summer training report

1. SUMMER TRANING REPORT
AT
NEEL METAL PRODUCTS LIMITED
PROJECT
IMPROVE PRODUCTION WITH THE HELP OF
GANGING OF DIES
SUBMITTED BY
Mohit keshav
R880211030
B.Tech Mechatronics
3RD Year

2. CERTIFICATE
This is to certify that,
Mr. Mohit keshav
Student of UNIVERSITY OF PETROLEUM AND ENERGY STUDIES have done a Project
“INCREASE IN PRODUCTION WITH THE HELP OF GANGING OF DIES” under my
guidance. This Work is done to my satisfy action under requirement of “SUMMER
INTERNSHIP PROJECT” for the Academic Year 2014.
Mr. Ishwar Singh Hada
(Asst. Manager)
NEEL SHEET METAL
PRODUCTS PVT LIMITED
JBM GROUP, PANTNAGAR

3. ACKNOWLEDGEMENT
It is indeed a great pleasure and privilege to present this report on training at NEEL METAL
PRODUCTS JBM GROUP, PANTNAGAR.
I am extremely grateful to my training and placement officer for issuing a Training letter, which
made my training possible at NEEL METAL PRODUCTS JBM GROUP, PANTNAGAR.
First, I thank The HR Head, MR. B.M Adhikari for considering my potential in doing this
summer internship and providing this wonderful opportunity.
I would like to express my gratitude to Mr. Ishwar Singh Hada for his invaluable suggestions,
motivation,guidance and support through out the training. His methodology to start from simple ant
then deepen through made me to 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 the project and see the light of success.
I am very thankful to friends, colleagues and all other persons who rendered their assistance
directly or indirectly to complete this project work successfully.
Dated- June 2014 Mohit Keshav

4. ABOUT COMPANY
JBM Group began its journey of excellence in 1983. The organization commenced operations as a
manufacturer of LPG Cylinders for the Delhi-NCR region of India. Moving strength to strength, assisted
with experience and knowledge, JBM Group entered into the automotive industry in 1985.
In 1986, the Group signed a joint venture with Maruti Suzuki India Ltd for the manufacturing of sheet
metal components and assemblies. The journey began with a vision to expand the business in the
automotive sector by keeping abreast with market trends and global technology.
Headquartered at Delhi-NCR, JBM Group is a diversified conglomerate with presence in automotive,
engineering & design services, renewable energy and education sectors. The organization’s commitment
towards all stakeholders and community has made it a leading manufacturing and engineering player.
The milestones and achievements of JBM Group gave the energy for diversification and establishment of
multiple business units in order to meet the needs of customers. The organization’s management follow a
unique business model to create empowered companies that enjoy the best of entrepreneurial
independence, assisted with leverage of group-wide synergies.
Overview
JBM Group is a focused, dynamic and progressive organization that provides customers with
value added products, services and innovative solutions. The Group has a diversified portfolio to
serve in the field of automotive, engineering & design services, renewable energy and education
sectors and has an infrastructure of 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 focusing on quality
delivery, solutions approach, product development processes, flexible manufacturing systems
and contract manufacturing.
JBM Group is primarily a tier- 1 supplier to the automotive OEM 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.
The Group has alliances with more than 20 renowned companies globally and the associations
include Arcelor Mittal, Cornaglia, Dassault Systems, JFE Steel Corporation, Magnetto (CLN
Group), Ogihara, Sumitomo and many more. The organization’s structure enables each business
unit to chart its own future and simultaneously leverage synergies across its competencies.

5. INTRODUCTION TO THE COMPANY
COMPANY PROFILE
Name: JAY BHARAT MARUTI LTD.
Division: NEEL METAL PRODUCTS LIMITED
Head Quarters: DELHI
Established: 1983
Turnover: Rs.4500 Crores(overall)
Employees (No.): AROUND 15,000

6. Vision
“Expanding leadership in our business through people, keeping pace with market trends and
technology.”
Core Values
We believe in ...
Simplicity,by keeping a low profile externally and having clear, open and effective
communication within the organization.
Teamwork, with well-defined responsibilities and accountability.
Relationships of trust amongst people, through well-defined job responsibility and authority.
According top priority to customer focus,through prompt and appropriate response.
Respect and care for all those dedicated to meeting commitments.
TECHNOLOGY
Technology, Innovation and People serve as the 3 key pillars of the JBM foundation. Core to this
philosophy is a constant quest for excellence by enhancing technology, enabling innovation and
empowering people, thereby, creating consistent value for all stakeholders.
JBM Group has always kept a close watch on the dynamic needs of its customers and continues
the journey of efficiency by enhancing the technology at every stage. The organization has
collaborated with best global technology partners; possess state-of-the-art manufacturing
facilities and highly automated processes. These advantages have established new benchmarks
that have aided in providing superior quality and flawless technical perfection to the
organization's deliverables.
The continuous commitment towards excellence and consistent efforts to innovate have brought
excellent growth results for the Group. Apart from incorporating sophisticated technology, JBM
Group aims to not only exceed expectations, but to create value through innovation. The long
standing commitment to nurture research and development has brought the organization a long
way since its commencement 3 decades ago.

7. Environment, Health & Safety
At JBM, sustainability is the way of doing business. The Group aligned its goals for
environment, health and safety, making an impact across its value chain worldwide. Together
with the suppliers, customers and stakeholders, JBM strives to maintain highest standards to
preserve and protect the environment, as well as enhance the health and safety of the Group’s
employees and communities.
DEPARTMENT IN THE NEEL METAL PRODUCTS JBM, PANTNAGAR
1) Press shop
2) Paint shop
3) Quality department
4) Engineering department
5) IT department
6) Weld shop
7) Finance department
8) Purchase department
9) Maintenance department

8. PROJECT TITLE
TO INCREASE THE PRODUCTION OF PRESS SHOP WITH THE HELP OF
GANGING OF DIES.
ABSTRACT
Now a days we see industry works on 6 factors. These factors are very much responsible for the
growth of a industry. These are
1) Safety
2) Productivity
3) Quality
4) Cost
5) Delivery
6) Moral
But here in this project we are concentrating on only on factor i.e. increase in productivity. Here
we are using a method of ganging of dies in which two similar dies are mounted on a press
machine. This help us reduction of productivity time. Which will enhance the productivity. So
this method is very much effective in increase the productivity of the material. This is cost and
time saving method which will help in the betterment of the industry.
PART NO.-DZ161013
PART NAME : GUSSET HEAD
THEORY:-
Here the work is done on 250T press machine. In the production of gusset head there are mainly
4 steps are involved. These processes are also shown in table according to there steps. Suitable
dies are used with respect to the process followed. Gusset head is generally a BAJAJ part which
are used in platina bikes. These parts gives the support to the engine.
The pictorial view of gusset head is shown in the figure which is given below.

9. METHODOLOGY:-
1. First step all the sheets of metal is procured from the vendor.
2. The grade of the material is checked by the inspection department. In inspection these
three things are checked. Wrong size of the metal sheet, grade of the metal sheet and the
visual defects of the metal sheet.
3. Now the first operation is to be performed i.e. Blanking. It is done to extract the profile
sheet from the metal sheets. In this the operation the profile sheet should be according to
our need . it should be dent, scratch and burr free.
4. Second operation which to be performed is Forming. In this draw is done on the blanked
profile sheet. In this operation complete bend should be done, scratch should be taken
care of through oiling, crack/ thinning should be regularly checked.
5. After this Piercing is to be performed. It a type of operation which is totally opposite of
blanking. In this pierced profile sheet is avoided rest is considered. Dimension of us/os
has to be maintained,& location of hole should not be displaced.
6. Last step is Bending and Trimming. In this side part of gusset is bend and extra part of
the sheet is trimmed.

10. TABLE:-
Process
Description
Incoming source
of variation
Product
characterstics
Expected/actual
strokes (per
hour)
Receiving
Inspection
Wrong size
Wrong grade
Visual defects
1.5+/-0.1
260*1250 +/-2mm
Blanking Improper profile
Dent/scratch
Free from
Burr
Dent
Crack
250/150
Forming Incomplete bend
Scratch
Crack
Dislocation
Free from
Burr
Crack
Scratches
250/160
Piercing Dim us/os
Hole/slot size
Location
Free from
Burr
Crack
Visual defects
250/170
Bending-trimming No thinning
Incomplete profile
Scratch
burr
Free from
Burr
Crack
Thinning
Visual defects
250/180

11. Blanking-
FORMING

12. Piercing
Bending-
NOW IF APPLY 2 DIES IN SAME PRESS THEN THE OPERATION CAN BE
PERFORMED AT FASTER RATE
TO USE GANGING OF DIES THE FOLLOWING THINGS SHOULD BE TAKEN INTO
CONSENDERATION

13. 1. Power of the press.
2. Size of the bluster bed.
3. Size of the dies.
4. Shut height of the die.
5. Shut height of the press.
6. Tonnage required for the die.
Now let’s assume that the die is having the same shut height and is between in given range of
shut height of the press.
Condition for dies are :-
Length – 910mm
Shut height -650mm
Width – 500mm
Now consider we are having a press which is having the bluster bed which can accommodate
approximately 2 dies. We are having such presses in our industry.
CALCULATION :- (Cost Estimation)
Procurement for the metal sheet- 45 rupees per kg
Dimensions of sheet -1230x260mm
Weight of on sheet- 1.020 kg
Thickness of the sheets- 1.5mm
Scraps cost -25 rupees per kg
Generally cost is estimated with the help of 5 M. These are
1. Man
2. Machine
3. Material
4. Management
5. Method

