SRI SIDDHARTHA ACADEMY OF HIGHER EDUCATION

(Declared as Deemed University Under Section 3 of the UGC Act, 1956

Approved by AICTE, Accredited by NBA, NAAC ‘A’ Grade) AGALKOTE,
TUMAKURU – 572107
KARNATAKA

Internship Report Carried Out at

“Fitwel Tools And Forgings Pvt.Ltd.”

Submitted by
S D ADARSH
(20TPE01)
3rd SEM

In partial fulfilment of

MASTER OF TECHNOLOGY IN
THERMAL POWER ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

SRI SIDDHARTHA INSTITUTE OF TECHNOLOGY
(A CONSTITUENT COLLEGE OF SRI SIDDHARTHA ACADEMY OF HIGHER
EDUCATION)
MARALUR, TUMAKURU -572105
2020-2021
 Life cycle of Camshaft 2020-21

ACKNOWLEDGEMENT

The satisfaction and euphoria that accompany the successful completion of any task
would be incomplete without mentioning the people who made it possible and their support had
been a constant source of encouragement which crowned our efforts with success.

I am deeply indebted and would like to express my sincere thanks Dr. M S

Raviprakasha, Principal, S.S.I.T, Tumakuru, for providing me an opportunity to carry out this
Internship.

I express my deep sense of gratitude to Dr. Harish Kumar, HOD, Department of

Mechanical Engineering, S.S.I.T, Tumakuru, for his guidance, constant encouragement and
wholehearted support.

My special thanks to Dr. T B Prasad, Professor, Department of Mech., S.S.I.T, for his
guidance, constant encouragement and wholehearted support.

I would like to express my sincere thanks to all the staff members of Mechanical
Engineering Department, S.S.I.T. for their valuable guidance and support.

Finally, I would like to express my sincere gratitude to Mr.B V Raghavendra, Asst

Manager Finance and all the Staff and management at Fitwel Tools And Forgings Pvt.Ltd for
providing me an opportunity to carry out this internship at their company.

S D ADARSH

(20TPE01)
3rd SEM, M Tech, (TPE)

Dept. of Mechanical Engineering, SSIT, TUMAKURU Page 2

 Life cycle of Camshaft 2020-21

TABLE OF CONTENTS

COMPANY PROFILE 5-17

CHAPTER-1 INTRODUCTION 18-29

1.1 INDUCTION HEATING
1.2 FORGING
1.2.1 STEPS OF IMPRESSION DIE FORGING
1.2.2 STANDADR FORGING EQUIPMENTS
1.3 TRIMMING
1.4 BASIC HEAT TREATMENT
1.4.1 HEAT TREATMENT THEORY
1.4.2 STAGES OF HEAT TREATMENT
1.4.2.1 HEATING STAGE
1.4.2.2 SOAKING STAGE
1.4.2.3 COOLING STAGE
1.5 SHOT BLASTING
1.5.1 TECHNOLOGIES USED
1.5.1.1 WHEEL BLASTING
1.5.1.2 AIR BLASTING
1.5.2 EQUIPMENT USED IN SHOT BLASTING
1.6 PRODUCT INSECTION
1.6.1 VISUAL INSPECTION
1.6.2 MAGNETIC PARTICLE INSPECTION
1.6.3 X-RAY OR RADIOGRAPHIC TESTING

Dept. of Mechanical Engineering, SSIT, TUMAKURU Page 3

 Life cycle of Camshaft 2020-21

CHAPTER-2 SHOP FLOORS 30-32

2.1 COMPONENTS OF SHOP FLOOR
2.2 WHAT IS SHOP FLOOR MANAGEMENT
2.3 OBJECTIVES OF SHOP FLOOR MANAGEMENT
2.4 BENEFITS OF SHOPFLOOR MANAGEMENT

CHAPTER-3 CASE STUDY 33-40

3.1 RAW MATERIAL CUTTING
3.2 BILLET HEATING
3.2.1 BENEFITS OF INDUCTION HEATING
3.3 HOT FORGING
3.4 TRIMMING
3.5 HEAT TREATMENT
3.6 SHOT BLASTING
3.7 VISUAL INSPECTION
3.8 MAGNETIC PARTICLE INSPECTION
3.9 PACKING AND DISPATCH

CHAPTER-4 CONCLUSION 41

SUGGESTIONS 42

Dept. of Mechanical Engineering, SSIT, TUMAKURU Page 4

 Life cycle of Camshaft 2020-21

Antharasanahalli, Tumakuru, Karnataka 572106

Overview
Our M.D. Mr.D.R.Subramanya B.Sc., B.E., a first generation entrepreneur;
Incorporated M/S Fitwel Tools and Forgings Pvt. Ltd. in the year 1983. Commercial production
commenced in the year 1987 with the manufacturing of Hand tools as core business.
Five years later, Fitwel moved towards the Automobile industry through the manufacturing
of Maruti Udyog Rocker arms through M/S Sansera Engineering Pvt. Ltd.. The high precision
demands both on dimensions and weight have since become a norm at Fitwel.
M/S Fitwel Tools and Forgings Pvt. Ltd. was ISO/TS 16949:2009 certified in the year 2002
and has been ISO/TS 14000 certified in the year 2014. Fitwel became a Subsidy of M/S Sansera
Engineering Pvt. Ltd. in the year 2005.
Having started as a small scale industry with only one hammer line, we have gradually
grown and have 17 forging lines, comprising hammer, friction screw press and pneumatic press
lines and a well-equipped CNC shop.
Today, our forging output is 2 Million components a month and machined output is close to
100,000 components every month. We cater to the Auto sector, Power tools, Hand tools, Heavy
machinery, Agricultural and Special purpose markets. 
 

