt and mud. As the two wheelers have an open type of body
and chain drives in free environment so there a definite chance of rusting and
corrosion occurs. So chain case prevents the chain from above factors. In India,
the Women wear their traditional dresses like Sari, Ghaghara and many other
dresses which consists a huge round of cloth covering their legs. So when they
sit on back side of two wheelers by wearing these dresses it creates definite
chances of tear of cloth by contacting with driven chain. It makes the condition
of accident many times women also get dead in this case. In other cases of
developing countries like India, Pakistan, African Countries traffic rules are not
so effective. On a single two wheeler more than allowed person travel. It also
creates definite chances of accident by contact with driving chain and chain
can also tear their dress or contact of clothes can make them snagged. So the
chain case is highly essential in two wheelers of India. It works like chain case
and dress guard both. It completely encloses chain and protects it from
contamination.
Theory:- Here the work done on the Honda Unicorn KSPG bike chain case. In
the joining of chain case 5 steps are involved. Pre discharge inspection of this
involves 2 steps. The parts of this chain case are jointed with the spot welding.
This spot welding consist two copper electrodes which transfer a higher
voltage through part this generates high heat at transfer spot and this heat
joint part by a spot. Sheet metal is used to make chain case. The chain case
consists 7 parts which make one side case. It is differentiated in two Left and
Right part in this L part is engaged with Dust cover. Due to the high strength
and low in weight Aluminium is used to make Unicorn chain case.
Spot Welding:-
Spot welding is one of the oldest welding processes. It is used in a wide range
of industries but notably for the assembly of sheet steel vehicle bodies. This is
a type of resistance welding where the spot welds are made at regular
intervals on overlapping sheets of metal. Spot welding is primarily used for
joining parts that are normally up to 3 mm in thickness. Thickness of the parts
to be welded should be equal or the ratio of thickness should be less than 3:1.
The strength of the joint depends on the number and size of the welds. Spot-
weld diameters range from 3 mm to 12.5 mm.
To create heat, copper electrodes pass an electric current through the work
pieces. The heat generated depends on the electrical resistance and thermal
conductivity of the metal, and the time that the current is applied. The heat
generated is expressed by the equation:
E=I2*R*t
Where E is the heat energy, I is the current, R is the electrical resistance and t
is the time that the current is applied.
Copper is used for electrodes because it has a low resistance and high thermal
conductivity compared to most metals. This ensures that the heat is generated
in the work pieces instead of the electrodes.
Galvanized steel (i.e. steel coated with zinc to prevent corrosion) requires a
different welding approach than uncoated steel. The zinc coating must first be
melted off before the steel is joined. Zinc has a low melting point, so a pulse of
current before welding will accomplish this. During the weld, the zinc can
combine with the steel and lower its resistivity. Therefore, higher levels of
current are required to weld galvanized steel.
Electrode force:-
An adequate target value for the electrode force is 90 N per mm2. One
problem, though, is that the size of the contact surface will increase during
welding. To keep the same conditions during the whole welding process, the
electrode force needs to be gradually increased. As it is rather difficult to
change the electrode force in the same rate as the electrodes are
"mushroomed", usually an average value is chosen.
Diameter of the electrode contact surface:-
One general criterion of resistance spot-welding is that the weld shall have a
nugget diameter of 5*t1/2, “t” being the thickness of the steel sheet. Thus, a
spot weld made in two sheets, each 1 mm in thickness, would generate a
nugget 5 mm in diameter according to the 5*t½-rule. Diameter of the electrode
contact surface should be slightly larger than the nugget diameter. For
example, spot welding two sheets of 1 mm thickness would require an
electrode with a contact diameter of 6 mm. In practice, an electrode with a
contact diameter of 6 mm is standard for sheet thickness of 0.5 to 1.25 mm.
This contact diameter of 6 mm conforms to the ISO standard for new
electrodes.
Squeeze time:-
Squeeze Time is the time interval between the initial application of the
electrode force on the work and the first application of current. Squeeze time
is necessary to delay the weld current until the electrode force has attained
the desired level.
Weld time:-
Weld time is the time during which welding current is applied to the metal
sheets. The weld time is measured and adjusted in cycles of line voltage as are
all timing functions. One cycle is 1/50 of a second in a 50 Hz power system.
