ET101112

VISVESVARAYA TECHNOLOGICAL UNIVERSITY
JNANASANGAMA, BELAGAVI - 590018
Internship Report
On
“STUDY OF SHEET METAL MANUFACTUING PROCESS”
Submitted in partial fulfillment for the award of degree of
B.E Degree in Mechanical Engineering
Submitted by
RASHID ASHRAF A T
(USN: 2GP17ME415)
VIII SEMESTER, 2019-20
Internship Carried Out

At
M/S PEENYA FINE COMPONENT Pvt. Ltd.,

# 47-55/9-13, Raghavendra Industrial Estate, Tigalarapalya Main Road, Near Peenya II
Stage , Bangalore – 560058, India
DEPARTMENT OF MECHANICAL ENGINEERING

GOVERNMENT ENGINEERING COLLEGE MAJALI KARWAR -581345
FEB – 2020
DECLARATION
I, Rashid Ashraf A T bearing USN No. 2GP17ME415 student of VIII

semester, B.E degree in Mechanical Engineering Government engineering
college majali karwar declare that this internship program titled “Press Tools
and Design of Tool Development” is original work carried out by me, the
undersigned at Peenya Fine Components Pvt. Ltd., after endorsement and
authorization from Government engineering college majali karwar, in partial
fulfillment of the curriculum requirements prescribed by Visvesvaraya
Technological University , Belagavi in the B.E Degree choice based credit
system scheme.
The content in this report is not submitted to any other university partially or
wholly for the award of any other degree.
Rashid Ashraf A T
USN: 2GP17ME415
VIIISem, B.E
Mechanical Engineering
Date: 20-2-2020
Place: MAJALI
i
ACKNOWLEDGEMENT
First, I would like to thank Mr. ABDUL WAHEED, Chief Executive Officer of
Peenya Fine Comp. for giving me the opportunity to do the internship at the company. It
was a wonderful experience.
My heartfelt gratitude to Mr. Mussaddiq ahmed, assistant engineer and my

external guide, for guiding and giving me and giving me valueable information regading
the sheet metal manufactuing process.
I would also like to thank Mr. Sadiq Pasha, Managing repesentative peenya fine
comp PVT.LTD and Mr. Tariq hafeezi, internal guide and assistant professor at BCE for
accepting my intent of doing the internship at the company.
I would also like to thank the staff and my compadre at the industry for their
patience and openness for creating a wonderful learning experience and further increasing
my interest in sheet metal manufacturing and have new plans for my future career.
ii
TABLE OF CONTENTS
DECLARATION .......................................................................................................................................... i
ACKNOWLEDGEMENT ........................................................................................................................... ii
TABLE OF CONTENT ............................................................................................................................. iii
ABSTRACT ................................................................................................................................................ iv
CHAPTER 1 .............................................................................................................................................. 1-2
1.1 ABOUT THE COMPANY............................................................................................................................ 1
1.2 ABOUT THE MANAGEMENT .................................................................................................................... 1
1.3 COMPANY’S CLIENTS ............................................................................................................................. 2
CHAPTER 2 ............................................................................................................................................ 3-11
2.1INTRODUCTION ....................................................................................................................................... 3
2.2 PRESS TOOL OPERATIONS: .................................................................................................................... 3
2.3 SHEET METAL FORMING ........................................................................................................................ 4
2.3.1 What is sheet metal ........................................................................................................................ 4
2.3.2 Sheet metal making pocess ............................................................................................................ 4
2.3.3 Diffrence betwwen hot and cold rolled steel ................................................................................ 5
2.3.4 Diffrent grades of sheet metal........................................................................................................ 7
2.3.5 Sheet metal operations................................................................................................................... 8
CHAPTER 3 ....................................CUTTING TOOL OPERATION ...................................... 12-15
3.1 BLANKING TOOL ...................................................................................................................................12
3.2 PIECING TOOL .......................................................................................................................................13
3.3 TRIMMING TOOL ...................................................................................................................................14
3.4 BENDING TOOL......................................................................................................................................15
3.5 FORMING AND DRAWING TOOL .............................................................................................................15
CHAPT1ER 4………….…………………… PRESSES ...................................................................... 16-18
4.1 MECHANICAL PRESSS ............................................................................................................................16
4.2 HYDRAULIC PRESS ................................................................................................................................17
4.3 PNUEMATIC PRES ..................................................................................................................................19
CHAPTER 5………………………….. MEASURING INSTRUMENTS ......................................... 20-26
5.1 INTRODUCTION .....................................................................................................................................20
5.1.1 Vernier caliper..............................................................................................................................20
5.1.2 Micrometer ...................................................................................................................................21
5.1.3 Height guage ................................................................................................................................22
5.1.4 Bore guage....................................................................................................................................23
5.1.5 Slip guages....................................................................................................................................23
5.1.6 Feeler guage .................................................................................................................................24
5.1.7 Radius guage ................................................................................................................................24
5.1.8 Plug guages ..................................................................................................................................25
5.2 INSPECTION...........................................................................................................................................25
5.2.1 The need of inspection ..................................................................................................................26
5.2.2 The objectives of inspection ..........................................................................................................26
5.2.3 Third party verification ................................................................................................................26
CHAPTER 6………………….SHEET METAL FABRICATION PROCESS ............................. 27-29
6.1 INTRODUCTION ................................................................................................................................27
6.2 SHEETMETAL FABRICATION PROCESS STEPS .....................................................................................27
INTERNSHIP REFLECTION .................................................................................................................. 30
INTERNSHIP OUTCOME ........................................................................................................................30
REFRENCES ...............................................................................................................................................31
iii
ABSTRACT
This report documents the work done and observed during the 4 week internship
done at Peenya Fine Comp (p) ltd in the department of sheet metal manufactuing (PRESS
SHOP II).
The report presents the tasks observed and completed by myself under the
supervision of trainers in the industry which includes understanding the basic
knowledge for, understanding the working of various sheet metal stamping machines in
the factory, learning the difference between mechanical, hydraulic and pneumatic
machines, knowing the applications of each machines.
iv
STUDY OF SHEET METAL MANUFACTUING POCESS
CHAPTER 1
INTRODUCTION
1.1 About The Company
Peenya Fine Comp is one of the most respected and relied upon sheet metal
stamping company in South India for more than 25 years, catering directly to the
assembly lines of global Tier 1 corporations such as Whirlpool of India Ltd., Automotive
Axles Ltd. &Avtec Ltd. to name a few. They are committed in the quality and they are a
certified ISO 9001-2008 company.With a growing number of young minds at work with
some of the most experienced practitioners in the sheet-metal and automotive industry,
Peenya Fine Comp is a company that commits to deliver what it espouses.
Their mission statement is “raising the bar”, and the company ensures it is doing so
with the quality of their output. Supplying sheet metal stamped parts across the global
customers is the company’s vision.
1.2 ABOUT THE MANAGEMENT
ABDUL WAHEED | CHIEF EXECUTIVE