Our current scope of manufacturing is in precision forged components, ranging from 18gm
to 5,000gm.

All forging related heat treatment operations are carried out in-house and is monitored and
controlled. By a well-equipped metallurgical lab. Forging Die and Tool Design / manufacturing is
carried out in-house by our fully equipped design dept. and tool room, thus ensuring direct control
over the quality of all the products.

Dept. of Mechanical Engineering, SSIT, TUMAKURU Page 5

 Life cycle of Camshaft 2020-21
Value addition through value engineering and customer satisfaction is at the core of our business
and focus.

Dept. of Mechanical Engineering, SSIT, TUMAKURU Page 6

 QUALITY POLICY
" TO ACHIEVE AND MAINTAIN LEADERSHIP IN PRECISION FORGING INDUSTRY BY
CUSTOMER SATISFACTION AND CONTINUAL IMPROVEMENT METHODS "

QUALITY OBJECTIVE
ZERO CUSTOMER COMPLAINT
MAINTAIN 100% DELIVERY PERFORMANCE
IMPROVING PROCESSES BY VALUE ENGINEERING
Forgings
Manufacture of precision forged (Horizontal and Vertical) and machined components is our forte
with an capacity to manufacture over 1.9 million forged parts per month.

Typical components include: Arm Valve rocker, Gear Shift Fork, Connecting Rods, for the Auto
Sector. Control Levers, Tensioning Levers, Pump Barrels, Pump Housing, Gear Shafts, Drive
Shafts, Rotor Forge, Cam Shafts for the Diesel Pump application, Flanges, Bushes, Races and
various other precision forged components for both automotive and Non automotive
sectors.                              

Padded rocker arms Roller type rocker arms

Control Levers / Tension Levers Barrels           

 Link Forgings Axles and Spindles

Gears Long And Short Gears

Connecting Rods Cam shafts

Housings Pump housings

  

 Miscellaneous Flanges

Hand Tools Hand Tools                    

 Crank Shafts Rings & Bushes

Gears shifters Plugs                         

 
Machined Components

Flanges Machined Components

Barrels
Infrastructre
In today’s highly competitive market, to be able to provide an end to end solution makes a
significant difference to our customers.

Making sure that we have the entire relevant in-house infrastructure ensures comprehensive
planning and well-informed decisions.

Design & Development

 Drafting seats powered by the latest iteration of AUTOCAD.
 Modelling seats run on UNIGRAPHICS 8.5 for Die and Tool modelling.
 NX CAM is used for NC Programming.
 Over sees New Product Development for maximum control over tool and design.
 Fixture design for the machine shop requirement.
 Manages APQP and PPAP documentation.

Die Manufacturing
 Miller Die Welding for high tensile MIG and TIG welds.
 In house die block heat treatment facility. (Stress relieving, Die Pre-heating, Controlled
cooling chamber)
 Die Block Preparation via conventional machines.
 Trimming tool Manufacturing.
 Equipped with hi precision Wire type and spark type EDMs.
 Cavity milling via advanced mill and turn centres.
 Machine Shop
 Fourteen CNC Turn Centres, of ACE designers, Pride, Askar microns make, To cover a
whole range of component sizes.
 Two turn Centres capable of Die manufacturing.
 Three VMCs exclusively for Die Milling, of MAKINO and TAL makes.
 Two VMCs for part manufacturing, both of AMS makes.
 Other facilities Include
 Broaching
 Riveting
 Key Milling
 Heat treatment facility for pins via Induction hardening.
We are keen on expanding our machining capacity and ready to support our customers in their
requirements.

Forge Shop
Drop Hammer Route:
 One line of 1.5 Ton hammer.
 line of 1.25 Ton hammer.
 Three Lines of 1 Ton hammers.
 Three lines of 0.75 Ton Hammers.
 Two lines of 0.5 Ton hammers.

Hydraulic Hammer Route:

 One Line of 0.5Ton hammers.

Friction Screw Press(FSP) Route:

 One Line of 250 Ton FSP
 Two lines of 350 Ton FSP
 One Line of 560 Ton FSP
 
Direct Drive FSP Route:
 One line 250 Ton DDFSP

Pneumatic Press Route:

 Two Lines of 1600 Ton Hasenclever Presses
 One Line of 700 Ton Ajax Press

Pre Forging:
 Two Pneumatic hammers.
 One Hasenclaver Reduce Roller.
 
All Forging lines are equipped with Induction heaters, Mechanical trimming presses for flash
removal and conveyers for rapid part movement.Supported by two DISA Wheel arbitrators and six
presses for cold working operations on the components forged.

Heat Treatment
 Five Continuous Mesh belt furnaces of varying wattage (45kW, 75 kW, 90kW, 120kW,
150kW) and capacities for coverage across the spectrum of components.
 Use of SKADA interface for furnace PLC design.
 Three Bogie hearth furnaces.
 One Pit type furnace.
 In-house heat treatment operations include:
 Hardening and Tempering.
 Annealing.
 Sub Critical Annealing.
 Normalizing.
 Tempering.
 Metallurgy
 The Metallurgy dept. is equipped with hardness testers for
 Brinnel (Two 187.5 kg and one 3000kg)
 Vickers
 Rockwel (Two no’s)
 Abrasive cutter machine. For local cutting requirements.
 Muffle furnace for lab testing.
 Micro scope with camera extension for micro structure analysis and imaging.
 Hot and Cold mould machines.
 Fully capable Raw material verification via:
 Spark spectral analysis on inward raw material inspection.
 Reagent based cross verification of inward bound Raw material.
 Step down checking.
 Grain size analysis of forged components for quality assurance.
 Rain flow analysis via acid pickling.