(When the weld time is taken from American literature, the number of cycles
has to be reduced due to the higher frequency (60Hz) that is used in the USA.)
As the weld time is, more or less, related to what is required for the weld spot,
it is difficult to give an exact value of the optimum weld time. For instance:
The weld time shall cause the nugget diameter to be big when welding thick
sheets.
The weld time might have to be adjusted to fit the welding equipment in case
it does not fulfil the requirements for the weld current and the electrode force.
(This means that a longer weld time may be needed.)
The weld time shall cause the indentation due to the electrode to be as small
as possible. (This is achieved by using a short weld time.) The weld time shall
be adjusted to welding with automatic tip-dressing, where the size of the
electrode contact surface can be kept at a constant value. (This means a
shorter welding time.) When welding sheets with a thickness greater than 2
mm it might be appropriate to divide the weld time into a number of impulses
to avoid the heat energy to increase. This method will give good-looking spot
welds but the strength of the weld might be poor. By multiplying the thickness
of the sheet by ten, a good target value for the weld time can be reached.
When welding two sheets with the thickness 1 mm each, an appropriate weld
time is 10 periods (50Hz).
Hold time is the time, after the welding, when the electrodes are still applied
to the sheet to chill the weld. Considered from a welding technical point of
view, the hold time is the most interesting welding parameter. Hold time is
necessary to allow the weld nugget to solidify before releasing the welded
parts, but it must not be to long as this may cause the heat in the weld spot to
spread to the electrode and heat it. The electrode will then get more exposed
to wear. Further, if the hold time is too long and the carbon content of the
material is high (more than 0.1%), there is a risk the weld will become brittle.
When weld galvanized carbon steel a longer hold time is recommended.
Weld current:-
The weld current is the current in the welding circuit during the making of a
weld. The amount of weld current is controlled by two things; first, the setting
of the transformer tap switch determines the maximum amount of weld
current available; second the percent of current control determines the
percent of the available current to be used for making the weld. Low percent
current settings are not normally recommended as this may impair the quality
of the weld. Adjust the tap switch so that proper welding current can be
obtained with the percent current set between seventy and ninety percent.
The weld current should be kept as low as possible. When determining the
current to be used, the current is gradually increased until weld spatter occurs
between the metal sheets. This indicates that the correct weld current has
been reached.
Methodology:-
1. First step all the sheets of metal is procured from the vendor
2. The grade of the material is checked by the inspection department. In
inspection these three things are checked. Wrong size of the metal sheet,
grade of the metal sheet and the visual defects of the metal sheet.
3. Then in the series of making Right side of case first operation is performed
in this step we joint upper R body to Patch A and Patch B.
4. Patch A has two spots points and Patch B has four spot points.
5. One point of Patch A also will be jointed with bolt support to body
6. One corner point of Patch B also will be jointed with bolt support to body.
7. Right Side of Chain case is final now.
8. Then in the series of making Left side of case first operation is performed in
this step we joint upper L body to Plate A, Plate B and Plate C.
9. Plate A has two spot points Plate B has four spot points and Plate C has
four spot points too.
10. Swing arm patch also will be attached with Plate B at Corner.
11. These Plates A, B, C will further used for fitment of case with body.
12. Then we joint Dust Guard on L body. Dust Guard has seven spot points.
13. In last Plate D will attach with both sides and then chain case will go for
PDI.
1. In first step of PDI we measure the holes via gauge and inspect the position
of hole and joints.
2. In second step of PDI we test the strength of joint via performing stretch
test. Scratch and Roundness of edges and corner also perform again here.
3. Then Chain case will send for Painting.
The whole procedure of making Chain Case will take 20 seconds to complete
with PDI. Making process of Right and Left Part has been done parallel. The
annual defects of the pieces are 2% of total.
Conclusion of Project:-
Joining procedure of Chain Case of Honda Unicorn has been completed. The
total find error is 5% on my work.
Object:- Painting Procedure of Chain Case of Honda Unicorn KSPG, Connecting
Rod of Honda Unicorn KSPG and Honda Activa KWPG.