OFFICER |
Abdul Waheed holds over 30 yrs of experience in
the industry, and has been actively involved with different
areas of production, maintenance & quality. He was an
integral part of Press Comp International, before founding
Peenya Fine Comp Pvt. Ltd., along with his partners; in the
year 1990. His vision and dedication to this company has
been outstanding, and as more and more clients
Continue to place thier trust in his expertise and entrepreneurship; it goes a long way in
proving the passion with which he works. Having travelled extensively across the
MSiddle-East, China & Germany, Mr. Waheed, possess a distinct understanding of
cutting-edge manufacturing & production technologies, and has chalked out some very
ambitious plans for the expansion of the firm, which would lead to better efficiencies,
more value for the clients, and see the firm scaling greater heights.
DEPARTMENT OF MECHANICAL ENGINEERING Page 1

ASHRAF VOHRA | CHIEF FINANCIAL OFFICER |
Ashraf Vohra is qualified CPA, a consultant and

previously a board member to various companies in India
and the Middle East. He currently runs a successful
financial and investment consultancy in Bangalore. As chief
financial officer to this company, Mr. Ashraf has been
instrumental in financing the expansion of the company to
its Current state, and is responsible
For developing key strategic measures to drive the company’s growth.
SYED SHAKEEL ADEEB | DIRECTOR- FINANCE |
Syed Shakeel Adeeb is one of the key members of

the management at Peenya Fine Comp. Having worked in
Saudi Arabia with various illustrious companies, at key
roles, he carries with him, a solid experience of over 25
years in different facets of accountancy. He has been a
Chief Accountant and has held responsible posts with MNCs like the Tarsh Holdings-
Mauritius. He has also travelled to Taiwan on his different business expeditions. Mr.
Shakeel has been quite instrumental in streamlining the finances of the firm, lowering its
overall costs and hence creating more value for the firm. He continues to work towards
the firm’s goals with continued dedication and imparting his invaluable expertise.
1.3 COMPANY’S CLIENTS:

CHAPTER 2
SHEET METALS
2.1 Introduction
Almost all the processes happening in this company is sheet metal pressing/stamping.
So, I happened to come across lots of press tools designed to produce a variety of
components that are thesn supplied to their clients.
Press tools may be defined as a mechanical device used for production of variety of
components in large capacity by applying an external force by the aid of machine tool
called as a press.
The press tools are manufactured based on the idea of mass production, if the number
of pieces/components to be manufactured is below 1000 components this process might
not be the most economical one. Majority of the mechanical industries manufacture
components in mass. The major reason for mass production is to satisfy the customer
requirements, consistency and to effectively reduce the cost of production.
Press tools are commonly used in hydraulic, pneumatic, and mechanical presses to
produce the sheet metal components in large volumes. Generally press tools are
categorized by the types of operation performed using the tool, such as blanking,
piercing, bending, forming, drawing, trimming etc. The press tool will also be specified as
a blanking tool, piercing tool, bending tool etc based on the types of operations performed
by that tool.
2.2 Press Tool Operations
Press tool operations can be broadly divided into two categories; one involving
cutting operations and the other involving non cutting operations.
Cutting operations are those which shear the sheet metal into two or more pieces
depending on the design of the die. Examples of cutting operations are blanking,
trimming, piercing etc .Non cutting operations are those which do not cut or separate the
sheet metal, instead the sheet metal is bent or pressed in order to give it a shape.
Examples of non cutting operations are bending, forming and drawing.

