SIX WEEKS INDUSTRIAL TRAINING

REPORT

SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR

Six Week Industrial Training

At

HERO CYCLES LIMITED, LUDHIANA

(From 5 June 2017 to 17 July 2017)

SUBMITTED BY

Name- SHUBHKARMAN SINGH CHAGGAR

Branch- MECHANICAL
Roll No. - 151115
Univ. Roll No. - 1508199

DEPARTMENT OF MECHANICAL ENGINEERING

GURU NANAK DEV ENGINEERING COLLEGE

Ludhiana, India
 ACKNOWLEDGEMENTS

 I express my sincere gratitude to Dr Sehajpal Singh Khangura, Principal, Guru Nanak Dev
Engineering College for giving me the opportunity to undergo six week industrial training at Hero
Cycles Limited.

The constant guidance and encouragement received from Er K.S Mann Dean T&P, GNDEC
Ludhiana has been of great help in carrying out the project work and is acknowledged with
reverential thanks.

I would like to express a deep sense of gratitude and thanks profusely to Pankaj Munjal , Director
of Hero Cycles Ltd. Without the wise counsel and able guidance, it would have been impossible in
this manner.

We are especially thankful to Mr. J.C. Verma (Asst. Gen. Manager, Personnel) and
Mr. Surinder (HOD), for guiding and encouraging us to pursue this report and providing us their
precious time during which they helped us in troubleshooting the problems we faced.
I would also like to thank everyone who has knowingly & unknowingly helped me throughout my
project.

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 TABLE OF CONTENTS

SNO TITLE PAGE

NO
1 COMPANY PROFILE 5
2 BRIEF INTRODUCTION TO MUNJAL GROUP 6
3 HISTORY 7
4 BICYCLE 8
5 TUBULAR SECTION 14
6 RANGER SECTION 15
7 RIM PLANT 19
8 RIM POLISH 27
9 RIM ELECTROPLATING 29
10 ASSEMBLY SECTION 33
11 BONDRISING SECTION 34
12 PAINT SHOP 36
13 SADDLE UNIT 39
14 HAC PLANT 41
15 ETP PLANT 42
16 MEE PLANT 47
17 BIBILIOGRAPHY 48

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 COMPANY PROFILE

Table 1: Company Profile

BusinessType Exporter / Manufacturer / Supplier

Industry Bicycles

Products Exporter, Supplier and Sports cycles, fancy cycle, kids cycle, ranger cycle, motor
Manufacturer cycle steel rim
Founded 1956

Headquarters Ludhiana, Punjab, India

Chairman Mr. Pankaj Munjal

Revenue ₹3000 crore (2015-2016)

Slogan Cycle of Life

Hero Cycles Limited, is the world’s largest integrated bicycle manufacturing company (by
volume). Hero Cycles, the flagship company of the O. P. Munjal Group Of Companies, has been
enjoying a position of high repute not only in India but also in some of the most advanced
countries of the world, which is a manifestation of unparalleled quality of Hero Cycles. Started in
1956 as a small bicycle parts manufacturer & supplier, Hero Cycles gradually emerged as the
world’s largest manufacturer of bicycles. Currently, Hero Cycles is a renowned brand in more than
seventy-five countries in the world.

Hero Cycles has always been striving for perfection, which is ensured by constant innovation. The
hunt for innovative techniques to produce the best bicycles is endless at Hero Cycles. The constant
innovation has helped the company to follow the new trends to its advantage by identifying
emerging requirements and expanding its product portfolio.

It was in 1986 when Guinness Book of world records first named Hero Cycles as the largest
producer of bicycles. Since then, the company has been maintaining its top position. The Hero
plant is currently rolling out one bicycle every nine seconds.

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BRIEF INTRODUCTION TO O.P. MUNJAL
GROUP

GROUP COMPANIES

Hero Cycles

The Hero Cycles Limited manufactures various kinds of bicycles and bicycle related products.
Hero Cycles entered Guinness Book of world records in 1986 for manufacturing the maximum
number of bicycles. The top rank has since then been maintained by the company. In 1999-2000, it
hit another milestone by producing more than 5.1 million bicycles. Currently, the company is
producing as many as 19,000 bicycles per day and exporting them to more than 75 countries
worldwide apart from cater the needs of domestic market. The manufacturing facility located at
Ludhiana in the State of Punjab.

 Hero Motors Ltd.

A company with global focus specializes in gears & transmission assemblies for recreational
products, passenger cars and 2 wheelers, a company with Global focus. With in-house design
facility the company provides complete end to end solution. The company has technical tie up with
Magna Styre, which compliments company's core competencies in gears and transmission
business. The state of art facility is located in Ghaziabad, around 40 KM from Delhi. Over 90% of
production is OE exports, primarily to Bombardier Rotax & BMW. ZF Hero Chassis Systems Pvt.
Ltd.

It is a joint venture company of Hero Motors Limited with ZF Lemforder Corporation of Germany.
The company secures European technology and expertise in chassis technology for small car
segment in India. The company is a full service supplier for car chassis technology to car makers in
the high growth Indian market. The company has two facilities located at Talegaon and Halol.

Munjal Kiriu Industries Pvt. Ltd.

