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ABBAS4 Merged
ABBAS4 Merged
INTERNSHIP REPORT
Submitted By
MD ABBASKHAN
THANA KUSHNOOR
BENGALURU-560001
YEAR OF SUBMISSION:(JUNE,2023)
INTERNSHIP REPORT ON
BY
MD ABBASKHAN
SACHEEN KUMAR B
LECTURER
THANA KUSHNOOR
BENGALURU-560001
BONAFIDE CERTIFICATE
SIGNATURE SINGNATURE
EXAMINERS 1______________________
EXAMINERS 2_____________________
DECLARATION OF CANDIDATES
DATE:
PLACE:
SINGNATURE OF CANDIDATE
NAME: MD ABBASKHAN
REGISTER NO-310ME21302
DEPARTMENT OF TECHNICAL EDUCATION
CERTIFICATE
The Internship report has been approved as it satisfies the academic requirement
in respect of Internship work prescribed for the said diploma
I am deeply thankful to our beloved Principal Shri RajShekar Patil sir for his support and
giving permission to get more technical knowledge in company
I am deeply thankful to HOD of Mechanical Department Anteshwar Wadale sir for his
motivation to complete my internship work in Mascor precisions pvt. Ltd.
I am deeply thankful to our cohort owner Sacheen kumar B sir for his time and effort, and for
their commitment to my success to complete my Internship in Mascor precisions pvt. Ltd.
+
TABLE OF CONTENT
SL.NO TOPIC NAME PAGE
NO
01 CHAPTER 1
OVERVIEW OF THE ORGANIZATION 1-3
CONCLUSION
MASCOR PRECISIONS PVT. LTD.
CHAPTER 1
Overview of the organization:
A Joint Venture started in 2017 between MASO, India & SIFCOR, France for
‘Engine Components and Critical Precision Forgings and Machinings’, Mascor is a
Greenfield project on the Aurangabad – Pune road, a short way from Aurangabad
City.
Maso Group, one of the well-known companies in India is known for offering
differentiated products, services and technology-based solutions to its customers.
The Group's main business is manufacturing precision gears & shafts, sub-assemblies,
forged and machined components.
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MASCOR PRECISIONS PVT. LTD.
1.1 Organizational Structure:
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MASCOR PRECISIONS PVT. LTD.
1.2 Vision and mission of the organization:
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MASCOR PRECISIONS PVT. LTD.
CHAPTER 2
Roles and responsibilities of personnel in the organization:
2.1 Roles:
A quality assurance specialist is a professional who is responsible for
monitoring, inspecting and proposing measures to correct or improve an
organizations final product in order to meet established quality standards.
2.2 Responsibilities:
Ensure that standards and safety regulations are observed.
Address and discuss issues and proposed solutions with superiors.
Document quality assurance activities and create audit reports.
Make recommendations for improvement.
Create training materials and operating manuals.
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MASCOR PRECISIONS PVT. LTD.
By material type, further, the market has been segmented into aluminum, steel,
and others. The aluminum segment is expected to dominate the market over the
forecast period owing to its greater tensile strength and performance to high
temperature and pressure.
The increasing sales and production of passenger cars, coupled with rising
expenditure power of the individuals in developing countries, are likely to drive the
market. The governments incentives and subsidies are expected to propel the
adoption of electric vehicles and expected to restrain the growth of the connecting rod
market over the forecast period.
The market has been segmented into north America, Europe, Asian pacific
and the rest of the world. Asia pacific is expected to dominate the market during the
forecast period owing to the ease of availability of labor and raw material at a lower
cost in this region for the production of components. The rising production and sales
in developing countries such as china and india are also likely to drive the market
over the forecast period.
North America is also expected to show good growth in the market over the
forecast period. Euorpe is expected to have sluggish growth in the connecting rod
market over the forecast period. The OMEs in this region are investing in research
and development of the new product to curb air pollution caused by vehicle emission.
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MASCOR PRECISIONS PVT. LTD.
CHAPTER 3
STUDY AREA
The main focus of the quality inspector is:
To check the forged connecting rod thickness for machining operation.
To produce high quality of products within given tolerance and remove the
undersize and oversize jobs and keep it in rework bin or rejection bin.
To focus on each and every dimension of the job is ok or not ok.
To focus on the first piece report and hourly report to reduce rejection of jobs.
Take all rejection and rework jobs details for identification that
what problem occurs to rejection in jobs.
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MASCOR PRECISIONS PVT. LTD.