2.3 Sheet Metal Forming
Sheet metal forming is a process where pieces of sheet metal are modified to its
geometry rather than removing any materials. The applied process generates a force that
stresses the material to deform. This in turn gives the possibility to bend and form
the sheet to a variety of complex shapes.Many industries, producing home appliances,
toys and PC’s. Most of these products have metal casings that are made by cutting and
bending sheet metal.
2.3.1 What is sheet metal?
Sheet metal is metal formed by an industrial process into thin, flat pieces. Sheet
metal is one of the fundamental forms used in metalworking and it can be cut, bentand
formed into a variety of shapes. Countless everyday objects are fabricated from sheet
metal.
2.4 Sheet Metal Making Process:
Melting: Sheet metal can be made from a variety of different metals including
aluminum, steel, copper, brass, nickel, tin, sterling silver and titanium. No matter what
type of metal is used, the first step is to melt the metal in a container called a crucible.
Pouring: When the metal is completely melted, it is poured out of the crucible and into
a rectangular mold. The metal must be kept hot as it is poured into the mold so that it does
not begin to harden outside of the mold.
Pickling: When the metal has cooled completely, it is taken out of the mold. We now
have a rectangular block of metal known as an ingot. The ingot is then dipped into a
mixture of chemicals to be cleaned; a process known as pickling.
Rolling: Once the ingot has been cleaned, it is put through a press. The press consists
of two large rollers that thin out the metal. The press rollers are then moved closer
together and the metal is run through again. Ingots may have to be run through the press
several times before they reach the desired thickness.
Rolling is classified according to the temperature of the metal rolled. If the

temperature of the metal is above its recrystallization temperature, then the process is

known as hot rolling. If the temperature of the metal is below its recrystallization
temperature, the process is known as cold rolling. In terms of usage, hot rolling processes
more tonnage than any other manufacturing process, and cold rolling processes the most
tonnage out of all cold working processes
Annealing: As the ingot is run through the press the metal will become increasingly
harder. It may be necessary to anneal the metal several times throughout the rolling
process. Annealing the metal consists of heating it up and then pickling it again. During
the annealing process the metal is only made warm-it is not melted again.
Shipping: After the metal reaches the desired thickness, it is either shipped flat or
rolled into a coil. Finished sheet metal is anywhere from .05 millimeters to 15
centimeters thick.
2.5 Diffrence between hot rolled steel and cold rolled steel
2.4.1 Hot rolled steel:
Hot rolled steel is steel that has been roll-pressed at very high temperatures—over
1,700˚F, which is above the re-crystallization temperature for most steels. This makes
the steel easier to formb, and resulting in products that are easier to work with.
To process hot rolled steel, manufacturers first start with a large, rectangular
length of metal, called a billet. The billet is heated and then sent for pre-processing,
where it is flattened into a large roll. From there, it is kept at a high temperature and
run through a series of rollers to achieve its finished dimensions. The white-hot
strands of steel are pushed through the rollers at high speeds. For sheet metal, rolled
steel is spun into coils and left to cool. For other forms, such as bars or plates,
materials are sectioned and packaged.
Steel shrinks slightly as it cools. Since hot rolled steel is cooled after processing,
there is less control over its final shape, making it less suitable for precision
applications. Hot rolled steel is often used in applications where minutely specific
dimensions aren’t crucial. Railroad tracks and construction projects often use hot
rolled steel.

Hot rolled steel can often be identified by the following characteristics:
 A scaled surface—a remnant of cooling from extreme temperatures
 Slightly rounded edges and corners for bar and plate products (due to shrinkage and
less precise finishing)
 Slight distortions, where cooling may result in slightly trapezoidal forms, as

opposed to perfectly squared angles
Benefits of hot rolled steel
Hot rolled steel typically requires much less processing than cold rolled steel,
which makes it a lot cheaper. Because hot rolled steel is allowed to cool at room
temperature, it’s essentially normalized—meaning it’s free from internal stresses that can
arise from quenching or work-hardening processes.
Hot rolled steel is ideal where dimensional tolerances aren’t as important as

overall material strength, and where surface finish isn’t a key concern. Where surface
finish is a concern, scaling can be removed by grinding, sand blasting, or acid-bath
pickling. Once scaling has been removed, various brush or mirror finishes can also be
applied. Descaled steel also offers a better surface for painting and other surface coatings.
2.4.2 Cold rolled steel
Cold rolled steel is essentially hot rolled steel that has been through further
processing. Once hot rolled steel has cooled, it is then re-rolled at room temperature to
achieve more exact dimensions and better surface qualities.
Cold “rolled” steel is often used to describe a range of finishing processes, though
technically “cold rolled” applies only to sheets that undergo compression between rollers.
Steel forms that are pulled, such as bars or tubes, are “drawn,” not rolled. Other cold
finishing processes include turning, grinding, and polishing—each of which is used to
modify existing hot rolled stock into more refined products.

Cold rolled steel can often be identified by the following characteristics:
 Better, more finished surfaces with closer tolerances

 Smooth surfaces that are often oily to the touch
 Bars are true and square, and often have well-defined edges and corners
Advantages of Sheet Metal Parts
 High strength
 Good dimensional accuracy
 Good surface finish
 Relatively low cost
 Easy to manufacture
2.4.3 DIFFRENT GRADES SHEET METAL
SL NO Grades of steel size Applications
0.9x650x220 FOR CYLINDER LINER
1 CR IS 513EDD 2x950x2500
1x1250x2500 FOR ANODE ENDEOVER
0.9x1250x2500 FOR RETAINER SPRING

2 CR IS 513 D
2.5x1250x2500 FOR TOP HINGE
3 HR IS 1079 3x1250x2500 PLATE AS DRIVE
3X1250X2100 DRIVE PLATE

4 HR IS 1079D
6x1250x4720 COVER HOUSING

2.5x1250x2500
5 HR IS 2062 4x1250x3150 GAS TOP PAN
6x1500x4720
-
6 HR IS 5968 7X1240X4900
0.3X1220X1750 PLATE MOTOR
7 GP IS 277 1.5X1250X2640 PROTECTOR BASE
1.2X83XCOIL
 CR =COLD ROLLED
 HR=HOT ROLLED
 GI=GALVANIZED IRON
2.4.4 Sheet metal operations
 Shearing  Shaving
 Blanking  Cut off
 Punching  Coining
 Trimming  drawing
 Parting  Sizing
 Lancing  Forming
 Notching  Riveting
 Perforating  Plasnishing
 Embossing  Extrusion
Shearing: Shearing is a metal fabricating process used to cut straight lines on

flat metal stock. During the shearing process, an upper blade and a lower blade are forced
past each other with the space between them determined by a required offset. Normally,
one of the blades remains stationary.The fig 2.1 shows the shearing operation.