Primer is a paint product that allows finishing paint to adhere much better
than if it was used alone. For this purpose, primer is designed to adhere to
surfaces and to form a binding layer that is better prepared to receive the
paint. Because primers do not need to be engineered to have durable, finished
surfaces, they can instead be engineered to have improved filling and binding
properties with the material underneath. Sometimes, this is achieved with
specific chemistry, as in the case of aluminium primer, but more often, this is
achieved through controlling the primer's physical properties such as porosity,
tackiness, and hygroscope.
In practice, primer is often used when painting many kinds of porous materials,
such as concrete and especially wood (see detailed description below). Priming
is mandatory if the material is not water resistant and will be exposed to the
elements. Priming gypsum board (drywall) is also standard practice with new
construction because it seals the wall and aids in preventing mould. Primers
can also be used for dirty surfaces that, for some reason, cannot be cleaned, or
before painting light colours over existing dark colours.
Primers can usually be tinted to a close match with the colour of the finishing
paint. If the finishing paint is a deep colour, tinting the primer can reduce the
number of layers of finishing paint that are necessary for good uniformity
across the painted surface.
There may be a maximum time frame within which a topcoat should be
applied over the primer after the primer dries, in order to achieve maximum
performance. Depending on the primer, the next coat of paint should be
applied as quickly as 24 hours or you may have as long as 2 weeks. Painting
after the suggested timeframe may cause performance issues depending on
the specific situation. Supposedly, you want to apply the finish coat of paint
before the primer fully cures on a molecular level. Doing this allows maximum
adhesion/bonding of the topcoat to the primer. If top coating after the
suggested timeframe, consider using a "self priming" topcoat. For definitive
answers on recommended repainting timeframe, check the primer
label/website, or contact the manufacturer directly. Recoat timeframe is most
likely a more critical factor in exterior application because of the more extreme
climatic exposure.
Metal hydroxides/oxides do not provide a solid surface for the paint to adhere
to, and paint will come off in large flakes. Using a primer will provide extra
insurance against such a scenario. An additional reason for using a primer on
metal could be the poor condition of the surface. A steel part can be rusty, for
example. Of course, the best solution is to thoroughly clean the metal
(blasting), but when this is not a viable option, special kinds of primers can be
used that chemically convert rust to the solid metal salts. And even though
such surface is still lacking in comparison to the shiny clean metal, it is yet
much better than weak, porous rust.
Methodology:-
Loading
Knock of Degreasing
Degreasing
Surface Activation
Phosphatising
DM Water Rinse 1
DM Water Rinse 2
Tag Rag
Primer Coat
Base Coat
Top Coat
Unloading
Preparations for the Painting Procedure:-
1. For the Hot Water Rinse: Here we take a sump tank for containing of water
than we heat that up to 40 to 60˚C with maintaining of 0.5 to 1.2 Kg/cm2
pressure. Here we take normal water which is usually available.
2. For Knock of Degreasing: Here we take a cleaning chemical in a tank and
maintain 40 to 60˚C temperature, 0.5 to 1.2 Kg/cm2 pressure and alkalinity
30 to 35 ml.
3. For Degreasing: Here we again maintain the cleaning chemical condition as
Knock of Degreasing.
4. For Water Rinse 1: Here we take water in a tank and maintain pressure at
0.5 to 1.0 Kg/cm2 and pH value at 8.0 to 10.0.
5. For Water Rinse 2: Here we again take water in tank and maintain pressure
at 0.5 to 1.0 Kg/cm2 and pH value at 8.0 to 9.0.
6. For Surface Activation: Here we take a special chemical in tank for that
maintains pressure at 0.5 to 1.0 Kg/cm2 and pH value at 8.0 to 10.0.
7. For Phosphatising: We take a coat of phosphate for that maintain pressure
at 0.8 to 1.0 Kg/cm2, Temperature at 40 to 50˚C, Total Acidity 20 to 24 ml,
Free Acidity 0.6 to 0.8 ml and Tonner Value at 2 to 4 ml.
8. For DM Rinse 1: We take water in tank and maintain pressure at 0.5 to 1.0
Kg/cm2 and pH value at 5 to 6.
9. For DM Rinse 2: We take water in tank and maintain pressure at 0.5 to 1.0
Kg/cm2 and pH value at 6.5 to 7.0.
