A PRACTICAL TRANING REPORT ON MICROTEK FORGING L.T.

D
Submitted in Partial fulfillment for the award of the degree of

BACHELOR OF TECHNOLOGY In Mechanical Engineering

SESSION 2013-14
Submitted to:Mr. Nitin Sharma Head of Department (Mechanical Engineering) submitted by:Pankaj Kumar Yadav 10ejmme030 B.Tech IV Yr. / VIIsem.

JAIPUR INSTITUTE OF ENGINEERING AND MANAGEMENT

GADOTA, NH-8(MAIN JAIPUR-AJMER HIGHWAY), JAIPUR (RAJ.)-303007

RAJASTHAN TECHNICAL UNIVERSITY, KOTA

COMPANY PROFILE

ABOUT

Microtek forging is a unit of bajaj motors.It is Fully Equipped with all the facilities. Bajaj Auto Limited is an Indian two-wheeler and three-wheeler manufacturing company. Bajaj Auto manufactures and sells motorcycles, scooters and auto rickshaws. Bajaj Auto is a part of the Bajaj Group. It was founded by Jamnalal Bajaj in Rajasthan in the 1930s. It is based in Pune, Mumbai, with plants in Chakan (Pune), Waluj (near Aurangabad) and Pantnagar in Uttarakhand. The oldest plant at Akurdi (Pune) now houses the R&D centre Ahead. Bajaj Auto is the world's third-largest manufacturer of motorcycles and the second-largest in India. It is worlds largest three-wheeler manufacturer. On 31 March 2013, its market capitalisation was INR 520 billion (US$ 9.57 billion), making it India's 23rd largest publicly traded company by market value. The Forbes Global 2000 list for the year 2012 ranked Bajaj Auto at 1,416. The plant was established in Year 2000 and started its commercial production in the Year 2001. ISO 9001:2000 certified from TUV and in process to obtain TS 16949 and ISO 14001.

MISSION

1. 2. 3. 4. 5.

Focus on value based manufacturing. Fostering team work & enhancing the capability of the team . Continual Improvement . Total Elimination of wastes . Pollution Free & Safe Environment .

PRODUCTS OF COMPANY
Microtek forging is a large manufacture a large number of automotive forged components. It Is a large Manufacturer of Automotive Forging Components as Stub Axle, Spindle Rear, fork, Rocker Arm. Crank Shaft, bridge Fork bottom, Gear Blank are following there

STUB AXLE:-

A stub axle is an axle that is connected to an assembly that mounts on one side of a trailer. It does not go all the way across the trailer like a typical straight axle does. The stub axle typically is part of an assembly that includes the spring and shock mounts and is connected so that it can move freely as an integral part of the trailer's suspension.

By using a stub axle assembly on a trailer, it is able to traverse rough roads without disturbing its load. The axle works much like an independent suspension on a sports car and allows each tire and wheel assembly to move independently. This drastically improves cornering as well as braking characteristics, especially on slippery roads.

Most units are cast into the axle assembly and the entire piece is one single part, although others are independent assemblies that fit into a receptacle on the trailer and are a separate component. In either case, the axle typically has a single wheel and tire bolted to it. Occasionally, this axle can be used in a dual-wheel application as well.

The stub axle, in most cases, is easily replaced if broken. Most axles are bolted into a mounting assembly and can be simply removed by loosening a few bolts and sliding the broken stub out of the housing. In the cast units, the entire unit with stub must be replaced. This typically requires the removal of the springs and shocks as well.

While some axle failures can be welded, this is not advised in most cases. The stress and leverage on a stub axle is so great that many welded ones can break during a typical turn. As the trailer is turned, the axle has to slide the tire throughout the entire turn. This causes the repaired stub to strain and pull against the weld. In most cases, failure will occur with the axle breaking off at the weld.

SPINDLE REAR:-

A spindle is a part of a vehicle's suspension. Tying the wheel and tire into the steering system, the spindle is in the front of the vehicle in most cases; however, some front -wheel drive vehicles also have rear spindles. The spindle pivots between the upper and lower A frames or on the strut. Both the inner and outer wheel bearings ride on the spindle and the retaining nut on the end secures the wheel into position. On most vehicles, the front brake caliper is also mounted on the spindle.

Acting like a short axle, a spindle is used to attach a wheel assembly to a vehicle. Typically manufactured from a forged piece of steel, spindles must be extremely strong and durable to support the weight of the vehicle. While most spindles utilize a wheel hub to mount the wheel and tire in place, some wheels are mounted directly onto the spindle without the use of a hub. These wheels are known as spindle mount wheels.

Often, trailers and farm implements use spindles in place of solid, full-length axles. These spindles are subjected to incredible loads and occasionally break. When this happens, it is seldom possible to weld the spindles in place and repair them. New spindles are used to replace broken ones and are typically changed as a complete unit. The use of spindles

instead of axles on machinery allows for better articulation and movement of the tires and suspension from side to side.

A vehicle's spindles rarely require specialized maintenance. Greasing the inner and outer wheel bearings and ensuring that a cotter key is in place in the castle nut are usually all that is required. Most spindles fail due to heat from a dry or over-tightened wheel bearing or stress from turning a very sharp corner. When the unit is turned too sharp, it causes the tires to skid and be dragged around the turn. This dragging produces a tremendous amount of stress and load on the spindles, often cracking and breaking them.

In order to prevent breakage, trailers often use several spindle-mounted wheel assemblies paired with an air lift system to raise select wheels up and off of the road when making sharp turns. Once the rig has completed its turn, the tag axles or spindles are once again lowered to the road. This arrangement allows multiple wheels to evenly disperse the load's weight to prevent damage to the spindles.

FORK:-

ROCKER ARM:-

A rocker arm (in the context of an internal combustion engine of automotive, marine, motorcycle and reciprocating aviation types) is an oscillating lever that conveys radial movement from the camlobe into linear movement at the poppet valve to open it. One end is raised and lowered by a rotating lobe of the camshaft (either directly or via a tappet (lifter) and pushrod) while the other end acts on the valve stem. When the camshaft lobe raises the outside of the arm, the inside presses down on the valve stem, opening the valve. When the outside of the arm is permitted to return due to the camshafts rotation, the inside rises, allowing the valve spring to close the valve.

CRANK SHAFT:-

The crankshaft, sometimes abbreviated to crank, is the part of an engine that translates reciprocating linear piston motion into rotation. To convert the reciprocating motion into rotation, the crankshaft has crank throws or crankpins, additional bearing surfaces whose axis is offset from that of the crank, to which the big ends of the connecting rodsfrom each cylinder attach. It is typically connected to a flywheel to reduce the pulsation characteristic of the four-stroke cycle, and sometimes a torsional or vibrational damper at the opposite end, to reduce the torsional vibrations often caused along the length of the crankshaft by the cylinders farthest from the output end acting on the torsional elasticity of the metal.

BRIDGE FORK BOTTOM:-

Bridge fork bottom is device which use in fornt suspension of the automobile vechiles.It controls the movement of front suspension.

GEAR BLANKS:-

PROCESS OF MANUFACTURING OF PRODUCTS

1. HOT FORGING:- forging is a mass production techniquewhich hammers the metal between two dies. Half ofthe die is attached to the hammer (upper section)and half to the anvil (lower section). The hot metal isplaced in the lower half of the die and struck oneon more time with the upper die. This forces themetal to flow in all directions, filling the die cavity.Excess metal squeezed out between the die faces iscalled flash or flashing. After the forging iscompleted the flash is cut off in another press with atrimming die.

2. A METAL SHAPING PROCESS:- The metal to beformed is first heated then shaped by forcing it intothe contours of a die, this force can be in excess of 2000 tons. The drop forging process can beperformed with the material at varioustemperatures;Hot Forging During hot forging the metals are heated toabove their recrystallization temperature. The mainbenefit of this hot forging is that work hardening isprevented due to the recrystallization of the metalas it begins to cool.

3. CLOSED DIE:- Forging comprises of a die on the anvilwhich resembles a mould, the ram which falls andstrikes the top of the metal billet can also beequipped with a die. The heated metal billet isplaced on the lower die while the ram drives downforcing the metal to fill the contours of the dieblocks.

4. Process details Closed-die forging A heated blank is placed between 2 halves of a die.

5. A single compressive stroke squeezes the blank intothe die to form the part. In hammer or drop forgingthis happens by dropping the top of the mould froma height. An alternative is to squeeze the mouldstogether using hydraulic press.

6. Once the die halves have separated, thepart can be ejected immediately using an ejector pin.The waste material flash is removed later.

7. Parts of sizes up to 25 tons can be produced with closed die forging 2. Closed die forging can produce near netshapes that will require only a small amountof finishing 3. Economic (profitable) for large runs ofproduct.

8. . MATERIAL AND SHAPES :- 1. Any metal can be forged, provided the blank is hot enough (( 60% of the melting temperature).2. Typical possible sizes for closed dies range from 10g to 10kg, depending on complexity.3. The part is left with good surface and mechanical properties, although cold-forging can perform even better.

9. Complex parts can be formed using a series of forging dies with increasing levels of detail.. A draft (taper) angle has to beincorporated to allow easy removal of the part.. Any waste material squeezed between the die halves, called flash, is readily recycled.

10. The materials that are used most commonly in forging are:- aluminium, copper, nickel, mild steel,stainless steel, and magnesium.Best Material: Mild Steel Worst Material: Magnesium