Fig 2.1 Shearing Operation
Blanking: Blanking is a metal fabricating process, during which a metal work piece is
removed from the primary metal strip or sheet when it is punched. The material that is
removed is the new metal work piece or blank.The blanking process forces a metal punch
into a die that shears the part from the larger primary metal strip or sheet.The most
common materials used for blanking include aluminum, brass, bronze, mild steel, and
stainless steel. Due to its softness, aluminum is an excellent material to be used in the
blanking process.The below fig.2.2 shows the blanking operation.
Fig.2.2 blanking operation

Piercing: Piercing is a shearing process where a punch and die are used to create a hole
in sheet metal or a plate. The process and machinery are usually the same as that used in
blanking, except that the piece being punched out is scrap in the piercing process.The
piercing operation and the Pierced Componant is as shown in fig.2.3.
Fig.2.3 Piercing operation
Parting: Separating a part from the remaining sheet, by punching away the material
between parts. The fig 2.4 shows the parting of the metals.
Lancing: Lancing is a piercing operation in which the work piece is sheared and bent
with one strike of the die. A key part of this process is that there is not reduction of
material, only a modification in its geometry. This operation is used to make tabs, vents,
and louvers.The fig 2.5 shows the lancing of sheet metal.
Notching: Punching the edge of a sheet, forming a notch in the shape of a portion of the
punch.The typical notched sheet metal componant is as shown in the fig.2.6.
Fig.2.4 parting Fig.2.5 lancing Fig. 2.6 Notching
Sizing: The sizing operation is a squeezing operation that minimizes the thickness of
the metal. Sizing is performed in an open die and only the surface where the die and work
piece touch will be sized. Many ferrous metal castings are sized to sharpen corners and
flatten holes around piercings. Sizing pressure is determined by area to be sized, the metal
used, and the change in metal thickness from the operation. Sizing is usually performed
on semi-finished parts or parts that require an accurate finish.
Trimming: Punching away excess material from the perimeter of a part, such as
trimming the flange from a drawn cup. Trimming is a finishing operation in which
shearing off of burrs from the cut edges is carried out in order to make the edges smooth
and also impart dimensional accuracy.the fig.2.7 shows the trimming excess material
from the cylindrical componant.
Fig. 2.7 Trimming
Perforating: It is similar to piercing only difference is that holes produced are not in a
round shape. In this process, multiple holes which are very small and close together are
cut in the sheet metal.the perforated material is as shown in the fig.2.8.
Embossing: Certain designs are embossed on the sheet metal. Punch and die are of the
same contour but in opposite direction.The fig 2.8 shows the embossed componant.
Coining: Similar to embossing with the difference that similar or different impressions
are obtained on both the sides of the sheet metal.
Fig 2.7 Perforating Fig 2.8 Embossing

Shaving: In sheet metal cutting, the lower the clearance value the higher the edge's
quality. Shaving is a secondary process that can be used to improve edges of cuts that
have already been made. Shaving uses very little clearance to perform a straight, smooth,
accurate cut to only the end of the edge
Drawing: drawing is a sheet metal forming process in which a sheet metal blank is
radially drawn into a forming die by the mechanical action of a punch. It is thus a shape
transformation process with material retention
Forming: Sheet metal forming processes are those in which force is applied to a piece
of sheet metal to modify its geometry rather than remove any material. The applied force
stresses the metal beyond its yield strength, causing the material to plastically deform, but
not to fail.
Fig.2.9 Shaving operation fig.2.10 drawing fig.2.11 forming

CHAPTER 3
CUTTING TOOL OPERATIONS
3.1 Blanking Tool
 When a component is produced with one single punch and die where the entire
outerprofile is cut in a single stroke the tool iscalled a blanking tool.
 Blanking is the operation of cutting flatshapes from sheet metal.
 The outer area of metal remaining after a blanking operation is generally
discarded aswaste.
 Size of blank or product is the size of the die & clearance is given on punch.
 It is a metal cutting operation
Fig.3.1 Blanking Tool

3.2 PIERCING TOOL

Piercing involves cutting of clean holes with a resulting scrap slug*. The
operation is called die cutting and can also produce flat components where the die, the
shaped tool, is pressed into a sheet material employing a shearing action to cut holes. This
method can be used to cut parts of different sizes and shapes in sheet metal, leather and
many other materials. Piercing operation can be carried out before or after or at the same
time of the blanking operation.
Fig 3.2 Piercing Tool
Blanking tool and piercing tool are very similar in design.The main difference between
simple variations of these tools is the allotment of clearance. In blanking operation,
clearance is given to the punch. The component size is equal to that of the die. Here, slug
is the desired part. In piercing operation, clearance is given to the die. The component
size is equal to the punch. Here, slug is scrap.

