A

Report on

AUTOMATIC RUBBER PIPE CUTTIG MACHINE

At

“MAFLOW INDIA PVT LTD”

Third Year
Production Engineering (S/W)

by

Mr. CHINMAY SUDHIR CHITRAKAR

Exam Seat No - T150087512

Under the Guidance of

Mr. J.M.Khade

DEPARTMENT OF PRODUCTION ENGINEERING

D.Y.PATIL COLLEGE OF ENGINEERING
AKURDI, PUNE-44
ACADEMIC YEAR 2017-18

PRODUCTION ENGINEERING DEPARTMENT Page i

 Q

DEPARTMENT OF PRODUCTION ENGINEERING

D.Y.PATIL COLLEGE OF ENGINEERING
AKURDI, PUNE-44
ACADEMIC YEAR 2017-18

CERTIFICATE

This is to certify that, MR. CHINMAY SUDHIR CHITRAKAR of TE Production S/W

Engineering, [T150087512] has satisfactorily completed his Industrial in Plant Training and
Project entitled “AUTOMATIC RUBBER PIPE CUTTIG MACHINE” at “MAFLOW
INDIA PVT LTD” from 15th JULY 2018 to 15th JANUARY 2019 in the partial fulfilment for
the course of TE Production (Sandwich) Course of Savitribai Phule Pune University during
academic year 2018-2019.

Date: -

Mr. Dr. V. A. Kulkarni

College Guide Head of Department

External Examiner :

PRODUCTION ENGINEERING DEPARTMENT Page ii

 ACKNOWLEDGEMENT

With due respect and gratitude I convey my sincere thanks to the management of
MAFLOW INDIA PVT LTD. for giving me this opportunity to undergo my training in quality
department.
I present this report, a written testimony of my invaluable training. I was privileged to
work in the company’s Quality Section with the company officers.
It is my privilege to express my deep sense of gratitude, devotion and regards to
Mr.J.M.KHADE Dept. of Production (Sandwich) Engg. for consistent guidance and for being a
constant motivation. I owe all my respect to them for helping me to do such inexhaustible work
with fresh enthusiasm.
I also thank Mr.PANKAJ GHULE (HR -Department) for giving me this golden
opportunity of doing internship project in MAFLOW INDIA PVT LTD, Pune.
I thank the entire Quality Department team for their support and willingness to help me out.

CHINAY SUDHIR CHITRAKAR

B.E (Production –Sandwich)

PREFACE

PRODUCTION ENGINEERING DEPARTMENT Page iii

Training in a company like MAFLOW INDIA PVT LTD was truly a great experience and an
opportunity of lifetime skill improvements. The working environment and the people with their
unmatched knowledge, provide the perfect place for anyone to complete their Industrial training.

MAFLOW INDIA PVT LTD is a bottomless well of knowledge and skill. The variety of
machines and equipment available in one roof is just not found anywhere else. MAFLOW
INDIA PVT LTD has always been up to-date with the latest technological developments and
does its best to implement them.

The general awareness of workshop ethics and work culture is imbibed in the employees and
distinctively felt all around. The training and assignment work gave me an opportunity to be a
part of this esteemed organization, thus absorbing me into the area of discipline and technology.

In this report, I have written most of the things that I have done and studied during my training,
although quite a bit of it was practical and involved understanding and grasping the basic
fundamental concepts.

CONTENTS

PRODUCTION ENGINEERING DEPARTMENT Page iv

 Acknowledgement……………………………………………………………………….iii
Abstract…………………………………………………………………………………. iv
1. Introduction………………………………………..………………….………………...01
1.1 Background……………………………………………………………………………...01
1.2 Hard Turning Process……………………………………………………….…………...01
1.3 Benefits of Hard turning over Grinding Process…………….………………………….03
1.4 Grinding versus Hard Turning…………………………………..………………………04
1.5 Workpiece Material…………………………………………………..………………….04
1.6 Tool Material…………………………………………………………………..………...05
2. Conclusion……………………………………………………………………………….37
3. References……………………………………………………………………………….38

CHAPTER 1

PRODUCTION ENGINEERING DEPARTMENT Page v

1.1COMPANY PROFILE
INTRODUCTION TO MAFLOW INDIA PVT LTD

Fig. 1 Shows Maflow India pvt ltd.

