A STUDY ON THE SHEET METAL

FABRICATION AND PRECISION

MACHINED PARTS OF
QUALITECH INDUSTRIES,
HOSUR

AN INPLANT TRAINING REPORT

Submitted by

RAGA VARSHA C K (AC16UME124)

In partial fulfillment for the award of the degree

of

BACHELOR OF ENGINEERING
in

MECHANICAL ENGINEERING
ADHIYAMAAN COLLEGE OF ENGINEERING (Autonomous)
(Accredited by NBA- AICTE, New Delhi, Accredited by NAAC- UGC,
New Delhi with ‘A’ Grade)

ANNA UNIVERSITY: CHENNAI - 600 025

JULY 2019

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 ANNA UNIVERSITY: CHENNAI - 600 025

BONAFIDE CERTIFICATE

This is to certify that the Inplant Training Report entitled “ A study on the sheet
metal fabrication and precision machined parts of QUALITECH
INDUSTRIES, Hosur”, in partial fulfilment of the requirements for the award
of the Degree of Bachelor of Engineering is a record of original training
undergone by RAGA VARSHA.C.K ( AC16UME124 ) during the year 2019-20
of her study in the Department of Mechanical Engineering , under my supervision
.

SIGNATURE SIGNATURE

Dr.CHANNANKAIAH, M.E.,Ph.D, Mr.A.K.SARAVANAN, M.E.,

PROFESSOR & HEAD
Department of Mechanical Engineering,
Adhiyamaan College of Engineering,
(Autonomous)
Dr. M. G. R. Nagar, Hosur – 635109.
FACULTY INCHARGE
Assistant Professor
Department of Mechanical Engineering,
Adhiyamaan College of Engineering
(Autonomous),
Dr.M.G.R.Nagar,Hosur – 635109.

Submitted to the Mechanical Engineering, Adhiyamaan Engineering College (Autonomous),

Hosur, for the examination held on____

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 ACKNOWLEDGEMENT

First of all I thank my God Almighty for giving his grace to do this inplant
training successfully.
It is one of the most difficult tasks in life to choose the appropriate words
to express one’s gratitude towards the beneficiaries.

I would like to express my sincere gratitude to

Mr .M.MOHAN(MANAGER) ,QUALITECH INDUSTRIES, for his keen
interest and affection towards us.

I would like to express my sincere gratitude to Mr.C.ARUL for his

guidance and teaching throughout my training .

I would like to express our sincere gratitude to our beloved principal

Dr.G.RANGANATH, M.E., Ph.D., for his keen interest and affection towards
us.

We are highly indebted to Dr.CHANNANKAIAH, M.E.,Ph.D.,Professor

and head, Department of Mechanical Engineering, Adhiyamaan College of
Engineering, Hosur, for his guidance and valuable comments received through
our Inplant Training

And last but not least, we express our deep gratitude to our parents and to
our friends for their encouragement and support.

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 TABLE OF CONTENTS

CHAPTER TITLE PAGE.NO

NO
BONAFIDE CERTIFICATE I

COMPANY CERTIFICATE II

ACKNOWLEDGEMENT III

LIST OF FIGURES IV

I INTRODUCTION 6

1.1 IMPORTANCE 6

1.2 OBJECTIVE 6

1.3 SCOPE 6

1.4 PERIOD OF TRAINING 6

II COMPANY PROFILE 7

2.1 INTRODUCTION 7

III 3.1 ACTIVITIES OF VARIOUS DEPARTMENT 8

3.1.1 PURCHASE DEPARTMENT 8

3.1.2 PRODUCTION DEPARTMENT 8

3.1.3 RESEARCH AND DEVELOPMENT 9

3.1.4 MARKETING DEPARTMENT 9

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 3.1.5 ACCOUNTING AND FINANCE 9

3.2 RAW MATERIALS USED 10

3.3 MAJOR PRODUCT: BRACKET 10

3.4 PROCESSES INVOLVED 11

3.4.1 SHEARING 11

3.4.2 PRESSING 12

3.4.3 WELDING 12-13

3.4.4 POWDER COATING 14-15

3.5 INFRASTRUCTURE &MACHINERIES- PRESS SHOP 16

IV CONCLUSION 17

LIST OF FIGURES

FIGURE NO TITLE PAGE NO

3.1 HYDRAULIC SHEARING 11
MACHINE
3.2 CO2 WELDING 13
3.3 POWDER COATED 14
ALUMINIUM EXTRUSIONS
3.4 POWDER COATING 15
SPRAY GUN

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 CHAPTER 1

INTRODUCTION

This is a report of my inplant training in “QUALITECH INDUSTRIES “,Hosur. In my

training I saw many operations related to Mechanical Engineering.

1.1 IMPORTANCE
Inplant training is important for engineering students as it gives industrial exposure to
them while studying. Students will deal with the real life projects throughout the inplant
training, with the course knowledge.

1.2 OBJECTIVE
To learn about the concepts involved in sheet metal fabrication and to get an exposure
in working Environment.

1.3 SCOPE
I have learnt many new mechanical processes which is related to gear manufacturing
process. I understood how a company functions and various management principle employed
in governing an Establishment.

1.4 PERIOD OF TRAINING

The schedule of my In-plant training was from 25/02/2019 to 02/03/2019 and from
04/04/2019 to 15/04/2019 which included sixteen days. During the period of training I have
observed various processes about sheet metal fabrication and precision machined parts.

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 CHAPTER 2

COMPANY PROFILE

2.1INTRODUCTION

QUALITECH INDUSTRIES was started in august 2003. It was established to develop

manufacturing of precision machined and sheet metal fabricated components. They focus on
developing new products with their customers.
Their vision is to establish a competitive alignment with best in class suppliers to meet
customer’s cost, Technology, Quality and Delivery requirements.
It has one manufacturing location. The industry is specialized in supply of machining and
sheet metal fabrication parts. Sheet metal fabrication is using sheet metal to build metal
machines and structures. It can be a complex process involving many different professionals.
Businesses that specialize in sheet metal fabrication are commonly referred to as fabrication
shops, or fab shops for short. Sheet metal fabrication generally involves cutting and burning the
sheet metal. Special tools, such as band saws, are used to cut the sheet metal. Band saws have
special hardened blades and are capable of feeding the sheet metal to ensure even cutting.
Sheet metal fabrication also involves the use of hydraulic breaks. With hydraulic breaks,
sheet metal fabrication is simplified, as they help create bends at predetermined angles. Rolling
machines are also used in sheet metal fabrication to form steel into round sections.
Another main focus of sheet metal fabrication is welding. After the sheet metal parts are formed,
they are assembled and tack welded into place. Various welding techniques can be used in sheet
metal fabrication to avoid warping or other visual defects. These include using a stout fixture,
welding in a staggered manner, covering the metal with sand during the cooling process, and
special straightening processes.

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 CHAPTER III

3.1ACTIVITIES OF VARIOUS DEPARTMENT

3.1.1PURCHASE DEPARTMENT:
One role of the purchasing department is to procure all necessary materials needed for
production or daily operation of the company or government organization. For a manufacturing
company, this might include raw materials such as iron, steel, aluminum or plastics, but it also
might include tools, machinery, delivery trucks or even the office supplies needed for the
secretaries and sales team.

In a retail environment, the purchasing department makes sure there is always sufficient
product on the shelves or in the warehouses to keep the customers happy and keep the store
well-stocked.

3.1.2PRODUCTION DEPARTMENT:
The production department in a business organization is that department which engages in the
manufacturing or production of goods for the business organization. The production
department is headed by the production manager. Other workers in this department include
technicians, engineers, designers, machine operators etc.

The functions of the production department:

 The production department manufactures goods for the business which are then
sold in order to bring revenue for the business.
 The production department is also responsible for the designing of the goods or
products of the business which are sold to other businesses or to the general
public.
 Every aspect of production is controlled by the production department. By
controlling production, the department efficiently uses things such as labor,
machines and materials judiciously in order to prevent any wastage.

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3.1.3RESEARCH AND DEVELOPMENT:
Before a new product is developed, a research and development department conducts a
thorough study to support the project. The research phase includes determining product
specifications, production costs and a production time line. The research also is likely to
include an evaluation of the need for the product before the design begins to ensure it is a
functional product that customers want to use.
The research paves the way for the development phase. This is the time when the new product
is actually developed based on the requirements and ideas created during the research phase.
The developed product must meet the product guidelines and any regulatory specifications.

3.1.4MARKETING:
The Marketing Department plays a vital role in promoting the business and mission of an
organization. It serves as the face of your company, coordinating and producing all materials
representing the business. It is the Marketing Department's job to reach out to prospects,
customers, investors and/or the community, while creating an overarching image that
represents your company in a positive light.

3.1.5ACCOUNTING AND FINANCE:

The accounting department is responsible for recording and reporting the cash flows, both in
and out, of a company. There are five basic roles or functions within the department:
 Accounts receivable
 Accounts payable
 Payroll
 Financial controls
 Financial reporting

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3.2 RAW MATERIALS USED:

 8mm-IS 2062-IS2062 is a product standard of Bureau of Indian Standards. It

specifies standards for Hot Rolled Medium and High Tensile Structural Steel. IS 2062
steels are mainly used for structural purpose.

CHEMICAL COMPOSITION %

C Si Mn N P S Cr Mo

max 0.23 0.40 max 1.50 max 0.012 max 0.045 max 0.045

 8mm BSK 46-BSK- BIG STEEL KEG can be produced by controlled cooling after hot
rolling

3.3MAJOR PRODUCT:BRACKET

The chassis in the truck is the structural mainframe. The chassis frame configuration in a
truck till today is designed on conventional lines. It has two main longitudinal members
throughout the length of the truck and has cross members supporting throughout the length of
two longitudinal members and are riveted . For cars and lighter vehicles other types are
available. The two longitudinal sections of the chassis are robust enough to carry the main
play load. Based on the research and development planning, it is expected to achieve a better
performance of truck cross member bracket. The unbalanced forces produced from the
dynamic conditions, which causes the structure vibrations are absorbed by the brackets.

The truck cross member bracket forms the backbone of the truck and its chief function is to
safely carry the maximum load wherever the operation demands. Basically, it must absorb
static engine weight, propeller shaft, centrifugal force and gyroscopic couple and absorb
shock loads over twisting, pounding and uneven roadbeds when the vehicle moving along the
road. The cross members function as a resistance to the shear forces and bending loads while
the cross members give torsion rigidity to the frame.

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3.4PROCESSES INVOLVED :

3.4.1SHEARING:

A shear force is applied that will cut off part of a sheet. The cut off ‘blank’ becomes the
workpiece. Shearing, also known as die cutting, is a process which cuts stock without the
formation of chips or the use of burning or melting. In strict technical terms, the process of
“shearing” involves the use of straight cutting bladesorm of sheet metal or plates, however
rods can also be sheared. Shearing-type operations include: blanking, piercing, roll slitting,
and trimming.
When you apply a high pressure tool through a metal plate and remove part of the metal, the
process is called shearing. Shear machining devices include punching machines, which make
small discs, and blanking machines, which produce washers and similar objects.

Both mechanical and hydraulic machines can perform shear machining. Hydraulic shears cut
and score sheet metal quickly and accurately. They work well for factories that do a lot of metal
fabrication. In addition, hydraulic shears are best if the operation requires intense pressure.
They don’t require a lot of maintenance, will operate continuously, and are fast and quiet.
Hydraulic shear machines also take up less space than mechanical shear machines while
applying the same amount of pressure.

Fig.3.1Hydraulic shearing machine

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3.4.2PRESSING:

Hydraulic press is a tool to produce compressive force by means of fluid.

Such forces can be used for the press work application such as blanking, punching,
piercing, coining, trimming etc.

Press work is a method of mass production involving the cold working of metals, usually in
the form of thin sheet or strip.
Press working processes make use of large forces by press tools for a short time interval which
results in cutting or shaping the sheet metal. Since, press working does not involve heating of
the parts, close tolerances and high surface finish can be obtained on the part. Since presses
can produce components at fairly fast rates, the unit cost of labor for operating the press is
fairly low.
Press working forces are set up, guided and controlled in a machine referred to as a Press. Thus
an attempt has been made to automize the process of press work using Hydraulic mechanism
in press machine. The inputs and outputs of the control system including hydraulic mechanism
are solely mechanical such as rotating shaft or reciprocating plunger. The prime renumeration
of implementing this system is the movement of the mechanical devices can be operated by
means of hydraulic components such as actuators to initiate the movement which could be in
the form of lever to apply manually or by means of switches to operate automatically.
Furthermore, direction control valves have been implemented to control the directions of piston
movements and regulate the same. Thus, the whole mechanism has been simplified with the
use of hydraulic equipments.

3.4.3WELDING:

Welding is a fabrication process that joins materials, by using high heat to melt the parts
together and allowing them to cool causing fusion. Co2 welding and arc welding were used.

CO2 WELDING:

In CO2 arc welding, the welding wire wound in coil is fed into the welding torch by the
feeding motor automatically. The welding wire that is electrified through the contact tip

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becomes the electrode to strike an arc between itself and the base metal. The arc heat melts
the wire and the base metal to join two pieces of base metal. In this case, in order that the
weld metal will not be affected by oxygen and nitrogen in the atmosphere, CO2 gas is
supplied from the nozzle of the welding torch to shield the weld pool.

Fig.3.2
co2 welding

ARC WELDING:

Arc welding is a welding process that is used to join metal to metal by using electricity to
create enough heat to melt metal, and the melted metals when cool result in a binding of the
metals. It is a type of welding that uses a welding power supply to create an electric
arc between a metal stick ("electrode") and the base material to melt the metals at the point of
contact.

The welding area is usually protected by some type of shielding gas, vapor, or slag.

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3.4.4POWDER COATING
Powder coating is a type of coating that is applied as a free-flowing, dry powder. powder
coating is typically applied electrostatically and then cured under heat. The powder may be a
thermoplastic or a thermoset polymer. It is usually used to create a hard finish that is tougher
than conventional paint. Powder coating is mainly used for coating of metals, such
as household appliances, aluminium extrusions.

Fig.3.3 Aluminium extrusions being powder coated

The powder coating process involves three basic steps:

1. Part preparation or the pre-treatment

2. The powder application
3. Curing

Part preparation processes and equipment:

Removal of oil, dirt, lubrication greases, metal oxides, welding scale etc. is essential prior to
the powder coating process. It can be done by a variety of chemical and mechanical methods.
The selection of the method depends on the size and the material of the part to be powder
coated, the type of impurities to be removed and the performance requirement of the finished
product.

Chemical pre-treatments involve the use of phosphates or chromates in submersion or spray

application. The pre-treatment process both cleans and improves bonding of the powder to
the metal.

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Another method of preparing the surface prior to coating is known as abrasive blasting
or sandblasting and shot blasting. Blast media and blasting abrasives are used to provide
surface texturing and preparation, etching, finishing, and degreasing for products made of
wood, plastic, or glass.

Powder application processes:

Fig.3.4 Example of powder coating spray guns

The most common way of applying the powder coating to metal objects is to spray the
powder using an electrostatic gun, or corona gun. The gun imparts a positive electric charge
to the powder, which is then sprayed towards the grounded object by mechanical or
compressed air spraying and then accelerated toward the workpiece by the powerful
electrostatic charge. There is a wide variety of spray nozzles available for use in electrostatic
coating.

Curing:
When a thermoset powder is exposed to elevated temperature, it begins to melt, flows out,
and then chemically reacts to form a higher molecular weight polymer in a network-like
structure. This cure process, called crosslinking, requires a certain temperature for a certain
length of time in order to reach full cure and establish the full film properties for which the
material was designed. Normally the powders cure at 200 °C (390 °F) for 10 minutes. The
curing schedule could vary according to the manufacturer's specifications. The application of
energy to the product to be cured can be accomplished by convection cure
ovens, infrared cure ovens, or by laser curing process. The latter demonstrates significant
reduction of curing time.

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3.5INFRASTRUCTURE AND MACHINERIES-PRESS SHOP:

S.No Machine Description Tonnage Stroke length

1 Shearing m/c 350

2 Press break 350

3 Pneumatic press 250 30-140

4 Pneumatic press 200 22-140

5 Mechanical press 100 10-140

6 Pneumatic press (with 160 66-265

die cushion)

7 Hydraulic press 200 250-300

8 Mechanical press 150 45-125

9 Mechanical press 100 45-125

10 Mechanical press 50 30-80

10 Mechanical press 30 30-85

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 CHAPTER IV
CONCLUSION
Thus the inplant training provided me wholesome knowledge about the sheet metal fabricated
parts. Apart from the technical knowledge. I have learned more industrial experience .

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