Company Profile of Aspee Springs Limited: Swami Parmanand Engineering College

SWAMI PARMANAND ENGINEERING COLLEGE
ASPEE SPRINGS LIMITED
COMPANY PROFILE OF ASPEE SPRINGS LIMITED

ASPEE SPRINGS LIMITED is a part of Aspee Group of Companies. It was established in the
year 1984 at NH22, 25-26 Km stone, Chandigarh-Ambala Road. Chandigarh is well connected with all
the Metro Cities and Major Cities of India by Rail, Road & Air. It has today become the leading
manufacturer of washers, circlips, bushes, retaining rings, clips and other similar automotive parts in the
country. We are supplying to a number of OEM’s as on date.
With the expansion of the automobile sector the company also expanded its production and added
the latest and best machines to its production capacities. Presently the company has Precision High
Speed Power Presses with facilities of Austempering Furnaces, Fluidised Bed Furnace as also Gas
Carburising Furnaces to cater to the requirement of varied heat treatment processes like Austempering,
Carburising, Nitro Carburising and Gas Carburising. The company has a specialised Grinding shop. The
company has added components like Precision Sheet Metal Components, Formed Bushes from Stainless
Steel and Brass, Machined and Broached bushes, Hose Clips, Clamps, Cotter Pins, Spring Washers and
a host of other components in special designs and requirements. The company has also put in place NC
and CNC turning Machines as also the facility of Gas Carburising for manufacture of Rollers and
Fulcrum Pins for the Automobile Industry.
The manufacturing facilities were also established at different locations for locational advantages
and presently the company has units established and fully operational at: Punjab, Himachal Pradesh,
Maharashtra, and Chennai.
To cater to the requirement of buyers like M/s Hero Honda Motors Limited, M/s Maruti Udyog
Limited, M/s Bajaj Auto Limited, M/s Mohindra Sona Limited, M/s Brakes India Limited, M/s Federal
Mogul Goetze India Limited, M/s Sona Koyo Steering Systems Limited, M/s Suzuki Motorcycles India
Pvt. Ltd., and a host of other leaders in the Automobile Industry.
The plant started its quality management journey by ISO 9001:2000 certification by BVQI in
2004. Now it is certified as per TS-16949 by TUV-SUD.
Financial Status: Turn Over for the Last year was 120 Crores approx.
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Adherence to stringent
Quality Standards
Through Concentrated
Team Efforts
aimed to achieve
Total Customer Satisfaction
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ASPEE FORMATION AND PRESENT STATUS
1962 – KAUR & SINGH - Delhi

Address: B-35/4, G.T. Karnal Road, Indl. Area, Delhi-110033
Phone: 011-27141910, 27141911 Fax: 011-27135779
1984 – ASPEE SPRINGS Pvt. Ltd.

Product Range: Circlips, Precision Washers, Special sheet metal Components,
Bushes Clamps and Plastic Components.
Address: 25-26 KM, Chandigarh-Ambala Road, Gholumajra
P.O.-Dappar-140506 Distt-S.A.S. Nagar (Mohali)
Phone: 01762-280973, 280170 Fax: 01762-280972
1994 – Aspee Becomes a Joint Stock Company – ASPEE SPRINGS LIMITED In

Corporation of ASPEE PRECISION PVT. LTD. for precision machined
components.
Address: 25-26 KM, Chandigarh-Ambala Road, Gholumajra
P.O.-Dappar-140506 Distt-S.A.S. Nagar (Mohali)
Phone: 01762-280973, 280170 Fax: 01762-280972
1999 – New Unit of ASPEE becomes operational at Baddi (HIMACHAL PRADESH) Unit-II
Product Range: Circlips, Washers, Clamps, Special sheet metal Components etc.
Address: 236, HPSIDC, Indl. Area, Baddi, Distt.-Solan (HIMACHAL PRADESH)
Phone: 01795-246149, 247418
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2004 – ASPEE SPRINGS LIMITED – Chakan(PUNE)
In Maharashtra a new unit set up for the manufacture of similar components to cater to
-the market available in the region.
Address: Plot No. 16-17, MIDC Indl. Area, Near Badave Autocom Ltd.,
Chakan (Mahalunge), PUNE-410501
2008 – ASPEE SPRINGS LIMITED – Chennai

In Chennai, a new unit set up for the manufacturing of similar components to cater to the
-market available in the region.
Address: C4-C5-C6, SIPOCAT Industrial Estate ,
IRRUNGOTTAKOTAL—SRIPERUMBUDUR.
2009 – ASPEE SONS – Baddi(HIMACHAL PRADESH)

Address: Vill. Kuranwala, The. Baddi Distt.-Solan (HIMACHAL PRADESH).
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COMPANY ORGANISATION CHART (Production Department)
Mr.Sukhjyot Singh Matharoo (MANAGING DIRECTOR)
Mr. S.C. Mehta (GENERAL MANAGER-PRODUCTION)
Er.Jaspreet Singh(Quality Assurance)
Mr. Balbeer Singh(Store Incharge)
Er. Harkesh Kumar.(Senior Engineer)
Er.Rohit Sharma (Junior Engineer) Er.Vipak Kumar (Junior Engineer)
PROJECT UNDERTAKEN
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1. TIME STUDY :-
The simple meaning of time study is managing the time for achieving goal. Time study skills are
very essential for every person because it actually saves our time and makes our work very perfect.
This skill teaches our managing in all situations such as work load, stress, machining, production,
kaizen, rejection, etc.
IMPORTANCE OF TIME STUDY:-

Time study is very important for our personal & professional life. The importance of time study
would strike us at some point of our career. We would be inundated with work, and we will need to
assess how to manage our time. There are a few facts and reasons to know why time study is
important for success.
(a)Time is a limited source:-

We know that time is a limited source. There is a Chinese proverb that says no amount of gold
will buy your time that has past we would naturally need to cherish it. Once time is lost, we can
never make up for it.
(b)Small steps build into big goals:-

To achieve success, we take time. Career success doesn’t come in a day. So, for achieving goal we
need time study. Like this way small steps build into big goals.
(c) Efficiency of our work relates to time:-

We shall be efficient at our work place. It will give us a competitive advantage over our
colleagues when bosses see us as an efficient worker; we become a competitive advantage to our
unit.
(d) Time study manages our stress:-

The time studies help to reduce our stress. If we have poor time management skills works gets
back logged. We start to complain about being over loaded. However we fail to realise that it is our
lack of management that created this stress.
(e) Time study on priority of work:-

Good time study skill involved the process of knowing when to do what and what is urgent and
important. When we are able to crystallise on what is important, we will attend to that task on
priority that needs our focus. We become thereby more effective.
2. BASIC STUDY OF POWER PRESS :-
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A. APPLICATIONS OF MECHANICAL POWER PRESSES
PRESS: - A mechanically powered machine that shears, punches, forms, or assembles metal or
other material by means of cutting, shaping, or combination dies attached to slides. A press consists
of a stationary bed (or anvil), and a slide (or slides) having a controlled reciprocating motion toward
and away from the bed surface, the slide being guided in a definite path by the frame of the press.
Fig: - A Mechanical Power Press.
Major components of a mechanical power press are the frame, motor, flywheel, crankshaft,
clutch and brake.
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Frame: A rigid steel structure of the frame helps in keeping the stress & deflections within the
permissible limits and assures the maximum strength even under the highest load.
Motor: Electric motors convert electric energy into mechanical energy, and can be operated
with AC power from an electric outlet or AC generator. It is connected to flywheel by V-belt drive
and hence transmits power or torque to the flywheel.
Flywheel: It is a wheel that rotates constantly when the motor is energized and whose purpose
is to store kinetic energy during the nonworking portion of the press cycle, and to release energy
during the working portion of the press cycle.
Crankshafts: It converts circular motion to linear motion.
Clutches: It connect the rotating flywheel with the crankshaft causing the press to stroke. The
clutch on a mechanical power press is either a full revolution or a part revolution clutch. The full
revolution clutch transfers motion from the flywheel to the ram or slide through a mechanical
connection. The connection cannot be broken until one revolution has been completed. A part
revolution clutch is also referred to as a friction clutch. Motion is transmitted by two pieces of
material being pushed against one another. This type of clutch can be disengaged at any time.
Brake: It stops the motion of the slide or ram. The brake may be a constant drag type
(common on a full revolution clutch machine) or it may be engaged only while the clutch is
disengaged (common on a part revolution clutch machine).
B. TYPES OF MECHANICAL POWER PRESSES
Mechanical power presses may be classified by Functional type and Structural type.
1. Structural Types of Mechanical Power Presses:-

Mechanical power presses range in size from units designed for bench mounting, with work
areas of a few square inches, to machines that stand tens of feet high, with work areas tens of feet
square. Mechanical power presses may be used to produce parts as small as wire terminals to as large
as a truck frame.
Two general frames used for mechanical power presses are the "C" frame and the straight side
frame.
 The "C" frame:- The "C" frame is similar to a "C" clamp

in appearance, with the lowest part of the "C" supporting the
bed and the slide mounted in the upper part of the "C".
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Fig., A C-Type Frame.
 Straight Side Frame:- The frame consists of a bed to which four corner post arrangements
called uprights are attached. The uprights support the final frame member, the crown of the
machine. The slide of the machine is attached to a crankshaft in the crown of the press and
moves vertically between the uprights.
Fig., A Straight Side or H-Frame Type.
2. Functional Types of Mechanical Power Presses:-

All mechanical power presses use an electric motor as the drive source, which stores energy
to enable the press to "crunch" through metal or other material at the bottom of the stroke. Although
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other types of power presses are mechanical in nature, such as hydraulic presses, the term
mechanical power press is used to refer to those presses that drive the press slide with a crankshaft.
The crankshaft is supported by main bearings, and the slide hangs from the crankshaft through one
or more connections called pitmans. The slide is at its highest point when the crankshaft throw is
straight up, and at its lowest when the crankshaft is straight down (bottom dead centre); therefore,
the stroke of the press is twice the crankshaft throw.
The working area of the machine is the space between the slide and the bolster plate that sits
on the bed of the press. The shut height is adjustable. The shut height is the distance between the
bottom of the slide and the top of the bolster plate, with the crankshaft at bottom dead centre.
To stroke the press, the crankshaft is coupled to the flywheel which always turns when the
motor is running. This coupling may be accomplished directly or through gears. Gears allow the
press to travel slower, exerting more force. Flywheels on a non-geared press are always located on
the crankshaft. If bearings freeze up, the press will begin stroking.
A clutch is used to connect the flywheel to the crankshaft. The type of clutch used
determines if the press is a part or full revolution clutch mechanical power press.
The full revolution clutches are positive clutches that cannot slip. Once engaged, the full
revolution clutch drags the crankshaft through one complete revolution before it can be disengaged
by a mechanism that physically pulls the clutch pin, key, or jaw free of the flywheel.
The full revolution clutch has a limited number of engaging points. When the operator trips
the clutch mechanism, the pin falls against the surface of the flywheel or gear and "rides" the
surface until falling into an engaging point. When the pin falls into an engaging point, the flywheel
turns the crankshaft and strokes the slide.
The full revolution mechanical power press uses a friction brake that is always applied to
hold the slide stationary when the clutch is not applied. When engaged, the clutch overrides the
friction brake. The brake is usually applied directly to the crankshaft.
The part revolution mechanical power press sometimes uses a positive clutch that is forced to
engage and disengage by air pressure, springs, etc. Normally, a radial or disk type friction clutch is
used for more torque. These types of clutches are where two plates get squeezed together and can be
engaged or disengaged. At this point in the slide stroke, the clutch is usually engaged with air
pressure and released with a lack of air pressure. The brakes are spring applied air released brakes.
3. Production Modes of Mechanical Power Presses:-

There are three main factors to be considered in production modes:
 Press strokes automatically.
 Press strokes continuously.
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 Material to be fabricated is fed manually or automatically. Possible production modes are the
same for both part and full revolution mechanical power presses.
a. Production Modes - Manual Control of Press
i) Single Stroke with Manual Feed ─ Operator places part into the point of operation and tells the
machine to make one stroke then stop.
ii) Single Stroke with Automatic Feed ─ Operator manually instructs the machine to make one
stroke then stop. Material is fed into the machine automatically.
iii) Maintained Continuous with Manual Feed ─ Continuous stroking which requires the operator
to manually maintain pressure on operating controls. Normally used where operator strip feeds
material through the dies.
iii)Maintained Continuous with Automatic Feed ─ The operator is used as an observer who stops
the feed if parts jam, misfeed, or the end of the roll is reached.
b. Production Modes - Automatic Control of Press with electro-pneumatic feed
i) Continuous with Manual Feeding ─ Press runs automatically, operator manually feeds strip
material into the dies.
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ii) Continuous with Automatic Feeding ─ Press is started by the operator, strokes continuously
with material fed into dies and removed automatically. Monitors are used to stop the press if
jam, misfeed, or end of roll occurs.
iii)Single Stroke with Feed Automatically Initiating Each Press Stroke ─The "feed" places the
material into position and tells the press to make a single stroke and stop. The material is again
moved into position by the "feed" and the process is repeated.
iv)Continuous on Demand ─ Material stacks up until a specific amount is accumulated then the
press goes automatic until material is exhausted. Press stops, repeats when specific amount of
material stacks up again.
Fig., Automatic Controlled Press with electro-pneumatic feed.
3. PROCESS QUALIFICATION :-
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Every significant change in the processes, or the introduction of any new process, must
undergo proper qualification prior to its implementation. This will ensure that the affected process
flow will still be capable of consistently meeting the specifications of the form, fit, and function of
the final products, even after the change.
Different process changes will have different effects on the process, so there can be no
single, standard procedure for qualifying a change. The qualification procedure defined for a process
change must therefore be custom-made for the change being qualified. Furthermore, the qualification
of a change usually requires that no degradation in the quality and reliability of the final products will
be introduced, even if the change is being implemented to serve another purpose, e.g., productivity or
cycle time. Thus, in the context of this discussion, process qualification refers to the process of
ensuring that the change will not result in any degradation in the quality and reliability of the final
products.

Most Production companies follow a basic flow when defining the qualification plan for a
process change or a new process, namely:
1) Identify potential failure modes and failure mechanisms that the process change may bring
about;
2) Subject samples to the appropriate reliability stresses to accelerate these potential failure
mechanisms;
3) Test the samples to determine if they are still acceptable after completing the reliability
stresses.

This basic flow works on the premise that the process change may be qualified for
implementation if the final products will not exhibit any failures associated with the change.

The key to a good qualification plan is the excellent anticipation or prediction of what potential
failure mechanisms the process change will trigger. When once the potential failure mechanisms
have been defined, the selection of the reliability tests will follow based on the accelerating factors
pertaining to the mechanisms.
PROCESS FLOW CHART
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START
RECEIVE MATERIALS FROM STORE
COILING
COILING MACHINE
BLANKING HOLING
POWER PRESS
INSTRUMENT
INSPECTION
HEAT TREATMENT
DEBURRING GRINDING
CLEANING
PHOSPHATING DERUSTING
SURFACE TREATMENT
GAUGING
RE-INSPECTION 100% VISUAL
PACKING & DISPATCHING
STOP
4. CIRCLIP PRODUCTION :-
Circlips were developed over 60 years ago as a cost saving alternative to fastening such as
machined collars on shafts or washer and pin assemblies and still offer the same benefits of a single
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fastening mechanism by reducing material waste and the number of components. However, today
there are many variations to the basic Internal and External types; developed out of the special needs
of the consumer for various strength and design characteristics. Circlip means which resist the loads.
Types: A & B & E type

For A & B type sizes ranging from 14mm~95mm.
External Circlips:
The external circlips are usually made by using high quality of spring steel. The
product is suitable for the majority of normal engineering application, providing a
rigid, yet tough, load bearing shoulder on a shaft.
Internal Circlips:
The internal circlips are usually made by using high quality of spring steel. The
most common form of internal which is suitable for most normal engineering
application e.g., in an engine cylinder acts as a rigid shoulder within a bore.
E Circlips:
These Circlips are radially applied, i.e. are fitted directly onto the groove from
the sides of the shaft.
Material:
 Spring Steel.
 Stainless Steel.
 Phosphor Bronze.
 C-80, which means Average Carbon content in hundredths of a percent.
Composition: C : 0.75 - 0.90%
Mn : 0.50 - 0.90%
Si : 0.10 - 0.35%
S&P : 0.04% max
Operations Performed In Power Press Shop for the Production of Circlips
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(i) COILING :-
Coiling is a special type of circlip rolling process into a circular C-shape by a coiling
machine, where the main basement of the product can be adapted.
COILING MACHINE OPERATION:-

In the process of coiling a specific coiling/rolling machine is performed for the benefit of the
production of circlip rolls &coils. In the machine of coiling special attachment is done for the
coiling operation of circlip. So for the production a different shapes and sizes of rollers of 2-6 pair
arrangements are used to perform and maintaining the shape and thickness of the product coil. At
the end of the specific length of wire is cut off by the vertical upward & downward adjacent High
Speed Steel tool actuated by a flywheel arrangement & at last we get the product as the shape of
coil like C-type.
STANDARD ACCESSORIES ON COILING MACHINE:-
 Horizontal and Vertical Straightening Device.

Clamping Device for Adjusting pressure of feeding
rollers, clamping device for Coiling Mandrel,
retractable mandrel, Brake arrangement for feeding
Rollers, Piece Counter, Electric Control Panel and
electricals, complete set of tools to cover entire wire
diameter range of the machine.
Fig., A coiling machine.
Fig., Rollers arrangement in coiling machine.
 AUTOMATIC WIRE DECOILER OR UNWINDER :-

The decoiler starts and when the Coiling Machine require Wire. As soon as sufficient wire in
the form of Loop is available, the decoiler stops, only to start again as required. This intermittent
operation is performed automatically with use of proximity switches and solid state control panel.
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Incase the wire gets entangles or cannot be fed for any reason, the decoiler and coiling machine
motors cutoff automatically, preventing the wire from breaking.
In a heavy duty De-coiling machine, coils are loaded on its internal diameter on the
expandable drum of the De-coiler with three/four self centering Coil location Jaws. Centering is
done by movement of screw on the front side. Main shaft of high carbon steel toughened to
withstand heavy loads, mounted on two radial ball bearings and has shoe type brake to on it to
maintain desired tension during decoiling. It is very suitable for small strip thickness and strips
with high surface finish. Body is made of heavy steel fabrication.
Features:-
 Load carrying capacity of 2 to 2.5 Tonne.

 Min opening 350mm & Max of 600mm.
 Max strip width 600mm.
Fig., Decoiler or Unwinder with four self centering jaws.
(ii) BLANKING :-
Blanking is an appropriate assigned process for scrape removing or metal removing from the
coiled product or from the sheet metal.
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In this process of blanking, striking or falling force is used by means of die fitted power
press to remove or blank the coiled piece in to circlip shape. The power press can be of mechanical,
electro-pneumatic, hydraulic type and the automatic feed type for the desired working conditions
(blanking). So for the starting of the operation of blanking of the coil onto the metal sheet we can
first place it at the centre circular circlip to the lower set of die. After placing apply the release lever
which can be hand or foot operated or the combination of two for disengaging the clutch of pin type
or jaw type to give the ram stoke. Hence the clutch if free from the flywheel and the ram stroke is
produced by the upper part of die for blanking the metal sheet quickly and separate the metal or
scrape. For blanking the metal the desired tonnage of the power press is varying from 20 ton to 200
ton.
(iii) HOLING :-
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Holing is the process of removing the metal from the blanked circlip into a desired specific
dimensioned diameter.
The operation process consists of placing the blanked circlip to the lower part of the die and
disengaging the clutch from the flywheel to get the ram stroke and hence the hole is produced by the
upper end of the die. The work is then ejected by manually which can be removed by the help of
spoke and the automatic process which is done by the compressed air. The flow of air is discharged
through the nozzle fitted just near the lower portion of the die. It is actuated by the ramming
movement of the die and hence the air with maximum velocity is discharged through the nozzle and
hence the holed metal is ejected from the die and is accumulated in the container provided just near
the press.
The desired tonnage for the holing operation is ranging from 1 ton to 20 ton according to the
thickness of the material of circlip.
5. REDUCE THE CURRENT PPM REJECTION 9500 IN PRODUCTION

LINE TO 6500 – 7000 IN 6 WEEKS :-
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MAIN CAUSES OF REJECTION :-
Cause:- (i) It can be caused due to misalignment of die.

(ii) It can cause due to Improper setting of die.
(iii) It can be due to die defect.
(iv) It can be due to unintended on work.
Remedies:- The remedies are –align the die, set the die properly, check the die
periodically for its wear and concentrated on work. By using higher tonnage can
also overcome the difficulties.
Q: HOW TO CONTOL THE REJECTION?

SUGGESTIONS
1: High Grade Raw Material.
2: Machine Maintenance.
3: Using Some Kind Of Instruments Installed In M/C Like Sensors, Indicator Etc.
4: Training Of Workers & Supervisors.
5: Inspection on Every Stage.
6: Proper Transportation & Handling of Materials.
7: Monthly Audit at Vendor Works.
8: Weekly Production Planning.
9: Using Compound Die for Better Quality.
10: Quality Rating Programme for Operators.
11: Healthy & Good Working Conditions for Workers.
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PRACTICAL APPLICATIONS
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1. INSTRUMENTAL APPLICATION
A.VERNIER CALIPER :-
The vernier calipers give a direct reading of the distance measured to high accuracy. They are
functionally identical, with different ways of reading the result. These calipers comprise a calibrated
scale with a fixed jaw, and another jaw, with a pointer, that slides along the scale. The distance
between the jaws is then read in different ways for the three types.
The simplest method is to read the position of the pointer directly on the scale. When the
pointer is between two markings, the user can mentally interpolate to improve the precision of the
reading. This would be a simple calibrated caliper; but the addition of a vernier scale allows more
accurate interpolation, and is the universal practice; this is the vernier caliper.
Vernier calipers can measure internal dimensions, external dimensions using the lower jaws,
and in many cases depth by the use of a probe that is attached to the movable head and slides along
the centre of the body. This probe is slender and can get into deep grooves that may prove difficult
for other measuring tools.
Fig., A vernier caliper.
Parts of a vernier caliper:
1. Outside jaws: used to measure external diameter or width of an object
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2. Inside jaws: used to measure internal diameter of an object
3. Depth probe: used to measure depths of an object or a hole
4. Main scale: scale marked every mm
5. Main scale: scale marked in inches and fractions
6. Vernier Scale gives interpolated measurements to 1/10 mm or better
7. Vernier Scale gives interpolated measurements in fractions of an inch
8. Retainer: used to block movable part to allow the easy transferring of a measurement
B. OUTSIDE MICROMETER :-
A micrometer is a device incorporating a calibrated screw used widely for precise
measurement of small distances in mechanical engineering and machining as well as most
mechanical trades, along with other metrological instruments. The outside micrometer is typically
used to measure wires, spheres, shafts and blocks.
Fig., An outside micrometer.
A micrometer is composed of:

Frame
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The C-shaped body that holds the anvil and barrel in constant relation to each other. It is thick
because it needs to minimize flexion, expansion, and contraction, which would distort the
measurement.
Anvil
The shiny part that the spindle moves toward, and that the sample rests against.
Sleeve / barrel / stock

The stationary round part with the linear scale on it. Sometimes vernier markings.
Lock nut / lock-ring / thimble lock

The knurled part (or lever) that one can tighten to hold the spindle stationary, such as when
momentarily holding a measurement.
Screw
The heart of the micrometer, as explained under "Operating principles". It is inside the barrel.
Spindle
The shiny cylindrical part that the thimble causes to move toward the anvil.
Thimble
The part that one's thumb turns. Graduated markings.
Ratchet stop
Device on end of handle that limits applied pressure by slipping at a calibrated torque.
2. HEAT TREATMENT APPLICATION
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Heat treatment is a method used to alter the physical, and sometimes chemical properties of a
material. The most common application is metallurgical.. Heat treatment involves the use of heating
or chilling, normally to extreme temperatures, to achieve a desired result such as hardening or
softening of a material. Heat treatment techniques include annealing, case hardening, precipitation
strengthening, tempering and quenching.
Austempering:-
Austempering, is a heat treating process for ferrous metals. It is used to
increase strength, toughness, and distortion. Heating a medium-to-high carbon ferrous metal to
an austenitic condition then cooling the object rapidly enough to avoid the formation of pearlite to a
temperature above the martensite start (Ms) temperature and isothermally holding the part for a time
sufficient to produce the desired microstructure. In steel, that structure is bainite, a structure
consisting of acicular ferrite and fine carbides. In higher silicon cast irons the resultant microstructure
is ausferrite, a multi-phase microstructure consisting largely of acicular ferrite and carbon stabilized
austenite.
The metal is heated into the austenite region and then quenched into an appropriate heat
extraction medium (usually molten nitrite/nitrate salt) at a temperature between about 400°F and
750°F (200°C to 400°C). The metal is held at that temperature until the austenite transforms to
bainite (in steels) or ausferrite (in cast irons). The part is then removed from the quench and washed.
Since the austempering reaction takes place uniformly throughout the whole part over several
minutes or hours, the process produces a material that has uniform, predictable growth and no
cracking.
The austempering temperature is selected based on the desired hardness. A higher austempering
temperature will produce a lower hardness. A lower austempering temperature will produce a higher
hardness.
Hardening and tempering (quenching and tempering):-
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To harden by quenching, a circlip metal (usually steel) must be heated into the austenitic crystal
phase and then quickly cooled. Depending on the alloy and other considerations, cooling may be
done with forced air or other gas (such as nitrogen), oil, polymer dissolved in water, or brine. Upon
being rapidly cooled, a portion of austenite (dependent on alloy composition) will transform
to martensite, a hard, brittle crystalline structure. The quenched hardness of a circlip metal dependson
its chemical composition and quenching method. However, metals such as austenitic stainless steel
and copper, produce an opposite effect when these are quenched: they anneal. Austenitic stainless
steels must be quench-annealed to become fully corrosion resistant, as they work-harden
significantly.
Carburising:-
Carburizing is a heat treatment process in which iron or steel is heated in the presence of
another material (but below the metal's melting point) which liberates carbon as it decomposes. The
outer surface or case will have higher carbon content than the original material. When the iron or
steel is cooled rapidly by quenching, the higher carbon content on the outer surface becomes hard,
while the core remains soft and tough. It is used to improve the surface characteristics such as wear
and corrosion resistance, hardness and load-bearing capacity.
Carburization of steel involves a heat treatment of the metallic surface using a gaseous, liquid,
and solid or plasma source of carbon. The modern techniques apply carbon-bearing gases or plasmas
(such as carbon dioxide or methane). The process depends primarily upon ambient gas composition
and furnace temperature, which must be carefully controlled, as the heat may also impact the
microstructure of the rest of the material. For applications where great control over gas composition
is desired, carburization may take place under very low pressures in a vacuum chamber.
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Normalising:-
A heat treatment process that has the object of relieving internal stresses, refining the grain size
and improving the mechanical properties. The steel is heated to 800-900ºC according to analysis,
held at temperature to allow a full soak and cooled in still air.
Applied to only when the hardened work piece is avobe or below the specified hardness,
normalising can soften, harden or stress relieves a material, depending on its initial state. The
objective of the treatment is to counter the effects of prior processes, such as stamping, holing,
blanking, bending etc. by refining the existing non-uniform structure into one which enhances
machinability/formability or, in certain product forms, meets final mechanical property requirements.
A primary purpose is to condition a steel so that, after subsequent shaping, a component responds
satisfactorily to a hardening operation (e.g. aiding dimensional stability).
DETAILS OF TRAINING:-
Page-28
A. PROJECT UNDERTAKEN:-
1. Time Study.
2. Basic Study of Power Press.
3. Process Qualification.
4. CIRCLIP production.
5. Reduce the Current PPM Rejection 9500 In Production Line To 6500 – 7000 in 6 weeks.
B. PRACTICAL APPLICATIONS:-
1. MEASUREMENT BY USING VERNIER CALIPER & MICROMETER.
2. HEAT TREATMENT.
C. OTHER APPLICATIONS:-
1. SURFACE TREATMENT PROCESS.
2. GAUGING.
3. GRINDING & DEBURRING.
4. PACKING & DISPATCHING.
CONCLUSION:-
Training is an investment and hence one should be able to get due returns in terms of better
quality of workmen and engineers for future. I have done my training at ASPEE SRINGS
Page-29
LIMITED, Dappar. During this six week period of my training I learn many things related to
production industry and its documentation work. This has increased my knowledge and practicability
about the vast field of Production industry. For experience everything in the company was my
experience. This training was not only about the knowledge, more like personal development. One
day I have learned how to operate the power press, and I have produced 160 pcs of circlip in 2 hourse
of my training time. The other activity that I have learned is to take the measurement with vernier
calliper & outside micrometer. I have worked as a team member in my training period. The best
achievement for me is to reduce the rejection of product quantity by 30% by means of my team work.
I have also able to learn about the heat treatment process like austempering, hardening & quenching,
normalising, carburising etc. I definitely enjoy being with everyone in the company. I am sure it will
be my precious memory after this training.
BIBLIOGRAPHY/REFERENCES
Website
Page-30
http://www.aspeeindia.com/
Search Engine
http://www.google.co.in
http://en.wikipedia.org/
Books
“Generic Skills & Entrepreneurship Development” By Poonam Goyal.

“ Aspee Springs Limited Manual”
“Production Technology by P.C. Sharma”
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SWAMI PARMANAND ENGINEERING COLLEGE

ASPEE SPRINGS LIMITED