Diffrence between Blanking And Piercing
Blanking Piercing
Punching or blanking is a process in whic h the It is a process by which a hole is cut (or
punch removes a portion of material from the torn) in metal. It is different from punching
larger piece or a strip of sheet metal. If the small in that piercing does not generate a slug.
removed piece is the useful part and the rest is Instead, the metal is pushed back to form a
scrap, the operation is called blanking. jagged flange on the back side of the hole.
The piece cut out is called as blank and may be

A pierced hole looks somewhat like a bullet
further processed. Blanks are often cut out of a
hole in a sheet of metal.
sheet or strip.
Blanking wastes certain amount of material.

When designing a sheet metal blanking process
Size of the component is generally larger in
the geometry of blanks should be nestled as
piercing than blanking.
efficiently as possible to minimize the material
waste.
3.3 TRIMMING TOOL
When cups and shells are drawn from flat sheet metal the edge is left wavy and
irregular, due to uneven flow of metal. This irregular edge is trimmed in a trimming die.
Shown is flanged shell, as well as the trimmed ring removed from around the edge. While
a small amount of Material is removed from the side of a component in trimming tool.
Fig 3.3 Trimming Tool

3.4 BENDING TOOL
Bending tools apply simple bends to stampings. A simple bend is done in which
the line of the bend is straight. One or more bends may be involved, and bending tools are
a large important class of press tools.
Fig 3.4 Bending Tool
3.5 FORMING AND DRAWING TOOL
Forming tools apply more complex forms to work pieces. The line of bend is
curved insteadof straight and the metal is subjected to plasticflow or deformation.
Drawing tools transform flat sheets of metal into cups, shells or other drawn
shapes by subjecting the material to severe plastic deformation.
Fig 3.5 Drawing Tool

CHAPTER 4
PRESSES
In the company, all three kinds of presses were used i.e., mechanical presses,
pneumatic presses and hydraulic presses Presses are chosen based on the characteristics
of the manufacturing process.
A brief overview about these presses is given below:
4.1 MECHANICAL PRESSES
Mechanical presses belong to a class of machine tools that encompass a wide range of
different machine types. Primarily, the mechanical press transforms the rotational force of
a motor into a translational force vector that performs the pressing action. Therefore, the
energy in a mechanical press comes from the motor. These types of presses are generally
faster than hydraulic or screw presses, (actually the screw press may also be classified as
a mechanical press). Unlike some presses, in a mechanical press, the application of force
varies in both speed and magnitude throughout the distance of the stroke. When
performing a manufacturing operation using a mechanical press, the correct range of the
stroke is essential.The typical mechanical press is as shown in fig 4.1.
Fig 4.1 Mechanical Presses

Presses are chosen based on the characteristics of the manufacturing process. Mechanical
press machine tools are commonly used in metal forging manufacture, and sheet metal
working. The desired application of force will dictate the type of machine required.
Extrusion will often necessitate a more consistent force over a longer distance. However,
a mechanical press may often be a good choice for impact extrusion, since a fast, quickly
repeatable application of force over a limited distance is what is needed for that type of
manufacturing process. The most powerful mechanical presses in modern manufacturing
industry will have a press capacity of about 12,000 tons.
 The speeds in which mechanical presses can be ran are higher than hydraulic
presses. This allows for higher production and efficiency.
 Consistency of tonnage at bottom of the stroke. With a mechanical press, you’re
maximum tonnage delivery happens in a smaller window as compared to a
hydraulic press. However, this again helps attribute to the speed at which
mechanical presses can be ran because you know the absolute limit of what your
press will be hitting at the bottom of its stroke.
 In the company the minimum capacity of the mechanical press is 5 Ton.
 And the maximum capacity of the mchanical press is 150 Ton.
4.2 HYDRAULIC PRESS
Hydraulic presses are a powerful class of machine tools; they derive the energy
they deliver through hydraulic pressure.
Fig 4.2 Hydraulic Press

Hydraulic presses are a powerful class of machine tools they derive the energy
they deliver through hydraulic pressure. Fluid pressure, in a particular chamber, can be
increased or decreased by the use of pumps, and valves. Sometimes devices and systems
may be used to increase the capacity of the pumps in more powerful presses. These
presses can operate over a long distance and at a constant speed. Hydraulic presses are
generally slower relative to other press machine types. This involves longer contact with
the work, therefore the cooling of the work can be an issue when hot forming a part with
hydraulic force. Hydraulic presses are capable of being the most powerful class of
presses. Some may be as large as buildings, and can deliver awesome pressure. The
largest hydraulic presses are capable of applying 75,000 tons, (150,000,000 lbs), of force.
The hydraulic press shown in fig 4.2 is being used to manufacture a metal forging.
Extrusion is also a very common use for such a press, although extrusion is often
performed horizontally.
The hydraulic press depends on Pascal's principle-the pressure throughout a

closed system is constant. One part of the system is a piston acting as a pump, with
modest mechanical force acting on a small cross-sectional area; the other part is a piston
with a larger area which generates a correspondingly large mechanical force. Only small-
diameter tubing (which more easily resists pressure) is needed if the pump is separated
from the press cylinder.
Pascal's law: Pressure on a confined fluid is transmitted undiminished and acts

with equal force on equal areas and at 90 degrees to the container wall.A small effort
force acts on a small piston. This creates a pressure which is transferred through the
hydraulic fluid to a large piston.
Press Tool is the process which is used to produce the sheet metal components.
Operations like Blanking, piercing, bending, forming etc. can be performed using press
tool process. The basic operation that is performed using press tool is blanking and
piercing. Both blanking and piercing process includes shearing of the sheet metal;
therefore initially the shearing strength of the sheet metal material has to be determined.
Advantages of hydraulic press

