Winter training

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WINTER TRAINING REPORT
AT
NEEL METAL PRODUCTS LIMITED
HARIDWAR
SUBMITTED TO SUBMITTED BY
MR. HARISH KUMAR PRANSHU PRAKASH TIWARI
(RA1611011010207)

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CERTIFICATE
This is to certify that
MR. Pranshu Prakash Tiwari
Student of SRM institute of science and technology have done an in-plant
internship on “DIFFERENT WELDING TECHNIQUES USED IN BOLERO BODY
MAKING” under my guidance. This work is done to satisfy my action under
requirement of “WINTER INTERNSHIP PROJECT”
MR. Harish Kumar
Sr. Executive Engineer
NEEL SHEET METAL PRODUCT
PVT LIMITED
JBM GROUP, HARIDWAR

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Declaration by the student
I Pranshu PrakashTiwari, student of B.tech (Automobile) hereby declarethat
the projecttitled “Different Welding Technique” which is submitted by me to
Department of Automobile, SRMINSTITUTEOF TECHONOLOGY, CHENNAI, in
partial fulfilment of requirement for the award of the degree of Bachelor of
Technology in Automobile has not been previously formed the basis for the
award of any degree, diploma or other similar title or recognition.
Signature
Date Name and Signature of Student
PRANSHUPRAKASH TIWARI

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ACKNOWLEDGEMENT
It is indeed a great pleasureand privilegeto present this report on training at NEEL
METAL PRODUCTS JBM GROUP, HARIDWAR. I am extremely grateful to my training and
placement officer for issuing a Training letter, which mademy training possibleat NEEL
METAL PRODUCTS JBM GROUP, HARIDWAR. First, I thank TheHR MR. Rajat Kapoor for
considering my potential in doing this summer internship and providing this wonderful
opportunity. I would liketo express my gratitudeto MR. Harish Kumar for his invaluable
suggestions, motivation, guidanceand supportthroughout thetraining. His
methodology to start from simpleant then go through mademeto bring out this project
report without anxiety. Thanks to all other JBM officials, operators and all other
members of JBM, yet uncounted for their help in completing theproject and see the
light of success. I am very thankful to friends, colleagues and all other persons who
rendered their assistancedirectly or indirectly to completethis project work
successfully.
Pranshu Prakash Tiwari

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INDEX
1) SAFETY PRECAUTIONS
2) ABOUT COMPANY
3) WELDING
4) EVOLUTIONOF WELDING
5) DIFFERENTTYPEOF WELDING
6) PROCESS FLOW CHART
7) DIFFERENTMODELS OF BOLERO
8) PROCESS INVOLVED INBOLERO MAKING
9) DIFFERENTTOOLS USEHERE
10) OTHER THANBOLERO BODYWELDING
11) WELDING TECHNIQUEUSEINJBM
12) MIG WELDING
13) ADVANTAGEAND DISADVANTAGEOF MIG WELDING
14) SPOTWELDING
15) ADVANTAGEAND DISADVANTAGEOF SPOTWELDING
16) CONCLUSION

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SAFETY PRECAUTIONS
1) YOU CAN BE THE BEST BUT YOU CAN’T
TRUST A MACHINE.
2) Protect every bit of your skin from the UV light.
3) Work in areas that are well ventilated.
4) Wear a vapour mask if needed.
5) Protect your eyes by using safety goggles.
6) Be aware of your surroundings before you begin to work so
that you can avoid having fires.
7) A CO2 one is the best for welding and a bucket of sand is
also a good thing to have.
8) Cotton clothing tends to be safer than synthetics that are
more likely to catch fire, but it’s often ideal to get flame
resistant jackets.