Manufacture's and market a wide range of Air conditining tubes for passenger car and
trucks, with systems of world class technology to the total satisfaction of customers in domestic
and overseas markets.

The history of MAFLOW Group dates back to 1935 with of rubber hoses for the
transmission of liquids within hydraulic systems. From 1994 till 2017, Maflow Group launched
eleven production plants in eight countries in four continents. The Company sustains its
leadership through eight manufacturing units which produce world class products backed by
comprehensive marketing and service /parts network throughout the country.

AREAS OF ACTIVITY:

Automotive: Boryszew Group is the largest Polish producer in the automotive sector. Its plants
manufacture plastic elements (lockers, cockpits, handles, engine covers, etc.) as well as hydraulic
break hoses and air conditioning tubes.

Non-ferrous metals: Boryszew Group specializes in aluminium, copper, zinc, and lead
processing. The Group makes technologically advanced products for the automotive, electro-
technical, construction and packaging industries. Boryszew invests in environmentally friendly
solutions, believing that sustainable development is the key to building permanent value chains.

PRODUCTION ENGINEERING DEPARTMENT Page vi

Chemicals: Boryszew Group manufactures fluids for de-icing of airplanes as well as polyester
fibres, PET flakes, polyamides and battlefield effects simulators, which are used for special
effects in the film industry as well. In Poland, Boryszew is best known for Borygo, which is the
best-selling radiator fluid produced in the Sochaczew plant.

MAFLOW COSTUMERS

We supply our products to the greatest world car manufacturers, such as: Volkswagen Group,
General Motors, Renault Nissan, Jaguar Land Rover, PSA Peugeot Citroën, Volvo Car
Corporation, BMW, FCA as well as to the producers of truck vehicles, such as: Volvo GTT
(Volvo Truck, Renault Truck), Daimler Truck, Scania, Paccar Group (DAF, Leyland).

COMPANY BUSINESS

AIR-CONDITIONING TUBES FOR PASSENGER CARS

Maflow created solutions for air-conditioning hoses that allow to build air-conditioning systems
in any type of passenger car. The reduction of particular elements’ size allows to develop
modern systems for traditional cars as well as for electric cars equipped with heat pumps.

AIR-CONDITIONING TUBES FOR TRUCKS

Maflow manufactures air-conditioning hoses for the largest European truck producers. We also
manufacture hoses for other commercial vehicles and own ready-for-use solutions for any kind
of air-conditioning application.

RUBBER AIR-CONDITIONING HOSES AND TUBES FOR OTHER

SYSTEMS

customers will find thiscomponents used in the most important car systems, such as tubes for:
power steering, oil cooling system, active suspension, clutch control, fuel lines, LPG, CNG gases
lines, brake system assistance, brake hoses for trucks, turbocharger tubes, cooling tubes.

DEPARTMENTAL PROFILE

PRODUCTION ENGINEERING DEPARTMENT Page vii

Human Resource:
The Human Resources from Maflow set strategies and develop policies, standards, systems,
and processes that implement these strategies in a whole range of areas. The following are a
typical of a wide range of organizations.

Engineering:
This department is concerned for making the drawings according to customer’s requirement
which fits into IBR standards. This drawings are sent to R&D department for checking after
which they are sent to production department

Research &Development:
At R&D new product design and development is done so that the product is meaningful for the
organization. The customer needs put by marketing department are fully considered for
designing the products.