3.1 Material
comparison of Possible Materials
Comparison of Mechanical Properties of possible connecting rod materials
(JJ fl)(J)l4J(5J
Material Selection
The material used for the manufacture of the connecting rod used in
Chevrolet Big Block Gen V V8
8.2 l, i.e., Chevrolet Performance Connecting Rods
• Heat-treatable
• Low iron-carbon alloy steel, Nickel -Chromium-Molybdenum
• Addition of molybdenum prevents the steel from being susceptible to
temper brittleness
• Utilized where other alloy steels do not have the hardenability togive the
required strength
• May be heat treated to high strength levels while maint aining good
roughness
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MASCOR PRECISIONS PVT. LTD.
• Good balance of tensile strength, yield strength, toughness and hardness
• Ability to attain highstrengths in the heat·treated condition
• Good fatigue resistance, shock and impact resistance
Forging Considerations:
Forging should be carried out between
980 •c and 1230 •c. Parts should be
slow cooled after forging in sand etc. (1)
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3.2 ChemicalComposition
)
Element Content (%)
Sulphur, S 0.04
Phosphorous, P 0.035
3.3PhysicalProperties
The physical properties of A ISIalloy steel are given in the following table.
Melting point
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MASCOR PRECISIONS PVT. LTD.
3.4 Mechanical-properties
The mechanicalproperties of annealed A ISIalloy steel are displayed in the following table.
Propertie Metric
Tensile strength s 745 MPa
Yield strength 470 MPa
Bulk modulus (typical for steel) 140 GPa
Shear modulus (typicalfor steel) 80 GPa
Elast ic modulus
190-210
Poisson's ratio GPa
Elongation at break 22%
Reduction of area 0.27-0.30
50%
Hardness, Brinell 217
Hardness,Knoop (converted from Brinell hardness) 240
Hardness, Rockwell B (converted from Brinell hardness) 95
Hardness, Rockwell C (converted from Brinell
hardness. Value below normal HRC range,for
comparison purposes only) 17
Hardness,Vickers (converted from Brinell hardness) 228
Machinability (annealed and cold drawn. Based on
50
100 machinability for ASTM 1212 steel.)
Force on the piston due to gas pressure and inertia of the reciprocating parts
rrD2
=
Force due to gas pressure FL px-
28
= mR. w 2 • r (cos(} + ' : )
0
Inertia force of reciprocating parts F1
I
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3.6 Design of Connecting Rod
Dimensions of cross-section of the connecting rod
For I-Section
+ [ I
l +a Kxx 12
•
We,·about y-axis =CA/l+a
12 [for both ends fixed, I = L
[ I
!+a L
2Kyy
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MASCOR PRECISIONS PVT. LTD.
3.7 Possible Methods for ManufacturingSemi Product
There are three primary methods of manufacturing connect ing rods: casting,
powdPr metal manufacturing rolled plate stock, and forging.
Casting
Advantages Disadvantages
• Low cost • Low strength character istics
• light dimensionaltolerance • Porosity
The shape of the connect ing rod does not permit the use of cast ing as a method of
manufacturing the semi product because of the complexity of design which is not possil>le lu
creale l>y caling. Presence of non-uniform sect ion thickness willcreate shrinkage cav ities and
hot spots. (10)
Powder MetalManufacturing.
Advantages Disadvantages
• High tolerance • High cost of powder metal,tooling
• Uniform materialcomposition • Lack of grain flow strength
• Good surface finish • Low tensile & impact strength
• Good materialutilization • Limited part size and complexity
Considering the number of parts produced, this process is not economica lly viable.
Produced parts have low strength compared to forging. (11)
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MASCOR PRECISIONS PVT. LTD.
3.8 Forging
Forging involves heating a piece of bar stock or rod stock (referred to as a forge slug)
to a forging temperature, placing the heated forge slug into a two-piece forging die defining a
cavity within,and forging the forge slug using a forging press or forging hammers with
multiple impacts. The part is then machined to finished dimensions.
Forging can be somewhat labour intensive due to the amount of machining which is
necessary to produce the finished article,but it produces a product which has strength
characteristics which are superior to those produced by casting or powder
metalmanufacturing. This results from the fact that the natural grain of rolled metalstock is
maintained in the finished product. The natural grain extends along the fulllength of the forged
rod,from one end where it is expanded. The naturalgrain is not truncated, as is the case with a
billet.
