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SUMMER INTERNSHIP REPORT 2016 (MECHANICAL ENGINEERING)

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"A die is a specialized tool used in manufacturing industries to cut or shape material mostly using a press. Like molds, dies are generally customized to the item they are used to create. Products made with dies range from simple paper clips to complex pieces used in advanced technology".

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SUMMER INTERNSHIP REPORT 2016 (MECHANICAL ENGINEERING)

  1. 1. RAY-HANS PRECISION TOOLS PRIVATE LIMITED SUMMER INTERNSHIP REPORT (20/06/2016 - 05/07/2016) MAR ATHANASIUS COLLEGE OF ENGINEERING KOTHAMANGALAM 686 666, KERALA Ph. 0485-2822363 SUBMITTED BY: AMAL BABU B13ME410 DEPARTMENT OF MECHANICAL ENGINEERING MAR ATHANASIUS COLLEGE OF ENGINEERING, KOTHAMANGALAM
  2. 2. DEPARTMENT OF MECHANICAL ENGINEERING, MACE KLM 1 | P a g e Disclosure by the Internship Supervisor This is to confirm that I have read the report and that the information enclosed is correct and contains no confidential information. Company: Supervisor’s Name: Supervisor’s Signature: Date:
  3. 3. DEPARTMENT OF MECHANICAL ENGINEERING, MACE KLM 2 | P a g e Acknowledgement I am very thankful to NEST GROUP for giving me the opportunity to undertake my summer training at their prestigious RAY-HANS PRECISION TOOLS PRIVATE LIMITED. It was a very good learning experience for me to have worked at this site. I would like to convey my heartiest thanks to Mr. Arun Kumar M C, General Manager, I would also like to give my heart-felt thanks to Mr. Naushad M, HR Manager, who heartily welcomed me for the internship, Mr. Joby Devasia who guided and encouraged me all through the summer training and imparted in-depth knowledge of the programme, Mr. Sajith Mohan, QA/QC Head . Also I would like to thank Mr. Kuriakose E.J, who assisted and guided me whenever I needed. I would like to thank all the department heads of RAY-HANS, for giving their precious time and valuable guidance during my internship programme. I am extremely thankful to Dr. Deviprasad Varma P R, Head of department, Mechanical Engineering, Mar Athanasius College of Engineering, Kothamanagalam for providing me facilities to work in, without which this work would not have been possible. Last but not the least; I would like to thank all the staff of RAY-HANS family, for being so helpful during this summer training.
  4. 4. DEPARTMENT OF MECHANICAL ENGINEERING, MACE KLM 3 | P a g e Preface Every student of Bachelor of Technology in Mechanical Engineering, has an essential requirement to do 15 days of internship in any of the well reputed organization. The purpose of this program is to acquaint the students with practical applications of theoretical concepts taught to them during conduct of their course. Really, it was a nice opportunity to have a close comparison of theoretical concept in practical field. This report may depict deficiencies on my part but still it is an output of a student’s efforts, for which I beg pardon. The output of my analysis is summarized in a shape of Internship the contents of the report Shows the detail of sequence of these.
  5. 5. DEPARTMENT OF MECHANICAL ENGINEERING, MACE KLM 4 | P a g e Abstract The report covers the following aspects of internship:  Table of contents.  Introduction of Ray-Hans Precision Tools Private Limited.  Departments of Ray-Hans.  Description of tools and techniques learned.  Schedule of internship.  Skills learned.  My role as an internee.  Conclusion.