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About Company
JBM Group began its journey of excellence in 1983. Theorganization commenced
operations as a manufacturer of LPG Cylinders for theDelhi-NCR region of India. Moving
strength to strength, assisted with experienceand knowledge, JBM Group entered into
theautomotiveindustryin 1985.
In 1986, theGroup signed a joint venturewith Maruti-Suzuki India Ltd for the
manufacturing of sheet metal components and assemblies. Thejourney began with a
vision to expand thebusiness in theautomotivesector by keeping abreast with market
trends and global technology. Headquartered at Delhi-NCR, JBM Group is a diversified
conglomeratewith presencein automotive, engineering & design services, renewable
energy and education sectors.
The organization’s commitment towards all stakeholders and community has madeit a
leading manufacturing and engineering player. Themilestones and achievements of JBM
Group gavetheenergy for diversification and establishment of multiplebusinessunitsin
order to meet theneeds of customers. Theorganization’s management follow a unique
business model to createempowered companies that enjoy thebest of entrepreneurial
independence, assisted with leverageof group-widesynergies.

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Overview
JBM Group is a focused, dynamic and progressiveorganization thatprovidescustomers
with valueadded products, services and innovativesolutions. TheGroup has a
diversified portfolio to servein thefield of automotive, engineering & design services,
renewable energy and education sectors and has an infrastructureof 35 manufacturing
plants, 4 engineering & design centres across 18 locations globally.
With turnover of USD 1.2 billion, JBM Group has broadened its horizons by focusingon
quality delivery, solutionsapproach, productdevelopmentprocesses, flexible
manufacturing systems and contractmanufacturing. JBM Group is primarilya tier- 1
supplier to theautomotiveOEM industry and caters services to esteemed clients that
include Ashok Leyland, Bajaj Auto Ltd, Fiat, Ford, General Motors Corporation, Honda,
Hero, JCB, Mahindra, Maruti-Suzuki, Renault, Nissan, TATA, Toyota, TVS, Volvo-Eicher,
Volkswagen and many more. TheGroup has alliances with morethan 20 renowned
companies globally and theassociationsinclude Arcelor Mittal, Cornaglia, Dassault
Systems, JFE Steel Corporation, Magnetto (CLN Group), Ogihara, Sumitomo and many
more. The organization’s structureenables each business unit to chart its own future
and simultaneously leveragesynergies across its competencies.

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JBM NMPL HARIDWAR
Company Profile
Company Name : JBM GROUP
Division : NMPL PVT LIMITED
Headquarter : Delhi
Established : 1983
Turnover : USD 1.2 BILLION
Vision:
“Expanding leadership in our business by creating
an agile environment that delivers excellence and delight to
stakeholder through the power of people and technology.”

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DEPARTMENTS IN THE NEEL METAL PRODUCTS LTD.,
Haridwar Plant
1) Weld shop
2) Paint shop
3) Quality department
4) Engineering department
5) IT department
6) Press Shop
7) Finance department
8) Purchase department
9) Maintenance department

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DIFFERENT MODELS OF BOLERO
1) EX
2) SLE
3) SLX
4) ZLX

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PROCESS FLOW CHART
WJ-8 REAR+CENTRE FLR
ASSY
WJ-9 UNDER BODY
COMPLETE
WJ- 21 MAIN FRAMING
WJ-22 BODY RESPOTING
ROOF TOP STN
BACK DOOR ASSY HINGE
FIT
METAL FINISHING
BODY OFF BIW
WJ-14 RH SIDE ASSY
COMPLETE
WJ-11 RH SIDE PANNEL +
REAR CNR ASSY
WJ-10 RH REAR CORNER ASSY
WJ-10 LH OTR+ AIR DUCT
ASSY
WJ-11 LH SIDE PANNEL OTR+
REAR CENTRE ASSY
WJ-14 SIDE ASSY COMPLETE
WJ-15 SIDE ASSY RESPOT
TRANSMISSION COVER
FENDER ASSY
FACIA ASSY
REAR FLOOR ASSY
CENTRE FLOOR ASSY
FRONT FLOOR ASSY