3.10 Pre-heating
The materialwill be pre-heated by induction heater up to llSO°C (7). The bar
diameter is 32 mm, materialis carbon steel,therefore the time of heating is 1,75 min (10
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3.11 Type of forging machine was selected in context with table
Type of the forging machine willbe hammer. The forging energy was calculated (13):
mb =
11 = U = 1,16 t
SmeralKHZ2A
Forging energy [kJ) 20
Oampingsurface for dies [mm] 250 x 440
Low est height of dies [mm] 250
Max. stroke of ram [mm] 400
No.of ram runs [min1·J 20
Installed power [kW) 30
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3.12 Advantages of forging :
• Directional flow enables the improvement of impact and mechanical resistance
properties.
• Minimum porosity.
• Facilitates inspection in non-destructive tests.
• Elimination of chemical segregations.
• Better metallic yield.
• Saving in machining hours.
Height (depth) H.
h/f <= 2
h/f >= 4
Tolerances of forged part are based on EN 10243-1. Tolerance grade for most of
forgings is F,
material AISI 4340 has 0.40% of carbon, which places it into the group of steels
M1 (C≤0,65%).
The ratio between the weight of the forging (1365 g) and its envelope (6 kg) is
0,23. Therefore, the group is 5s.
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3.14 Manufacturing of Final Product:
After the semi-finished part is finished, machining should be performed.
First of all, the preform should be annealed to enlarge its machinability.
Then the main shape will be done on a turning machine. Afterwards it is
important to machine the functional parts – piston end bore, crank end bearing
surface, bolt holes and threads and when it is done, the part will be surface
hardened.
After Finishing this operation, grinding will take also its part. The whole
procedure is described with all details in Appendix C.
The list of tools is specified in Appendix E.Of course, there are several
checks (dimensions and surface roughness) during the procedure.
3.15 Annealing:
Induction heater is used for pre-heating the preform for forging. It will be
also used for annealing.
A full anneal may be done at 844°C (7) followed by controlled (furnace)
cooling at a rate not faster than 15°C per hour down to 315°C. From 315°C it may
be air cooled (7).
Annealing realigns the internal molecular structure to make the metal
stronger which imbibes this steel with excellent durability.
5 Axis VMC (Vertical Milling Centre).
5 Axis VMC (16) was selected with respect to the work dimensions and
the machining operations to be performed on the semi product.
The machine is ideally suited for connecting rod manufacturing as all
machining operations can be completed in one machine and the rotating table
provides a variety of clamping methods so that multiple operations can be
completed in one process.
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CHAPTER 4
MANUFACTURING METHODS
4.1 Introduction to manufacturing method optimization:
The optimization of the current connecting rod’s manufacturing process
was developed considering quality and cost as main goals parameters. By
calculating how every tolerance in the process steps affects to the final dimensions,
it is possible to evaluate which tolerances should be modified to improve the
process.
Moreover, studying the connecting rod’s manufacturing process, some
possible improvements related to the process sequence were thought up to reduce
the tolerance chains.
Thus, a tolerance chain analysis was performed for the current and
proposed solutions to assess the achieved enhancement.
b) Boring
c) Drilling
d) Counterboring
e) Thread Tapping
f) Chamfering
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18
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4.3 Post Machining Operations:
After machining is completed, the bearing end cap is separated from the
rod part using fracture splitting and then assembled with bolts and bearings in the
Rotary Table Assembly Machine (17).
The finished part is checked for cracks in a magnetic crack detection machine.
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CHAPTER 5
RESULT AND DISCUSSION
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CHAPTER 6
Conclusion:
The task of this internship project report was to describe a manufacturing
process for selected part, that is connecting rod. The basic design (taken from
Chevrolet V8 Big Block Engine), calculations and material selection were
done.The material is AISI 4340 alloy steel, which is steel with Carbon, Nickel,
Chromium and Molybdenum. This material is cut from rod, then forged by close-
die forging in a hammer machine. After this procedure, semi-product is annealed
to make the machining easier. The machining is done on CNC 5 axis VMC and
fracture split and assembled in a Connecting Rod Crack and Assembly module.
In appendices, are described all process plan operations, as well as all
selected tools, used gauges and machines. In the process plan were calculated
basic operation times (for turning machine) to see, how time demanding is each
operation.
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Reference:
Maximizing hardness and toughness in 8260 steel. www.astmsteel.com
The effects of surface hardening on fracture toughness of carburized steel.
Fracture toughness and strength corrosion characteristics of ultrahigh
strength 4340 steel.
The engineering tool box.www.engineeringtoolbox.com
Fundamental of modern manufacturing.
WWW.MASO-GROUP.COM
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