10.For Dry off Oven: Maintain Temperature at 90 to 100˚C.
11.For Coating: A spray paint equipment is required and Water-Grease
Solution to prevent walls from Coat.
12.For Paint Baking Oven: Maintain Temperature at 130 to 140˚C.
*Cleaning chemical for KOD and chemical for Surface Activation are patented
products of company. They don’t disclose composition and name of these.
These chemicals are only known by their work.
Process:-
1. In first step chain case, connecting rod loaded on Hangers. This hanger is
attached with the 249 meter long belt. On the whole length of belt 416
hangers are attached.
2. Then these loaded parts went to first chamber which is Hot Water Rinse
chamber. In this chamber hot water rain dropped on the parts which cleans
all the dirt and all other things.
3. Then these loaded parts went to next chamber which is KOD (Knock of
Degreasing) chamber. In this chamber a cleaning chemical dropped on the
parts which remove water from surface, other dirt which cannot be
cleaned by water and extra material.
4. Then these parts went to next chamber degreasing chamber which again
perform KOD action. This is for precautions that if any impurity is left that
will definitely clear here.
5. Then it went to Industrial Water Rinse 1 chamber where distilled water
clears the cleaning chemical.
6. In next chamber industrial Water Rinse 2 again distilled water rain over
parts and clean them.
7. Then they sanded to Surface Activation chamber where a chemical
dropped on parts and this rain activates surface of parts for next step.
8. Then parts went into Phosphatising chamber here rain of phosphate occurs
over parts which creates a layer of phosphate over them. This coat of
phosphate makes paint properly bind with part.
9. Then in DM Rinse Water 1 chamber these parts again cleans. This cleans
the unwanted phosphate coating and impurity (if left).
10.Then in DM Rinse Water 2 chamber these parts again cleans. This again
cleans impurity (if left).
11.In next step it sanded to air blower chamber which dries water from parts.
12.After air blowing it went to Water Dry Oven chamber here it heats up to 90
to 100˚C which definitely removes water from parts.
13.After these pre treatment processes now Parts come into TAG RAG
chamber. Here workman manually check all parts and put some another
parts (which have some error in painting in previous cycle).
14.Now after manually checking parts sanded to Primer Coat chamber here a
medium viscous paint has been painted manually via spray paint gun. Here
a gel mixture of Water-Grease continuous flow on chamber wall to prevent
walls from Paint.
15.Then parts sanded to Base Coat chamber here a high viscous paint has
been panted manually over Primer Coated part. This creates a second layer
of paint on Parts.
16.Then parts sanded to Top Coat chamber (if required) here a low viscous
paint has been painted manually via spray paint gun on Base Coated Parts.
This process is only necessary for some parts. Usually this is not required.
17.Then at last parts sanded to Paint Bake Oven here they left for the Baking
at temperature of 130 to 140˚C for 20 minutes. This makes paint
permanently bind with part.
18.After the baking process parts unloaded from Hangers for PDI
19.The whole process runs at 1.6m/min speed of belt.
Chemical Tests:-
Water Rinse:
Free Acidity:
One of the most common instruments for measuring kinematic viscosity is the
glass capillary viscometer.
In coating industries, viscosity may be measured with a cup in which the efflux
time is measured. There are several sorts of cup- e.g. Zahn cup, Ford viscosity
cup- with usage of each type varying mainly according to the industry. The
efflux time can also be converted to kinematic viscosities (centistokes, cSt)
through the conversion equations.
The Ford viscosity cup is a simple gravity device that permits the timed flow of
a known volume of liquid passing through an orifice located at the bottom.
Under ideal conditions, this rate of flow would be proportional to
the kinematic viscosity (expressed in stokes and centistokes) that is dependent
upon the specific gravity of the
draining liquid. However, the
conditions in a simple flow cup are
seldom ideal for making true
measurements of viscosity. It is
important when using a Ford Cup and
when retesting liquids that the
temperature of the cup and the liquid
is maintained, as ambient temperature
makes a significant difference to
viscosity and thus flow rate.
The original Ford Cup was based on Imperial (US) measurement of the
aperture.