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DIFFERENT STAGES FOR BOLERO BODY
1) FENDER ASSEMBLY AND FACIA
In this assembly we take different sheet metals to form
fender for Bolero body by using Mig welding and Spot
welding.
2) FLOOR ASSEMBLY
In this assembly we take the small child parts to make
three different floor for our Bolero. The three floor are

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rear floor, centre floor, back floor. Different floor
required different number of spot. It depend on their
strength.
3) SIDE ASSEMBLY
In this assembly line we take small child parts to make
right and left hand side of our Bolero.
4) MAIN LINE ASSEMBLY
Starts from assembling all floor together. At first then
coming at next step with the help of robots we join our
side assembly to our body parts. Then we join our top
floor to the body. At next step we join doors to our
Bolero. Then facia and back door.

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FRONT FLOOR ASSEMBLY OF REAR, FRONT, CENTRE FLOOR
TOP FLOOR ASSEMBLY DOOR ASSEMBLY
ASEEMBLY OF FRONT BONNET SIDE FINISHING
FINAL BODY METAL FINISHING

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5) METAL FINISHING
In this step with the help of different tools like grinder
machine, Dent puller machine we remove all the cracks
and unfinished surface. At last with the help of visual
inspection we check it pass it for the paint shop. This is
very crucial step because if the body is not perfect then
it will create problem during paint.
Different tool use here
1) Dent puller machine
2) Grinder
3) Integrated transformer gun
4) Non-Integrated transformer gun
5) Torque meter
6) Stationary spot welding machine, etc

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OTHER THAN BOLERO WELD SHOP
JBM NMPL HARIDWAR GROUP ALSO MAKE
BODY FOR THREE WHEELER, TWO WHEELER
BODY FOR HERO GROUP.
JBM ALSO HAVE HERE PRESS SHOP IN WHICH
IT MAKE CHILD PART OF DIFFERENT PARTS OF
BOLERO, THREE WHEELER, Two WHEELER.
JBM GROUP IS ALSO HAVE It’s PAINT SHOP IN
WHICH IT PUT A COAT OF 17 DIFFERENT
CHEMICALS TO PROTECT OUR BOLERO BODY
FROM RUST AND OTHER CHEMICALS EFFECT
SO THAT PAINT WILL BE THERE FOR LONG
TIME.

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WELDING
Welding is a fabrication or sculptural process that joins materials,
usually metals or thermoplastics,by causing fusion, which is distinct
from lower temperature metal-joining techniques such
as brazing and soldering,which do not melt the base metal. In addition
to melting the base metal, a filler material is typically added to the joint to
form a pool of molten material (the weld pool) that cools to form a joint
that is usually stronger than the base material. Pressure may also be
used in conjunction with heat, or by itself, to produce a weld. Welding
also requires a form of shield to protectthe filler metals or melted metals
from being contaminated or oxidized.

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EVOLUTION OF WELDING
1) The history of joining metals goes back several millennia. The earliest
examples of this come from the Bronze and Iron Ages in Europe and
the Middle East.
2) The middle Ages brought advances in forge welding, in which
blacksmiths pounded heated metal repeatedlyuntil bonding occurred.
In 1540, Vannoccio Biringuccio published De la pirotechnia.
3) Sir Humphry Davy discoveredthe "short-pulse" electricalarc and
presented his results.
4) Inventors Nikolai Benardos (Russian) and Stanisłal Olszewski
(Polish) created the first electric arc welding method known as carbon
arc welding using carbon electrodes.
5) World War I caused a major surge in the use of welding processes,
with the various military powers attempting to determine which of the
several new welding processes would be best.The British primarily
used arc welding, even constructing a ship, the "Fullagar" with an
entirely welded hull.
6) Major advances were made in welding technology, including the
introduction of automatic welding in 1920,in which electrode wire was
fed continuously. Shielding gas became a subjectreceiving much
attention, as scientists attempted to protectwelds from the effects of
oxygen and nitrogen in the atmosphere.
7) Other recent developments in welding include the 1958 breakthrough
of electronbeam welding, making deep and narrow welding possible
through the concentrated heat source.