Quality Assurance
Quality is relevant and critical through all processes from receipt of raw material to dispatch of
finished goods. Achieving and maintaining quality is made possible by contribution towards it at
every stage.   

 Profile projector with built in CAD interface.

 Surface plates and Vernier height gauges and callipers.
 Variety of appropriate Attribute gauges.
 Roughness Testing.
 Magnaflux Particle Inspection.
Major Customers
Awards
 

Recepient of many an awards

Year Customer Award Title

201 DELPHI-TVS Best Supplier award for "CONSISTENT QUALITY

2 RATING"  for the year 2012

201 REXROTH Best "SUPPLIER PERFORMANCE AWARD” for 2010

0 BOSCH

200 DELPHI-TVS Best Supplier award for "CONSISTENT QUALITY RATING"  for
9 the year 2009

200 BOSCH Best Supplier award for  " MAXIMISING VALUE TO CUSTOMER
9 " for the year 2009

200 BOSCH Achieved a level of " 0 " PPM in their Supplies for the Year 2006
6

200 BOSCH Achieved a level of " 0 " PPM  in their Supplies for the Year 2005
5

200 BOSCH Best supplier award for “CONSISTENT QUALITY RATING“ for

3 the year  2003
 CHAPTER-1
INTRODUCTION

1.1 INDUCTION HEATING

Induction heating is the process of heating electrically conductive materials like metals
by electromagnetic induction, through heat transfer passing through an induction coil that creates
an electromagnetic field within the coil to melt down steel, copper, brass, graphite, gold, silver,
aluminium, and carbide. An induction heater consists of an electromagnet and an electronic
oscillator that passes a high-frequency alternating current (AC) through the electromagnet. The
rapidly alternating magnetic field penetrates the object, generating electric currents inside the
conductor, called eddy currents. The eddy currents flow through the resistance of the material, and
heat it by Joule heating. In ferromagnetic and ferrimagnetic materials, such as iron, heat also is
generated by magnetic hysteresis losses. The frequency of the electrical current used for induction
heating depends on the object size, material type, coupling (between the work coil and the object
to be heated) and the penetration depth.

An important feature of the induction heating process is that the heat is generated inside the object
itself, instead of by an external heat source via heat conduction. Thus objects can be heated very
rapidly. In addition there need not be any external contact, which can be important where
contamination is an issue. Induction heating is used in many industrial processes, such as heat
treatment in metallurgy, Czochralski crystal growth and zone refining used in the semiconductor
industry, and to melt refractory metals that require very high temperatures. It is also used in
induction cook-tops for heating containers of food; this is called induction cooking
1.2 FORGING

Forging is a manufacturing process involving the shape of metal using

localized compressive forces. The blows are delivered with a hammer (often a power hammer) or
a die. Forging is often classified according to the temperature at which it is performed: cold
forging (a type of cold working), warm forging, or hot forging (a type of hot working). For the
latter two, the metal is heated, usually in a forge. Forged parts can range in weight from less than
a kilogram to hundreds of metric tons.[1][2] Forging has been done by smiths for millennia; the
traditional products were kitchenware, hardware, hand tools, edged weapons, cymbals,
and jewellery. Since the Industrial Revolution, forged parts are widely used
in mechanisms and machines wherever a component requires high strength;
such forgings usually require further processing (such as machining) to achieve an almost
finished part. Today, forging is a major worldwide industry.

1.2.1 STEPS OF IMPRESSION DIE FORGING

 Heating.
Pre-forged metal starts with metal blocks called "ingots," which come in a variety of
shapes and sizes depending on the part or component to be produced. These ingots are
heated to a near molten state where the metal still retains its shape but can be altered easily
with force.

 Pre forming.
In order to form a piece of the ingot to be pressed between the closed dies, the heated ingot
is edged and blocked with a press or hammer. Edging is done to increase the working cross
section and blocking is implemented to refine the shape for finish forging.

 Finish Forging.
To complete the shape, the preformed metal is forced into an impression between two dies;
this is where the metal takes on the general shape of the end product. Simple items may
 only need one press, but more complicated items may require multiple strokes at different
pressures or even different dies to design the final product.

 Cooling.
By coordinating the cooling of the metal, forgers can increase the strength of the final
product by deforming and optimizing the grain flow within the metal. A unique aspect of
impression die forging is the "flash," which is the excess metal that flows outside of the
dies. The flash cools and hardens rapidly causing it to be stronger than the metal in the
dies. This forces the metal in the dies to completely fill any cavities.

 Finishing.
Once a forged product has gone through the pressing process, trimming and other surface
treatment operations are performed in order to improve the dimensional accuracy of the
forged product. Surface treatment can be completed to enhance corrosion resistance and
improve the appearance of the finished forged product.

1.2.2 STANDARD FORGING EQUIPMENT

There are four primary tools that are used in the metal forging process depending on the exact
method being used.

 Hammers

The hammer, or power hammer, is a tool most commonly associated with forging. Whether
a hand-held hammer or a massive power hammer, the tool is used to repeatedly hit the
metal in order to deform it. As long as it possesses a 50,000 lbs driving force to deliver
high-pressure impact blows, a hammer can pound metal into shape.

