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INTERNSHIP REPORT AT
FREINS METAL LIMITED
from
16/05/19 to 21/05/19

SATHYABAMA ISNTITUTE OF SCIENCE AND TECHNOLOGY

Jeppiar Nagar, Rajiv Gandhi Salai, Chennai-600119

Submitted by
Rahul Srivatsan.M.R.
17SME065
Department of Mechanical Engineering
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DECALARTION

I hereby declare that this internship report is authentic record of

my work, performed at Freins Metal Ltd during the period of
16/05/2019-21/05/19.Submitted for the partial fulfilment of the
requirements for the award of degree of Bachelor of Engineering in
Mechanical, Sathyabhama Institute of Science and technology and
the interpretations therein are based on the material collected by
myself.
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ACKNOWLEDGEMENT
Firstly, I would like to thank Mr. Balaji for guiding me in a
right way to improve technical knowledge in subject and
helping me in getting permission for doing my internship at
Freins. His immense knowledge in subject and his
experience not only made me inspired but also gave me
confidence to achieve a valuable position in my life. I would
like to thank all the departments of FREINS who helped me
in doing internship comfortably.
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TABLE OF CONTENTS

1) About FREINS
2) Plunger
a) Working
b) Application
3) Control plan of a plunger
a) Tool shop
b) Machining
i) Wickman
ii) Gildemeister
c) Process flow for Wickman, Gildemeister
4) Quality check before operation
5) Daily machine checklist
6) Quality checks for a plunger
7) Measuring instrument
8) Types of plunger
9) Learning experience
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FREINS METAL LIMITED

Freins Metal Limited is a Public incorporated on 26 June

1992 located at SIDCO industrial estate, Ambattur, Chennai.
Freins metal ltd is a unit of Brakes India Ltd. It is a dedicated
unit as it manufactures around 10 lakh plungers a month
making it one of the largest plunger manufacturing
companies in India. It has a strong customer base which
includes Nissan, Honda, TATA, Maruthi Suzuki etc. It
operates 14hrs a day from 8 AM to 10 PM.
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PLUNGER

A plunger is a piston like reciprocating part moving within the cylinder of a pump or
hydraulic device. The invention of the plunger pump is attributed to Samuel Morland
based on a patent of 1675.

Operation

Plunger pumps are reciprocating pumps that use a plunger or piston to move media
through a cylindrical chamber. The plunger or piston is actuated by a steam powered,
pneumatic, hydraulic, or electric drive.
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Rotary piston and plunger pumps use a crank mechanism to create a reciprocating motion
along an axis, which then builds pressure in a cylinder or working barrel to force gas or
fluid through the pump. The pressure in the chamber actuates the valves at both the
suction and discharge points. Plunger pumps are used in applications that could range
from 70 to 2,070 bar (1,000 to 30,000 psi). Piston pumps are used in lower pressure
applications. The volume of the fluid discharged is equal to the area of the plunger or
piston, multiplied by its stroke length. The overall capacity of the piston pumps and
plunger pumps can be calculated with the area of the piston or plunger, the stroke length,
the number of pistons or plungers and the speed of the drive. The power needed from the
drive is proportional to the pressure and capacity of the pump.

Seals are an integral part of piston pumps and plunger pumps to separate the power fluid
from the media that is being pumped. A stuffing box or packing is used to seal the joint
between the vessel where the media is transferred and the plunger or piston. A stuffing
box may be composed of bushings, packing or seal rings, and a gland.

Plunger pumps component materials are chosen for wear and contact with the media
type. Component materials include bronze, brass, steel, stainless steel, iron, nickel alloy,
or other material. For example, plunger pumps that function in general service or oil
service applications often have an iron cylinder and plunger. The plunger, discharge
valves, and suction valves come in contact with the media type transferred, and material
choices are based on the fluid transferred. In power applications where continuous duty
plunger pumps are needed, solid ceramic plungers may be used when in contact with
water and oil, but may not be compatible for use with highly acidic media types.
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Plunger pump in Hydraulic brake system

In a hydraulic brake system, when the brake pedal is pressed, a pushrod exerts force on
the piston(s) in the master cylinder, causing fluid from the brake fluid reservoir to flow
into a pressure chamber through a compensating port. This results in an increase in the
pressure of the entire hydraulic system, forcing fluid through the hydraulic lines toward
one or more calipers where it acts upon one or more caliper pistons sealed by one or
more seated O-rings (which prevent leakage of the fluid).
The brake caliper pistons then apply force to the brake pads, pushing them against the
spinning rotor, and the friction between the pads and the rotor causes a braking torque to
be generated, slowing the vehicle. Heat generated by this friction is either dissipated
through vents and channels in the rotor or is conducted through the pads, which are made
of specialized heat-tolerant materials such as Kevlar or sintered glass.

