INTERNSHIP REPORT

COMMERCIAL VEHICLE WHEEL DESIGN

AND HYDRAULIC SYSTEMS

Under the Supervision of

WHEELS INDIA LIMITED

TVS Group, Padi, Chennai - 600053
(12-01-2024 TO 25-01-2024)

Submitted by
SAI KARTHIK M S (210101034)
A report submitted in partial fulfillment of the requirements for the Award of Degree of

BACHELOR OF ENGINEERING IN AERONAUTICAL ENGINEERING

RAJALAKSHMI ENGINEERING COLLEGE
 DEPARTMENT OF AERONAUTICAL ENGINEERING

Rajalakshmi Engineering College

(An Autonomous Institution)
ADDRESS

CERTIFICATE

This is to certify that the “Internship report” submitted by SAI KARTHIK M S

(Regd. No.: 2116210101034) is work done by his and submitted during 2023 –
2024 academic year, in partial fulfilment of the requirements for the award of
the degree of BACHELOR OF ENGINEERING in AERONAUTICAL
ENGINEERING, at WHEELS INDIA LIMITED, TVS Group, Chennai.

SUBMITTED TO

Dr. Suresh Chandra Khandai,

Head of the Department,
Department of Aeronautical Engineering.
CERTIFICATE
 ACKNOWLEDGEMENTS

First I would like to thank the Training Manager Mr. Saravanan, Wheels India Limited,
Chennai for giving me the opportunity to do an internship within the organization.
I also would like all the people that worked along with me in Wheels India Limited
with their patience and openness they created an enjoyable working environment.
It is indeed with a great sense of pleasure and immense sense of gratitude that I
acknowledge the help of these individuals.
I am highly indebted to the staff, Mr. Rajarathinam and Mr. Bejoy Sugin Jacob for
the facilities provided to accomplish this internship.
I would like to thank my Head of the Department Dr. Suresh Chandra Khandai for
his constructive criticism throughout my internship.
I would like to thank Mr. Anantha Ramakrishnan, Union President, WIL, Mr.
Satish, Maintenance In-charge, Mr. Veer Kumar, Supervisor and Mr. Rahul, Engineer
Trainee for their support and advices to get and complete internship in above said
organization.
I am extremely great full to my department staff members and friends who helped me
in successful completion of this internship.

Sai Karthik M S
(210101034)
 Table of Contents
1. PROCESS LEARNING:...................................................................................................................................5
2. MACHINERY WORKING PRINCIPLES:.........................................................................................................6
3. SYSTEMATIC OPERATING PROCEDURES:....................................................................................................6
INTRODUCTION
Background
The internship at Wheels India Limited, a prominent subsidiary of the esteemed TVS Group,
emerged as a pivotal opportunity to delve into the intricate world of industrial wheel
manufacturing. Founded on a legacy of excellence, Wheels India Limited is renowned for its
contributions to the automotive sector, making it an ideal setting for a comprehensive
learning experience.

Objectives of the Internship

The primary objective of this internship was to gain practical insights into the manufacturing
processes and operations associated with wheel production. The focus extended beyond the
end product, aiming to understand the fundamental principles of machinery operations,
hydraulic systems, manufacturing parameters, and welding techniques. By immersing myself
in these aspects, I sought to enhance my knowledge and skills, particularly in optimizing
manufacturing processes and ensuring precision and quality control.
The overarching goal was to bridge the gap between theoretical knowledge and practical
application, aligning my academic background in aeronautical engineering with the
intricacies of industrial manufacturing. This internship not only provided a hands-on
understanding of wheel production but also aimed to cultivate transferable skills that would
be instrumental in my future endeavours as an aeronautical engineer. Through this
engagement, the objective was to contribute meaningfully to the manufacturing processes
while preparing for the dynamic challenges of the aerospace industry.
This internship report encapsulates a comprehensive reflection on the journey, learnings, and
significant contributions made during this enriching experience at Wheels India Limited.