 Presses

Presses use either mechanical or hydraulic pressure to apply continuous pressure

on forging dies. This kind of equipment requires a 50,000 ton driving force to
vertically squeeze metal into die cavities with controlled high pressure. Instead
 of hitting the metal repeatedly to deform it, the metal is slowly pressed into the
dies.

 Upsetters

Upsetter forging is similar to press forging, however, the main difference is that
an upsetter is a forging press that is used horizontally. Instead of forcing the
metal downward into a die, the metal is moved into the die impression in a
horizontal direction.

 Ring Rollers

Ring rollers are used to produce rings with diameters from just a few inches to over 300
inches. Ring rollers squeeze out a one-piece ring, which removes the need for welding. It
turns a hollow round piece of metal under extreme pressure against a rotating roll.

Fig 2.1 Hot forged product

1.3.TRIMMING

Trimming is a manufacturing process that is used as a finishing operation for forged parts, in order
to remove flash. Flash is a characteristic common in most metal forgings.Trimming basically
presses a part through a cutting die that runs the periphery of the work. The cutting die are
precisely designed to remove the flash from a particular part. Most often it is desirable to perform
this operation while the work is still hot for maximum efficiency, therefore it is usually
incorporated into the larger production process. For more delicate forgings, flash can be ground or
cut off using different methods. For certain metal forgings, this is an extremely quick and easy
method for the removal of the extra material.

1.4.BASIC HEAT TREATMENT

The process of heat treating is the method by which metals are heated and cooled in a
series of specific operations that never allow the metal to reach the molten state. The
purpose of heat treating is to make a metal more useful by changing or restoring its
mechanical properties. Through heat treating, we can make a metal harder, stronger, and
more resistant to impact. Also, heat treating can make a metal softer and more ductile.
The one disadvantage is that no heat-treating procedure can produce all of these
characteristics in one operation. Some properties are improved at the expense of others;
for example, hardening a metal may make it brittle.

1.4.1 HEAT-TREATING THEORY

The various types of heat-treating processes are similar because they all involve the
heating and cooling of metals; they differ in the heating temperatures and the cooling
rates used and the final results. The usual methods of heat-treating ferrous metals (metals
with iron) are annealing, normalizing, hardening, and tempering. Most nonferrous metals
can be annealed, but never tempered, normalized, or case-hardened. Successful heat
treatment requires close control over all factors affecting the heating and cooling of a
metal. This control is possible only when the proper equipment is available. The furnace
 must be of the proper size and type and controlled, so the temperatures are kept within the
prescribed limits for each operation.

Even the furnace atmosphere affects the condition of the metal being heat-treated. The
furnace atmosphere consists of the gases that circulate throughout the heating chamber and
surround the metal, as it is being heated. In an electric furnace, the atmosphere is either air
or a controlled mixture of gases. In a fuel-fired furnace, the atmosphere is the mixture of
gases that comes from the combination of the air and the gases released by the fuel during
combustion. These gases contain various proportions of carbon monoxide, carbon dioxide,
hydrogen, nitrogen, oxygen, water vapor, and other various hydrocarbons. Fuel-fired
furnaces can provide three distinct atmospheres when you vary the proportions of air and
fuel. They are called oxidizing, reducing, and neutral.

1.4.2 STAGES OF HEAT TREATMENT

Heat treating is accomplished in three major stages:

Stage l: - Heating the metal slowly to ensure a uniform temperature.
Stage 2:- Soaking (holding) the metal at a given temperature for a given time.
Stage 3: - Cooling the metal to room temperature.

1.4.2.1 Heating Stage

The primary objective in the heating stage is to maintain uniform temperatures. If uneven
heating occurs, one section of a part can expand faster than another and result in
distortion or cracking. Uniform temperatures are attained by slow heating. The heating
rate of a part depends on several factors. One important factor is the heat conductivity of
the metal. A metal with a high-heat conductivity heats at a faster rate than one with a low
conductivity. Also, the condition of the metal determines the rate at which it may be
heated. The heating rate for hardened tools and parts should be slower than unstressed or
untreated metals. Finally, size and cross section into the heating rate. Parts with a large
cross section require slower heating rates to allow the interior temperature to remain close
 to the surface temperature that prevents warping or cracking. Parts with uneven cross
sections experience uneven heating; however, such parts are less apt to be cracked or
excessively warped when the heating rate is kept slow.

1.4.2.2 Soaking Stage

After the metal is heated to the proper temperature, it is held at that temperature until the
desired internal structural changes take place. This process is called SOAKING. The
length of time held at the proper temperature is called the SOAKING PERIOD. The is
used for metals that require a rapid cooling rate, and soaking period depends on the
chemical analysis of the oil mixtures are more suitable for metals that need a metal and
the mass of the part. When steel parts are slower rate of cooling. Generally, carbon steels
are uneven in cross section, the soaking period is deterred- water-hardened and alloy
steels are oil- hardened. Nominee by the largest section.

Ferrous metals are normally quenched in water. Temperature is called the SOAKING
PERIOD.This is used for metals that require a rapid cooling rate, and soaking period
depends on the chemical analysis of the oil mixtures are more suitable for metals that
need a metal and the mass of the part. When steel parts are slower rate of cooling.
Generally, carbon steels are uneven in cross section, the soaking period is deterred-
water-hardened and alloy steels are oil-hardened. Nominee by the largest section, ferrous
metals are normally quenched in water.