Din Cup 4 mm., standard DIN 53211 (cancelled) ISO Cup 2, 3, 4, 5, 6, 8 mm.
standard ISO 2431 AFNOR Cup 2,5, 4, 6, 8 mm. standard NF T30-014 ASTM Cup
1,2,3,4,5 standard ASTM D1200
Here Paint used for Painting Chain Case, Connecting Rod is Nerolec Paint.
The Ford Viscosity Cup which is used in Company has volume of 100-106 ml.
Total Time is 30 min. in Painting Procedure of Chain Case & Connecting Rod.
Coat Type Ford Viscosity Cup Value
Primer Coat 15-18 sec
Base Coat 17-20 sec
Top Coat 15 sec
Total annual error in painting of Chain Case and Connecting Rod is 0.2%.
Conclusion of Project:-
Painting procedure of the Chain Case of Honda Unicorn and Connecting Rod of
Honda Unicorn and Honda Activa is completed. No error was found in working
procedure.
Object:- Making process of Step Pillion of Honda Activa.
Abstract:- Step Pillion or Foot Rest is provided for the relaxation of back sitter
foot. This is made of Mild Steel and attached with the frame. Honda Activa has
two foot rest Left Side and Right Side. This step pillion is jointed via Mig
Welding Process and it is jointed to frame via Electric Arc Welding.
MIG Welding:-
Metal Inert Gas (MIG) welding, sometimes referred to by Gas metal arc
welding (GMAW) welding or metal active gas (MAG)welding, is a welding
process in which an electric arc forms between a
consumable wire electrode and the work piece metal(s), which heats the work
piece metal(s), causing them to melt, and join. Along with the wire electrode,
a shielding gas feeds through the welding gun, which shields the process from
contaminants in the air. The process can be semi-automatic or automatic. A
constant voltage, direct current power source is most commonly used with
GMAW, but constant current systems, as well as alternating current, can be
used. There are four primary methods of metal transfer in GMAW, called
globular, short-circuiting, spray, and pulsed-spray, each of which has distinct
properties and corresponding advantages and limitations.
Equipment of MIG:-
To perform gas metal arc welding, the basic necessary equipment is a welding
gun, a wire feed unit, a welding power supply, an electrode wire, and
a shielding gas supply.
Welding Gun:-
The typical GMAW welding gun has a number of key parts—a control switch, a
contact tip, a power cable, a gas nozzle, an electrode conduit and liner, and a
gas hose. The control switch, or trigger, when pressed by the operator, initiates
the wire feed, electric power, and the shielding gas flow, causing an electric arc
to be struck. The contact tip, normally made of copper and sometimes
chemically treated to reduce spatter, is connected to the welding power
source through the power cable and transmits the electrical energy to the
electrode while directing it to the weld area. It must be firmly secured and
properly sized, since it must allow the electrode to pass while maintaining
electrical contact. On the way to the contact tip, the wire is protected and
guided by the electrode conduit and liner, which help prevent buckling and
maintain an uninterrupted wire feed. The gas nozzle directs the shielding gas
evenly into the welding zone. Inconsistent flow may not adequately protect
the weld area. Larger nozzles provide greater shielding gas flow, which is useful
for high current welding operations that develop a larger molten weld pool. A
gas hose from the tanks of shielding gas supplies the gas to the nozzle.
Sometimes, a water hose is also built into the welding gun, cooling the gun in
high heat operations.
The wire feed unit supplies the electrode to the work, driving it through the
conduit and on to the contact tip. Most models provide the wire at a constant
feed rate, but more advanced machines can vary the feed rate in response to
the arc length and voltage. Some wire feeders can reach feed rates as high as
30.5 m/min (1200 in/min), but feed rates for semiautomatic GMAW typically
range from 2 to 10 m/min (75–400 in/min)
Tool style:-
Power Supply:-
Most applications of gas metal arc welding use a constant voltage power
supply. As a result, any change in arc length (which is directly related to
voltage) results in a large change in heat input and current. A shorter arc
length causes a much greater heat input, which makes the wire electrode melt
more quickly and thereby restore the original arc length. This helps operators
keep the arc length consistent even when manually welding with hand-held
welding guns. To achieve a similar effect, sometimes a constant current power
source is used in combination with an arc voltage-controlled wire feed unit. In
this case, a change in arc length makes the wire feed rate adjust to maintain a
relatively constant arc length. In rare circumstances, a constant current power
source and a constant wire feed rate unit might be coupled, especially for the
welding of metals with high thermal conductivities, such as aluminium. This
grants the operator additional control over the heat input into the weld, but
requires significant skill to perform successfully.