OVERVIEW

Key Roles and Tasks

As a Project Intern at Wheels India Limited, my primary focus was to immerse myself in the
intricacies of industrial wheel manufacturing processes. Tasked with understanding the
systematic operating procedures, my responsibilities revolved around gaining a deep
comprehension of the working principles of the machinery involved. This hands-on
engagement provided a unique opportunity to delve into the core of manufacturing,
emphasizing the technical aspects that drive efficiency and quality.

1. Process Learning:
Immersed myself in each stage of the wheel manufacturing process, from raw material
preparation to the final assembly.
Gained insights into the specific processes involved in shaping, forming, and finishing
wheel components.
2. Machinery Working Principles:
Delved into the functionality of the machinery used in wheel production, understanding
the principles governing their operation.
Analysed the role of hydraulic systems, automated controls, and precision tools in the
manufacturing workflow.
3. Systematic Operating Procedures:
Explored and documented the systematic operating procedures followed in the
manufacturing facility.
Participated in the development and refinement of standard operating procedures,
ensuring adherence to quality and safety protocols.
 ABSTRACT

This internship experience at Wheels India Limited provided a comprehensive

journey into the realm of industrial wheel manufacturing. The initial phase involved a
deep dive into the manufacturing process of wheel rims, where I gained insights into each
stage from raw material preparation to the final assembly. This foundational knowledge
set the stage for a more intricate exploration.

The second phase of my experience centred on understanding the machinery integral to

the manufacturing process. Delving into the working mechanisms of these sophisticated
machines was a pivotal aspect of my learning. I navigated through the intricacies of
hydraulic systems, automated controls, and precision tools, unravelling the technological
tapestry that forms the backbone of industrial wheel production.

The final phase honed in on the manufacturing intricacies of wheel discs, emphasizing the
assembly process and welding techniques. Engaging in these processes not only
broadened my understanding of wheel manufacturing but also provided hands-on
experience in crafting components that are fundamental to the automotive industry.

Overall, this internship was a dynamic exploration of the nuances within industrial wheel
manufacturing. From the fundamental processes to the intricate machinery and the final
assembly, each phase contributed to a holistic understanding. These experiences have not
only fortified my technical knowledge but have also shaped me as an individual ready to
contribute meaningfully to the intricacies of the manufacturing sector, specifically in the
automotive industry.
1. INTRODUCTION TO WHEEL MANUFACTURING

Wheel manufacturing using sheet metals is a complex and intricate process that involves
the systematic fabrication of key components such as the rim and the wheel disc. This
comprehensive procedure plays a crucial role in ensuring the structural integrity and
performance of wheels, which are foundational components in the automotive industry.
The manufacturing process typically follows a methodical sequence, beginning with the
creation of the rim, followed by the fabrication of the wheel disc, and concluding with
precision welding or fixing using lugs to assemble the final wheel product.

The initial stage of manufacturing involves the meticulous shaping of sheet metals to craft
the rim, which serves as the outermost structure of the wheel. The rim not only provides
the outer circumference but also contributes significantly to the size, design and overall
strength of the wheel. Following the rim formation, attention turns to the manufacturing
of the wheel disc – the central part of the wheel that connects to the vehicle's axle. This
step involves intricate processes to ensure dimensional accuracy, weight optimization,
and structural durability, aligning with the performance requirements of diverse
automotive applications.

The final phase of wheel manufacturing entails welding or fixing the rim and wheel disc
using lugs. This critical step demands precision and expertise, as it directly influences the
overall functionality and safety of the wheel. The integration of lugs ensures a secure and
durable connection between the rim and the wheel disc, reinforcing the structural integrity
of the assembled wheel.

In this intricate manufacturing process, each step is pivotal in crafting wheels that meet
stringent industry standards. This introduction sets the stage for a detailed exploration
into the methodologies, technologies, and precision engineering involved in the sheet
metal manufacturing of wheels, uncovering the intricate usage of technology that defines
the automotive wheel manufacturing landscape.
1.1 STANDARD OPERATING PROCEDURE

Fig: Flow Chart representing the Wheel Manufacturing process

Coiling or Rolling:
Initiate the process by marking and coiling or rolling the sheet metal into a well-defined
coil of the specified diameter. Ensure precision in coiling to meet the design requirements
of the wheel rim.

Edge Flattening and Flash Welding:

Flatten the edges of the coiled sheet metal to prepare it for the flash welding process.
Employ flash welding techniques to seamlessly join the edges, ensuring a strong and
consistent bond.

Flash Trimming and Edge Clipping:

Trim excess flash resulting from the welding process to achieve the desired rim
dimensions. Simultaneously, carefully clip the edges to refine the shape and ensure
uniformity.

Flare Pressing Using Hydraulic Machine:

Employ a hydraulic machine to perform flare pressing on both ends of the rim. This
step imparts the necessary curvature to the rim ends, aligning with design specifications.

Roll Forming Operation:

Initiate the roll forming operation to shape the rim into the desired profile. The roll
forming machine employs a series of rollers to gradually mold the sheet metal into the
predetermined cross-sectional configuration.

Expansion for Even Diameter and Ovality Correction:

Expand the rim to achieve an even diameter, correcting any ovality. Utilize suitable
equipment to ensure the dimensional accuracy and structural uniformity of the rim.
 Valve Hole Punching:
After the expansion process, position the rim to punch a valve hole at the flange. This
hole is strategically located to facilitate the protrusion of the tube valve. Use specialized
equipment to ensure precision and accuracy in creating the valve hole.

Burr Removal:
Immediately following the valve hole punching, conduct a thorough removal of any
burrs or sharp edges around the newly created hole. This step is crucial to enhance safety
and prevent damage to the tube during assembly.

Quality Inspection:
Conduct a rigorous quality inspection at the end of the manufacturing process. Check
for weld integrity, dimensional accuracy, and overall conformity to design specifications.

Final Inspection and Packaging:

Perform a final inspection to validate the overall quality and integrity of the
manufactured rim. Once approved, proceed with the packaging of the finished rims, ready
for distribution or further assembly.

Note: Ensure that all personnel involved in the manufacturing process adhere strictly to
safety protocols, and equipment is maintained regularly to guarantee optimal
performance. Continuous monitoring and process adjustments may be necessary to
uphold the highest standards in rim manufacturing.

1.2 STANDARD OPERATING PROCEDURE: WHEEL RIM MANUFACTURING

1. Coiling or Rolling:

Fig: Process diagram of a roll coiling Machine inside the machine

The Work piece (Sheet metal of specific dimensions) is Lifted and placed into a conveyer
pusher into the Coiling machine. The rollers inside the machine are placed in such a way that,
the sheet is bent to form a roll of specific diameter. The edges of the coiled sheet metal is
flattened so as to facilitate the welding process.

2. Flash Welding:

Fig: Flash Butt welding operation performed on the edge of the coiled rim
Flash welding is a preferred method in the manufacturing of wheel rims due to its high-speed
and efficient nature, making it ideal for mass production in the automotive industry. This
automated process ensures consistent and repeatable results, producing strong, reliable joints
with minimal distortion in materials such as steel and aluminium alloys commonly used in
wheel rims. The cost-effectiveness, cleanliness, and ability to weld complex shapes further
contribute to its suitability for wheel rim fabrication.

3. Flash Trimming and Edge Clipping:

Fig: Flash Trimming process done on the welded flash joint

Trimming the flash after flash welding on a wheel rim is crucial for achieving a polished
appearance and ensuring uniformity in the welded joints. This process removes excess
material, contributing to a clean and aesthetically pleasing surface. Beyond aesthetics,
trimming reduces unnecessary weight, promoting improved balance in the wheel assembly
and enhancing overall vehicle performance. Additionally, it eliminates potential safety
hazards by preventing sharp edges or burrs. The trimmed wheel rims are more compatible
with other components, facilitating proper fit and alignment, and undergo quality control
measures to meet specified standards. Ultimately, this step enhances customer satisfaction by
delivering wheel rims that combine functionality with a refined and consistent appearance.

4. Flare Pressing Using Hydraulic Machine:

Fig: The Welded wheel rim being flare pressed

Flare pressing in wheel manufacturing is a vital process that forms the bead seat on the wheel
rim, facilitating secure tire mounting. This step creates a flange that enhances structural
integrity, prevents tire slippage, and ensures uniformity in the bead seat's shape and
dimensions across all rims. The flared bead seat not only aids in maintaining an airtight seal
for proper tire inflation but also provides compatibility with tire designs commonly used in
the automotive industry. Carefully monitored for quality assurance, flare pressing is crucial
for producing wheel rims that prioritize safety, stability, and optimal performance in
collaboration with tires.

5. Roll Forming Operation:

Fig: Roll forming operation to establish the cross section profile

Rim rolling forming is a crucial operation in wheel rim manufacturing, specifically focused
on shaping and contouring the rim's outer edge or lip. This process imparts the necessary
structural characteristics and aesthetic features to the rim. The key steps in rim rolling
forming include material selection, initial blanking to create circular blanks, and the use of
specialized machinery equipped with rolling dies. The rolling operation precisely shapes the
outer circumference of the wheel rim, forming the desired lip and enhancing the overall
appearance. Trimming excess material, finishing, and quality inspections follow to ensure
dimensional accuracy and structural integrity. Rim rolling forming is instrumental in
achieving the final profile of the wheel rim, contributing significantly to its strength, stability,
and compatibility with tires. The precision and consistency of this operation are critical for
producing high-quality wheel rims that meet industry standards and customer expectations.

6. Expansion for Even Diameter and Ovality Correction:

 Fig: Hydraulic Horizontal Rim Expander that corrects the ovality of the Rim

Rim expanding for ovality correction is a specialized operation in wheel rim manufacturing
designed to address any deviations from a perfectly round shape, known as ovality, in the
rim. Ovality may occur due to various factors, including manufacturing processes or material
characteristics. The rim expanding process aims to achieve a uniform circular shape for
optimal performance and aesthetics. The key steps in this operation include identifying areas
with ovality, using specialized equipment to apply controlled force to those areas, and
gradually restoring the rim to its intended circular profile. This corrective measure ensures
that the wheel rim meets precise specifications, minimizing any negative impact on tire
mounting, vehicle balance, and overall performance. Following rim expanding, the rims
undergo additional inspections to confirm the effectiveness of the ovality correction and to
maintain the high quality and standards expected in wheel rim manufacturing.
7. Valve Hole Punching:

Fig: A Valve Hole is punched on the flange of the Rim

Valve hole punching is a crucial operation in wheel rim manufacturing, where precision is
key to ensuring proper tire inflation and optimal performance. This process involves
determining the precise location for the valve hole on the rim based on design specifications,
followed by cutting a circular blank as the starting point. Specialized machinery, such as a
punch press or hydraulic equipment, is then used to accurately create the valve hole at the
designated position. Post-punching, deburring is carried out to eliminate any sharp edges,
contributing to safety during tire installation. A thorough quality inspection follows to
confirm that the valve hole meets specified dimensions and tolerances, ensuring compatibility
with standard tire valves and maintaining effective sealing capabilities. Depending on the rim
design and material, optional surface treatments like painting or coating may be applied.
Overall, valve hole punching is a critical step that ensures the functionality and safety of the
wheel rim in collaboration with the tire.

8. Burr Removal:
 Fig: The Burr or Swarmf is removed by planishing and chamfering

Burr removal is a crucial operation in wheel rim manufacturing that focuses on eliminating
sharp or uneven edges (burs) that may result from various manufacturing processes. After
processes such as punching, cutting, or forming, the identification of burs is followed by the
use of specialized deburring tools or machinery to systematically remove them from the rim
edges. This deburring operation is essential for ensuring a consistent and smooth edge quality
across the entire rim, mitigating safety risks during tire mounting and handling. Thorough
quality inspections are conducted to verify the successful removal of all burs, confirming that
the rim meets safety standards and design specifications. Optional surface treatments, such as
painting or coating, may be applied post-deburring to enhance the rim's appearance and
provide additional protection. Overall, burr removal plays a vital role in enhancing the safety,
functionality, and overall quality of wheel rims, contributing to a hazard-free interface during
tire installation and usage.
Then, the manufactured rims are sent into quarantine and quality inspection is performed. It is
then considered for Disc assembly or welding.