During the soaking stage, the temperature of the metal is rarely brought from room temperature to
the final temperature in one operation; instead, the steel is slowly heated to a temperature just
below the point at which the change takes place and then it is held at that temperature until the
heat is equalized throughout the metal. We call this process PREHEATING. Following preheat;
the metal is quickly heated to the final required temperature. When apart has an intricate design, it
may have to be preheated at more than one temperature to prevent cracking and excessive
warping. For example, assume an intricate part needs to be heated to 1500°F for hardening. This
part could be slowly heated to 600°F, soaked at this temperature, then heated slowly to 1200°F,
and then soaked at that temperature. Following the final preheat, the part should then be heated
quickly to the hardening temperature of 1500°F.

NOTE: Nonferrous metals are seldom preheated, because they usually do not require it,
and preheating can cause an increase in the grain size in these metals.

1.4.2.3 Cooling Stage

After a metal has been soaked, it must be returned to room temperature to complete the
heat-treating process. To cool the metal, you can place it in direct contact with a
COOLING MEDIUM composed of a gas, liquid, solid, or combination of these. The rate
at which the metal is cooled depends on the metal and the properties desired. The rate of
cooling depends on the medium; therefore, the choice of a cooling medium has an
important influence on the properties desired. Quenching is the procedure used for
cooling metal rapidly in oil, water, brine, or some other medium. Because most metals are
cooled rapidly during the hardening process, quenching is usually associated with
hardening; however, quenching does not always result in an increase in hardness; for
example, to anneal copper, you usually quench it in water. Other metals, such as air-
hardened steels, are cooled at a relatively slow rate for hardening. Some metals crack
easily or warp during quenching, and others suffer no ill effects; therefore, the quenching
medium must be chosen to fit the metal.
1.5 SHOT BLASTING
The term “shot blasting” refers to the process of propelling abrasive media material with
centrifugal or mechanical force. Shotblasting has an entirely different pressurizing system than
sandblasting. This abrasive treatment method uses a device similar to a spinning wheel to
centrifugally accelerate shot-like material and blast it against a surface.

Shotblasting is a much more aggressive abrasive technique than sandblasting. It’s usually used for
larger and more difficult preparation objects that need a strong application force and a denser
media material to clean and prepare a surface. Shotblasting also requires strict containment as the
force of blasted shot could cause collateral damage if the process isn’t confined.

You’ll often find shot blasting centrifugal abrasion treatment in large-scale operations. That could
be in shot blasting tanks where steel shot or grit blasts rough surfaces like automobile frames
being restored or steel containers being recycled. You’ll also find shot blasting at work where
engine components require peening to increase malleability.

1.5.1 TECHNOLOGIES USED

 Wheel blasting

 Air blasting

1.5.1.1 Wheel blasting

Wheel blasting directly converts electric motor energy into kinetic abrasive energy by rotating a
turbine wheel. The capacity of each wheel goes from approximately 60 kg per minute up to
1200kg/min. With these large amounts of accelerated abrasive, wheel blast machines are used
where big parts or large areas of parts have to be derusted, descaled, deburred, desanded or
cleaned in some form.

Often the method of transportation of the components to be blasted will define the type of
machine: from simple table machines to integrated, fully automatic manipulator machines for full
series automotive manufacturers, through to roller conveyors and strip descaling systems.
1.5.1.2 Air blasting

Air blast machines can take the form of a blast cabinet, the blast media is pneumatically
accelerated by compressed air and projected by nozzles onto the component. For special
applications a media-water mix can be used, this is called wet blasting.

In both air and wet blasting the blast nozzles can be installed in fixed positions or can be operated
manually or by automatic nozzle manipulators or robots
The blasting task determines the choice of the abrasive media, in most cases any type of dry or
free running abrasive media can be used.

1.5.2 EQUIPMENT USED IN SHOT BLASTING

 Tumble blast equipment: Tumble blasts allow continuous blasting cycles with continual
abrasive recycling. These machines have built-in rubber belt and steel flight models in
different sizes.
 Swing table blast wheels: Direct drive blast wheels swing out for loading and unloading
abrasive media.
 Table blasters: These are fixed equipment components with direct drive wheels mounted
inside the blast cabinet.
 Spinner hangers: These direct drive blast wheels have rotating spindles that allow
loading and unloading abrasive media during a continuous blast cycle.
 Hanger blast equipment: Blast systems can be fitted with trolleys and hung on manual
Y-track monorails for specific shot blasting operations.
 Cylinder blasters: Certain shot blast equipment specializes in removing rust and old paint
from all forms of metal cylinders.
1.6. PRODUCT INSPECTION
INSPECTION is an organized examination or formal evaluation exercise. In engineering,
inspection involves the measurements, tests, and gages applied to certain characteristics in regard
to an object or activity. The results are usually compared to specified requirements and standards
for determining whether the item or activity is in line with these targets. Some inspection methods
are destructive; however, inspections are usually nondestructive.

Nondestructive examination (NDE), or nondestructive testing (NDT), are a number of

technologies used to analyze materials for either inherent flaws (such as fractures or cracks), or
damage from use. Some common methods are Visual, Microscopy, Liquid or Dye penetrant
inspection, Magnetic particle inspection, Eddy current testing, X-ray or Radiographic
testing, and Ultrasonic testing.

1.6.1 VISUAL INSPECTION

Visual Inspection, or Visual Testing (VT), is the oldest and most basic method
of inspection. It is the process of looking over a piece of equipment using the naked eye to look for
flaws. It requires no equipment except the naked eye of a trained inspector.

Visual inspection can be used for internal and external surface inspection of a variety of
equipment types, including storage tanks, pressure vessels, piping, and other equipment.