Electrode:-
Shielding Gas:-
Shielding gases are necessary for gas metal arc welding to protect the welding
area from atmospheric gases such as nitrogen and oxygen, which can cause
fusion defects, porosity, and weld metal embrittlement if they come in contact
with the electrode, the arc, or the welding metal. This problem is common to
all arc welding processes; for example, in the older Shielded-Metal Arc Welding
process (SMAW), the electrode is coated with a solid flux which evolves a
protective cloud of carbon dioxide when melted by the arc. In GMAW,
however, the electrode wire does not have a flux coating, and a separate
shielding gas is employed to protect the weld. This eliminates slag, the hard
residue from the flux that builds up after welding and must be chipped off to
reveal the completed weld.
The choice of a shielding gas depends on several factors, most importantly the
type of material being welded and the process variation being used. Pure inert
gases such as argon and helium are only used for nonferrous welding; with
steel they do not provide adequate weld penetration (argon) or cause an
erratic arc and encourage spatter (with helium). Pure carbon dioxide, on the
other hand, allows for deep penetration welds but encourages oxide
formation, which adversely affect the mechanical properties of the weld. lts
low cost makes it an attractive choice, but because of the reactivity of the arc
plasma, spatter is unavoidable and welding thin materials is difficult. As a
result, argon and carbon dioxide are frequently mixed in a 75%/25% to
90%/10% mixture. Generally, in short circuit GMAW, higher carbon dioxide
content increases the weld heat and energy when all other weld parameters
(volts, current, electrode type and diameter) are held the same. As the carbon
dioxide content increases over 20%, spray transfer GMAW becomes
increasingly problematic, especially with smaller electrode diameters.
Argon is also commonly mixed with other gases, oxygen, helium, hydrogen,
and nitrogen. The addition of up to 5% oxygen (like the higher concentrations
of carbon dioxide mentioned above) can be helpful in welding stainless steel,
however, in most applications carbon dioxide is preferred. Increased oxygen
makes the shielding gas oxidize the electrode, which can lead to porosity in the
deposit if the electrode does not contain sufficient deoxidizers. Excessive
oxygen, especially when used in application for which it is not prescribed, can
lead to brittleness in the heat affected zone. Argon-helium mixtures are
extremely inert, and can be used on nonferrous materials. A helium
concentration of 50%–75% raises the required voltage and increases the heat
in the arc, due to helium's higher ionization temperature. Hydrogen is
sometimes added to argon in small concentrations (up to about 5%) for
welding nickel and thick stainless steel work pieces. In higher concentrations
(up to 25% hydrogen), it may be used for welding conductive materials such as
copper. However, it should not be used on steel, aluminium or magnesium
because it can cause porosity and hydrogen embrittlement.
Operation:-
For most of its applications gas metal arc welding is a fairly simple welding
process to learn requiring no more than a week or two to master basic welding
technique. Even when welding is performed by well-trained operators weld
quality can fluctuate since it depends on a number of external factors. All
GMAW is dangerous, though perhaps less so than some other welding
methods, such as shielded metal arc welding. The basic technique for GMAW is
quite simple, since the electrode is fed automatically through the torch (head
of tip). By contrast, in gas tungsten arc welding, the welder must handle a
welding torch in one hand and a separate filler wire in the other, and in
shielded metal arc welding, the operator must frequently chip off slag and
change welding electrodes. GMAW requires only that the operator guide the
welding gun with proper position and orientation along the area being welded.
Keeping a consistent contact tip-to-work distance (the stick out distance) is
important, because a long stick out distance can cause the electrode to
overheat and also wastes shielding gas. Stick out distance varies for different
GMAW weld processes and applications. The orientation of the gun is also
important—it should be held so as to bisect the angle between the work
pieces; that is, at 45 degrees for a fillet weld and 90 degrees for welding a flat
surface. The travel angle, or lead angle, is the angle of the torch with respect to
the direction of travel, and it should generally remain approximately vertical.