Hero Motors Limited and Kiriu Corporation, a Company from Sumitomo Group of Japan formed a
Joint Venture Company, Munjal Kiriu Industries (P) Ltd. to manufacture Brakes Discs, Brakes
Drums, Cylinder block, Pressure plate, Brake plate and Steering Knuckles for automotive original
equipment manufacturers in the Indian and overseas market. The company's manufacturing facility
is located at Manesar in Haryana.

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 HISTORY

 The four Munjal brothers, namely, Late Brijmohan Lal Munjal, Late Satyanand Munjal, Late Om
Prakash Munjal and Late Dayanand Munjal, established Hero group.
 The brothers hailed from a small town called Kamalia, now in Pakistan.
 The brothers established a business of bicycle spare parts in the year 1944 in Amritsar.
 After partition and independence of India, the brothers moved to Ludhiana and started a bicycle
unit called Hero Cycles with a capital of Rs.50000 in 1956 raised as a bank loan. The rise of the
company attracted indigenous talent in the form of skilled engineers, technocrats, administrators
and entrepreneurs who helped in building an ancillary industry around the bicycle industry.
 By 1975, Hero became the largest manufacturer of bicycles in India with a production of 7500
cycles per day.
 In 1984, Hero group joined Honda Motors of Japan to create Hero Honda Motors Limited which
soon became one of the market leaders in motor-cycle sales in India.
 In 1986, Hero Cycles produces over 18,500 cycles a day, the highest in global reckoning. With the
48% share of the Indian market, this volume has catapulted Hero in the Guinness Book of World
Records as the largest bicycle manufacturer in the world.
 By 2004, Hero Honda became the world's largest manufacturer of two-wheelers with over 48%
market share in India

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 BICYCLE

A bicycle, often called a bike or cycle, is a humanpowered, pedaldriven, singletrack vehicle,

having two wheels attached to a frame, one behind the other.

Figure 1: Source - www.herocycles.com

The basic shape and configuration of a typical upright, or safety bicycle, has changed little since
the first chaindriven model was developed around 1885.But many details have been improved,
especially since the advent of modern materials and computeraided design. These have allowed for
a proliferation of specialized designs for many types of cycling.

USES

• From the beginning and still today, bicycles have been and are employed for many uses. In a
utilitarian way, bicycles were used for transportation, bicycle commuting, and utility cycling. It
could be used as a 'work horse', used by mail carriers, paramedics, police, messengers, and general
delivery services.
• The bicycle is also used for recreational purposes, such as bicycle touring, mountainbiking,
physical fitness, and play. Bicycle competition includes racing, BMX racing, track-racing,
criterium, roller racing and time trial. Major multistage events are the Tour of California, Giro
d'Italia, the Tour de France, the Vuelta a España, and the Volta aPortugal.
• Bicycle use can be seen by the police for surveillance, while the military uses bicycles for
scouting, troop movement, supply of provisions, and patrol.

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 TYPES

• Bicycles can be categorized in many different ways: by function, by number of riders, by general
construction, by gearing or by means of propulsion.
• The more common types include utility bicycles, mountain bicycles, racing bicycles, touring
bicycles, hybrid bicycles, cruiser bicycles, and BMX Bikes.
• Unicycles, tricycles and quadracycles are not strictly bicycles, as they have respectively one, three
and four wheels, but are often referred to informally as "bikes".

DYNAMICS
A bicycle stays upright while moving forward by being steered so as to keep its center ofmass over
the wheels. This steering is usually provided by the rider, but under certain conditions may be
provided by the bicycle itself.
The combined center of mass of a bicycle and its rider must lean into a turn to successfully
navigate it. This lean is induced by a method known as counter steering, which can be performed
by the rider turning the handlebars directly with the hands or indirectly by leaning the bicycle.
Shortwheelbase or tall bicycles, when braking, can generate enough stopping force at the front
wheel to flip longitudinally. The act of purposefully using this force to lift the rear wheel and
balance on the front without tipping over is a trick known as a stoppie.

1. BICYCLE FRAME
A bicycle frame is the main component of a bicycle, onto which wheels and other components are
fitted. The modern and most common frame design for an upright bicycle is based on the safety
bicycle, and consists of two triangles, a main triangle and a paired rear triangle. This is known as
the diamond frame. Frames are required to be strong, stiff and light, which they do by combining
different materials and shapes.

Figure 2: Source- www.google.com

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 VARIATIONS IN BICYCLE FRAME

Besides the ubiquitous diamond frame, many different frame types have been developed for
thebicycle, several of which are still in common use today.

1. Diamond Frame

• In the diamond frame, the main "triangle" is not actually a triangle because it consists of four
tubes: the head tube, top tube, down tube and seat tube. The rear triangle consists of the seat tube
joined by paired chain stays and seat stays.

• The rear triangle connects to the rear fork ends, where the rear wheel is attached. It consists of the
seat tube and paired chain stays and seat stays. The chain stays run connecting the bottom bracket
to the rear fork ends. The seat stays connect the top of the seat tube (often at or near the same point
as the top tube) to the rear fork ends.

2. Stepthrough

• Stepthrough bicycle frames had a top tube that connected in the middle of the seat tube instead of
the top, resulting in a lower stand over height. The design has since been used in utility bikes to
facilitate easy mounting and dismounting for both genders, and is also known as a stepthrough
frame or an open frame. Another style that accomplishes similar results is the mixte.