Alternatively, in a drum brake, the fluid enters a wheel cylinder and presses one or two
brake shoes against the inside of the spinning drum. The brake shoes use a similar heat-
tolerant friction material to the pads used in disc brakes.
Subsequent release of the brake pedal/lever allows the spring(s) in the master cylinder
assembly to return the master piston(s) back into position. This action first relieves the
hydraulic pressure on the caliper, then applies suction to the brake piston in the caliper
assembly, moving it back into its housing and allowing the brake pads to release the rotor.

The hydraulic braking system is designed as a closed system: unless there is a leak in the
system, none of the brake fluid enters or leaves it, nor does the fluid get consumed
through use. Leakage may happen, however, from cracks in the O-rings or from a puncture
in the brake line. Cracks can form if two types of brake fluid are mixed or if the brake fluid
becomes contaminated with water, alcohol, antifreeze, or any number of other liquids.
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CONTROL PLAN FOR MANUFACTURING A PLUNGER

Tool shop

1.MATERIAL SELECTION

STEEL:
Green-Blue
White-Green
Red Aluminium

ALUMINUM:
Red-Violet
Yellow – Violet

2.OILS TO BE USED:
Veedol-For lubrication

Rustop- Prevents rusting

Diesel-for cleaning

3.GAUGES
GH- HEIGHT gauge
GD- Depth gauge
GP-Plug gauge
STD-standard gauge
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MACHINING
A plunger can be manufactured either by a Wickman multi spindle machine or using
Gildemeister

WICKMAN
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Flow process of Wickman:

1. Bar material from tool store
2. Blank Machining
3. Slot milling
4. Spherical drilling
5. Retainer hole rearing &washing
6. Heat treatment (SQF)
7. Major O.D. through grinding
8. Barrolling
9. Final Inspection and Packing
10. Blackening
11. Receiving inspection
12. Despatch

GILDEMEISTER
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Flow process of Gildemeister:

1. Bar material from tool store
2. Blank Machining
3. Spherical drilling
4. holes drilling
5. Deburring (neaten and smooth the rough edges)
6. Heat treatment
7. Major O.D. through grinding
8. Barrolling
9. Final Inspection and Packing
10. Blackening
11. Receiving inspection
12. Despatch

Quality Check before operation:

1. Verify drawing/control plan for required plunger
2. Daily machine maintenance check list
3. Poka Yoke checklist
4. Gauge calibration
5. Daily machine checklist
6. Clean the machine
7. Check the oil level in circulating lubricating oil
8. Check the oil level in internal lubrication oil tank and machine tank
9. Poke Yoke/Kaizen
10. Tool fixture tightness & condition
11. Function of end bar reset

Quality Check before operation:

1. Dimension checking
2. Move to tag
3. Follow as per PCC/SPC control plan
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Difference between Wickman and Gildemeister

Wickman Gild.

Cam position Bottom Top

Productions/cycle High Comparatively

low
Speed Can be varied Cannot be varied

Quality checks for a plunger:

• Check whether the plunger is free from damage

• Burr check
• Check for Dent marks
• Check for rust and sharpening on corners
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Instruments used for checking various dimensions of a plunger:

Dial Indicator:

A dial test indicator, also known as a lever arm test indicator or finger indicator, has a
smaller measuring range than a standard dial indicator. A test indicator measures the
deflection of the arm, the probe does not retract but swings in an arc around its hinge
point.

Roughness tester

Roughness is an important parameter when trying to find out whether a surface is

suitable for a certain purpose. Rough surfaces often wear out more quickly than smoother
surfaces. Rougher surfaces are normally more Roughness Tester Overview vulnerable to
corrosion and cracks, but they can also aid in adhesion. A roughness tester is used to
quickly and accurately determine the surface texture or surface roughness of a material. A
roughness tester shows the measured roughness depth (Rz) as well as the mean
roughness value (Ra) in micrometers or microns (µm)
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Height measurment:

Runout checker:

Total Runout is measured by fixing the all datum points and rotating the part along the
rotational axis. The part is usually constrained with a set of V-blocks or a spindle of some
sort that will constrain the part while allowing it to rotate. To measure total runout, a
series of gauges must be linked to take their measurement in reference to each other –
similar to how cylindricity is measured.
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TYPES OF PLUNGER:

Wheel Cylinder plunger Clutch Actuation plunger

Tandem master cylinder plunger

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LEARNING EXPERIENCE:

This internship has been an excellent and rewarding experience. Have been
able to meet managers and subordinates of FREINS, and was very easy to
conveniently interact with them. I hope it will surely help me with
opportunities in the future.
I came to know about the corporate culture and how challenging the work is.
The way they plan, analyse and deliver the product within the deadline is
amazing.
I acquired a deep knowledge on how a product is manufactured right from
choosing the raw materials to dispatch
I have learnt the practical aspect of many concepts and had a hands-on
experience in this internship.
Finally, I would like to conclude that FREINS METAL is one of the fastest
growing companies.
FREINS manufactures 10 lakh plungers a month and it is achieved only
through the hard work and commitment of the employees. Hence, it is the
dedicated units of Brakes India.