 It is quite in operation.
 Built-in overload protection.
 It is safe compared to mechanical press.
 It offers a full-power stroke.
 Greater versatality compared to the mechanical press.
4.3 PNEUMATIC PRESSES

Pneumatic presses are controlled by the manipulation of pressurized air. The air is
forced into a tube which fills with the air and applies pressure that causes the press to
move downwards. Once the press' stroke is finished, the air is evacuated through valves,
and mechanical springs cause the pump to move upwards again.
Fig 4.3 Pneumatic Press
Pneumatic press is finding its way onto shop floors to shoulder workloads
normally reserved for mechanical and hydraulic presses at nearly half the capital
equipment cost. The main advantages of Pneumatic Presses are their speed. It can carry
on ten times swifter than hydraulic presses. Pneumatic baling presses are much faster than
hydraulic baling presses, and that means there are many jobs they can perform faster and
more efficiently.

CHAPTER 5
MEASUING INSTRUMNENTS
5.1 Introduction
Measuring instruments and gauges are used to measure various parameters such as
clearance, diameter, depth, ovality, trueness, etc. These are critical engineering
parameters, which describe the condition of the working machinery. Below, there is a
compiled list of mechanical measuring instruments and mechanical gauges which are
extensively used in mechanical measurements for the recording of different parameters.
5.1.1 Vernier Calipers
Fig 5.1 vernier caliper
The measuring tips are so designed as to measure inside as well as outside dimensions
 Upper jaws: used to measure external diameter or width of an object

 Lower jaws: used to measure internal diameter of an object
 Depth probe: used to measure depths of an object or a hole
 Main scale: gives measurements of up to one decimal place (in cm)
 Main scale: gives measurements in fraction (in inch)
 Vernier gives measurements up to two decimal places (in cm)
 Vernier gives measurements in fraction (in inch)
 Retainer: used to block movable part to allow the easy transferring a measurement
 The fig 5.1 show the variuos componant of vernier caliper

Apart from vernier calipers, to simplify things there are few calipers where the vernier
scale is eliminated and replaced by a dial or a digital reading as shown in fig 5.2 and fig
5.3.
Fig 5.2 Vernier Caliper With A Dial (Dial Caliper)
Fig 5.3 Digital caliper
5.1.2 Micrometers
Fig 5.4 Micrometers

A micrometer is a tool used for the precise measurement of very small objects.
A micrometer can measure the length and thickness of whatever object fits between its
anvil and spindle.
Micrometer parts
 As shown in fig 5.4 the micrometer has the following parts.

 Frame: The C-shaped body that holds the anvil and barrel in constant relation to
each other.
 Anvil: The shiny part that the spindle moves toward, and that the sample rests
against sleeve or the barrel
 Screw: The heart of the micrometer, It is inside the barrel. This references the fact
that the usual name for the device in German is Messschraube, literally
"measuring screw".
 Spindle: The shiny cylindrical component that the thimble causes to move toward
the anvil.
 Thimble: The component that one's thumb turns. Graduated markings.
 Ratchet: Device on end of handle that limits applied pressure by slipping at a
calibrated torque.
5.1.3 Height Guage
Vernier height gauge is similar to vernier caliper but in this instrument the
graduated Bar is held in a vertical position and it is used in conjunction with a surface
plate.
Fig 5.5 Vernier Height Gauge

A vernier height gauge consists of
 The Base.The base is massive and robust in construction to ensure rigidity and
stability.
 A vertical graduated beam or column supported on a massive base.
 Attached to the beam is a sliding vernier head carrying the vernier scale and a
clamping screw
 An auxiliary head which is also attached to the beam above the sliding vernier
head. It has fine adjusting and clamping screw.
 A measuring jaw or a scriber attached to the front of the sliding vernier
5.1.4 Bore Guage
Fig 5.6 Bore Guages
A bore gauge is a collective term for the tools that are unique to the process of
accurately measuring holes.which is used to accurately measure the inside diameter of a
hole, cylinder or pipe. In conjunction with a micrometer, a bore gauge will give you the
exact reading of a bore size. A typical bore gauge is as shown in the fig 5.6 is comprised
of a shaft with a dial indicator at the top and a measuring sled at the base.
5.1.5 Slip Guages
Slip gauges is defined as a very accurately ground block of hardened steel used to
measure a gap with close accuracy: used mainly in tool-making and inspection. Gauge

blocks (also known as gage blocks, Johansson gauges, slip gauges, or Jo blocks) are a
system for producing precision lengths.
Fig 5.7 Slip Gauges
The individual gauge block is a metal or ceramic block that has been
precision ground and lapped to a specific thickness. Gauge blocks come in sets of blocks
with a range of standard lengths. In use, the blocks are stacked to make up a desired
length.
Need of Slip Gauges:
Thus there is a need of instrument which can measure fine tolerance limit. The
means to do so are 'slip gauges'. They can be used to measure tolerances in the range of
0.001 to 0.0005 mm very accurately.
5.1.6 Feeler Guages:
Fig 5.8 feeler gauges

A feeler gauge is a tool used to measure gap widths. Feeler gauges are mostly
used in engineering to measure the clearance between two parts.The feeler gauges are
shown in fig 5.8.
5.1.7 Radius Guages
Fig 5.9 Radius gauges
Radius gauge, also known as a fillet gauge, is a tool used to measure the radius of an
object. Radius gauges require a bright light behind the object to be measured. The gauge
is placed against the edge to be checked and any light leakage between the blade and edge
indicates a mismatch that requires correction.A typical radius gauges is shown in fig 59.
5.1.8 Plug Guages:
Fig 5.10 plug gauges