Maintenance:
The maintenance department is well developed to repair service and maintain recreational
areas, buildings, structures, supporting infrastructure of the built environment, company is
seen by this department. The department is having good tools for respecting handling of the
machines.

Finished Goods Store:

The Finished goods store department looks after all packaging activities starting from
labelling of box up to dispatching it to the customer with all the packaging ergonomics. The
department also avoids physical damages during transportation by designing boxes.

Quality:

PRODUCTION ENGINEERING DEPARTMENT Page viii

The quality department processes the after product engineering. Once the product gets
developed, all the physical tests are performed so that the quality of the product is easy to
define. Department consists of all important machines which help to get accurate dimensions,
angles

QUALITY DEFINATION:

1] American Society for Quality-"Meeting the requirements and expectations in service or

product that were committed to" and "Pursuit of optimal solutions contributing to
confirmed successes, fulfilling accountabilities".
2] Philip B. Crosby: "Conformance to requirements."
3] Joseph M. Juran: "Fitness for use."
4] Genichi Taguchi: "Uniformity around a target value."
5] Robert Pirsig: "The result of care."
6] Six Sigma "Number of defects per million opportunities."
7] Peter Drucker: "Quality in a product or service is not what the supplier puts in. It is what
the customer gets out and is willing to pay for."

QUALITY:

Q= Quality
P = Performance Q=P/E
E=Expectations

1.6.3QUALITY INSPECTION:

Quality inspections are measures aimed at checking, measuring, or testing of one or more
product characteristics and to relate the results to the requirements to confirm Compliance.

PRODUCTION ENGINEERING DEPARTMENT Page ix

 The importance of quality inspection

Quality inspection serves three main purposes:

1. Identification of the problem
2. Preventing its occurrence
3. Elimination of the problem

Stages of Quality Inspection: There are three stages of inspection of valves in "MAFLOW"
1. Incoming Inspection
2. In-process Inspection
3. End of line & Testing.

 INCOMING INSPECTION:

When the material arrives at store gate, it has to be inspected by the quality department. If the
material is accepted by the quality department, raw material is delivered in stores location else
it is informed to the purchase department and material is returned to the vendor. Raw material
delivered may be aluminium pipe or rubber pipe depending upon the requirement. While
inspecting the raw material, we check material of the component, dimensions, quantity, visible
defects (surface finish, burrs).

If received material we check,

 Description
 Size and class
 Material of component
 Dimensions

PRODUCTION ENGINEERING DEPARTMENT Page x

  Maflow logo
 Material using PMI
 Hardness
 Diameter
 If inspection is carried out at vendor’s premises, a complete record of inspection
and testing activities is collected and thoroughly verified during in-coming
inspection.
 Record of verification is maintained to evidence conformance with purchase
requirements.
 If the manufacturing process of the product purchased requires validation, the
required records are collected during the vendor inspection or with the supply.

All the inspection reports, Material Test Certificates and dimensional reports are verified
and reviewed by a qualified QC person. The documents are stamped and signed by him

 IN-PROCESS INSPECTION

The in-process inspection of any product is done at different stages by QC
personnel. The documents are accordingly kept updated on completion of
inspection.

All the procedure of acceptance / rejection is done by QC personnel independently.

Dimensional inspection of machined parts is carried out according to the machining
drawing.

Edges, roughness of the machined parts is also checked.


 INSTRUMENT USED FOR INSPECTION:

PRODUCTION ENGINEERING DEPARTMENT Page xi

 1] VERNIER CALIPER

 Vernier calliper consists of three main elements, viz. beam, fixed jaw and
movable jaw’s beam.
 Main scale is engraved on the beam and Vernier scale is engraved on movable
jaw beam.
 Main scale is the only true scale, and Vernier scale is designed scale.
 The sliding jaws moves along the beam.
 By using Vernier, following measurement can be done.
1] Outside Dimensions (Outside jaws)
2] Inside Dimensions (Inside jaws)
3] Depth (using Depth bar)
4] Step measurement (Using step surface)

Dial Vernier Calliper: In this instrument, a small, precise rack and pinion drives a pointer
on a circular dial, allowing direct reading without the need to read a Vernier scale.
Typically, the pointer rotates once every inch, tenth of an inch, or 1 millimetre. The least
count of dial Verniercallipers used in company was 0.02 mm. Two models were available.
The range of one was 300mm while that of the other was 600mm.