Visual inspection is simple and less technologically advanced compared to other methods. Despite
this, it still has several advantages over more high-tech methods. Compared to other methods, it is
far more cost effective. This is because there is no equipment that is required to perform it. For
similar reasons it also one of the easiest inspection techniques to perform. It is also one of the most
reliable techniques. A well-trained inspector can detect most signs of damage.

1.6.2 MAGNETIC PARTICLE INSPECTION

Magnetic particle Inspection (MPI) is a non-destructive testing (NDT) process for detecting

surface and shallow subsurface discontinuities in ferromagnetic materials such
as iron, nickel, cobalt, and some of their alloys. The process puts a magnetic field into the part.
The piece can be magnetized by direct or indirect magnetization.
Direct magnetization occurs when the electric current is passed through the test object and a
magnetic field is formed in the material. Indirect magnetization occurs when no electric current is
passed through the test object, but a magnetic field is applied from an outside source. The
magnetic lines of force are perpendicular to the direction of the electric current, which may be
either alternating current (AC) or some form of direct current (DC) (rectified AC).

The presence of a surface or subsurface discontinuity in the material allows the magnetic flux to
leak, since air cannot support as much magnetic field per unit volume as metals.To identify a leak,
ferrous particles, either dry or in a wet suspension, are applied to a part. These are attracted to an
area of flux leakage and form what is known as an indication, which is evaluated to determine its
nature, cause, and course of action, if any.

1.6.3 X-RAY OR RADIOGRAPHIC TESTING

Radiographic Testing (RT) is a non-destructive testing (NDT) method which uses either x-rays or
gamma rays to examine the internal structure of manufactured components identifying any flaws
or defects.

In Radiography Testing the test-part is placed between the radiation source and film (or detector).
The material density and thickness differences of the test-part will attenuate (i.e. reduce) the
penetrating radiation through interaction processes involving scattering and/or absorption. The
differences in absorption are then recorded on film(s) or through an electronic means. In industrial
radiography there are several imaging methods available, techniques to display the final image, i.e.
Film Radiography, Real Time Radiography (RTR), Computed Tomography (CT), Digital
Radiography (DR), and Computed Radiography (CR).
 CHAPTER – 2
SHOP FLOORS

Beginning with the Industrial Revolution era, a workshop may be a room, rooms

or building which provides both the area and tools (or machinery) that may be required for the
manufacture or repair of manufactured goods. Workshops were the only places of production until
the advent of industrialization and the development of larger factories. In the 20th and 21st
century, many Western homes contain a workshop in the garage, basement, or an external shed.
Home workshops typically contain a workbench, hand tools, power tools and other hardware.
Along with their practical applications for repair goods or do small manufacturing runs,
workshops are used to tinker and make prototypes.

Workshops may vary in industrial focus. For instance, some workshops may focus on automotive
repair or restoration. Woodworking is one of the most common focuses, but metalworking,
electronics work, and many types of electronic prototyping may be done.

2.1 Components of a Shop Floor

Here are some important components of a shop floor −

 Material − This is either a man-made material or a natural resource. Material is a vital

part which is used to make or develop some product.

 Machinery, Equipment and Tools − Depending on the sector of production, there are
various mechanical, electrical, electronic and thermal equipment along with various tools
used on the shop floor. This factor speeds up the production and improves productivity of
the business.

 Information Technology − Today’s shop floors are equipped with Shop Floor Control
Systems (SFC), Manufacturing Execution Systems (MES), Manufacturing Operations
Management (MOM) Software, Quality Management Software (QMS), Real Time Data
Retrieval from shop floor operations, and other such simulators.
  Quality Control − When the product is ready, it is required to undergo certain quality
tests and criteria to meet customer satisfaction. The Quality Control Section of a shop
floor ensures that the product is flawless and up to the customer’s satisfaction.

 Store Room − It stores spare parts and other such inventories. If there is an appropriate
store room layout, its management is shrewd and there are proper SOPs in place, it will
certainly reduce operational costs to quite an extent. An up-to-date store helps to predict
the budget accurately.

 Staff − Skilled and experienced staff is a great contributor to successful production on the
shop floor. Such staff can work with minimal errors and maximum perfection.

2.2 What is Shop Floor Management?

Shop floor management is developing and managing the shop floor operations, inventory,
equipment and workers. The following diagram displays the general phases of a
manufacturing/processing/assembly business.
A shop floor being the participant of a production phase, its management requires dealing and
handling all those factors which are directly involved in production.

2.3 Objectives of Shop Floor Management

Here are some important objectives of shop floor management −

 Routing movement of material on shop floor appropriately.

 Sequencing the procedures and processes taking place on shop floor.

 Scheduling of workforce, resources and operations.

 Finding deviation from standard procedures and processes.

 Identifying loopholes in shop floor communication.

2.4 Benefits of Shop Floor Management

Some vital benefits of shop floor management are given below −

 Increased operational efficiency through standardization of operations.

 Reduction in occurrence of errors in work.

 Revealing of loopholes in production or processes.

 Increases productivity of the staff.

 Positive impact on the revenue of a manufacturing business.

CHAPTER – 3
CASE STUDY

MY RESPONSIBILITIES:

As an intern, I was given the responsibility to move around the Forging plant, familiarize
myself with the shop floor, observe the production process, check the product life cycle of
CAM SHAFT and submit observations in the form of a report.

FORGING OF CAM SHAFT(CS159)

A camshaft is a rod which rotates and slides against a piece of machinery in order to turn
rotational motion into linear motion. This change of motion is accomplished by the camshaft
moving further and closer from the axis of rotation as the camshaft is pushed by the machinery.
These moving pieces of the shaft are the cams. The linear distance moved is called the 'throw'.