However, the desirable angle changes somewhat depending on the type of
shielding gas used—with pure inert gases; the bottom of the torch is often
slightly in front of the upper section, while the opposite is true when the
welding atmosphere is carbon dioxide.
The use of an inert gas makes this type of welding less portable than arc
welding which requires no external source of shielding gas
Parts:-
1. Holder
2. Cable Tie
3. R Pipe
4. Straight Pipe
5. Stay
6. Patgn (Thick and Thin)
7. Gusset Stay
8. MIG Welding
Methodology:-
1. First step all the sheets of metal is procured from the vendor
2. The grade of the material is checked by the inspection department. In
inspection these three things are checked. Wrong size of the metal sheet,
grade of the metal sheet and the visual defects of the metal sheet.
3. After this all inspection Gusset Holder will join with R Pipe and Straight
Pipe.
4. In next step Patgn will join with upper made assembly.
5. Further Stay will join with made assembly.
6. Then Cable Tie and Gusset Stay will join with assembly in left side assembly
of pillion whole process is same but cable tie will not be jointed. Then it will
send to PDI.
Total time for the making of step pillion of Honda Activa is 20 second.
Conclusion of Project:-
Abstract:- A frame is the main structure of the chassis of a motor vehicle. All
other components fasten to it; a term for this design is body-on-frame
construction.
These include:
A motorcycle frame includes the head tube that holds the front fork and allows
it to pivot. Some motorcycles include the engine as a load-bearing, stressed
member. The rear suspension is an integral component in the design.
Traditionally frames were steel, but titanium, aluminium, magnesium,
and carbon-fibre, along with composites of these materials, are now used.
Because of different motorcycles' varying needs of cost, complexity, weight
distribution, stiffness, power output and speed, there is no single ideal frame
design.
Material used for Frame:-
Steel
Aluminium
Carbon Fibre
Titanium
Magnesium
Composite
Spine or Backbone
Single Cradle
Half-Duplex Cradle
Full Duplex Cradle
Perimeter
Beam
Pressed
Monocoque
Trellis
Underbone
Arc welding is a type of welding that uses a welding power supply to create
an electric arc between an electrode and the base material to melt the metals
at the welding point. They can use either direct (DC) or alternating (AC)
current, and consumable or non-consumable electrodes. The welding region is
usually protected by some type of shielding gas, vapor, or slag. Arc welding
processes may be manual, semi-automatic, or fully automated. First developed
in the late part of the 19th century, arc welding became commercially
important in shipbuilding during the Second World War. Today it remains an
important process for the fabrication of steel structures and vehicles.
Power Supply:-
To supply the electrical energy necessary for arc welding processes, a number
of different power supplies can be used. The most common classification is
constant current power supplies and constant voltage power supplies. In arc
welding, the voltage is directly related to the length of the arc, and the current
is related to the amount of heat input. Constant current power supplies are
most often used for manual welding processes such as gas tungsten arc
welding and shielded metal arc welding, because they maintain a relatively
constant current even as the voltage varies. This is important because in
manual welding, it can be difficult to hold the electrode perfectly steady, and
as a result, the arc length and thus voltage tend to fluctuate. Constant voltage
power supplies hold the voltage constant and vary the current, and as a result,
are most often used for automated welding processes such as gas metal arc
welding, flux cored arc welding, and submerged arc welding. In these
processes, arc length is kept constant, since any fluctuation in the distance
between the wire and the base material is quickly rectified by a large change in
current. For example, if the wire and the base material get too close, the
current will rapidly increase, which in turn causes the heat to increase and the
tip of the wire to melt, returning it to its original separation distance.
The direction of current used in arc welding also plays an important role in
welding. Consumable electrode processes such as shielded metal arc welding
and gas metal arc welding generally use direct current, but the electrode can
be charged either positively or negatively. In welding, the positively
charged anode will have a greater heat concentration and, as a result,
changing the polarity of the electrode has an impact on weld properties. If the
electrode is positively charged, it will melt more quickly, increasing weld
penetration and welding speed. Alternatively, a negatively charged electrode
results in more shallow welds. Non-consumable electrode processes, such as
gas tungsten arc welding, can use either type of direct current (DC), as well as
alternating current (AC). With direct current however, because the electrode
only creates the arc and does not provide filler material, a positively charged
electrode causes shallow welds, while a negatively charged electrode makes
deeper welds. Alternating current rapidly moves between these two, resulting
in medium-penetration welds. One disadvantage of AC, the fact that the arc
must be re-ignited after every zero crossing, has been addressed with the
invention of special power units that produce a square wave pattern instead of
the normal sine wave, eliminating low-voltage time after the zero crossings
and minimizing the effects of the problem.