2] MICROMETER

PRODUCTION ENGINEERING DEPARTMENT Page xii

 Micrometre screw gauge works on the principle of nut and bolt.
 Micrometre consists of a screw with fixed pitch and nut arrangement.
 The end of screw acts as a spindle/anvil in the base of frame.
 Spindle can be advanced or retracted by using thimble connected to spindle.
 The barrel has engraved lines of main scale (LC=0.5mm) which is true scale.
 Thimble has circular scale with number of divisions engraved on it.
 A lock nut is provided for locking a dimension.
 Ratchet screw provides a stop, if excessive pressure is applied by the anvils, which is one of
the most important parts for avoiding errors.
 When two jaws touch each other, zero reading is excepted. If it is not observed, error can be
adjusted by rotating barrel itself.

3] POSITIVE MATERIAL IDENTIFICATION (PMI) GUN

It is a specialized non-destructive testing method. The composition of alloys of which the raw
materials are made up of can be determined. It can be used to verify if the material
composition is same as that mentioned in the Material Test Certificate (MTC). A number of
similar looking materials which cannot be distinguished visually are used in valve
manufacturing. Hence, in such cases PMI provides the solution

PRODUCTION ENGINEERING DEPARTMENT Page xiii

 ASSIGNMENT NO 1
AUTOMATIC RUBBER PIPE CUTTIG MACHINE

Project Objective:

. The objectives of this project are to design and develop an automatic pipe cutting machine to
achieve low cost cutting.

 It works fast and reduces the cutting time.

 equipment is not designed using complicated components.

 Respond as per user’s input.

Background of Project

Labour is a major problem for the industries. Many time’s situations happen that labourers
strike for their personal benefits which results in performance degradation and loss in efficiency.
As a result the company have to bear great loss and hence cannot achieve their desired profit and
goals .The system of automation in industry can solve this problem in a very effective way.

The automation system solves labour problems which saves cost, increases accuracy and
decreases human errors. After surveying we conclude that, for some basic processes which are
time consuming like rubber tube cutting, packaging etc. they use human resources. If we
introduce automation to these basic processes then it will be fruitful regarding the company’s
development and profit gain as it improves the system in many ways.

we found out our industry need a solution that is very efficient, fast and economical for cutting
various lengths of rubber tube which are required for producing hoses. So we try to make cost
effective rubber pipe cutting machine. Company is using conventional method for pipe cutting
from conventional method the production rate is very low because they have to measure the
length of pipe for every piece before cutting which also take more time. Also sometimes pipe
unequal length as well as more man power is required.

PRODUCTION ENGINEERING DEPARTMENT Page xiv

Problem profile
Problems of Conventional pipe Cutting Method
1)Time required for pipe cutting is more.
2) More manpower is required.
3) More floor space is required.
4) time is required to measure every piece of pipe before cutting

METHODOLOGY
A. Defining the Specifications of Machine
The basic need of automatic pipe cutting is to cut the wire
of required length in required number of pieces, without
labour, efficiently. So we decided to make a project named ‘Automatic
Rubber pipe cutting machine. For that we decided some specifications
given
below:
1) To cut required length of pipe.
2) The diameter of pipe should be automatically adjustable.
3) The spool is provided to store pipe stock.
4) Guide tubes are provided to keep pipe in straight direction.
For making of the automatic pipe cutting machine we will follow
this procedure below:-So firstly we decided to make a virtual
design of the project and then we finalize that a final design for
project