A camshaft on an internal combustion heat engine is a device that controls both the input of fuel
and the expulsion of exhaust fumes. It consists of several radial cams, each displacing intake or
exhaust valves. This camshaft is connected to the crankshaft via belt, chain or gears. This ensures
consistent timing of the valves in relation to the motion of the pistons.

Conventionally, the hot forging method was used in the manufacture of camshafts, which
comprises melting a material by heating, compressing the melted material in a die to form a
roughly formed piece, cutting the roughly formed piece, quenching and tempering the cut piece
and subjecting the thermally treated piece to a finishing treatment to obtain a camshaft.

The experimental procedure for the project work can be listed as:
1. Raw material cutting
2. Billet heating
3. Hot forging
4. Trimming
5. Heat treatment
6. Shot blasting
7. Visual inspection
8. Magnetic Particle Inspection
9. Packing and dispatch
 The first and foremost job for the experiment is the specimen preparation. Prescribed amount
of material is imported from the company prier to 3 months of forging.

Supplier Arjas Steel

Material grade EN207
Specimen size 35mm(Dia), 156mm(Length)
Heat no. 64314
Color code Black And White
Used in CS159

Raw material composition:

Chemical composition-

%C %Mn %P %S %Si
Minimum 0.16 0.60 0.030 0.045 0.10
Maximum 0.21 0.80 0.0.50 0.065 0.30
Actual 0.20 0.78 0.013 0.530 0.24

%Cr %Al
Minimum 0.60 0.40
Maximum 0.80 0.60
Actual 0.71 0.5

Mechanical property-Hardness(BHN)-Min=140

Max=190

Actual=144

3.1 Raw material cutting

Billet shearing is a chip less production process of raw parts for bulk metal-forming operations
by cutting semifinished products as bars and wires into billets.

The methods used for this are:

1.Shear cutting

Shear cutting is the separation of workpieces by two blades moving in opposite directions past
each other without the formation of chips or the use of burning or melting.

2.CSNC cutting

3.Sawing

Sawing is a process where in a narrow slit is cut into the workpiece by a tool consisting of a
series of narrowly spaced teeth. Sawing is used to separate work parts into two or more pieces.

3.2 Billet heating

In a hot forging process, a part is heated over the material recrystallization temperature prior to
forging. This process enables a part to be molded with minimum pressure and produces finished
parts that have a reduced residual stress, thus making it easy for machining or heat treatment.
Induction heating provides a better option than furnace heating, as it delivers quick and
efficient heat in forging applications. This process depends on electrical currents to generate heat
within the part.High power density ensures instant heating, with rigorous control over the heated
area. With recent developments in solid-state technology, induction heating has become an easy
and low-cost heating technique.

3.2.1 Benefits of Induction Heating

Induction heating offers a number of benefits for forging applications. It provides safe and reliable
heating, promotes quick heating to realize higher volumes and better productivity, ensures
accurate and uniform heating of components, and cuts down energy consumption when compared
to other heating techniques.

This process is a clean, non-contact heating method and can be easily incorporated into production
cells. Generally, induction heating is utilized for heating metal billets and bar ends before forging.
Nonetheless, a number of factors have to be considered when using induction heating for forging
applications.

Factors like size of the heated parts, radiation loss, and time for through-heating should be taken
into account.
 Fig.1 Time for through heating.

Besides the amount of energy needed to heat the component to the forging temperature, the size of
the component also determines the operating frequency of the induction system so as to improve
operating efficiency.

Moreover, during the production of induction coils, significant amount of energy is lost from the
hot part due to radiation. However, this can be controlled using thermal insulation.

Additionally, the induction process generates heat within the part, but the heat is produced close to
the exterior surface and takes time to reach the core of the part. Generally, a 75 mm-diameter bar
will take 150 seconds to heat to the center, while 20 mm-diameter bar ends will take less than 10
seconds (figure .1).

Here the metal is heated to 12500C.

Induction used is of 450Kwh.(Inductotherm)

The heated metal is sent for forging through the conveyer to Hammer/Press engine as per
requirement.
3.3 Hot forging

Here the machine used for forging is 700 Press machine. This machine has capacity of 700 ton
able to press the billet to its prescribed size and shape using the dies fixed to it. Die no-UF6M

The billet which is pre heated to certain temperature is brought under dies fixed to the machine.
Where two workers handle it carefully. One worker helps in loading the billet on to the dies while
other takes care of wellness of the die. Lubricator used to keep the dies cool is prepared in the ratio
10lit water: 1L LS73 oil. One worker cleans the dies before the placing the billet on it. Then the
billet is pre pressed and next it is placed in the die and pressed 3 times between the dies to have a
proper impression. Using the tongs the pressed billet is placed on to the next conveyer. Per shift
around 3000 pieces are forged.

3.4 Trimming
Trimming is the process of removing extra material from the forged part. Here a worker places the
forged part on to the trimming press machine and allows upper die to fall over the lower die. Due
to this, extra material from the forged part is trimmed off. The excess part trimmed is separated
and collected in bin, and the product is passed over the cold conveyer where it is cooled by the
fans.

Trimming machine used here is of 150ton capacity.

Trimming machine characteristics:

Cycle time of a single product-15sec

Production as per cycle time-1700(100%)

1360(80%)

Material weight Raw material-1.82Kg

Forged component -1.46Kg

Flash-360gm

3.5 Heat treatment

The process of heat treatment is carried out first by heating the material and then cooling it
by air. The purpose of heat treatment is to soften the metal, to change the grain size, to
modify the structure of the material and to relieve the stress set up in the material after hot
and cold working. The metal is primarily heat treated to create matrix microstructures and
associated mechanical properties not readily obtained in the as-cast condition. As-cast
matrix microstructures usually consist of ferrite or pearlite or combinations of both,
depending on cast section size and/or alloy composition.