3. Cantilever

• In a cantilever bicycle frame the seat stays continue past the seat post and curve downwards to
meet with the down tube. Cantilever frames are popular on the cruiserbicycle, the lowrider bicycle,
and the wheelie bike. In many cantilever frames the only straight tubes are the seat tube and the
head tube.

4. Recumbent

• The recumbent bicycle moves the cranks to a position forward of the rider instead of underneath,
generally improving the slipstream around the rider without the characteristic sharp bend at the
waist used by racers of diamondframe bicycles.

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 Fig.3 .Source www.google.com

FRAME TUBES
The diamond frame consists of two triangles, a main triangle and a paired rear triangle. The main
triangle consists of the head tube, top tube, down tube and seat tube. The rear triangle consists of
the seat tube, and paired chain stays and seat stays.

Figure 4: Source- www.google.com

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• Top tube

The top tube or crossbar connects the top of the head tube to the top of the seat tube.

Stepthrough frames usually have a top tube that slopes down steeply to allow the rider to mount
and dismount the bicycle more easily. Alternative stepthrough designs may include leaving out the
top tube out completely, as in monocoque mainframe designs using a separated or hinged seat
tube, and twin top tubes that continue to the rear fork ends as with the Mixte frame. These
alternatives to the diamond frame provide greater versatility, though at the expense of added
weight to achieve equivalent strength and rigidity.

Control cables are routed along mounts on the top tube, or sometimes inside the top tube. Most
commonly, this includes the cable for the rear brake, but some mountain bikes and hybrid bicycles
also route the front and rear derailleur cables along the top tube.

• Down tube

The down tube connects the head tube to the bottom bracket shell. On racing bicycles and some
mountain and hybrid bikes, the derailleur cables run along the down tube, or inside the down tube.
On older racing bicycles, the shift levers were mounted on the down tube. On newer ones, they are
mounted with the brake levers on the handlebars.

Bottle cage mounts are also on the down tube, usually on the top side, sometimes also on the
bottom side. In addition to bottle cages, small air pumps may be fitted to these mounts as well.

• Seat tube

The seattube contains the seatpost of the bike, which connects to the saddle. The saddle height is
adjustable by changing how far the seatpost is inserted into the seat tube. On some bikes, this is
achieved using a quick release lever. The seatpost must be inserted at least a certain length; this is
marked with a minimuminsertionmark.

The seat tube also may have brazeon mounts for a bottle cage or front derailleur.

• Chain stays

The chainstays run parallel to the chain, connecting the bottom bracket shell to the rear forkends or
dropouts. When the rear derailleur cable is routed partially along the down tube, it is also routed
along the chain stay. Mountings for disc brakes will be attached to the chain stays. There may be a
small brace that connects the chain stays in front of the rear wheel and behind the bottom bracket
shell.

Chain stays may be designed using tapered or untapered tubing. They may be relieved, ovalized,
crimped, Sshaped, or elevated to allow additional clearance for the rear wheel, chain, crankarms,

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 or the heel of the foot.

• Seat stays

The seatstays connect the top of the seat tube (often at or near the same point as the top tube) to the
rear fork dropouts. A traditional frame uses a simple set of paralleled tubes connected by a bridge
above the rear wheel. When the rear derailleur cable is routed partially along the top tube, it is also
usually routed along the seat stay.

Many alternatives to the traditional seat stay design have been introduced over the years.On most
seat stays, a bridge or brace is typically used to connect the stays above the rear wheel and below
the connection with the seat tube. Besides providing lateral rigidity, this bridge provides a
mounting point for rear brakes, fenders, and racks. The seat stays themselves may also be fitted
with brake mounts. Brake mounts are often absent from fixedgear or track bike seat stays.

• Bottom bracket shell

Figure 5: Source- www.herocycles.com

The bottom bracket shell is a short and wide tube, relative to the other tubes in the frame that runs
side to side and holds the bottom bracket. It is usually threaded, often lefthand threaded on the
right (drive) side of the bike to prevent loosening by fretting induced precession, and righthand
threaded on the left (nondrive) side. There are many variations, such as an eccentric bottom
bracket, which allows for adjustment in tension of the bicycle's chain. It is typically larger,
unthreaded, and sometimes split. The chain stays, seat tube, and down tube are all typically
connect to the bottom bracket shell.

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 TUBLAR SECTION

In Tubular Section two main parts of bicycle are manufactured

1. Frame
2. Fork

FRAME
It is a rigid structure formed of quadrant and rear triangle of a bicycle. Frame is a part which holds
the front wheel of the bicycle.

Figure 6: Source- Tubular Plant

BICYCLE FORK

Figure 7: Source- Tubular Plant

A bicycle fork is the part of a bicycle that holds the front wheel. A fork typically consists of two
blades which are joined at the top by a fork crown (cup). Above the crown, a steerer tube (column)
attaches the fork to the bicycle and the handle bar (via a stem) allowing the user to steer the
bicycle. The steerer tube of the fork interfaces with the frame via bearings called a headset
mounted in the head tube
COMPONENTS OF FORK
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H
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COLUMN
FORK CUP
BLADE

1. COLUMN: Column is a cylindrical pipe. The length of the column tube should be greater than
but approximately equal to the head tube length.
2. FORK CUP: Fork cup is attached with column and blade through nailing and brazing. Then
fork will be attached with head tube (frame) through bearing.
3.BLADE : A fork consists of two blades. At the end of the blade, the front wheel will b attached.

