Practical Training Report

TRAINING REPORT 2019
PRACTICAL TRAINING REPORT
A TRAINING REPORT
Submitted by
NAME OF THE CANDIDATE

RAUNAK KUMAR
in partial fulfillment for the award of the degree

of
BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
At
CLG GROUP OF INSTITUTIONS CLG INSTITUTE OF

ENGINEERING & TECHNOLOGY JAWAI BANDH ROAD,
SUMERPUR PALI (RAJ)
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P a g e ii | 43
RAJASTHAN TECHNICAL UNIVERSITY, KOTA

2015-16
BONAFIDE CERTIFICATE
This is to certify that Mr. RAUNAK KUMAR S/O Mr. BHIMRAJ
of Mechanical Engineering Department, Jodhpur Institute of Engineering
& Technology having roll no. “16ECLME009” has completed his /her industrial
training during the academic year 2018-2019 as partial fulfillment of Bachelor
of Technology in Mechanical Engineering affiliated from Rajasthan Technical
University, Kota.
<<Signature of the Head of the <<Signature of the

Department>> SIGNATURE Guide>> SIGNATURE
ASSOCIATE PROF. PUSHPENDRA NENIWAL NAME OF THE GUIDE

HOD – MECHANICAL ENGINEERING DESIGNATION CLGIET,
SUMERPUR
Internal Examiner _____________________
External Examiner _____________________
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Acknowledgement
To make any endeavor successful, especially where the cooperation so many is needed, a lot of help
is needed from those who are in a position to help. In the Engineering field only theoretical knowledge
cannot satisfy an Engineer’s need and only on the basis an Engineer cannot do field work efficiently
therefore it is very important for an Engineering student to opt some training.
To get this knowledge every student of engineer college takes training according to his own branch in
a well established factory or an organization in which work is being done practical and how practical
work is managed in normal working condition. I am grateful to Mr. V Selvaraj the Manager- Training
and placement officer at Indo German Tool Room Ahmedabad, Gujarat, for giving me the permission
for training. I would like to take this opportunity to thank all those who made my Training at Indo
German Tool Room Ahmedabad, Gujarat not only possible, but also a learning experience.
I express my sincere thanks to the training incharge of Indo German Tool Room Ahmedabad for
their regular Guidance and their helpful nature without which I cannot complete my training.
I am also thankful to all the incharge of Indo German Tool Room Ahmedabad and their sub
ordinates and workers, which helped me a lot and shown the interest in us, it gives me a great
pleasure in presenting my training report on training done from Indo German Tool Room
Ahmedabad
Raunak Kumar
3 year (6 semester)
Mechanical Engineering
CLG Institute of Engineering And technology,
Sumerpur, pali (raj)
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CONTENTS
Title Page No
1. Introduction
i. Company Profile
ii. Vision mission
2. Training
i. Objective of training
ii. Production
a. Methods of production
b. Structure of Production
c. Production and tooling Solutions
3. Section I – Design
i. Research
ii. Design Requirements
iii. Preliminary Design
iv. Design for Manufacturing
v. General Information
vi. Design Rules
4. Section 2 – Electro-Discharge Machine
i. Principle of EDM
ii. Wirecut EDM
iii. Flushing
iv. Flushing Ram Type EDM
v. The Servo Mechanism
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vi. The Advantages of EDM
vii. EDMs at IGTR
5. Section 3 – CNC Milling
i. Working Principle
ii. Methods of Milling
iii. Types of cutting tools used in CNC Milling section
6. Section 4 – Injection Molding
i. Injection Moldingprocess Cycle
ii. Injection Moldingat IGTR
iii. Defects in Injection Moldingand their Troubleshooting
7. Section 5 – Stage Inspection
i. Specific Inspection
ii. Objectives of Inspection in Production Managements
iii. Methods of Inspection
8. Section 6 – Marketing
i. Work of Marketing Department in Business
ii. Role of Marketing Department
iii. Budgeting
iv. Managing Strategy
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1. INTRODUCTION
COMPANY PROFILE
 Indo German tool room, Ahmadabad is an institute for tool & die making and
training.
 Igtr is strategically located in the city of Ahmadabad ,the business center of

Gujarat.
 igtr Ahmadabad is equipped with the latest European machines and a motivated
and trained professional team .
 Igtr ahmedabad is a nationally known source for designing and manufacturing of

international quality of plastic moulds ,press tool, die casting dies an d jigs and
fixtures.
 igtr Ahmadabad under takes precision machining job work using states of art
machines and software .
 igtr Ahmadabad offers long term , medium term and short term training in the
areas of tool and die making and CAD/CAM CAE.
 igtr Ahmadabad provides cultured , disciplined and day one productive

manpower.
 igrt Ahmadabad offers specialized digital technology service in the area of

product development using CAD, CAE & RPT as well as tool analysis.
 igtr Ahmadabad offers quality control services including reverse engineering

third party inspection using latest equipments.
 Igtr ahmadabad offers plasma nitriding and metallurgy lab services.
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Vision Mission
 Self Sufficiency and beyond with sustained growth.

 Adopt e teaching practices including Computer Based Training / Web Based
Training
 Internationally acclaimed Centers of Excellence in product Developments Tool
Engineering & Allied Fields.
 Nurturing Socially Relevant Skill Development programs for improving
employment potential.
 Developing competitive edge over National & International Players.
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2. TRAINING
OBJECTIVE OF TRAINING
THE OBECTIVE OF TRAINING ARE :
To know about the mechanical and electrical power distribution of the industry.
To know about the motor, drivers, manual and automatic transmission used in the industry.
To know about the latest technologies implemented in the industry.
To get an idea about working of an industry.
PRODUCTION
Production: Production is a procedure develop to transform a set of input elements like men,
material, capital, information and energy into a specified set of output elements like finished
products and services and service in proper quantity and quality thus achieving the objective of
an enterprise.
Methods of Production:
 Job Production: In that type of production the different type of components are made
once and the production of that type of job may not be repeated in future.
 Batch production: In that type of production a large or medium quantity of

component is produced and after some particular interval that production is repeated in
future.
 Mass Production: In that type of production , the whole plant and machinery is used
for producing same type of components and only that type of production is done on the
plant.
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Structure of Production
For better quantity and quality of finished product and thus achieving the objectives of an enterprise
production has to work in a systematic manner. Hence production is divided into sub departments
in production. – Designing, Marketing, Production Planning and Control (PPC), Store, CNC
Turning and Milling, CNC EDM and Die sinkers and wire cut , Grinding, Conventional Milling
and Turning, Stage inspection , fitting section , quality control, heat treatment, injection
Moldingand press.
Production and Tooling Solutions of IGTR

 IGTR Offers An Array Of Cutting Edge Production And Job-Work Services To
Several Organizations Not Only In Gujarat And India, But Across The World.
The Spectra Covers The Entire Range Of Manufacturing Press Tools, Moulds,
Die Casting Dies, Jigs & Fixtures And Gauges. IGTR Also Undertake
Manufacturing Of Standard Parts, Components And Carry Out Precision Job
Work.
 IGTR Is Equipped With The State-Of-The-Art Facilities, All Under One Roof. The
Wide Range Of The Latest CNC Machines From The Best Of The European Make
That Provides 360 Degree Solutions To Precision Machining Covering The
Entire Spectrum Of Tool And Die Making.
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SECTION – 1
DESIGN
The design department involves the design of product and tool by using different modelling and
drafting software. It also involves reverse engineering of previous product and new product
development. The design consists of following steps:
Research:
Various stage of the design process can involve a significant amount of time spent on locating
information and research. Consideration should be given to the existing applicable literature,
problems and success associated with existing solutions, cost and marketplace need.
Design Requirements
Establishing design requirement analysis, sometimes termed problem definition, is one of the
most important elements in the design process and this task is often performed at the same time
as a feasibility analysis. The design requirement control the design of the project throughout the
engineering design process. These includes basic things like function, attributes, and
specification determined after assessing user needs. Some design requirement include hardware
and software parameters, maintainability, availability and testability.
Preliminary Design:
The preliminary design or high level design includes (also called feed), often bridges a gap
between design conception and detailed design, particularly cases where the level of
conceptualization achieve during ideation is not sufficient for full evaluation. So in this task, the
overall system configuration is defined and schematic diagrams and layout of the project may
provide early project configuration. During detailed design and optimization, the parameters of
the part being created will change but the preliminary design focus on creating the general
framework to build the project on.
DETAILED DESIGN:
Following FEED is the detailed design phase, which may consist of procurement of material as
well. This phase further elaborates each aspect of the project/ product by complete description
through solid modelling, drawings as well as specification.
Design for manufacturability:

Design for manufacturability (DFM) is the general engineering art of designing products in such
a way that they are easy to manufacture.
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 . Operating Parameters
 . Operating and non-operating environmental stimuli
 . Test requirement
 . External Dimension
 . Maintenance and testability provisions
 .Material requirements
 . Reliability requirement
 . External surface treatment
 . Design life
 Packaging requirements
 External marking
Computer aided design (CAD) programs have made detailed design phase more efficient. For
example, a CAD program can provide optimization to reduce volume without hindering a parts
quality.
It can also calculate stress and displacement using the finite element method to determine the
stress throughout the part.
GENERAL INFORMATIONS:
Product Details:
 Part Drawing
 CAD Data
 Sample
 Product name
 Drawing number
 Material & grade
 Shrinkage
Specify on product drawing area where
 Ejectors marks are not permitted

 Gate is not permitted
 Parting line are not permitted
 Weld line are not permitted
Moldingmachine data
 Make and model of machine
 Nozzle radius
 Platen bore diameter
 Platen detail
Types of clamping
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 Direct screwing
 With clamps
Locating ring
 Injection side diameter
 Ejection side diameter
Mould data
 Number of cavities
 Cavities arrangement
Parallel
Rows
Circular
Runner system
 Cold runner
 Direct sprue
 Sprue + runner
 Runner at parting line
 Insulated runner
Hot Runner
 Self-made
 Hot runner with pin point
 Hot runner with needle valve
Gates
 Film
 Ring
 Tab
 Submarine
 Banana
 Pin Point
Ejection System
 Round Pin
 Flat Pin
 Sleeve
 Stripper Plate
 Air Ejector
Automation standard
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 Semi-automatic
 Fully automatic
 The design procedure of plastic product involves following steps:
1) Consider machine specifications

2) Selection of machine criteria
 Calculation of shot weight
0.85 ×𝑊
 NS = 𝑚
 Shot weight by thumb rule = 1.2 X (wt. of the component)
 Calculation of clamping capacity
C
 NC =P
C X AM
 Calculation of plasticizing capacity
0.85xPxTc
 NP = 3600xm
Where,
NS, NP & NC = Number of cavities based on shot, plasticizing and clamping capacity
respectively.
W = Rated shot capacity for polymer in gm.
m = Product wt. per cavity in gm.
P = Rated plasticizing capacity for polymer in gm/hr.
Tc = Overall cycle time in seconds.
C = Rated clamping capacity in Tons.
Pc = Clamping pressure in tons/cm2 of projected area (0.630 tons/cm2)
Am = Projected area of Molding (cm2).
3) Design of cavity insert

4) Design of runner
5) Design of Sprue bush
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6) Design of guide pillar and guide bush

7) Design of core insert
8) Design of cooling system
9) Design of ejection system
Tonnage calculation:
Tonnage = Projected area X 1/3 injection pressure X no of cavities
Design Rules
- To shorten the cycle time decrease the wall thickness
- Uniform wall thickness will ensure uniform cooling and reduce defects
- Round corner to reduce stress concentration and fractures
- Inner radius = wall thickness
- Draft angle 1 degree to 2 degree to all wall parallel
- Add ribs for structural support (50- 60 % of wall thickness
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Section- 2
Electro-Discharge Machine
CNC Electro Discharge Machine
Principles of EDM
Electrical Discharge Machining (EDM) is a controlled metal-removal process that is used to

remove metal by means of electric spark erosion. In this process an electric spark is used as the
cutting tool to cut (erode) the workpiece to produce the finished part to the desired shape. The
metal-removal process is performed by applying a pulsating (ON/OFF) electrical charge of high-
frequency current through the electrode to the workpiece. This removes (erodes) very tiny pieces
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of metal from the workpiece at a controlled rate.
EDM Process
EDM spark erosion is the same as having an electrical short that burns a small hole in a piece of
metal it contacts. With the EDM process both the workpiece material and the electrode material
must be conductors of electricity.
The EDM process can be used in two different ways:
1. A preshaped or formed electrode (tool),usually made from graphite or copper, is
shaped to the form of the cavity it is to reproduce. The formed electrode is fed
vertically down and the reverse shape of the electrode is eroded (burned) into the
solid workpiece.
2. A continuous-travelling vertical-wire electrode, the diameter of a small needle or
less, is controlled by the computer to follow a programmed path to erode or cut a
narrow slot through the workpiece to produce the required shape.
Conventional EDM
In the EDM process an electric spark is used to cut the workpiece, which takes the
shape opposite to that of the cutting tool or electrode. The electrode and the workpiece
are both submerged in a dielectric fluid, which is generally light lubricating oil. A
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servomechanism maintains a space of about the thickness of a human hair between the
electrode and the work, preventing them from contacting each other. In EDM ram or
sinker machining, a relatively soft graphite or metallic electrode can be used to cut
hardened steel, or even carbide. The EDM process produces a cavity slightly larger
than the electrode because of the overcut.
Wire-Cut EDM
The wire-cut EDM is a discharge machine that uses CNC movement to produce the desired contour
or shape. It does not require a special shaped electrode, instead it uses a continuous-traveling
vertical wire under tension as the electrode. The electrode in wire-cut EDM is about as thick as a
small diameter needle whose path is controlled by the machine computer to produce the shape
required.
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Dielectric Fluids - Conventional EDM

During the EDM process the workpiece and the electrode are submerged in the
dielectric oil, which is an electrical insulator that helps to control the arc discharge. The
dielectric oil, that provides a means of flushing, is pumped through the arc gap. This
removes suspended particles of workpiece material and electrode from the work cavity.
Flushing
One of the most important factors in a successful EDM operation is the removal of
the metal particles (chips) from the working gap. Flushing these particles out of the gap
between the workpiece to prevent them from forming bridges that cause short circuits.
Flushing Ram Type EDM

Flushing is the most important function in any electrical discharge machining
operation. Flushing is the process of introducing clean filtered dielectric fluid into the
spark gap. Flushing applied incorrectly can result in erratic cutting and poor machining
conditions. There are a number of flushing methods used to remove the metal particles
efficiently while assisting in the machining process. Too much fluid pressure will
remove the chips before they can assist in the cutting action, resulting in slower metal
removal. Too little pressure will not remove the chips quickly enough and may result
in short-circuiting the erosion process
Wire EDM Dielectric Fluids

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The dielectric fluid must be circulated under constant pressure to flush (wash) away
the metal particles and assist in the machining or erosion process. If red sparks occur
during the cutting operation, the water supply is inadequate. To overcome this problem,
increase the flow of water until blue sparks appear.
The Servo Mechanism

Both wire and vertical EDM machines are equipped with a servo control mechanism
that automatically maintains a constant gap of about the thickness of a human hair
between the electrode and the workpiece. It is important for both machine types that
there is no physical contact between the electrode and the workpiece, otherwise arcing
could damage the workpiece and break the wire. The servomechanism advances the
electrode into the workpiece as the operation progresses and senses the work-wire
spacing and controls it to maintain the proper arc gap which is essential to a successful
machining operation.
Advantages of EDM
Conventional EDM machines can be programmed for vertical machining, orbital,
vectorial, directional, helical, conical, rotational, spin and indexing machining cycles.
This versatility gives Electrical Discharge Machines many advantages over
conventional machine tools.
• Any material that is electrically conductive can be cut using the EDM process.
• Hardened workpieces can be machined eliminating the deformation caused by heat
treatment.
• X, Y, and Z axes movements allow for the programming of complex profiles using
simple electrodes.
• Complex dies sections and molds can be produced accurately, faster, and at lower
costs.
• The EDM process is burr-free
. • Thin fragile sections such as webs or fins can be easily machined without deforming
the
part.
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Electro-Discharge Machines at IGTR

In IGTR, there are six types of electro-discharge machines which are as follows:
A. Electro discharge machine
1. Agie charmilles FO 23
2. ROBOFORM 20
3. ROBOFORM 40
4. MISTUBISHI EA28V
B. Wire cut electro discharge machine
5. Robofile 290
6. Robofile 510
Specifications of these machines are as follows:

1. Agie charmilles FO 23
WORKING RANGE
TABLE SIZE
2. Roboform 20
WORKING RANGE 350 X 250 X 250 mm
TABLE SIZE
3. Roboform 40
TABLE SIZE 700 X 500 mm
4. Mitsubishi EA28V
TABLE SIZE 1040 X 760 X 350 mm
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5. Robofile 290
6. Robofile 510
Measuring instruments used in CNC milling section
 Vernier caliper (Dial)

Least count – 0.01mm / 0.02mm
 Micrometer (outside,inside,depth)
Least count – 0.01mm
GUAGES USING IN CNC MILLING SECTION

 Dial gauge
 Plug gauge
 Slip gauge
 Pin gauge
 Bore gauge
CLAMPING DEVICES
 Step block
 Strap clamp
 C-clamp
 T- bolt
 Nut etc.
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Section – 3
CNC- MILLING
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WORKING PRINCIPLE
 -Milling is the cutting operation that removes metal by feeding, the work piece against
a rotating cutter having single or multiple cutting edges.
 -Good finish & accuracy maintain.
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METHODS OF MILLING
1. UP MILLING = Cutter rotates against direction of feed tool wear is milling more tool life
is low. Roughing method also known as conventional.
2. DOWN MILLING = Cutter rotates with direction of feed. Tool wear is less tool life is
high. Finishing method. Also known as climb milling.
TYPES OF CUTTING TOOL USE IN CNC MILLING

 ENDMILL
 FACEMILL
 THREADMILL
 SHELLMILL
 FEED MASTER
 U-DRILL
 BALL NOSE CUTTER
 CHAMFER TOOL
 BORING BAR
BASIC G-CODES
 G00 - Linear interpolation in rapid traverse mode.
 G01 – Linear interpolation in slow feed motion.
 G02 - Circular interpolation clockwise
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 G03 – Circular interpolation Anticlockwise

 G12 - Circular pocket milling clockwise
 G13 – Circular pocket milling counter clockwise
 G20 – Inch units
 G21 – Metric units
 G83 – Drilling cycle
 G84 - Tapping cycle
 G90 - Absolute programming
 G91 - Incremental programming
 G54 – work offset
BASIC M-CODES
 M03 – Spindle rotate clockwise
 M04 – Spindle rotate anti-clockwise
 M05 – Spindle stop
 M06 – Tool change
 M08 – Coolant on
 M09 – Coolant off
 M30 – Program end
 M99 – End of sub program
OFFSET SETTING
 Edge finder
Edge finder is mount on spindle.
It is cylinder shape and spring loaded.
 PROBE
Probe is sensing device.
 Z – SETTER (PRE SETTER GUAGE)
Use for taking z-offset and z-zero set.
MACHINE DETAIL OF CNC MILLING SECTION
 HASS UMC-750 (5 AXIS)

>CONTROLLER = HASS
>WORKING RANGE = 762 X 508 X 508 mm
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 HASS VF-1 (4 AXIS)

>CONTROLLER = HASS
>WORKING RANGE = 762 X 508 X 508 mm
 BFW BMV-70 (3 AXIS)

>CONTROLLER = SIEMENS 810D
>WORKING RANGE = 1500 X 800 X800mm
 MIKRON WF 52D (3 AXIS)

>CONTROLLER = HEIDENHAIN
>WORKING RANGE = 650 X 500 X 400mm
 MIKRON WF 32D (3 AXIS)

 DMC 70V(DECKEL MAHO 3 AXIS)

 DMC 70V (3 AXIS)

>CONTROLLER = SIEMENS
 HASS VF3 (3 AXIS)

>CONTROLLER = HASS
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Measuring instruments used in CNC milling section

 Vernier caliper (Dial)
Least count – 0.01mm / 0.02mm
 Micrometer (outside,inside,depth)
Least count – 0.01mm
GUAGES USING IN CNC MILLING SECTION

 Dial gauge
 Plug gauge
 Slip gauge
 Pin gauge
 Bore gauge
CLAMPING DEVICES
 Step block
 Strap clamp
 C-clamp
 T- bolt
 Nut etc.
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SECTION – 4
INJECTION MOLDING
An Injection Moldingmachine also known as an injection press, is a machine for manufacturing

plastic products by the injection Moldingprocess. It consists of two main parts, an injection unit
and a clamping unit.
Injection Moldingis a manufacturing process for producing parts in large volume. It is most
typically used in mass-production processes where the same part is being created thousands or
even millions of times in succession.
Parts to be injection moulded must be very carefully designed to facilitate the Moldingprocess; the
material used for the part, the desired shape and features of the part, the material of the mould, and
the properties of the Moldingmachine must all be taken into account. The versatility of injection
Moldingis facilitated by this breadth of design considerations and possibilities.
Product is made like power tool housing, electrical switches, Automotive dashboard & television
cabinets, dvds, battery covers, automotive bumpers etc. By injecting molten thermoplastic material
into a closed mould which is relatively cool.
There are three types of injection Moldingmachines:
 Hand Injection MoldingM/C

 Plunger type Injection MoldingM/C
 Reciprocating Screw Type Injection MoldingM/C
 IGTR has a reciprocating type injection Moldingmachines. General block diagram of this
type of machines are as follows:
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P a g e 25 | 43
This type of machine consists of following parts:

 Hopper
 Barrel
 Reciprocating screw
 Nozzle
 Mould system
 Hydraulic system
 Control system
 Clamping system
The Injection Moldingprocess cycle:

 The process cycle for injection Moldingis very short, typically between 2 seconds and 2
minutes, and consists of the following four stages:
1. CLAMPING - Prior to the injection of the material into the mould, the two halves of the
mould must first be securely closed by the clamping unit. Each half of the mould is attached to
the injection Moldingmachine and one half is allowed to slide. The hydraulically powered
clamping unit pushes the mould halves together and exerts sufficient force to keep the mould
securely closed while the material is injected. The time required to close and clamp the mould
is dependent upon the machine - larger machines (those with greater clamping forces) will
require more time. This time can be estimated from the dry cycle time of the machine.
2. INJECTION - The raw plastic material, usually in the form of pellets, is fed into the
injection Moldingmachine, and advanced towards the mould by the injection unit. During this
process, the material is melted by heat and pressure. The molten plastic is then injected into
the mould very quickly and the buildup of pressure packs and holds the material. The amount
of material that is injected is referred to as the shot. The injection time is difficult to calculate
accurately due to the complex and changing flow of the molten plastic into the mould.
However, the injection time can be estimated by the shot volume, injection pressure, and
injection power.
3. COOLING - The molten plastic that is inside the mould begins to cool as soon as it makes
contact with the interior mould surfaces. As the plastic cools, it will solidify into the shape of
the desired part. However, during cooling some shrinkage of the part may occur. The packing
of material in the injection stage allows additional material to flow into the mould and reduce
the amount of visible shrinkage. The mould cannot be opened until the required cooling time
has elapsed. The cooling time can be estimated from several thermodynamic properties of the
plastic and the maximum wall thickness of the part.
4. EJECTION - After sufficient time has passed, the cooled part may be ejected from the
mould by the ejection system, which is attached to the rear half of the mould. When the mould
is opened, a mechanism is used to push the part out of the mould. Force must be applied to
eject the part because during cooling the part shrinks and adheres to the mould. In order to
P a g e 26 | 43
facilitate the ejection of the part, a mould release agent can be sprayed onto the surfaces of the
mould cavity prior to injection of the material. The time that is required to open the mould and
eject the part can be estimated from the dry cycle time of the machine and should include time
for the part to fall free of the mould. Once the part is ejected, the mould can be clamped shut
for the next shot to be injected.
Injection MoldingMachines at IGTR

In IGTR, there are three injection Moldingmachines which are as follows:
 TOSHIBA 100 tones

 TOSHIBA 350 tones
 L&T 650 tones
Specifications of these machines are as follows:
 L&T 650 TONNES:
CLAMPING TONAGE 650 TONES

TIE BAR DISTANCE 1000 x 900 mm
(H*V)
MIN. MOULD HEIGHT 450mm
SHOT WEIGHT (PS) 4.1Kg
 TOSHIBA 350 TONNES:

(H*V)
SHOT WEIGHT (PS) .2 Kg
 TOSHIBA 100 TONNES:
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(H*V)
SHOT WEIGHT (PS) 210 gms
Defects in Injection Moldingand their Troubleshooting.

Following are some of the common defects in Injection Moulding. The solutions mentioned are
possible solutions and must be tried out with safety in mind. Please always follow the material
manufacturer and machine manufacturer's guidelines for safety
NO DEFECT IMAGE POSSIBLE POSSIBLE

REASON SOLUTION
Increase melt
1
temperature
Increase mould
temperature
Molten Plastic is not Increase injection speed

reaching the mould cavity
Short Shot section Increase injection
pressure if process is
pressure limited
Increase gate and

runner sizes
Check for Mould shut-

off and mould damage
2
Decrease melt
Molten Plastic is flowing temperature
into unwanted sections of
Flash the mould cavity Decrease mould
temperature
Decrease injection speed
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A differential cooling rate Decrease melt

of the melt in two sections temperature Experiment
4
Warpage with differential mould
of the moulded product
temperatures on the
fixed and movable sides
Increase pack and hold

pressures
Increase pack and hold

times
Increase cooling time

Increase venting in the
mould
5
Decrease injection speed
When air and gasses get
trapped inside the mould Decrease melt
Burn Marks cavity during plastic temperature
injection, the high pressure
Decrease Screw
results in the dieseling of
Rotation Speeds
the plastic resulting in the
burning of the plastic.
Dry material to
When moisture and/or a
suggested moisture
6 gaseous byproduct gets levels
mixed with the melt and is
injected in the mould Increase back pressure
cavity this moisture or gas
if embedded inside the Reduce melt temperature
melt can show up as
Bubbles
bubbles
Slow down the injection

speeds in the gate area
7
Profile the injection
speeds if necessary
Gate Blush Shows up at the gate when Experiment with

the material is sheared increasing and
decreasing melt
P a g e 29 | 43
differently compared to the temperatures or hot tip

rest of the part temperatures in case of
hot runner moulds
Reduce injection speed

8 Usually seen with the part
is thick causing the Increase melt
injected plastic to ‘snake temperature
fall’ on to the cold mould
surface and start freezing Change gate location
Jetting immediately. When the
fresh plastic come in it
does not blend well with
the first material causing
the jetting marks
P a g e 30 | 43
Section – 5
Stage Inspection
An inspection is, most an organized examination or formal evaluation exercise. In engineering
activities inspection involves the measurements, tests, and gauges applied to certain
characteristics in regard to an object or activity. The results are usually compared to
specified requirements and standards for determining whether the item or activity is in line with
these targets, often with a Standard Inspection Procedure in place to ensure consistent checking.
Inspections are usually non-destructive.
P a g e 31 | 43
Specific Inspection:
Manufacturing –
Quality related in-process inspection/verification is an essential part of quality control in

manufacturing
Inspection in manufacturing includes measuring, examining, testing, or gauging one or more

characteristics of a product or process and comparing the results with specified requirements to
determine whether is the requirements are met for each characteristic.
Common examples of inspection by measurement or gauging include using

a caliper or micrometre to determine if a dimension of a manufactured part is within
the dimensional tolerance specified in a drawing for that part, and is thus acceptable for use.
Objectives of Inspection in Production Management

Objectives of Inspection:
 To detect and remove the faulty raw materials before it undergoes production.
 To detect the faulty products in production whenever it is detected.

 To bring facts to the notice of managers before they become serous to enable them
discover weaknesses and over the problem.
 To prevent the substandard reaching the customer and reducing complaints.
 To promote reputation for quality and reliability of product.
Purpose of Inspection:
 To distinguish good lots from bad lots.

 To distinguish good pieces from bad pieces.
P a g e 32 | 43
 To determine if the process is changing.

 To determine if the process is approaching the specification limits.
 To rate quality of product.
 To rate accuracy of inspectors.
 To measure the precision of the measuring instrument.
 To secure products-design information.
 To measure process capability.
Methods of Inspection
There are two methods of inspection. They are: 100% inspection and sampling inspection.
 100% Inspection
This type will involve careful inspection in detail of quality at each strategic point or
stage of manufacture where the test is involved is non-destructive and every piece is
separately inspected. It requires more number of inspectors and hence it is a costly
method. There is no sampling error. This is subjected to inspection error arising out of
fatigue, negligence, difficulty of supervision etc.
 Sampling Inspection:
In this method randomly selected samples are inspected. Samples taken from different
patches of products are representatives. If the sample proves defective, the entire
concerned is to be rejected or recovered. Sampling inspection is cheaper and quicker. It
requires less number of Inspectors. It is subjected to sampling errors but the magnitude of
sampling error can be estimated.
P a g e 33 | 43
Section – 6
Marketing
Marketing is the study and management of exchange relationship. Marketing is the business
process of creating relationships with and satisfying customers. With its focus on the customer,
marketing is one of the premier components of business management.
Marketing department promotes business and drives sales of its products or services. It provides
the necessary research to identify target customers and other audiences.
The marketing department helps a business to do the following:
P a g e 34 | 43
 Build relationship with the audience: Creates awareness of the business

and its products as well as provide inputs that create interest for the audience. It brings in
new customers and creates new business opportunities for the enterprise.
 Involve the customer: It engages existing customers, tries to understand them

and hear what they have to say. It monitors the competition, creates new ideas, identifies
outlets, plans the strategy to involve customers and retain them.
 Generate income: Finally, the aim of the marketing department is to generate

revenue. All its activities are aimed at broadening the customer base and finding
opportunities that would create more revenue for the enterprise.
The Role of a Marketing Department

The Marketing Department plays a vital role in promoting the business and mission of an
organization. It serves as the face of your company, coordinating and producing all materials
representing the business. It is the Marketing Department's job to reach out to prospects,
P a g e 35 | 43
customers, investors and/or the community, while creating an overarching image that represents
your company in a positive light.
Depending on your company, the duties of the Marketing Department may include one or more
of the following:
 Defining and managing your brand. This involves defining who you are, what
you stand for, what you say about yourself, what you do and how your company acts.
This, in turn, defines the experience you want your customers and partners to have when
they interact with you.
 Conducting campaign management for marketing initiatives. Marketing

proactively identifies the products and services to focus on over the course of your sales
cycle, and then produces materials and communications that get the word out.
 Producing marketing and promotional materials. Your marketing department

should create the materials that describe and promote your core products and/or services.
They should be kept up-to-date as those products and services evolve.
 Creating content providing search engine optimization for your
website. Your website is often the first (and possibly the only) place people go for
information about you. Your marketing department will be responsible for keeping Web
content current, while also working to ensure your site comes up quickly when someone
searches for your type of business.
 Monitoring and managing social media. Marketing should contribute to,
manage and maintain your social media pages. It should also manage accounts and
carefully watch what’s being posted about you online.
 Producing internal communications. Your employees need to understand your

company, its values, its goals and its priorities. Marketing is often responsible for
employee communications through a newsletter and/or intranet.
 Serving as media liaison. When your company is cited in the media, a member of
the marketing department often acts as spokesperson for your company, or guides
executives in how to respond to media queries.
P a g e 36 | 43
 Conducting customer and market research. Research helps you define target
markets and opportunities and helps you understand how your products and services are
perceived.
 Overseeing outside vendors and agencies. Marketing is typically responsible for

selecting and managing the agencies and vendors who produce marketing materials and
or/provide marketing support. These may include ad agencies, print vendors, PR agencies
or specialists, Web providers, etc.
BUDGETING
Marketing departments work on budgets. They are given a certain amount of money to spend upon
creating a presence for the company or product in the market. It is the responsibility of the
marketing department to estimate the cost of all the marketing activities it intends to carry out and
prepare a budget that would use the allocated amount of money most efficiently. It is essential that
the marketing personnel stick to the budget.
MANAGING STRATEGY
Managing the key activities of a business to work together is another responsibility of the
marketing department. It is the duty of the marketing department to create and implement strategies
that would enhance the business activities of the enterprise.
P a g e 37 | 43

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TRAINING REPORT 2019

PRACTICAL TRAINING REPORT

NAME OF THE CANDIDATE

in partial fulfillment for the award of the degree

CLG GROUP OF INSTITUTIONS CLG INSTITUTE OF

RAJASTHAN TECHNICAL UNIVERSITY, KOTA

This is to certify that Mr. RAUNAK KUMAR S/O Mr. BHIMRAJ

of Mechanical Engineering Department, Jodhpur Institute of Engineering

training during the academic year 2018-2019 as partial fulfillment of Bachelor

of Technology in Mechanical Engineering affiliated from Rajasthan Technical

<<Signature of the Head of the <<Signature of the

ASSOCIATE PROF. PUSHPENDRA NENIWAL NAME OF THE GUIDE

Internal Examiner _____________________

External Examiner _____________________

ii. Vision mission

c. Production and tooling Solutions

ii. Design Requirements

iii. Preliminary Design

iv. Design for Manufacturing

vi. Design Rules

4. Section 2 – Electro-Discharge Machine

ii. Wirecut EDM

iv. Flushing Ram Type EDM

v. The Servo Mechanism

vi. The Advantages of EDM

vii. EDMs at IGTR

5. Section 3 – CNC Milling

ii. Methods of Milling

iii. Types of cutting tools used in CNC Milling section

6. Section 4 – Injection Molding

i. Injection Moldingprocess Cycle

ii. Injection Moldingat IGTR

iii. Defects in Injection Moldingand their Troubleshooting

7. Section 5 – Stage Inspection

ii. Objectives of Inspection in Production Managements

iii. Methods of Inspection

i. Work of Marketing Department in Business

ii. Role of Marketing Department

iv. Managing Strategy

 Igtr is strategically located in the city of Ahmadabad ,the business center of

 Igtr ahmedabad is a nationally known source for designing and manufacturing of

 igtr Ahmadabad provides cultured , disciplined and day one productive

 igrt Ahmadabad offers specialized digital technology service in the area of

 igtr Ahmadabad offers quality control services including reverse engineering

 Igtr ahmadabad offers plasma nitriding and metallurgy lab services.

 Self Sufficiency and beyond with sustained growth.

To know about the latest technologies implemented in the industry.

To get an idea about working of an industry.

 Batch production: In that type of production a large or medium quantity of

Production and Tooling Solutions of IGTR

Design for manufacturability:

 Ejectors marks are not permitted

 The design procedure of plastic product involves following steps:

1) Consider machine specifications

 Calculation of clamping capacity

 Calculation of plasticizing capacity

W = Rated shot capacity for polymer in gm.

m = Product wt. per cavity in gm.

P = Rated plasticizing capacity for polymer in gm/hr.

Tc = Overall cycle time in seconds.

C = Rated clamping capacity in Tons.

Pc = Clamping pressure in tons/cm2 of projected area (0.630 tons/cm2)

Am = Projected area of Molding (cm2).

3) Design of cavity insert