The equipment that is used for welding purposes is not very expensive and
can be afforded by all. It is also easy to use. This makes it very convenient
for people who want to weld using ARC welding.
You will generally think of welding equipment as being unwieldy and
heavy. The equipment used in ARC welding is portable making it very easy
for use in all places. It can be taken to any place and can also be inside a
confined place.
It is not necessary to have auxiliary gas shielding.
The reason that it is most used is that it is suitable for welding most metals
and alloys. So, you need not go in for different types of welding and can do
with ARC welding.
There is need to replace the weld electrode in ARC welding frequently. So,
care should be taken to do it whenever necessary.
The rate of deposition is lower than continuous electrode process.
It is necessary to remove the slag from the weld.
When welding, very bright is produced. The welding operator should be
very careful and wear protective glasses. The welder should also wear
protective gear, so that he is protected from electric shock, burns and
other problems that might arise while welding due to the high intensity of
heat.
Welding is an essential process for joining two metals and arc welding is
most commonly used because of the minimum equipment used and a
person with minimum training. So, you should consider the pros and cons
before starting to arc weld. Since the cons can all be taken care of and arc
welding is a very useful and simple process for welding, people should use
it for welding purposes.
Methodology:-
Diameter = 38.10 mm
Length = 929 mm
1. First step all the sheets of metal is procured from the vendor.
2. The grade of the material is checked by the inspection department. In
inspection these three things are checked. Wrong size of the metal pipe,
grade of the metal pipe and the visual defects of the metal pipe.
3. In after inspection step pipe is bended via Bending Machine which is made
by YLM Taiwan. It is a computer operated system. This machine used
Hydraulic energy for Clamping, Holding and Pressing. The pressure is used
to bend this pipe is 110 Kg/cm2 with maximum tolerance of 1 mm. Here
pipe is bended to a pre defined shape. Honda Avtiva has underbone type of
frame.
4. After bending the pipe sanded to Milling Section. In this section milling
section Drill holes in it during the drill operation water is used as coolant.
5. Than operation performed pipe sanded for Grinding Operation. In this
section Grinder wheel is used to finish surface and remove extra material
from pipe.
6. In next step of assembly a Rod opener and centre cross welding has to be
done.
7. Then this prepared pipe sanded for the assembly. In first step of assembly
pipe is pivoted and under covered.
8. In next step L shape bended pipe welded with Seat Lock, Duet Pipe and join
with 3 rubber clips.
9. Then a robot do Round welding of duet pipe. Rear frame is prepared by
going through these steps.
10.In the assembly of front frame first bended pipe join with Lower Cross via
Patch Welding
11.Then main pipe joint with Lower Cross via welding.
12.Then at next assembly main pipe head pipe, gusset pipe, step bar join via
welding and a wise harshness has clipped with it.
13.Then to make these permanent joint an open final welding has to be done.
14.Then an open final welding and round welding joint both side of frames.
15.Then main pipe gusset is jointed with round welding.
16.Then guide cable, RR break cable, guide throsed cable jointed and sand for
quality check.
In first step of quality check the completed frame grinded and reworked.
The fine boring operation has to be done where required.
Then tapping operation performed and Frame sand to PDI.
1. Due to the uneven grains many times wrinkle occur during bending. This
problem cannot be solved. This makes pipe waste.
2. Due to uneven force many times bending variation occurs. This is also a
insolvable problem and makes pipe waste.
1. Due to uneven grains notching problem occurs and this is also insolvable
problem and makes pipe waste.
2. Due to wear of drill jig many times holes drilling get uneven. This problem
can be solved via drilling with new jig.
1. Due to problem in pipe shape and grinding wheel more chip get removed
from pipe. This may make pipe waste.
2. Surface Finish
Conclusion of Project: