Abhishek 312 Report

Nadimpalli Satyanarayana Raju Institute of Technology (Autonomous) – Full Semester Internship Report
Department of ME, 2020-2021 Admitted Batch
Nadimpalli Satyanarayana Raju Institute of Technology

(Autonomous)
Sontyam 531 173, Andhra Pradesh
Common Rail Injection System
Report
Full Semester Internship
Submitted by
D V V S Abhishek
(20NU1A0312)
in partial fulfillment for the award of the degree of
BACHELOR OF TECHNOLOGY
in
Department of Mechanical Engineering
April, 2024
i
Nadimpalli Satyanarayana Raju Institute of Technology

(Autonomous)
Sontyam 531 173, Andhra Pradesh
Common Rail Machining
Report
Full Semester Internship
Carried out at
Delphi TVS Technologies Limited, Oragadam
in partial fulfillment for the award of the degree of
BACHELOR OF TECHNOLOGY
in
Department of Mechanical Engineering
April, 2024
ii
BONAFIDE CERTIFICATE
Certified that this internship report “Common Rail Machining” is the bonafide work of “D V V S
Abhishek (20NU1A0312)” who carried out Full Semester Internship under our supervision at
“Delphi TVS”, Oragadam, Chennai.
Mr G Siva Sai Ram Mr. N. Gunashekaran

Assistant Professor Supervisor
Department of Mechanical Engineering Department of Common Rail
Dr. V. Ananda babu Ph.D.
Associate Professor
Head Of the Department
iii
Table of Contents
No. Description Page Number
Name of the Company Delphi-TVS Technologies Ltd.,
Company URL https://delphitvs.com/
1 Profile of the Company V
2 Certificate of Full Semester Internship Vi
Learning Outcomes of Full Semester
3 1
Internship
4 Program Outcomes Addressed (List) 2
5 Abstract 3
6 Detailed Internship work 4-5
Learning Outcomes (PO – wise)
PO #1 6
PO #2 7
PO #3 8
PO #4 9
PO #5 10
7 PO #6 11
PO #7 12
PO #8 13
PO #9 14
PO #10 15
PO #11 16
PO #12 17
PSO #1 & #2 18&19
Rubrics (Internal Reviews & Final
8
Presentation Review)
Feedback
9 21
Write your experience with the company
Photo(s) of your internship
10 22
experience/Product/Other related
iv
Profile of the Delphi TVS Technologies limited.

Delphi-TVS is a joint venture between Delphi Corporation, USA and T. V. Sundaram Lyengar & Sons, India
manufacturing Diesel Fuel Injection Equipment for Cars, Sports Utility and Multi Utility Vehicles, Light
commercial Vehicles, Tractors, Single & Two Cylinder engines. Delphi is the largest automotive supplier in the
world and TVS is the largest automotive supplier in the world and TVS is the largest automotive system
supplier in India. The company has a sustained growth since it was set up. Delphu-TVS has obtained ISO/TS
16949 and ISO 14000 certifications. The companey has been honoured by the ACMA Gold Award for
Manufacturing Excellence Gold Award from Frost & Sulivan and Delphi Asia Pacific Environmental Excellence
Award. Delphi-TVS has also won the JIPM TPM Excellence Award (First Category).
Delphi-TVS has invested extensively on facilities, which include engine test cells, emissions test equipment,
endurance test rigs, pump calibrating rings and CAD sysytems to develop products and applications to meet
the ever increasing demands of customer requirement.
v
CERTIFICATE OF FULL SEMESTER INTERNSHIP
vi
Acknowledgement
I would like to take this opportunity to express my deepest gratitude to my internship supervisor, Mr G Siva Sai Ram,
Professor, Mechanical Engineering, N S Raju Institute of Technology (A), Visakhapatnam, who has persistently and
determinedly guided me during the whole course of this project. It would have been very difficult to complete this
project without his enthusiastic support, insight and advice. I am extremely thankful to Name of HOD, Designation &
Head of Mechanical Engineering Department for providing excellent lab facilities which were helpful in successful
completion of my internship program. Our utmost thanks also to all the Trainers of the Company for their support
throughout my Internship and Internship Institute Level Coordinator, Dr. P. N. E. Naveen, Associative Professor of
Mechanical Engineering.
I take immense pleasure in thanking Dr. Sambhu Prasad, Principal, Dr. J. Raja Murugadoss, Director, N S Raju
Institute of Technology (A), Sontyam, Visakhapatnam, for having permitted me to finish the Full Semester Internship.
We thank the MANAGEMENT of N S Raju Institute of Technology (A), Sontyam, Visakhapatnam, for providing the
various resources to complete the Full Semester Internship successfully. We are thankful to one and all who
contributed to my work directly or indirectly.
D V V S Abhishek
(20NU1A0312)
vii
Learning Outcomes of Full Semester Internship

As per Curriculum
1. Recognizes and articulates the conceptual knowledge involved in the task undertaken
2. Use the appropriate resources required to accomplish the task
3. Demonstrate the theoretical learning outcomes of the domain in task undertaken
4. Communicate well in various forms appropriately
5. Demonstrate a professional behavior with improved inter-personal skills
6. Coordinate with people from inter and multi-disciplinary setting
1
List of Program Outcomes

As per the Program of Study
PO1: Apply the knowledge of basic sciences and fundamental engineering concepts in solving
engineering problems (Engineering Knowledge)
PO2: Identify, formulate, review research literature, and analyze complex engineering problems
reaching substantiated conclusions using first principles of mathematics, natural sciences, and
engineering sciences. (Problem Analysis)
PO3: Design solutions for complex engineering problems and design system components or
processes that meet the specified needs with appropriate consideration for the public health
and safety, and the cultural, societal, and environmental considerations. (Design/Development
of Solutions)
PO4: Perform investigations, design and conduct experiments, analyse and interpret the results to
provide valid conclusions (Investigation of Complex Problems)
PO5: Select/develop and apply appropriate techniques and IT tools for the design & analysis of the
systems (Modern Tool Usage)
PO6: Give reasoning and assess societal, health, legal and cultural issues with competency in
professional engineering practices (The Engineer and Society)
PO7: Demonstrate professional skills and contextual reasoning to assess environmental/societal
issues for sustainable development (The Environment and Sustainability)
PO8: Demonstrate Knowledge of professional and ethical practices (Ethics)
PO9: Function effectively as an individual, and as a member or leader in diverse teams, and in multi-
disciplinary situations (Individual and Team Work)
PO10: Communicate effectively among engineering community, being able to comprehend and write
effectively reports, presentation and give / receive clears instructions (Communication)
PO11: Demonstrate and apply engineering & management principles in their own / team projects in
multidisciplinary environment (Project Finance and Management)
PO12: Recognize the need for, and have the ability to engage in independent and lifelong learning
(Life Long Learning)
PSO1: Demonstrate adequate core competency in designing and fabricating mechanical systems,
thermal and hydraulic machines, materials and similar others, and there by providing
sustainable computer aided solutions maintaining professional standards and value system
PSO2: Demonstrate adequate knowledge in the allied specialization of Mechanical Engineering that
adds value addition for professional practices
2
Abstract
During my Full Semester Internship (FSI) at Delphi TVS, Chennai, I received training in the common
rail injection system washing section the training encompassed operation, maintenance, and
troubleshooting of six essential machines: Brushing, Demagnetization, Pre-washing, HP Washing,
Passivation, Drying and borescope. This experience provided me with hands-on knowledge and skills
in quality control, ensuring the highest standards in the washing process. The internship enhanced my
practical skills in the automotive industry, particularly in the field of Common Rail injection systems.
Keywords: Delphi TVS, Chennai, internship, Common Rail Injection System, washing section, hands-
on experience, quality control, automotive industry.
3
Detailed Internship Work
Section – l: Weekly Progress in line with Daily Logs
Week-1 Training Program on safety & overview of the company

Week-2 Worked in line (Common Rail)
Week-13 Worked in Line (Assembly)
Section – Il: Introduction about the concept of the Internship
The Common Rail Injection System is an advanced technology used in diesel engines for controlling the fuel
supply to the engine. It operates by storing fuel at high pressure in a common reservoir, or "rail," and then
distributing it to each cylinder as needed.
How it Works:
In a common rail system, fuel is stored in a high-pressure reservoir called the common rail, which is supplied
by a high-pressure fuel pump. This fuel is then distributed to individual injectors at extremely high pressures.
Electronically controlled injectors then precisely meter the fuel into the combustion chamber. The pressure in
the common rail is maintained independently of engine speed and load variations.
4
Key Components:
Common Rail: A high-pressure reservoir that stores the fuel and distributes it to the injectors.
High-pressure Pump: A pump that pressurizes the fuel and delivers it to the common rail.
Injectors: Electronically controlled nozzles that spray fuel into the combustion chamber with high precision.
Advantages:
● Improved Fuel Efficiency: Common rail systems atomize fuel more efficiently, leading to better
combustion and, consequently, improved fuel efficiency.
● Reduced Emissions: By precisely controlling the amount of fuel injected into the combustion chamber,
the common rail system helps reduce harmful emissions.
● Increased Power and Performance: The system allows for multiple injections per combustion cycle,
which improves engine response and power delivery.
● Quieter Operation: The precise control over fuel delivery results in quieter engine operation compared
to traditional diesel engines.
● Flexibility: The system is highly adaptable and can be adjusted to work with different engine
configurations, making it suitable for a wide range of applications.
Applications:
The Common Rail Injection System is widely used in various diesel-powered applications, including:
● Automotive vehicles (cars, trucks, buses)
● Marine vessels
● Construction equipment
● Agricultural machinery
5
Section – IIl: Details of the Internship
I’ve taken my internship in one of the industries located in Chennai, Oragadam that is Delphi TVS
Technologies Limited for the complete semester as a part of Full Semester Internship. There were many
departments in the plant I have been allotted in the Common Rail injection systems (CR) in machining
department the supervisor has allocated me in washing department of common rail in which I need to go
through the following machines
 Brushing: - The brushing is one of the primary machines in which we use the input of common rail and
keep it vertically then through the rotary motion the brush with hard bristles to remove the internal burr
from the material.
 Demagnetization: - It is an essential process in which the magnetic properties of the material should
be removed completely the readings of magnetic properties should be 0-0.5 if it is more that 0.5 then
it’ll be ended up as a rejection
 Pre-Washing: - The Pre-Washing is the primary washing in which the component is placed horizontally
and coolant was been pumped through the component to remove dust for a time of 12 seconds and
later it uses air with high pressurized of 0.4 pressure in to remove the dust
 HP Washing: - High Pressurized washing (HP Washing) is the secondary washing technique in which
the rail is placed vertically in which the coolant is pumped with high pressure to remove metal dust and
burr.
 Passivation: - The passivation is a technique in which the rail is dipped into the coolant by which it
avoids corrosion by forming multiple layers of coolant and improves the life of the product.
 Boro Scope: - The Boro Scope is the last machine in which we use it for inspection purpose so that
the final output would be accurate we can see the interior of the rail through the mini camera so that if
there were any burrs / any disorders the rail will be put to rejections.
6
Section – IV: Final Outcome of the Internship

Learning Outcomes (Write in your own words not exceeding 200 words)
PO#1:
(Indicate how the theoretical knowledge of the courses taught helped you to do Full Semester
Internship)
Understanding basic science principles, particularly in fluid dynamics and thermodynamics, was essential in
grasping the complexities of the common rail injection system. This understanding facilitated a deeper
comprehension of the system's behavior, especially the interaction between fuel, air, and pressure, allowing
for the identification and analysis of various issues within the system. Applying engineering concepts, such as
problem-solving methodologies, was crucial in identifying, analyzing, and solving problems related to the
durability, performance, and efficiency of the injection system components. These concepts were pivotal in
troubleshooting, enabling the diagnosis and resolution of system performance issues. Additionally, they
contributed to optimizing the system, aiming to enhance efficiency, reduce emissions, and improve overall
performance.
7
PO #2:
(Indicate the ability of Problem Analysis)
The internship honed my ability to systematically identify, formulate, and analyze complex engineering
problems within the common rail injection system. By dissecting and comprehensively understanding the
system's behavior, I could effectively address issues related to its durability, performance, and efficiency
8
PO #3:
(Indicate the ability of Design and Development of Solutions)
My internship honed my ability to systematically design solutions for complex engineering problems within the
common rail injection system. By dissecting and comprehensively understanding the system's behavior, I could
effectively address issues related to its durability, performance, and efficiency
9
PO #4:
(Indicate your experiments being carried out in industry, if any)
The scope of this PO is irrelevant to my work carried out in my internship.
10
PO #5:
(Indicate the new tools, programming language, equipment learned during this program, if any)
Drying:
Purpose: The drying process removes any remaining moisture from the components after the washing and
passivation stages.
Procedure: Components are dried thoroughly using hot air, vacuum drying, or other methods to ensure they are
completely dry before further processing or assembly.
Boro scope Inspection:

Purpose: Boro scope inspection is a non-destructive testing method used to inspect internal features and
conditions of components, such as cracks, corrosion, or other defects.
Procedure: A Boro scope, which is a flexible optical device, is inserted into the component to visually inspect its
internal surfaces, ensuring it meets quality standards and specifications.
11
PO #6:
(Indicate how your Full Semester Internship is helpful for the Society)
12
PO #7:
(Indicate how the Full Semester Internship is helpful for the Environment and how it is
sustainable)
13
PO #8:
(Indicate the ethical practices followed in your Full Semester Internship)
● Upheld strict confidentiality agreements to protect proprietary information, ensuring that all work
conducted was in accordance with ethical standards and legal obligations
● Ensured that all work procedures adhered to safety standards, preventing any potential harm to myself,
colleagues, or the environment.
● Complied with all industry regulations, particularly those concerning public health, safety, and
environmental protection.
● Maintained honesty and accountability, avoiding any actions that could compromise the integrity of the
project or the company.
14
15
PO #9:
(Indicate your work experience in Full Semester Internship as an Individual and in a team)
This internship provided valuable insights into both individual and team-based work, laying a solid foundation
for my future endeavors in the field of engineering. By combining our knowledge and skills, we were able to
address complex engineering problems more comprehensively. Teamwork also played a significant role during
hands-on tasks, such as the brushing, washing, and inspection processes. We maintained open
communication, shared responsibilities, and supported each other to ensure the efficiency and quality of our
work.
16
PO #10:
(Indicate your improvement in Communication in Oral, Written and Graphical Communication)
I improved my oral communication during my internship by making sure to ask others regarding queries in the
production. This internship also helps me in improving written communication while preparing the report and
PPT
17
PO #11:
(Indicate your project management in Full Semester Internship)
18
PO #12:
(Indicate about the self learnt topics or self learnt skills, if any)
● Team work
● Collaborative learning
● Understanding New technology
● Creative
● Machining Process
19
PSO #1:
(Demonstrate adequate core competency in designing and fabricating mechanical systems, thermal
and hydraulic machines, materials and similar others, and there by providing sustainable computer
aided solutions maintaining professional standards and value system)
This internship experience provided me with the opportunity to apply theoretical knowledge to practical
situations, strengthening my ability to design and fabricate mechanical systems and provide sustainable
computer-aided solutions while maintaining professional standards and a strong value system.
20
PSO #2:
(Demonstrate adequate knowledge in the allied specialization of specialization of Mechanical
Engineering that adds value addition for professional practices)
This internship provided a solid foundation for applying theoretical knowledge to practical situations,
strengthening my ability to add value to professional practices in the field of Mechanical Engineering
21
RUBRICS
22
Overall Feedback
During my three-month full-semester internship at Delphi TVS, Chennai, where I worked on the common rail
injection system, the experience was highly rewarding and educational. I applied the knowledge of basic
sciences and fundamental engineering concepts effectively to solve engineering problems related to the
common rail injection system. This experience will be instrumental in my future endeavors.
23
24

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Nadimpalli Satyanarayana Raju Institute of Technology (Autonomous) – Full Semester Internship Report

Department of ME, 2020-2021 Admitted Batch

Nadimpalli Satyanarayana Raju Institute of Technology

Common Rail Injection System

in partial fulfillment for the award of the degree of

Department of Mechanical Engineering

Nadimpalli Satyanarayana Raju Institute of Technology

Common Rail Machining

Delphi TVS Technologies Limited, Oragadam

in partial fulfillment for the award of the degree of

Department of Mechanical Engineering

Mr G Siva Sai Ram Mr. N. Gunashekaran

Dr. V. Ananda babu Ph.D.

Profile of the Delphi TVS Technologies limited.

CERTIFICATE OF FULL SEMESTER INTERNSHIP

contributed to my work directly or indirectly.

Learning Outcomes of Full Semester Internship

List of Program Outcomes

Detailed Internship Work

Section – l: Weekly Progress in line with Daily Logs

Week-1 Training Program on safety & overview of the company

Section – Il: Introduction about the concept of the Internship

combustion and, consequently, improved fuel efficiency.

the common rail system helps reduce harmful emissions.

which improves engine response and power delivery.

to traditional diesel engines.

configurations, making it suitable for a wide range of applications.

● Automotive vehicles (cars, trucks, buses)

Section – IIl: Details of the Internship

Section – IV: Final Outcome of the Internship

The scope of this PO is irrelevant to my work carried out in my internship.

Boro scope Inspection:

The scope of this PO is irrelevant to my work carried out in my internship.

The scope of this PO is irrelevant to my work carried out in my internship.

conducted was in accordance with ethical standards and legal obligations

colleagues, or the environment.

The scope of this PO is irrelevant to my work carried out in my internship.

● Understanding New technology

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