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DIFFERENT TYPES OF WELDING
GMAW or Gas MetalArcWelding
GTAW or Tungsten Inert Gas :
Arc Welding or SMAW :

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Electric resistance welding
WELDING TECHNIQUE USE IN JBM
1) MIG WELDING
2) SPOT WELDING

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MIG WELDING:
1) This process is based on the principle of developing weld by melting-
faying surfaces of the basemetal using heat produced by a welding arc
established between base metal and a consumable electrode.
2) Welding arc and weld pool are well protected by a jet of shielding
inactive gas coming out of the nozzleand forming a shroud around the
arc and weld.
3) MIG weld is not considered as clean as TIG weld.
ELECTRICAL NOTES
CURRENT : 80-120 Amp
VOLTAGE : 18-24 Volt
CYCLE TIME : 12-16 Cycle
WIRE FEED RATE : 6-8 m/min
SHIELDING GAS : CO2
POWER SOURCE USE HERE: DC (WE NEED A CONSTANT
ELECTRIC SUPPLY THEREFORE WE USE DC HERE)
PENETRATION LEVEL : 30-70 % of metal
Thickness
Differencein stability of two welding arcs is primarily due to the fact that in
MIG arc is established between base metal and consumableelectrode (which is

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consumed continuously during welding) while TIG welding arc is established
between base metal and non-consumabletungsten electrode.
Consumableelectrode is fed automatically while torch is controlled either
manual or automatically. Therefore, this process is found more suitable for
welding of comparatively thicker.
Power source for MIG
1) Welding Depending upon the electrode diameter, material and
electrode extension required, MIG welding may use either constant
voltage or constantcurrenttype of the welding power source.
2) For small diameter electrodes (< 2.4 mm) when electrical resistive
heating controls the melting rate predominantly, constantvoltage
power source(DCEP) is used to take advantage of the self-regulating
arc.
3) Whereas in caseof large diameter electrode constant currentpower
sourceis used with variable speed electrode feed drivesystem to
maintain the arc length.
4) We use DC current in Mig welding. Because we need constant
electricity supply, which can be possibleonly DC current.
Shielding gases for MIG welding
Like TIG welding, shielding gases such as Ar, He, CO2 and their mixtures
are used for protecting the welding pool from the atmospheric gases.
Inertgases are normally used with reactive metal like Al, Mg and while
carbon dioxide can be used for welding of steel for reasonably good
quality of weld joints.
Effect of MIG welding process parameters
Among various welding parameters such as welding current, voltage and
speed probably welding current is most influential parameters affecting

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weld penetration, deposition rate, weld bead geometry and quality of
weld metal.
However, arc voltage directly affects the width of weld bead. An
increase in arc voltage in general increases the width of the weld.
Welding currentis primarily used to regulate the overall size of weld
bead and penetration.
Too low welding currentresults pilling of weld metal on the faying
surfacein the formof bead instead of penetrating into the work piece.
Excessiveheating of the work piece due to too high welding current
causes weld sag.
Optimum currentgives optimum penetration and weld bead width.
Selection of welding current is influenced by electrode stick out and
electrode diameter.
In general, high welding current is preferred for large diameter
electrodes with small electrode extension in order to obtain optimal
weld bead geometry. Increasein welding speed reduces the penetration.
ADVANTAGES OF MIG WELDING
1) Higher Productivity
2) Simple to Learn
3) Simple and Great Welds
4) Clean and Efficient
5) Versatile
6) Faster Welding Speed

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DISADVANTAGES OF MIG WELDING
1) Cost.
2) Limited Positions
3) Unsuitable for Outdoor Welding
4) FastCooling Rates
5) Unsuitable for Thick Metals
6) Shielding Gas

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SPOT WELDING
Resistance spot welding (RSW) is a process in which contacting metal surface points are
joined by the heat obtained from resistance to electric current. It is a subset of electric
resistance welding.
Electrical notes
The energy storage element allows the welder to deliver high instantaneous
power levels.
The welding transformer steps down the voltage and steps up the current. An
important feature of the transformer is it reduces the current level that the switch
must handle.
At the beginning of the weld, the contact resistances are usually high, so most of
the initial energy will be dissipated there.