Plug gauges, in some cases called pin gauges is as shown in fig 5.10 are
metrology tools whose purpose is to gage the inside diameters of holes that have been
drilled or machined into a manufactured part, component, or assembly. In its use, a
go plug gauge is designed to test the minimum dimensional limit of the hole (i.e. the
lower tolerance of the hole's diameter) which represents the maximum amount of
remaining material on the part or work piece.
5.2 Inspection
An inspection is an activity such as measuring, examining, testing or gauging one

or more characteristics of a product and comparing the results with specified requirements
in order to establish whether conformity is achieved for each characteristic. The term
inspection refers to the activity of checking products.
Inspection means checking of all materials, products or component parts at

variousstages during manufacturing. It is the act of comparing materials, products
orcomponents with some established standard.
5.2.1 The need for Inspection
In old days the production was on a small scale, different component parts were
made And assembled by the same craftsman. If the parts did not fit properly at the time of
Assembly, he used to make the necessary adjustments in either of the mating parts so
That each assembly functioned properly. Therefore, it was not necessary to make similar
parts exactly alike or with same accuracy as there was no need of inspection. Due to
technological development new production techniques have been developed.
The products are being manufactured on a large scale due to low cost methods of
mass Production. So, hand fit method cannot serve the purpose any more. Thus the
production of each component part becomes an independent process. Therefore, it
becomes essential that any part chosen at random should fit properly with any other
mating parts that too selected at random. This is possible only when the dimensions of the
component parts are made with close dimensional tolerances. This is only possible when
the parts are inspected at various stages during manufacturing. To save the time gauges
are used, which can tell whether the part manufactured is within the prescribed limits or
not.

5.2.2 The objectives of Inspection
 To ensure that the part, material or a component conforms to the established

standard.
 To meet the interchangeability of manufacture.
 To maintain customer relation by ensuring that no faulty product reaches the
Customers.
 Provide the means of finding out shortcomings in manufacture. The results of
inspection are not only recorded but forwarded to the manufacturing department
for taking necessary steps, so as to produce acceptable parts and reduce scrap.
 It also helps to purchase good quality of raw materials, tools, equipment which
governsthe quality of the finished products.
 It also helps to co-ordinate the functions of quality control, production, purchasing
and other departments of the organization.
5.2.3 Third party verification
Third party verification (TPV) is when an outside organization is used to review

and confirm a customer's information and intentions to ensure accuracy. Third-party
verification is typically done by conference call and often used with sales departments to
verify that a potential customer has interest in or agrees to a purchase before passing the
customer back or on to a sales person.

CHAPTER 6
SHEET METAL FABRICATION PROCESS
6.1 Introduction
Sheet Metal is a vital part of our daily life. Many parts and types of equipment
using sheet metal are out there in electronics, aerospace and almost all the fields. Sheet
metal fabrication is the process of converting sheet metal stock into the final sheet metal
product for being used in various applications. This process may vary from case to case
depending upon the requirement of the design specifications of the final sheet metal
product. But there are some general steps in a typical sheet metal fabrication process.
6.2 Sheet Metal Fabrication Process Steps
A typical Sheet Metal Fabrication Process involves the following steps:
1. Designing: The very first step in the process of sheet metal fabrication is to create
a design of the final product. In case you are manufacturing the product for
someone else, the design or a rough design idea will be provided by the client in
most cases. This is the case with most of the companies which are manufacturing
sheet metal products as an OEM (Original Equipment Manufacturer) for their
clients. Such companies or industries may not consider the designing process as a
part of the fabrication process.
Fig 6.1 Design of the Componant

In the process of creating the design of a sheet metal product, we have to

create a blueprint at first. That blueprint helps in creating a rough design of the
final product. On the basis of that rough design, the final design and drawings
(indicating all the specifications) are created to be used for manufacturing the final
sheet metal product.
2. Shearing: Sheet metals are produced in large coils. These coils are then cut to
the desired length so as to create the small length rectangular sheets. Further, the
manufacturers of these rectangular sheets supply them to the sheet metal
fabrication industries for their use. Blank-cutting is the process of cutting flat
sheet metal blank out of the large sheet. This is the second step in the fabrication
process. The size of the blank is as per the requirement of the design of the final
product. Shearing Machines are generally used for cutting sheet metal blanks.
Laser cutting, plasma cutting, water jet cutting are some more precise and
advanced methods for cutting.
3. Punching: After cutting the sheet metal blank of the required size, the step that
comes next in the fabrication process is punching. Punching operation is used to
create holes of various shapes and designs in the sheet metal blank. Punching
Machines (having punch and die) are generally used to perform this operation.
Laser cutting technology can also be used for optimum precision.
4. Bending: Now the next step is bending. Sheet metal is bent at various places and
angles as per the requirement of the design specifications. The bends are made in
such a sequence that any of the bends may not make any hurdle in the execution
of the next bend. The machine which is generally used to perform this task is
called Press Brake.
5. Finishing: After assembly of sheet metal parts, the final product is sent for the
finishing process. Finishing is performed to provide a required appearance and
other physical properties as per the requirements. It may be a simple cleaning. It
may also include some other processes like coating, painting, galvanizing, etc.
Some special heat treatments may also be performed to provide some special
properties needed for the product to survive in a special working environment.

