Industrial Training Seminar

SATISH H S
3rd sem M.Tech(CIM)
4PS12MCM12
 Company profile

RANE (MADRAS) LIMITED PLANT II

79/84, HOOTAGALLI INDUSTRIAL AREA,
MYSORE 570018.

Rane (Madras) Ltd is one of the top auto ancillary company and is a part of the
Rs.2709 crore
Rane group, engaged in the manufacture and distribution of steering and suspension
systems.
 RANES MISSION
Provide superior products and services to their customers and to maintain market
leadership.

Evolve as an institution that serves the best interests of all stakeholders.

Pursue excellence through total quality management.

Ensure the highest standards of ethics and integrity in all their actions.
 Down the memory lane
Founded as Rane Private Limited in 1929, started as a trading house, trading in
automobiles and parts. Represented General Motors, Renault, American Motors etc

As first diversification from trading, in 1959 Engine Valves Limited was established
for manufacturing IC engine valves.

In 1960 Rane (Madras) limited commenced manufacture of Steering Linkages (Tie

rod ends).

Rane Brake Linings Limited was established in 1964 for manufacturing friction
materials.

In 1965 Rane Madras Limited discontinued with its trading activities.

In 1975 Rane (Madras) Limited started manufacturing of Steering Gears.

RML Mysore division was started in the year 1985.

Rane Group Companies and Product Range
Plant Locations
 The 5 manufacturing facilities location and the product range following locations

Location Product Costumer Segment

Tractor and Commercial

SSLP, SGP, Hydraulic
Mysore plant vehicle segments, and
products
Hydraulic products

Puducherry plant SSLP,SGP Passenger Car segment

Tractors and small

Uttarakhand (Pantnagar)
SSLP,SGP commercial vehicles catering
plant
to customers in North India

Passenger Car, utility vehicle

Velachery (Chennai) plant
Varanavasi (Chennai) plant
SSLP mainly caters to exports
market
Light Commercial vehicle,
SSLP,SGP Heavy Commercial vehicle
and Utility vehicles segments
ORGANIZATION STRUCTURE
Layout of SSLP
 CASE STUDY
ISHIKAWA PRODUCT MODULE
In this cell the final part obtained is the drag link for cars like MARUTI
800 and OMNI. This final part is obtained by assembling ball pin and
socket which are manufactured in this cell and then finally assembling
them.
Ishikawa product module(Integrated cell)
 Process Flow in Integrated cell:
1. Raw materials from supplier to stores
2. Raw materials (Forged part) to the Integrated cell
3. Machining Process
I. Machining of Ball pin II. Machining of Socket
a) Turning a) Bore machining
b)Pin hole drilling b) Garter grooving
c) Pin hole chamfering c) Stem centering
d)Turning and Burnishing d) Stem turning
e) Thread rolling e) Thread rolling
f) Piercing
4. Heat Treatment
5. Inspection magnetic inspection for crack detection and other faults
6. Assembly Line

a) Roller peening
b) Boot greasing
c) Boot assembly
d) Boot clip assembly
e) Pre assembly90 deg correction and Packing
 Machining of Ball pin
1. Turning:

Machine Used: C.N.C. Turning machine

Process parameters:
PARAMETER SPECIFICATIONS

Speed 3150-2000 rpm

Feed 0.28-0.22 mm/rev

Tail stock pr. 16-20 Kg/cm2

Cutting medium Soluble oil

Tooling details:
TOOL DESCRIPTION TOOL LIFE
Per Edge No of Edges Total

TNMG 150608 Insert 200 6 1200

2. Pin hole drilling:
Machine Used: Drilling machine (AURAM)
Process parameters:
PARAMETER SPECIFICATIONS

Speed 1000-1750 rpm

Feed Auto

Cutting medium Soluble oil

Tooling details:
TOOL TOOL LIFE

Per Edge No of Edges Total

Drill jig 3.2 s.s drill 100 10 1000

3. Pin hole chamfering:

4. Turning and Burnishing:

Machine Used: Ball pin Turning &

Burnishing machine
Process parameters:
PARAMETER SPECIFICATIONS

Speed Fixed

Feed Hydraulic

Cutting medium Dry

Hydraulic Pr. 30-40 Kg/cm2
5. Thread rolling:

Machine Used: Thread rolling machine (PRAGA)

Process parameters:
PARAMETER SPECIFICATIONS

Hydraulic pressure 8-12 Kg/cm2

Dwell Time 2.0-4.0 sec

Cutting Medium Servo cut 945 Oil

Tooling details:
TOOL DESCRIPTION TOOL LIFE

Per Edge No of Edges Total

M12x1.25 RH 1 10000 10000

Thread
Rolls
 Machining of Socket:
1. Piercing:
Machine Used: Column drilling machine
Process parameters:
PARAMETER SPECIFICATIONS

Speed 315 rpm

Feed 0.315-0.5 mm/rev

Cutting medium Soluble oil

Tooling details:
TOOL DESCRIPTION TOOL
LIFE
Per
Edge

26.50mm T S 2F drill within 500

house made step
2. Bore machining:
Machine Used: Murata CNC center
Process parameters:
PARAMETER SPECIFICATIONS

Speed 2500 rpm

Feed 0.22-0.28 mm/rev

Cutting medium Soluble oil

Chuck pressure 16-20 kg/cm2

Tooling details:
TOOL NO DESCRIPTION TOOL LIFE
Per Edge No of Total
Edges
CNMG 120408 Insert 800 04 3200

CCMT 09T308 Special boring bar 500 2+2 2000

cutting Insert
3. Garter grooving:

Machine Used: Column drill machine

Process parameters:
PARAMETER SPECIFICATIONS

Speed 315 rpm

Feed 0.125 mm/rev

Cutting medium Soluble oil

Tooling details:
TOOL DESCRIPTION TOOL LIFE

Per No of Total
Edge Edges

Garter grooving tool of 8mm x 8mm 600 2 1200

HSS Sq.bar of constant length 47.5
mm to be used
4. Stem centering:

Machine Used: Drilling machine (AURAM)

5. Stem turning:
Machine Used: Takisawa
Process parameters:
PARAMETER SPECIFICATIONS

Speed 2000-2500 rpm

Feed 0.2-0.3 mm/rev

Cutting medium Coolant

Tooling details:
TOOL NO DESCRIPTION TOOL LIFE

Per Edge No of Edges Total

DNMH INSERT 200 4 800

6. Thread rolling:

Machine Used: Thread rolling machine

(PRAGA)
Process parameters:
PARAMETER SPECIFICATIONS

Hydraulic pressure 25-40 kg/cm2

Dwell Time 25-60 sec

Cutting Medium Servo cut 945 oil

Tooling details:
TOOL DESCRIPTION TOOL
LIFE
Total

M12x1.25 6g RH Thread Rolls 50000

for(M12)

M14x1.25x90 LH/ RH 50000

thread Rolls for (M14)
 Drag link assembly line:
1. Pre assembly:

Machine :PNEUMATIC
Used PRESS

Process parameters:
PARAMETER SPECIFICATIONS

Pneumatic 4-6 kg/cm2

pressure
2. Roller peening:

Machine Used: Roll peening machine

Laser
sensor
Process parameters: to ensure
PARAMETER SPECIFICATIONS
Internals.

Roller gap 1.250.1 mm

Pokayoke
Pneumatic pressure 4-6 kg/cm2 fixture to
detect
wrong
Dwell time 110-130 sec ballpin.
3. Boot grease filling:
Machine Used: Grease dispensing unit
(CENLUB)
Process parameters:
PARAMETER SPECIFICATIONS

Pneumatic pressure 4-6 kg/cm2

4. Boot assembly:
5. Boot clip assembly:

Machine :Boot clipping

Used machine

Process parameters:
PARAMETER SPECIFICATIONS

Pneumatic 4-6 kg/cm2

pressure

6. 90 deg correction and Packing:

 CONCLUSION

In this industrial training we have observed many of the process and

operation performed in fabrication department. Observation and
understanding of machining process in different machines were done. As
a case study Drag link assembly was observed.
 Bibliography:

Information from departments.

RML library.
Company Literature.
Annual reports.
Internet
1.www.rane.co.in
2.http://en.wikipedia.org/wiki/Rane_(Madras)_Ltd