B. Industrial pipe Cutting Machine Consist of Two Systems

1) Mechanical system
Electronics system

C. In Mechanical System Step by Step Done Procedure for on that Format of Design Given
Below
1) Making of a base of the mechanical part: fabrication work
2) Select the material for the fabrication work
3) Purchasing of required material from market
4) Checking of all loads acting on that frame

PRODUCTION ENGINEERING DEPARTMENT Page xv

D. We Decided to Make Mechanical
System into Different Sub-Category
1) Base
2) Rollers
3) Guide tubes
4) Sliding rails
5) Supports for mounting dc motors
6) Spring attachment
7) Pneumatic cylinder

CONCEPTUAL DESIGN

The base is made of angle bars of mild steel in a such a way that it can carry the whole
equipment. The bars are welded in a workshop on which metal sheet of mild steel is welded. The
first pair of rollers are attached to support in a order to uncoil the rubber pipe from spool stock
which are controlled by the dc motors which are further controlled by the microcontroller. The
pipe is passed through the guide tubes which keeps the wire in straight direction in such a way
that wire reaches exactly in between the two rollers. After this the cutter is mounted. When pipe
of required length is passed the first pair of rollers are stopped and the movement of cutter is
controlled by Pneumatic cylinder which is mounted on the support arms. When the compressor is
switched ON, the compressed air is flow to inlet of the pneumatic cylinder.
The pipe is placed between the upper and the lower blade. The lower blade remains stationary
while the upper blade is forced downward. The upper blade is usually angled so that the cut
progresses from one end to the other, thus reducing the required force.

PRODUCTION ENGINEERING DEPARTMENT Page xvi

When the pneumatic hand operated lever is moved forward, the piston starts moving in the
forward direction. The upper blade which are then forced against the pipe, cutting the material.
When the pneumatic hand operated lever is moved backward, the upper blade will come to the
original position (i.e., the upper blade will move upwards).
After the material is cut, adjust the pneumatic hand lever to the mid position (i.e., normal
position) and then the compressor is switched off

Fabrication of Mechanical System:

We are started to manufacture the pipe cutting machine .At first we made base for whole
assembly on which different mechanical parts are assembled. Base is made up of sheet metal
which is capable of carrying load of all mechanical parts .Manufacturing of base is done by spot
welding process, which is commonly used welding process.
Another important part of mechanical assembly is sliding unit .Sliding unit is mounted on base
by spot welding process. The main purpose of sliding unit is to adjust the wire diameter.
Bracket support are used on which D.C. motors are mounted with diameter 13mm. D.C. motors
of 30RPM with 0.5N-m torque are mounted below the support. There are four bracket support
used in the system,out of which two are connected to sliding unit and two are attached to base
assembly. Rollers of diameter 35mmwith centre whole 6mm are mounted on the bracket Rollers
are manufactured on lathe with different operations such as outer diameter turning, facing,
centering, growing of 0.5mm, machining of raw material of diameter 40mm,driiling,tapping.The
no of rollers used in the system is four.

Specification:
Pneumatic cylinder
stroke length=150mm
Diameter=50mm
Pressure=10bar
pipe cutter=8inch

CONCLUSION
Automatic Rubber Pipe Cutting System” provides high level of accuracy and exact cutting of
wires than the present cutting system in the market. Thus due to this the efficiency of production
is increased. This system
gives exact number of wires with the required length.
The circuit complexity is reduced in this system. As the complexity in the circuit is reduced, it is
easy to understand. The main advantage of this system is that the accuracy is increased and the
required result
is obtained in very less time. The time required to cut pipe is less compared to the manual cutting
of wires. Due to simple hardware it is handy for the people. As the price of the project is not
high, it is economically affordable and has been successfully implemented in the industry.

PRODUCTION ENGINEERING DEPARTMENT Page xvii

PRODUCTION ENGINEERING DEPARTMENT Page xviii