1.3TYPES OF WHEELS MANUFACTURED

There are different approaches to Wheel manufacturing. It is customised based on the

customer demands and requirements. But the basic types are:
 Lug Welded Wheels
 Completely welded Disc Wheels

1.3.1 Lugged Wheels:

1. Construction:
Lugged wheels, a traditional approach to wheel assembly, involve joining the rim and
wheel disc using lugs. These lugs, typically metal components, are secured with nuts or bolts,
creating a connection between the two main components.

2. Advantages:
Reparability: Lugged wheels offer a notable advantage in terms of repairability. The
modular construction allows for easier replacement of individual components, such as rims or
discs, without affecting the entire wheel assembly.
Versatility: The design of lugged wheels provides versatility, allowing them to be adapted
for various applications and configurations, providing flexibility in wheel design.
3. Disadvantages:
Weight: Lugged wheels may tend to be heavier due to the additional hardware required for
assembly, including lugs and nuts.
Complexity: The assembly process can be more intricate, and the presence of multiple lugs
and nuts may increase the risk of potential failures if not properly maintained.

1.3.2 Welded Disc Wheels:

1. Construction:
Welded disc wheels represent a modern approach where the rim and disc are seamlessly
integrated through welding. This welding process eliminates the need for additional nuts or
bolts, creating a more unified and streamlined structure.

2. Advantages:
Weight: Welded disc wheels often exhibit a lighter profile as they lack the extra hardware
associated with lugged wheels, contributing to potential weight savings.
Simplicity: The manufacturing process for welded disc wheels is generally simpler,
involving fewer components and potential points of failure.

3. Disadvantages:
Repair Difficulty: Repairing or replacing welded disc wheels can be more challenging, as
damage may require attention to the entire unit rather than individual components.
Limited Adaptability: Welded disc wheels may have limitations in terms of adaptability for
different applications compared to lugged wheels.

1.3.3 Application Considerations:

Lugged Wheels:
Lugged wheels find application in environments where repairability and adaptability are
critical, such as certain off-road or heavy-duty scenarios.
Welded Disc Wheels:
Welded disc wheels are commonly chosen for applications where weight reduction,
simplicity, and a more integrated design are prioritized. They are often seen in standard
passenger vehicles and performance-oriented applications.
The choice between lugged wheels and welded disc wheels depends on the specific
requirements of the application, considering factors like weight, repairability, complexity,
and adaptability. Manufacturers carefully select the wheel type that best aligns with the
intended use and performance characteristics of the vehicle or equipment, aiming to strike the
optimal balance between functionality and design.

1.4 WHEEL DISC MANUFACTURING: SYSTEMATIC OPERATING

PROCEDURE
: SYSTEMATIC OPERATING PROCEDURE
1. Sheet Metal Cutting:
In the initial stage, sheet metals are picked and placed into the conveyer belt running through
the puncher controller by a machine operator. The sheets are then cut into circular blanks
using a pneumatic punching machine. This machine utilizes compressed air to exert force on
a punch, effectively cutting out circular shapes from the sheet metal. The size and thickness
of the blanks are determined based on the design specifications and material requirements.

Fig: 1500 Ton Pneumatic Press used to make circular blanks

2. Centre hole punching and Bolt hole piercing
The process of punching a center hole and piercing bolt holes on a wheel disc using a
pneumatic press involves several steps. Here's a detailed explanation:
1. Setup:
The process begins with setting up the wheel disc on the bed of the pneumatic press. The disc
is securely positioned to ensure stability during the punching operation.
2. Tooling Selection:
Specific tooling, including punches and dies, is selected based on the design requirements of
the wheel disc. The tooling is chosen to create the desired size and shape of the center hole
and bolt holes.
3. Center Hole Punching:
The pneumatic press is activated, and the center hole punching tool is brought into contact
with the wheel disc. The tool exerts force on the material, creating a precise opening at the
center of the disc. This center hole is crucial for mounting the wheel disc onto the hub of the
vehicle.
4. Bolt Hole Piercing:
Subsequent to center hole punching, the tooling is replaced or adjusted to accommodate the
bolt hole piercing operation. The pneumatic press is then activated again, and the tool pierces
holes around the circumference of the wheel disc to create spaces for bolts. The placement
and number of bolt holes depend on the wheel design and mounting requirements.
The use of a pneumatic press in this process offers efficiency, speed, and precision. The
controlled application of force ensures accurate hole punching without causing damage to the
wheel disc. Overall, this operation plays a crucial role in preparing the wheel disc for
subsequent manufacturing stages and assembly into a complete wheel.