  6. 6. DEPARTMENT OF MECHANICAL ENGINEERING, MACE KLM 5 | P a g e Table of Contents Acknowledgement......................................................................................Error! Bookmark not defined. Preface..........................................................................................................................................................3 Abstract.........................................................................................................................................................4 Ray-Hans Precision Tools Private Limited ........................................................................................6 Departments In Ray-Hans Precision Tools Private Limited .........................................................7 Marketing Department..............................................................................................................................8 Store..............................................................................................................................................................8 Heat Treatment Shop...............................................................................................................................8 Design Section ...........................................................................................................................................9 o Drafting........................................................................................................................................... 10 o Sketching....................................................................................................................................... 10 o Computer Aided Design (CAD)............................................................................................... 11 Quality Assurance section ................................................................................................................... 11 Machine Tool Shop................................................................................................................................ 12 o Surface Grinding.......................................................................................................................... 12 o Jig Grinding & Profile Grinding................................................................................................ 12 o Wire EDM ...................................................................................................................................... 13 o Why EDM?.................................................................................................................................... 13 o CNC Milling ................................................................................................................................... 13 o Sink EDM....................................................................................................................................... 14 Tool Assembly......................................................................................................................................... 14 Plastic Moulding Department.............................................................................................................. 14 Internship Rotational Plan.................................................................................................................... 15 Skills and Techniques learned during Internship.......................................................................... 15 Role Of Internee During Internship ................................................................................................... 16 Conclusion................................................................................................................................................ 17 References ............................................................................................................................................... 17
  7. 7. DEPARTMENT OF MECHANICAL ENGINEERING, MACE KLM 6 | P a g e Introduction Ray-Hans Precision Tools Private Limited Ray-hans Precision Tools Private Limited is a tooling solution provider located in Special Economic Zone at Cochin, India, having around 250 employees. Make use world class equipments and machineries imported from leading manufactures in Germany, Japan, Swiss and USA. Ray-hans provides end to end solutions for tool and mould industry starting from design to component production. And capable of supplying precision tooling of International standards to Electronics, Automotive, Electrical and IT sectors. Customer base includes TE connectivity, DELPHI Connection Systems, NPOL and Yazaki. Specialized in:  Designing of Injection Moulds.  Manufacturing of Injection Moulds, Press tools and Fixtures  Manufacturing of Precision Machined Spares  Production of Molded Components Capabilities and Capacities: Methods, Machineries and Accessories used for various machining process allows to produce complex profiles and shapes required for precision tooling industry at an accuracy level of 2 to 5 microns. In order to achieve quality standards the whole machining activities are carried out in a controlled atmosphere, so that temperature difference doesn’t cause any deviations in the jobs when measured at customer end.
  8. 8. DEPARTMENT OF MECHANICAL ENGINEERING, MACE KLM 7 | P a g e Products and Services  Mould design o Multi-cavity molds o Hot Runner Molds  Manufacturing of Moulds & Dies & Fixtures.  Supply of Precision Machined Parts.  Production of Molded Components. Departments In Ray-Hans Precision Tools Private Limited  Marketing Department.  Store.  Training Department.  Designing Department  Engineering Department.  Machine Tool Shop.  N.C. Shop.  Heat Treatment Shop.  Quality Control.  Tool Assembly.
  9. 9. DEPARTMENT OF MECHANICAL ENGINEERING, MACE KLM 8 | P a g e Marketing Department Marketing departments fulfill the marketing needs and work to ensure the progress. o Market research. o Product development. o sales support. Store Major functions: o Receipt of incoming goods o Inspection of all receipts o Storage and preservation o Identification of all materials stored o Materials handling o Packaging o Issue and despatch o Maintenance of stock records o Stores accounting o Inventory control o Stock-taking Heat Treatment Shop Best in class machines and furnaces are provided in this section. Equipped with 4 atmospheric furnaces, which enables hardening, stress-relieving, tempering and annealing on various tool steel. And also learned about sub-zero treatment.
  10. 10. DEPARTMENT OF MECHANICAL ENGINEERING, MACE KLM 9 | P a g e Five sections were designed for our internship. These were first introduced to all of us. To tell us what they are doing and what will be our role in that internship during this period. We were pleased to get responsibilities and to hand on experience as it was the aim and purpose behind the programme. In these sessions we watch closely how the professionals are working to make that center unique and adorable for outer world, it was an example for us to learn to be a better professional. Design Section Our internship started as we enter into design section as the design is considered as the first step of any production and it display the end result before wasting material and it’s the best tool to communicate with your shop men, technician and others, so it compulsory to have basic knowledge of design for everyone. In design section you deal with the language of lines how they represent the end results of your dedicated work. We were first diverted to drafting then to proper design process The design section is based on three steps  Sketching  Manual  Computer aided Design (CAD) Design section. Quality Assurance section. Machine Tool shop. Tool Assembly section. Plastic Moulding Department.
  11. 11. DEPARTMENT OF MECHANICAL ENGINEERING, MACE KLM 10 | P a g e So we attended a Lecture on sketching on the very first day and started moving. The Trainer Mr. Joby Devasia introduced us with common sketching techniques and methods. Sketching is an entering step to design to draw the design on paper is an expert work so we were drawn into that. Drafting Technical drawing also known as drafting ,It is the act and discipline of composing drawings that visually communicate how something functions or is to be constructed. Technical drawing is essential for communicating ideas in industry and engineering. To make the drawings easier to understand, people use familiar symbols, perspectives, units of measurement, notation systems, visual styles, and page layout. Together, such conventions constitute a visual language, and help to ensure that the drawing is unambiguous and relatively easy to understand. These drafting conventions are condensed into internationally accepted standards and specifications that transcend the barrier of language making technical drawings a universal means of communicating complex mechanical concepts. Sketching A sketch is a quickly executed, freehand drawing that is not intended as a finished work. In general, sketching is a quick way to record an idea for later use, especially when the finished work is expensive and time consuming. We were given a number of tasks to execute them into drawing and we did it for two days and it was a brainstorming and learning session.
  12. 12. DEPARTMENT OF MECHANICAL ENGINEERING, MACE KLM 11 | P a g e Computer Aided Design (CAD) Computer-aided design (CAD) is the use of computer systems to assist in the creation, modification, analysis, or optimization of a design. CAD software is used to increase the productivity of the designer, improve the quality of design, improve communications through documentation, and to create a database for manufacturing. CAD output is often in the form of electronic files for print, machining, or other manufacturing operations. Ray-hans engineer’s subject knowledge along with systematic approach in performing each task ensures best quality and shorter lead time. A team of Tool makers and process engineers review each design to ensure Manufacturing easiness. Design center uses Creo 2.0 (ProE) software for designing activities and supported by mold flow analyzing software. Ray-hans expertise in hot and cold runner systems allows serving customer seeking high as well as low volume productions. Hardened core and cavity plates and inserts are used for moulds with higher volume components which ensure millions of shots without major overhauling. Duration of 7 days pass in no time but we learn a lot about mechanical designing as we were given some tasks to complete, which really helped us to understand PTC CREO 2.0 clearly. As an addition jigs and fixtures standards and their various design types were also elaborated. We are thankful to all design team members for their attention and co-operation. Quality Assurance section Precision tool manufactures requires high end quality assurance which is a part and parcel of the activity. We got exposed to a well defined Quality system, consisting of in process and final inspection which ensure 100% inspection for the entire die & mould parts and also sampling inspection for molded components to meet the customer requirements.
  13. 13. DEPARTMENT OF MECHANICAL ENGINEERING, MACE KLM 12 | P a g e In this section we got basic knowledge of Advanced measuring equipments like CMMs, Profile projectors, Digital height gauges, tool maker’s microscope and surface texture measuring machine. Machine Tool Shop. Creativity of designer and skill of tool engineer will not integrate unless supported by equally competent manufacturing expertise and advanced machineries. Ray-hans facility Machine tool shop is managed by senior managers and qualified and skilled workers they have all machining and manufacturing machinery. As well a dye fitting section along with calibration shop. In machine tool shop section we observe different machining and noted how they are making raw material valuable for industry. There was a job in process at that time. Manufacturing facility comprises of:  Surface Grinding There were 20 Surface Grinding machines of German and Japanese origin out of which, two are CNC Surface Grinding machines. We experienced Carbide Grinding, which is inevitable for High speed stamping and feed grinding which produces unconventional blind profiles in Surface Grinding.  Jig Grinding & Profile Grinding Jig Grinding and profile grinding facility is capable of producing spare parts for High-speed stamping. Complex and accurate Carbide punches and dies are made using Profile Grinding machine. Precise guiding parts for moulds and dies are finished in Jig Grinding machine.
  14. 14. DEPARTMENT OF MECHANICAL ENGINEERING, MACE KLM 13 | P a g e  Wire EDM Wire EDM machines imported from Swiss, uses wires of diameter ranging from 0.1 mm to 0.25 mm and EDM Drilling machines can do the drilling up to a diameter of 0.3 mm. Various grades of Steels, copper and carbides were also machined in these machines. These sophisticated machines process complex geometric shapes up to height of 150 mm. Why EDM? EDM can easily machine parts with very thin walls, complex geometry, narrow slots, small corner radii, very small features, etc. with virtually no mechanical stress. EDM can cut hardened steel, titanium, Inconel and other difficult materials without the limitations of traditional machining. EDM can achieve an excellent surface finish with no burrs right out of the machine. EDM can reduce production costs with stacked parts machining using wire EDM as well as multi-up fixturing for wire, sinker and hole pop EDM. Use EDM over broaching for better precision, accuracy and finish, no need to make a custom broach, and no risk of introducing unwanted debris into the finished part. Use EDM instead of short-run stamping for straight-edge cuts with sharp corners and no shear or break as well as reduced costs by eliminating the need for special tooling.  CNC Milling Equipped with 5 axis CNC machining centers, which are capable of producing complex shapes in Tool steels, graphite and copper. We saw the working of dedicated machine for graphite machining equipped with 42000 rpm spindle head.
  15. 15. DEPARTMENT OF MECHANICAL ENGINEERING, MACE KLM 14 | P a g e  Sink EDM There were Swiss and Japanese made 10 CNC Sink EDM machines, which are capable of making 5 to 10 microns dimensional accuracy and surface roughness value up to 0.2 Ra. These Machines have Quick Change Robotic interface up to 92 positions to perform continuous feeding of electrodes without manual interventions. For enhancing productivity they are equipped with “System 3R” reference system. Tool Assembly As we enter into 2nd week we were sent to Tool assembly section. After the first day the very next day we were involved in discussions to clear the concepts of Tool assembly, what the process is and how it is done. Tool assembly is an art which requires mechanical aptitude, experience and high hand skills. A well assembled mould or die calls for very few trials and corrections. Workers handful experience is in line to meet International manufacturing standards and practices.precision machined parts are individually suited for perfect matching. The systematic approach in assembling process ensures longer life for moulds and dimensional consistency in components. Plastic Moulding Department We move toward PMD section after the completion of Tool assembly there were last 2 days for the plastic molding section. That section was most modernized section of PITAC equipped with two modern medium capacity injection moulding machinery. These machines are specially designed for obtaining high dimensional accuracy and consistency. They were equipped with interchangeable screw diameter with inbuilt Hot Runner Controller system. To support precise moulding activity, make use ABONI FMX3-01 moisture analyzer
  16. 16. DEPARTMENT OF MECHANICAL ENGINEERING, MACE KLM 15 | P a g e Internship Rotational Plan o Design Section 1 WEEK 20/6/16-----26/6/16 o Quality Assurance section 1 DAY 27/6/16-----28/6/16 o Machine tool shop 2DAY 28/6/16-----30/6/16 o TOOL ASSEMBLY 2DAY 30/6/16-----02/7/16 o Plastic molding section 1DAY 04/7/16-----05/7/16 Skills and Techniques learned during Internship An internship assists with career development by providing real work experiences that provide students with opportunities to explore their interests and develop professional skills and competencies. During internships, We are provided with opportunities to apply what We learned in classes to actual practice. It is expected that we will also be challenged to examine how our attitudes, beliefs, and values influence the process. It was valuable time here in RAY-HANS PRECISION TOOLS PRIVATE LIMITED and we learn unlimited here are a few point I have summarized.
  17. 17. DEPARTMENT OF MECHANICAL ENGINEERING, MACE KLM 16 | P a g e We learnt about the leadership & Team work to do an effective work. We learnt about tactics to maintain discipline & How to deal with workers. We learnt How to control quality problems, defects in material, Laboratory Testing of Hardness of a material and How to meet the demands of customers. We also learnt about Designing. Further, important software like AutoCAD,Creo2.0 , Solid Works. We have learnt how to make a powerful team to achieve target and to solve their problem. We have learnt about all machining process and heat treatment process. We have learnt about CNC machining process in CNC cell Learn how to face Problems in industrial sector. We observe the heat treatment section more closely and that help us understand heat treatment process . Plastic moulding process was complete elaborated to us and we collected knowledge. We observe modern machine like Spark erosion and CMM machines along with advance machining center and small hole drilling machines. Role of Internee during Internship “I learned how to adjust myself in the work environment, how to deal with people at work - from the boss to the janitors. It’s a good and quality experience; The necessary kind of experience as it helps you realize what you want in future. “Also got the opportunity to evaluate myself under these stressful conditions”.
  18. 18. DEPARTMENT OF MECHANICAL ENGINEERING, MACE KLM 17 | P a g e Conclusion It was a wonderful learning experience at RAY-HANS PRECISION TOOLS PRIVATE LIMITED for two weeks in kochi. I gained a lot of insight regarding almost every aspect of plant. I was given exposure in almost all the departments at the plant. The friendly welcome from all the employees is appreciating, sharing their experience and giving their peace of wisdom which they have gained in long journey of work. I am very much thankful for the wonderful facility from RAY-HANS. I hope this experience will surely help me in my future and also in shaping my career. I am pretty sure that this facility has ability to achieve its goals as stated in vision statement.by following their quality statement. “We are committed to comply with customer requirements and Quality Management System Requirements and shall strive to continually improve the effectiveness of our Quality Management System to exceed customer expectations” References  http://tools.ray-hans.com/about_us.html  http://tools.ray-hans.com/Brochure.zip  http://www.slideshare.net

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