WAGING
RANGER SECTION
PROCESSES IN RANGER FRAME

It is a forging process in which the dimensions of an item are altered using dies into which the item
is forced. Swaging is a cold working process, used to reduce the diameter, produce a taper on
CHAIN STAY and SEAT STAY of bicycle.

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Figure 8: Source- www.google.com
MITERING

Mitering is a process of beveling the ends of the tube for making miter joints between them.
Mitering can be performed on mech. Presses or on milling machines or any other special purpose
machine.

BENDING
Tube bending is a type of metal forming processes used to permanently bend tubes at any angle.
The process of tube bending involves using mechanical force to push stock material pipe or tubing
against a die, forcing the pipe or tube to conform to the shape of the die. This is done on CNC
bending machine and mechanical bending presses.

.
MILLING

Milling is the machining process of using rotary cutters to remove material from a work piece
advancing (or feeding) in a direction at an angle with the axis of the tool. Horizontal milling
machine with end cutter is used to remove the metal stock from the top and bottom tubes.

WELDING

Two types of welding can be done on various tubes to form full frame:

Gas tungsten arc welding (GTAW) also known as TIG (tungsten, inert gas), uses a non-
consumable tungsten electrode to produce the weld. The weld area is protected from atmospheric
contamination by an inert shielding gas such as Argon or Helium.

Gas metal arc welding (GMAW) commonly termed MIG (metal, inert gas), uses a wire feeding
gun that feeds wire at an adjustable speed and flows an argon based shielding gas or a mix of argon
and carbon dioxide (CO2) over the weld puddle to protect it from atmospheric contamination.

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 EOVUB
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HAINSTYKDRLGCPFM
PROCESS FLOW CHART OF RANGER FRAME
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CO PROCESS FLOW CHART OF RANGER FORK
 RIM PLANT

Figure 9: Source- www.google.com

The rim is the outer edge of a wheel, holding the tire. It makes up the outer circular design of
the wheel on which the inside edge of the tire is mounted on vehicles such as automobiles.

RIM CHARACTERISTICS

 Diameter (effective): distance between the bead seats (for the tire), as measured in the plane of the
rim and through the axis of the hub which is or will be attached, or which is integral with the rim.
 Width (effective): separation distance between opposed rim flanges. The flange-to-flange width of
a rim should be a minimum of three-quarters of the tire section width. And the maximum rim
width should be equal to the width of the tire tread.
 Material: Various metals can be used for the rim. Commonly seen are alloys are
magnesium and aluminium, chrome and steel.

RIM PROFILES
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 Figure 10: Source- www.google.com

 Westwood
 Endric
 Hooked bead
 Hooked edge

SIZE: 12 to 28 inches in diameter

THICKNESS: 0.71 to 1.8 mm
WEIGHT: 150 gm to 2.5 kg
SPOKES: front wheel 32, rear wheel 40 (in general)

RIM PLANT BASIC FLOW CHART

Figure 11: Source-Rim Plant

RIM ROLLING MILL PROCESS FLOW

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SPKFBZ
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LOADING OF COIL ON DECOILER:
Rims are formed from a coil of steel in the form of thin sheets and size sheets of depends upon the

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rim required. Workers put the coil roll on decoiler with the help of lifts. Generally, Mild steel coils
are used.

Figure 12: Source- www.google.com

TIG WELDING:
Tungsten Inert Gas Welding is used to join the two rolls. When one roll is finished, next one is
joined to it using TIG welding.

Figure 13: Source- RimPlant

ACCUMULATION:
It is done with the Accumulator. When the MS roll of previous coil gets shorten (insufficient) for
next complete operation, then it is collected in accumulator. When new roll is attached, the
previously left roll is taken from accumulator and is used by join with new one by TIG welding.

DRAIN HOLES:
Drain holes are punched using punching apparatus to remove water collected in rim during rolling
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operation and in general use thereafter. Draining prevents corrosion.

STAMPING:
The rim size and name of company are stamped on the strip that goes further to rolls.

KNURLING:
Knurling is done by horizontal roll with knurling pores on it.

FORM ROLLING:
The profile of rim is formed by rolling mill. There are six sets of two high rolling mills that have a
specified profile that is formed on the strip.

Figure 14: Source- RIM PLANT

SEAM WELDING :

The edges formed by the form rolling process are welded to the flat surface of the rim using seam
welding. Resistance seam welding is a process that produces a weld at the faying surfaces of two
similar metals. Seam welding forms the weld progressively, starting at one end. Like spot welding,
seam welding relies on two electrodes made from of CuCrZr copper, having diameter of 400mm to
apply pressure and current. The electrodes are disc shaped and rotate as the material passes
between them.. The electrodes also assist the movement of the strip.

Figure 15: Source- RIM PLANT

PROFILE ROLLING:
After seam welding, depending upon the diameter of rim required, the bending machine bends the

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strip to take the shape of circular rim.

AUTO-CUTTING:
Rims are automatically cut according to required diameter with the help of automatic cutter.

Figure 16: Source- RIM PLANT

BUTT WELDING:
Front and rear part of cut rims are joined with the help of butt welding machine.

SIZING MACHINE:
It is used for Auto-Sizing of rims. Worker takes the rim and put it on the circumference of sizing
machine and it forms the rim to a perfect circle.

Figure 17: Source- RIM PLANT

AUTO-PUNCHING MACHINE:

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The machine punches holes on the circumference of the rim; number of holes depends on the
number of spokes required to the rim. One extra big hole is to be punched for tube air tap.Rolling
mill can be AC or DC driven.

Figure 18: Source- RIM PLANT

RIM POLISHING FLOW CHART

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RIM POLISH
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Auto-PnchigfRmsCevrMFpladBTEbyLIq
After Punching, rims are loaded on Bora machine where there is joint grinding over various
positions over the circumference of the rim.

BORA MACHINE: It is a joint polishing machine where rims after butt welding are grinded so as
to polish the joint and grind unnecessary materials. It has 11 arms that revolve around its
circumference. Different arms have grinders at various positions. It grinds 9 rims at a time.

Figure 19: Source- RIM PLANT

RIM POLISH AT TCE MACHINE: It stands for Technical Command Equipment. After grinding
by Bora machine, a robotic arm takes rim one by one and put that onto a TCE machine that grinds
the internal surface of rim and polishes it so smoothly that the joint is almost invisible.

There are 5 stages of polishing in which dazzy wheels of different grits are used for polishing.
The different stages are:
Type of polishing Grit size
Coarse polishing bead side 120
Tyre Side Coarse Polishing 80
Spoke Coarse Polishing 80
Spoke Coarse Polishing 120
Spoke Side Fine Polish 180

On an average 5 units are polished in one minute.

In manual polishing 4 units are completed in one minute by a team of three workers.

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After grinding and polishing the rims are sent for inspection to look for any signs of cracks or
damage .The faulty units are sent through the grinding and polishing processes again

Figure 20: Source- RIM PLANT

INSPECTION: After polishing, rims are checked for any remaining error or defect. If the rim is
fine, it is then sent to plating section. If it has defect, it is sent back by overhead railing to correct
the defect.

RIM ELECTRO-PLATING
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 Figure 21: Source-PlatingPlant

This process in manufacturing of rims is also known as TRI-NICKEL PROCESS. Following main
steps are followed in rim plating:-

LOADING ON JIGS: A worker takes the rim from conveyor and loads it on jigs. When the jig is
loaded, it is then taken by overhead conveyor for different operations in different tanks.

SOAK-CLEANING: In Soak-Cleaning, Oils, lubricants, etc. are removed from work-piece at a

temperature of about 60-70° for 7-8 minutes.
Alkaline soak cleaning is used to remove most soils. The solution typically contains alkalis,
phosphates, silicates, carbonates, soaps, and surfactants. Cleaning occurs by actions known as
emulsification, saponification, and dispersion. Most soak cleaners are operated at a temperature of
60 to 95 0C. The concentration of the solution is generally 4050 gm/Lt. This helps top remove the
layers of dirt or moisture present on the surface of the rim. The time that the rims are dipped is
usually around five minutes.

ANODIC-CLEANING: It is done using DC current. It removes grease and dust by its foaming
action around the part. Soak cleaning is unable to remove some contaminants, so it is used. This
process is mainly 4-5 minutes long.
The rims being cleaned are connected to the rectifier’s positive lead while in an alkaline (caustic
soda) electro cleaner solution. Low voltage (3–12 V) is used for around five minutes at a
temperature of 60950C. At the interface of the anodic part’s surface and the solution, oxygen is
liberated. A thin layer is removed from the surface. The scrubbing of these gas bubbles assists in
soil removal. Anodic cleaning is preferred as there is no hydrogen embrittlement. The density of
the solution is 511Be.

PICKLING: It is a surface treatment process which removes scale from the work piece.

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ACID DIP: In this process of plating, Phosphoric Acid is used for removal of paint or rust from
rims.

CHROME PLATING: Chrome of density 16-24 BE and at temperature of about 30-35°C is

deposited over the rim.

NICKEL PLATING:
For nickel plating, the electrolyte contains soluble nickel salts along with other constituents.When
dissolved, the nickel salts dissociate into divalent, positively charged nickel ions (Ni++) along with
negatively charged ions. When current flows, the positive ions react with twoelectrons and are
converted to metallic nickel at the cathode surface. At the anode, metallicnickel is dissolved to
form divalent, positively charged ions which enter the solution. Thenickel ions discharged at the
cathode are thus replenished by those formed at the anode.A layer of 68microns is generally plated
on the rims.
Typical formula and operating conditions for Watts nickel electroplating solutions:
The nickel sulphate is the primary source of nickel ions (Ni ++) with nickel chloride acontributing
source. Nickel chloride has two major functions – it appreciably increasessolution conductivity
thereby reducing voltage requirements and it is important in obtainingsatisfactory dissolution of
nickel anodes. Boric acid is a buffer and has the major function ofcontrolling the pH of the
solution.

SEMI BRIGHT NICKEL

Semi-brightdeposits are used for engineering nickel where ahigh luster is not desired. The solution
ph is 3.6-4.2at a temperature of 50600C. The concentration is 1319 Be. As semi-brightnickel is
used in situations where resistance to corrosion is important, the deposits must be free from
incorporated sulphur. Consequently additives which contribute sulphur to the coatings must be
avoided. Levelling agents include coumarin, 2butyne1 -4dioland other acetylenes. The grain
structure of semi-bright nickel deposits is usually columnar

TRINICKEL
The solution ph is 4.2-5.2at a temperature of 50600C. The concentration is 1622 Be. The tri-nickel
process provides high corrosion and tarnish resistance.

BRIGHT NICKEL
In bright nickel plating, four main classes of addition agents are used.

CARRIERS
These are usually aromatic organic compounds containing sulphur. The major function of carriers
is to refine the grain structure and to provide some increased lustre compared with additive free
solutions. They are not consumed rapidly by electrolysis.
BRIGHTENERS
In combination with carriers, brighteners produce brilliant deposits with good ductility and

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 leveling properties over a broad current density range. They are generally present in very low
concentrations and are consumed by electrolysis.

AUXILIARY BRIGHTENERS
These are sometimes incorporated to augment the luster attainable with carriers and brighteners or
to produce the brightness and levelling with thinner deposits.

NICKEL DRAGOUT
The drag-out tank is a rinse tank that initially is filled with pure water. As the plating line is
operated, the drag-out rinse tank remains stagnant and its chemical concentration increases as more
work is processed. Impacts of drag-out are increased chemical use and waste water generation. As
a result more rinse water is required. So to optimize the surface finish, there needs to appropriate
drag-out of the rims.

CHROME PLATING
Chrome plating uses electrolysis to bind a thin plate of chromium on to an object. There only two
essential constituents in conventional chromium plating bath chromic acid and one or more
catalyst acid radicals or anions. To convert a pure chromic acid solution to a chromic plating bath a
catalyst is necessary.

CHROME DRAGOUT 1

CHROME DRAGOUT 2

CHROME DRAGOUT 3

WATER RINSE (TWICE)

HOT WATER BATH

AIR DRIER: The rims are suspended out of the tanks for some time.
The total electroplating process takes about one hour and forty five minutes.
The rims are then sent for a final inspection.

FINAL INSPECTION
Two processes are done after rim plating. These are done in UNIT-5. They are:-

● Rim Lacing
● Rim Truing

RIM LACING: After the rims are checked by quality inspector, rims are loaded on conveyor to
lacing department. After inserting spokes to the hub, it is loaded on loading machine. Other end of
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spokes is fitted in holes on rim and it is fixed by a screw by machine. Machine works on
compressor and rotation is done by motor.

Figure 22: Source- www.google.com

RIM TRUING: This process is carried out at Rim Truing machine. It tightens all the spokes and
checks for any error in the rim and pass for tire and tube arranging.

Figure 23: Source- www.google.com

ASSMEBLY SECTION
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byFodCcPxpLf
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CYCLE ASSEMBLY PROCESSES

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CYCLE ASSEMBLY PROCESS FLOW CHART
● Rear Wheel Assembly: Chassis come on conveyor to the first section and a worker fits the chain
in sprocket and then insert rear tire. After tightening the chain, worker adjusts the tire and tight it in
the slots.
● Handle Assembly: On the next section, handle is assembled. Worker tightens the main nut after
inserting it and then adjusts the brake wires to the rear tire.
● Deraillure wire setting: Wires for the gear adjustment are tightened and fitted at this section.
● Rear Brake Assembly: Shoe Brake is fitted at this section. Wires to the brakes are adjusted
suitably and the brake is checked and then passed to next section.
● Front Brake Assembly: At this station, a rim is temporarily placed in place and then the front
brake is fitted. Wires to front brake are tightened and the rim is removed.
● Gears and Deraillure setting: When all the brakes are installed, the gears are set accordingly and
chain is checked over the gears.
● Front Wheel Tieing: Front wheel is not assembled in the fork but is tied to the frame with the help
of nylon tie.
● Handle and Front mud Tiening: Handle is tied so as to avoid its movement in the box and al so
the front mud is also tied to frame with nylon ties.
● Cycle Packing: At this section the cycle is packed in a cardboard box and then it is checked for all
necessary parts and weighed.
● Box Strapping: Cardboard box is strapped by a strapping machine which automatically put straps
on box and tightens it.

BONDRISING PLANT
Bonderising: This process is used to coat steel with an anticorrosive phosphate solution, usually in
preparation for the application of paint, enamel and lacquer. The Bonderizing Process is not only
used more extensively on sheet metal units requiring a type of finish that will provide a high
degree of rust resistance and maintain fine appearance over a period of time. Bonderizing is done
to remove rust, grease and dirt to make the part surface suitable for paint.

Chemical used: Gardoclean ( Nitride free liquid cleaner: Rust Inhibitor)

It is a light duty cleaner designed for in process metal fabrication operations when temporary
indoor rust inhibition is needed. Mainly used for light duty detergency. It removes coolants,
machine oil, shop oil etc.

There are four lines for Bonderising process in the plant.

Parts after fabrication come to this unit and are loaded in jigs carried by overhead cranes.

➢ Degreasing: It is a process of removing grease , machine oil etc from the parts and process them
for further painting process.
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➢ Water Rinse: After degreasing, parts are water rinsed so as to remove chemicals and to
maintain an optimum temperature of workpiece.

➢ De-Rusting: It is done by dipping parts in Gardo acid 2061 to remove rust.

➢ Phosphating: It is main process in the section and it prepares the base for painting process. If
this process is not done then the paint will not be applied properly.

➢ Passivation: It is done to reduce chemical reactivity of its surface. It removes free iron from the
surface of metal using acid solution to prevent rust.