3. Lug Welding:
Lug welding on a wheel disc is a pivotal stage in wheel manufacturing, where lugs or studs
are securely affixed to the disc to serve as anchor points for wheel attachment to the vehicle
hub. The process begins with the preparation of the wheel disc, ensuring a clean surface.
Lugs are strategically positioned based on the designated lug pattern, and the wheel disc is
securely held in a fixture for consistent lug placement. Welding equipment, such as MIG or
TIG welders, is then configured, and controlled heat is applied to melt the lug material,
forming a robust bond with the disc. Following the welding process, the assembly undergoes
cooling, and rigorous inspections ensure the welds meet structural and quality standards.
Optional surface treatments, such as painting or coating, may be applied for enhanced
aesthetics and corrosion resistance. The final inspection encompasses the entire wheel
assembly to guarantee that all components, especially the lug-welded disc, adhere to design
specifications and safety requirements, contributing to a reliable and durable end product.

1.5 RIM-DISC ASSEMBLY AND WELDING

Both the Rims and Wheel discs are washed with anti-corrosion solvent after returning from
inspection. The discs can either be welded completely to the rims or attached to the rims
using lugs. Both the methods have their advantages and serve unique purposes.

1.5.1 Lug Welding

The meticulous process of assembling a wheel disc to rims using lugs involves several
essential steps to ensure a secure and reliable connection. Following thorough inspections of
the wheel disc and rim, lugs are strategically placed on the wheel disc to serve as anchor
points for attachment to the rim. Careful alignment and positioning of the lug-welded wheel
disc with the corresponding features on the wheel rim are crucial for achieving balance and
stability in the final wheel assembly. Lugs, bolts, or nuts are employed to securely fasten the
components, with torqueing applied to specified values to ensure tight and robust attachment.
In instances where additional welding is necessary, it further enhances the structural strength
of the wheel. The assembled wheel undergoes balancing to optimize weight distribution and
minimize vibrations during vehicle operation. A final inspection verifies the integrity of the
lug attachment, alignment, and overall quality.

Fig: The wheel disc is attached to the rim with Bolts and nuts.

1.5.2 Completely Welded Wheels

In the production of completely welded wheels, a meticulous process is followed to ensure a
durable and high-quality assembly. The initial steps involve thorough cleaning of both the
wheels and rims. The wheel disc is then pressed onto the rim with precision using force to
create a secure connection. A robotic machine is employed to perform Submerged Arc
Welding (SAW), ensuring a strong and uniform weld along the entire circumference of the
assembly.
Following the welding process, the holes in the assembly undergo chamfering, which
involves the beveling or smoothing of the hole edges. This step is crucial for enhancing the
overall finish and facilitating subsequent processes. The naves, or central hubs, are planished
to achieve a smooth and even surface, contributing to the aesthetic appeal and functionality of
the wheel.
A critical phase involves the inspection of the chamfered holes and planished naves to ensure
that they meet stringent quality standards. Rigorous quality control measures are
implemented to verify the integrity of the welds, the precision of chamfering, and the
smoothness of the planished naves.
This comprehensive process not only results in completely welded wheels but also
emphasizes the integration of advanced technologies, such as robotic welding, to enhance
efficiency and precision. The combination of meticulous cleaning, precise pressing, robotic
welding, chamfering, and planishing, followed by thorough inspections, ensures that the
completely welded wheels meet the highest standards of durability, functionality, and visual
appeal.