6. Assembly: If all of the components of the final sheet metal product have been
created by performing the above-mentioned operations, now the next step comes.
The next step is the assembly of all of the sheet metal components. Most of the
time, welding is performed to assemble the sheet metal parts. In some cases, some
other options like riveting, adhesive bonding are also used for assembly.
CO2welding and spot welding are some of the welding options which are used in
the assembly of sheet metal parts
7. Quality Control: After performing all of the steps to produce a sheet metal
product, the final product is now checked to ensure the optimum quality. All
specifications are verified to match exactly to the given design. If any error is
observed, the piece is rejected and sent back for correction. The quality of
finishing is also verified. If everything is found OK, the piece is cleared for the
next step.
Fig 6.2 Final Componant
8. Packing: Now comes the last step in the sheet metal fabrication process. The final
product is packed and shipped to the client or the place of its use.

CHAPTER 7
INTERNSHIP REFLECTIONS
This internship proved to be a success for me in reasons more than one. My interests in
this area of engineering grew day after day and I’ll not be lying if I said I would study
further in this field. My communications, morale and knowledge improved
considerably.During my time in the industry, I was fortunate enough to experience
working of these machines first hand and learn many different aspects that goes in during
a project or product manufacturing process.
The first week of the internship, I was going around the industry looking at all the
pressing machines at work. The interest in those machines only grew after knowing the
process explanation. The only complaint I had was the noise the machines made while
stamping process, but it’s not something that could be helped as it was the bound to be in
any sheet metal stamping industry. The last two weeks were spent on the sheet metal
manufacturing procees of different componants and inspecting some of those. The
learning process here was interesting and peaceful.
Overall, my experience at Peenya Fine Comp. was positive and I’m very happy with
the amount of things that I have learned during this month long internship.
7.1 OUTCOMES FROM THE INTERNSHIP
TECHNICAL OUTCOMES:
1. Understanding working of pressing tools.
2. Understanding the different kinds of pressing machines and learning the
advantages and disadvantages of each.
3. Understanding difrrent grades of sheet metals and their uses.
4. Learning the basics of sheet metal manufacturing process.
5. Application of academic knowledge in industrial works.
NON TECHNICAL OUTCOMES:
1. This internship helped me enhance my communication skills.

2. Develop time management skills.
3. Improved my writing ability.

4. Understand the interactions between different departments and also between

workers and managers.
5. Learning to work in a group to achieve a common goal.

Refrences
I. peenya fine comp official website :http://www.peenyafinecomp.co.in/index.aspx

II. personal observation and the information provided by the company.

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VISVESVARAYA TECHNOLOGICAL UNIVERSITY

JNANASANGAMA, BELAGAVI - 590018

“STUDY OF SHEET METAL MANUFACTUING PROCESS”

Submitted in partial fulfillment for the award of degree of

B.E Degree in Mechanical Engineering

Internship Carried Out

M/S PEENYA FINE COMPONENT Pvt. Ltd.,

DEPARTMENT OF MECHANICAL ENGINEERING

I, Rashid Ashraf A T bearing USN No. 2GP17ME415 student of VIII

My heartfelt gratitude to Mr. Mussaddiq ahmed, assistant engineer and my

1.1 About The Company

1.2 ABOUT THE MANAGEMENT

ABDUL WAHEED | CHIEF EXECUTIVE

DEPARTMENT OF MECHANICAL ENGINEERING Page 1

ASHRAF VOHRA | CHIEF FINANCIAL OFFICER |

Ashraf Vohra is qualified CPA, a consultant and

SYED SHAKEEL ADEEB | DIRECTOR- FINANCE |

Syed Shakeel Adeeb is one of the key members of

1.3 COMPANY’S CLIENTS:

DEPARTMENT OF MECHANICAL ENGINEERING Page 2

2.2 Press Tool Operations

DEPARTMENT OF MECHANICAL ENGINEERING Page 3

2.3 Sheet Metal Forming

2.3.1 What is sheet metal?

2.4 Sheet Metal Making Process:

Rolling is classified according to the temperature of the metal rolled. If the

DEPARTMENT OF MECHANICAL ENGINEERING Page 4

2.4.1 Hot rolled steel:

DEPARTMENT OF MECHANICAL ENGINEERING Page 5

Hot rolled steel can often be identified by the following characteristics:

 A scaled surface—a remnant of cooling from extreme temperatures

 Slight distortions, where cooling may result in slightly trapezoidal forms, as

Benefits of hot rolled steel

Hot rolled steel is ideal where dimensional tolerances aren’t as important as

2.4.2 Cold rolled steel

DEPARTMENT OF MECHANICAL ENGINEERING Page 6

Cold rolled steel can often be identified by the following characteristics:

 Better, more finished surfaces with closer tolerances

Advantages of Sheet Metal Parts

 Good dimensional accuracy

 Good surface finish

 Relatively low cost

2.4.3 DIFFRENT GRADES SHEET METAL

SL NO Grades of steel size Applications

0.9x650x220 FOR CYLINDER LINER

1x1250x2500 FOR ANODE ENDEOVER

0.9x1250x2500 FOR RETAINER SPRING

3 HR IS 1079 3x1250x2500 PLATE AS DRIVE

3X1250X2100 DRIVE PLATE

DEPARTMENT OF MECHANICAL ENGINEERING Page 7

5 HR IS 2062 4x1250x3150 GAS TOP PAN

0.3X1220X1750 PLATE MOTOR

7 GP IS 277 1.5X1250X2640 PROTECTOR BASE

2.4.4 Sheet metal operations

Shearing: Shearing is a metal fabricating process used to cut straight lines on

DEPARTMENT OF MECHANICAL ENGINEERING Page 8

Fig 2.1 Shearing Operation