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ELECTRIC CURRENT USE HERE: 7-9 Kamp
VOLTAGE USE HERE : 180-220 Volt
FORCE : 240-280 Kg f
CYCLE TIME : 12-16
WATER TEMP : 25-300
C
ELECTRODE MADE OF : COPPER
POWER SOURCE : AC
Work-piecesare held together under pressure exerted by electrodes. Typically
the sheets are in the 0.5 to 3 mm.
The process uses two shaped copper alloy electrodes to concentrate welding
current into a small "spot" and to simultaneously clamp the sheets together.
Forcing a large current through the spot will melt the metal and form the weld
The amount of heat (energy) delivered to the spot is determined by the resistance
between the electrodes and the magnitude and duration of the current.
Applying too little energy will not melt the metal or will make a poor weld.
Applying too much energy will melt too much metal, eject molten material, and
make a hole rather than a weld.

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Applications
 Perhaps the most common application of spot welding is in the automobile
manufacturing industry, where it is used almost universally to weld the
sheet metal to form a car.
 Another application is spot welding straps to nickel–cadmium or nickel–
metal hydride cells to make batteries.
Effects
The spot welding process tends to harden the material, causing it to warp. This
reduces the material's fatigue strength, and may stretch the material as well
as anneal it
The physical effects of spot welding include internal cracking, surface cracks and
a bad appearance.
The chemical properties affected include the metal's internal resistance and its
corrosive properties.
COMMON CAUSES OF RESISTANCE SPOT
WELDING DEFECTS
1) Weld Current Low
2) Weld Current High
3) Weld Force Low
4) Weld Force High
5) Weld Time Short
Equipment Selection
1) Wrong Transformer
2) Wrong Cables or Shunts
3) Incorrect Cylinder
4) Incorrect Hoses
5) Wrong Electrodes (Tips)
Human Error and Project Set-Up Error
1) Electrode Wear
2) Incorrect Electrode Alignment
3) Electrode Faces Not Parallel
4) Electrode Skidding or Sliding
5) Dirty Welding Material.

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Advantages
1) Spotweldingisquickandeasy.
2) There isno needtouse any fluxesorfillermetal tocreate a joinbyspot .
3) Spotweldingcanbe performedwithoutanyspecial skill.
4) Automatedmachinescanspotweldinfactoriestospeedupproduction.
5) Sheetsasthinas 1/4 inchcan be spotwelded,andmultiple sheetsmaybe joinedtogetherat
the same time.
Disadvantages
1. A particularspotweldingmachine will be able toholdonlyacertainthickness of metal--
usually5 to 50 inches.
2) The size and shapesof the electrodeswill determine the size andstrengthof the weld.
3) If the currentis notstrong enough,hotenoughorthe metal isnot heldtogetherwith
enoughforce,the spotweldmaybe small or weak.
4) Warpingand a lossof fatigue strengthcanoccur aroundthe pointwhere metal hasbeen
spotwelded.
5) The appearance of the joinisoftenratherugly,andthere can be cracks. The metal mayalso
become lessresistanttocorrosion.

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CONCLUSION
It’s always a great opportunity to experience
the valuable exposure of an industry. There is
lot of difference between the Theories and
Practical. This Training enables me to
understand the aspects of professional life. I
like the working environment followed at JBM
GROUP NEEL METAL PRODUCTS LTD.
Hardwar and come to know how to deal with
our colleagues, our seniors, and operators.
The company’s members are well cultured &
well mannered. An effective process is followed
at NEEL METAL PRODUCTS LTD. but it
would become more valuable and impressive
by implementing certain efficient technique.
The company is constantly focusing on
providing better services, quality and reliability
to customers, and running successfully in this
era of competition.

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