The heat treatment used here is Normalization.

Normalizing is a type of heat treatment applicable to ferrous metals only. The purpose of
normalizing is to remove the internal stresses induced by heat treating, welding, casting,
forging, forming, or machining.

Stress, if not controlled, leads to metal failure; therefore, before hardening iron, you
should normalize it first to ensure the maximum desired results.Castings are usually
annealed, rather than normalized; however, some castings require the normalizing
treatment. Normalized iron are harder and stronger than annealed iron. In the normalized
condition, steel is much tougher than in any other structural condition. Parts subjected to
impact and those that require maximum toughness with resistance to external stress are
usually normalized. In normalizing, the mass of metal has an influence on the cooling rate
and on the resulting structure. Thin pieces cool faster and are harder after normalizing
than thick ones.
Material is heated in three stages. Where the temperature is increased gradually to not to
disturb the chemical composition of the material. The material is heated at 428 0C,7560C
and 9160C temperatures in the respective stages. And later allowed to cool at room
temperature.

3.6 Shot blasting

 This is the operation of forcibly propelling a stream of abrasive material against a surface under
high pressure to smooth a rough surface, roughen a smooth surface, shape a surface or remove
surface contaminants.

Here two workers are required to carry out the operation. All the normalized products are loaded
inside the machine and the doors are closed. Machine is turned on to let abrasive steel balls to hit
the materials at a pre defined speed through a nozzle and the products are made to roll so that they
are shot blasted equally on all the parts. The products of this step are later sent for inspection.

Fig 1.Material before and after shot blasting.

3.7 Visual inspection

This is the oldest and most basic method of inspection. It is the process of looking over a piece of
equipment using the naked eye to look for flaws. It requires no equipment except the naked eye of
a trained inspector. But this method has disadvantage of not being able to find the internal defects.
Only the defects that are visible to our naked eyes can be detected.

Various boards are fixed in the machine shop instructing the workers as to how should be the eye
movement when you hold a product for inspection. The pieces not having the required shape and
size are rejected. And the rejected pieces are sent back to their respective work shops for repair.
3.8 Magnetic Particle Inspection
This process puts a magnetic field into the part. The piece can be magnetized by direct or indirect
magnetization.

Direct magnetization occurs when the electric current is passed through the test object and a
magnetic field is formed in the material. Indirect magnetization occurs when no electric current is
passed through the test object, but a magnetic field is applied from an outside source. The
magnetic lines of force are perpendicular to the direction of the electric current, which may be
either alternating current (AC) or some form of direct current (DC) (rectified AC).

The presence of a surface or subsurface discontinuity in the material allows the magnetic flux to
leak, since air cannot support as much magnetic field per unit volume as metals. To identify a leak,
ferrous particles, either dry or in a wet suspension, are applied to a part.

These are attracted to an area of flux leakage and form what is known as an indication, which is
evaluated to determine its nature, cause, and course of action, if any.

Here the Lubricant is formed by the mixture of Cart jet Z801(Petroleum carrier oil) and
Fluorescent-F18 grade in the ratio of 1gm Powder to 1L Oil.

3.9 Packing and Dispatch

The products that are verified and meet the customer requirement are sent for packing and
dispatch. The packing department segregates the products and pack them in different boxes at pre-
defined numbers. Care is taken to make sure that the product doesn’t get damaged while being
shipped. Products are wrapped in bags and placed neatly in the boxes. Later the boxes are sealed.
The customer details and the box contents are sticked on the box. The packed boxes are sent for
dispatching.

The manager in the dispatching area verifies all the things mentioned below.

1.Quantity or Product details 2.Details of the customer 3.Quantity in the loose box

If there is any fault in the above mentioned things, the box is resent to the packing area for
correction. The corrected and verified boxes are loaded on to vehicles and shipped to the
customers.
 CHAPTER-4

CONCLUSION

Fitwel Tools & Forgings Private Limited seems to be employee oriented

company. With a huge number of employees working in the organization.

A good machined connecting rod is what we all want. But we never take any interest
in learning the steps followed in getting the final product. There are lots of hands
responsible for this production. Starting from the raw material supplier to the end
product supplier there are numerous steps involved in it.

Through this case study we were able to understand and know all the steps involved
in getting a finished connecting rod. This connecting rod in used in many of the
auto mobile and non auto mobile industries. We were able to understand how many
machineries are run to prepare this and how many people can be employed through
this.

Connecting rods are the basic requirement of any engine, and a small negligence at
any step of the process would lead to failure of the engine and in turn would give
bad name to the company. That is why the company takes larger responsibility in
preparing the products starting from step 1 to end.

By this study we could conclude that the raw material used for this production was
of weight 1.82Kg before the process began. And the end product’s weight was
1.46kg while the rest 360gm was the flash.
 SUGGESTIONS
1. In order to enhance exports, the company should see that there is timely
delivery of finished goods without fail.
2. The company is asked to maintain sufficient stocks of raw materials in the
period of short supply and anticipate price changes.
3. Few of the 5S boards in the company contain 0 grading for the first aid
availability. This issue has to be looked into.
4. Company can acquire more machinery to finish goods at the earliest. Making
it possible to employ more workers.
5. Proper clothing in the shop floor is still a concern. Needs more tougher rules.
6. Waste metal collecting bins have to be made larger surrounded by cage.