➢ Drying: Parts are dried with the help of hot air. It dries off all the chemicals from the parts at a
temp of about 110-120C

➢
Sno STAGES CHEMICAL TEMP REMARKS
(⁰C)

LOADING/
UNLOADING

1 Pre-degreasing Gardoclean 9x 80-90

2 Degreasing Gardoclean 9x 80-90

3 Water Rinse 1 RT Discarded once in a week

4 Water Rinse 2 RT

5 De-Rusting Gardoacid 45-60 Iron 7% max

2061

6 Water Rinse 3 Discarded once in a week

7 Water Rinse 4

8 Activation Gardoclean RT
261M

9 Phosphating Carbobond 50-55

159M+CC no2

10 Water Rinse 5 Discarded once in a week

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 11

12

13

14
Water Rinse 6

Passivation

Drier 1

Drier 2

LOADINGFCMPETSR
Gardoclean 1

PAINT SHOP

Following main steps are involved in paint shop:

50-60

110-120

➢ Loading of components: Frames and parts from bonderising are loaded are loaded on overhead
conveyor where they go to paint section
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➢ Components Cleaning: Frames are first off all cleaned manually by a worker to remove dust etc
.
➢ Primer Coating: An automatic primer coating machine sprays primer on the frames by its
reciprocationg motion. It is done at a rate of 4 hangers per minute ie 8 frames/min.

➢ Primer T/Up at booth: The parts of the frame that are left uncoated in the section are coated by
workers manually by spray guns that work on compressed air.

➢ Flash off Zone: In this zone there is evaporation of solvents before film forming or after painting
of another coat.

➢ Top Coat Painting: Paint of desired colour is sprayed by a hydraulic machine that reciprocates in
the chamber.

➢ Electrostatic Coating: It is a manufacturing process that employs charged particles to more

efficiently paint work piece. Paint in the form of atomized liquid is initially projected towards
conductive work piece.

➢ Baking: The frames are then heated at about 160C for 20 minutes so that the paint gets dried.

➢ Inspection: A workers manually inspects all the work pieces for any errors.

AUTOPOWDER COATING PLANT

PROCESS FLOW CHART

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● MATERIAL MOVEMENT: Parts from bonderising move on conveyor to auto powder coating
plant.
● LOADING: A worker loads the parts on powder coating line on jigs.

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● TAG RAG BOOTH: In this booth, worker cleans the parts by manually with the help of a special
cloth that collect all dirt from parts.
● AUTO POWDER COATING: Powder is sprayed on te parts by special machines that spray fine
jets of black powder.
● POST T/UP: If someplace on the part is left uncovered then a worker touches it up by a hand gun.
● BAKING OVEN: Parts are heated in the baking oven for a period of 45 minutes.
● INSPECTION: Inspection team checks all the parts for any possible error.
● UNLOADING: After inspection, the parts are sent to their respective departments for assembly.

SADDLE UNIT
Saddle is the main part of the cycle. The rider of the cycle get essential support while riding the
cycle, rider can may or may not put it whole weight on the saddle. The saddle comes in different
shapes and size according to the cycle model and market demand.

SEAT v/s SADDLE

There are a number of misconceptions about the saddle. The first is calling or thinking of it as a
seat. A seat is designed to bear your entire weight, while a saddle is something that carries you, but
not all of your weight

Figure 24: Source- Saddle Plant

Cooling and heating unit:

Cooling and heating units are provided in the saddle plant to control the temperature of the
moulding machine, Polyol tank, Iso cyanate tank and Polyol stirring tank. Specified temperature of
the Chemical tanks is 20°C30°C and according to the atmospheric conditions temperatures are
maintained by these cooling and heating units of the plant.

Degassing:

Degassing is the process of removing the involved gasses along with drying the moisture content
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from the surface of the mould. Degassing process uses the liquid petroleum gas (lpg) maintain
temperature of 600°C to 700°C. At this temperature plastic mould became dry and rugged which
further help PU foam to stick on the surface more properly.

Moulding procedure:

Moulding machine take 5 minutes to complete on circle. Moulding machine contain 30 moulds in
which seat base is fitted on the upper mould and the PVC sheet is placed on lower mould manually
by worker which is further properly placed by vacuum then mould moves to the next place where
PU foam is filled by the automatic machine in which Polyol and Iso mixture comes from mixing
tank in certain quantity required or mention according to the saddle model (eg. Kids saddle,
Standard jet etc) after that upper mould with seat base pushed down pneumatically and forced into
the PU foam make it spread over the seat base. The process goes to 4 minutes after which another
worker open the moulds and pulls the PU saddle out and again place the seat base on the upper
mould and process goes on.

Chemicals Used:

Polyol and Iso cyanate chemicals are used in the formation of the PU foam.

Polyol + Isocyanate PU foam

(43 : 1)

Trimming machine:

The saddle which comes from the moulding machine has excess pvc (poly vinyl chloride) sheet
which is cut on the trimming machine according to the saddle shape. This process is done
manually by worker to put the saddle under the trimming machine and to revolve it, by so all
extended PVC sheet from all side get trimmed and saddle put into the storage trolleys.

Stamping

Stamping is done in the end. Those saddles which are not defected are stamped with the

“HERO” manually by worker by placing it the stamp rod of stamping machine. Stamp of “HERO”
is marked right in the middle of the saddle in backside and further put into the storage tanks.

HERO AUTO COMPONENTS

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 (HAC PLANT)
QUALITY CHECK: Parts like Engine Guard, Sari Guard , Step Pillion , Carrier, Brake Pedal,
Gear changer ,etc which are brought from other manufacturers are checked here using various
gauges for proper dimension, geometry and defects.
After inspection parts are separated and sent for powder coating or chrome plating to respective
departments.
After top coating here in HAC plant a silver paint is painted at joints so as to prevent them from
rust.
Brake pedal is fitted with brake rod with help of pin and T.

All the parts are packed after quality check and are sent futher for shipment.

EFFLUENT TREATMENT PLANT

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 Figure 26: Source- www.google.com

Effluent Treatment Plant (ETP) is most cost Effective & technically proven system to remove
the unwanted, hazardous chemicals from the wastewater to meets the statutory pollution control
requirements, especially for chemicals, pharmaceuticals, phosphating and electroplating
wastewaters.

Industrial wastewater treatment covers the mechanisms and processes used to treat wastewater

that is produced as a by-product of industrial or commercial activities. After treatment, the treated
industrial wastewater (or effluent) may be reused or released to a sanitary sewer or to surface
water in the environment.

PROCESS FLOW AT ETP

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 Figure 27: Source- ETP Plant

The waste water from the Chromium and Nickel plant reaches Effluent treatment plant (ETP).
Here water is treated via various stages.

Water containing chromium and nickel elements is stored in the storage tank.

Hydrated Lime is added to the waste water.

Hydrated lime is also called Calcium hydroxide. Calcium hydroxide is an inorganic compound
with the chemical formula Ca(OH)₂. It is a colorless crystal or white powder and is obtained when
calcium oxide is mixed, or slaked with water. The hydrated lime increases the ph of the waste
water which is further transferred to the Reaction Tank.

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ADDITION OF POLYELECTROLYTE TO THE WASTE WATER

Polyelectrolytes are polymers whose repeating units bear an electrolyte group. Polycations and

polyanions are polyelectrolytes. These groups dissociate in aqueous solutions (water), making the
polymers charged. Polyelectrolyte properties are thus similar to both electrolytes (salts) and
polymers (high molecular weight compounds) and are sometimes called polysalts.

As soon as electrolyte is added to water (plus lime) COAGULATION occurs. Coagulation-

flocculation is a chemical water treatment technique typically applied prior
to sedimentation and filtration (e.g. rapid sand filtration) to enhance the ability of
a treatment process to remove particles.

In coagulation, we add a chemical such as alum which produces positive charges to neutralize the
negative charges on the particles. Then the particles can stick together, forming larger particles
which are more easily removed.

SEDEMENTS SETTLE DOWN AND LIGHTER WATER IS SEPERATED INTO ANOTHER

TANK.

HCL IS ADDED TO DECREASE THE pH OF WATER

THIS WATER IS PASSED THROUGH SERIES OF ACF .

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Activated carbon filters are generally employed in the process of removing organic compounds
and/or extracting free chlorine from water, thereby making the water suitable for discharge or use
in manufacturing processes. Eliminating organics in potable water, such as humic and fulvic acid,
prevents chlorine in the water from chemically reacting with the acids and forming
trihalomethanes, a class of known carcinogens.

Activated Carbon (AC) filtration, as with any water treatment method, is not capable of removing
every possible type of contaminant. For example, sodium, microbes, fluoride, and nitrates cannot
be removed with AC filtration. Water softening also cannot be achieved with AC filters. In
addition, heavy metals, such as lead, can only be removed with a very specific kind of activated
carbon water treatment, which is typically used only in residential point-of-use filters.

THIS WATER IS STORED IN ULTRA-FILTERATION FEED TANK (UFF)

WATER IS FED TO ULTRA-FILTER (UF).

Ultra Filtration (UF) is a type of membrane filtration in which hydrostatic pressure forces a liquid
against a semi-permeable membrane. A semipermeable membrane is a thin layer of material
capable of separating substances when a driving force is applied across the membrane.

Figure 28: Source- www.google.com

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 Figure 29: Source- www.google.com

WATER IS NOW FED TO RO

Figure 30: Source- www.google.com

Reverse osmosis (RO) is a water purification technology that uses a semi-permeable membrane to

remove ions, molecules, and larger particles from drinking water. In reverse osmosis, an applied
pressure is used to overcome osmotic pressure, a colligative property, that is driven by chemical
potential differences of the solvent, a thermodynamic parameter.

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 RO REJECT WATER

MEE PLANT

Figure 31: Source- www.google.com

Multiple effect evaporator is a thermal evaporation process, widely used for concentration of
various liquids in the form of solution, suspension, and emulsions concentration is accomplished
by boiling out of a solvent, normally water, from the liquid. In most cases, concentration resulting
from the evaporation process is the final product of the process.

A multiple-effect evaporator, as defined in chemical engineering, is an apparatus for efficiently

using the heat from steam to evaporate water. In a multiple-effect evaporator, water is boiled in a
sequence of vessels, each held at a lower pressure than the last.

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 BIBLIOGRAPHY
www.google.com

www.herocycles.com

www.wikipedia.com

www.quora.com

www.m4sciences.com

www.techinsider.com

www.asme.org

www.thecyclingblog.com

www.pedlars.com

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 THANKS

We express our deep gratitude to the officials of industry who allowed us to have access to the
industry during our 6 weeks industrial training and taught us the various aspects to be noted during
our time period in the industry.

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