14. but as per general idea we are calculating as cost 2 rupees per strokes ignoring all the all other
hidden cost.
Now according to table
Cost estimated for blanking- 2x150=Rs300
Cost estimated for forming- 2x160=Rs320
Cost estimated for percing-2x170=Rs340
Cost estimated for bending-trimming- 2x180=Rs360
Total cost-Rs1320
This is a rough calculated cost in this hidden cost are not involved like maintainace, worker
availability etc. are not included.
Now if re plan our process and mount 2 dies in one press
For example
Blanking and forming at a time in a single press having different dies. This will save time as well
as machine cost.
And similarly at the same time piercing and bending trimming operation can be done.
Now the calculation of cost
Cost for blanking and forming-2x150=Rs300
Cost for piercing and bending-2x170=Rs340
Total cost=Rs640
This is a rough calculated cost in this hidden cost are not involved like maintainace, worker
availability etc. are not included.
Advantages of ganging of dies
1. Cost saving
2. Time saving
3. Man power saving
4. Less press machine required
5. Utility of press machine increases

15. 6. Pace of work is fast
7. Production is high
Disadvantages of ganging of dies
1. Require bigger bluster bed
2. May require a dummy cushion when one die require cushion and other’s didn’t so
dummy cushion is given to the second die in order to balance it.
3. Tonnage of press should be greater or equal to the die required.
4. Shut height of both the dies should be same and should be in press shut height range.
Conclusion of Project
This method is very much effective in increasing the production rate. This works quite
efficiently. By using this method we can cover some parameter which is very much important for
every industry.

16. Dies and its Types:
Die:
The die may be defined as the female part of a complete tool for producing work in a press. It is
also referred to a complete tool consists of a pair of mating members for producing work in a press.
Types of dies:
The dies may be classified according to the type of press operation and according to the method
of operation.
(A): According to type of press operation:
According to this criterion , the dies may be classified as cutting dies and forming dies.
1: Cutting Dies:
These dies are used to cut the metal. They utilize the cutting or shearing action. The common
cutting dies are : blanking dies , perforating dies , notching dies , trimming , shaving and nibbling
dies.
2: Forming Dies:
These dies change the appearance of the blank without removing any stock. Theses dies include
bending, drawing and squeezing dies etc.
(B) According to the method of operation:
According to this criterion, the dies may be classified as : single operation or simple dies ,
compound dies , combination dies , progressive dies , transfer dies and multiple dies.
1: Simple Dies:
Simple dies or single action dies perform single operation for each stroke of the press slide. The
operation may be one of the operation listed under cutting or forming dies.
2: Compound Dies:
In these dies, two or more operations may be performed at one station. Such dies are considered
as cutting tools since, only cutting operations are carried out. Figure shows a simple compound
die in which a washer is made by one stroke of the press. The washer is produced by simulation
blanking and piercing operations. Compound dies are more accurate and economical in production
as compared to single operation dies.

17. 3: Combination Dies:
In this die also , more than one operation may be performed at one station. It is difficult from
compound die in that in this die, a cutting operation is combined with a bending or drawing
operation, due to that it is called combination die.
4: Progressive Dies:
A progressive or follow on die has a series of operations. At each station , an operation is performed
on a work piece during a stroke of the press. Between stroke the piece in the metal strip is
transferred to the next station. A finished work piece is made at each stroke of the press. While the
piercing punch cuts a hole in the stroke , the blanking punch blanks out a portion of the metal in
which a hole had been pierced at a previous station. Thus after the first stroke , when only a hole
will be punched , each stroke of the press produces a finished washer.

18. 6: Transfer Dies:
Unlike the progressive dies where the stroke is fed progressively from one station to another. In
transfer dies the already cut blanks are fed mechanically from one station to other station.
7: Multiple Dies:
Multiple or gang dies produce two or more work piece at each stroke of the press. A gang or
number of simple dies and punches are ganged together to produced two or more parts at each
stoke of the press.

19. HYDRAULIC AND MECHANICAL PRESSES
The press represents a specific type of machine tool, essential in the performance of industrial
manufacturing processes. Presses deliver energy through a force that acts over a distance or
stroke. One important application is in metal forging manufacture. The energy of the press is
used to close the die, forging the part within. Press machine tools apply force/energy to the work
differently than drop hammers, (that deliver energy to the work through a collision), hammers
are the other class of machine tools used to forge metal parts. Drop hammers are covered on the
previous page. This page will cover different types of press machines, their function, and
capabilities, although it is located in the metal forging section, forging is only one class of
manufacturing processes that employ presses.
Press machines are also the primary machine tool used in metal extrusion and sheet metal
fabrication processes. Hydraulic and mechanical presses are employed during sheet metal
forming to the extent that sheet metal processes, in general, are often referred to as press
working. Presses may be used in the manufacture of plastic parts. Machining operations, such as
broaching, may also require presses.
Press machine tools vary in size and in the amount of force they can output. The energy from a
press is often used to do work requiring a tremendous amount of force, such as a large amount of
plastic deformation of a sizable piece of metal. The method and nature by which a press machine
will deliver its energy will vary, dependent on its type.
Machine presses shown here are vertical, meaning that the force vector is up and down relative
to gravity. In many cases these same machine types are utilized horizontally, meaning the force
is delivered in a path perpendicular to the direction of the force of gravity. If the force be exerted

20. vertically, horizontally, or at some intermediate angle, the working principles of each type of
machine tool are the same.
Press machine tools are of two main types, hydraulic presses and mechanical presses. Selection
of a type of machine press depends on the factors of the manufacturing process. The first
consideration would be the basic type of process the press tool will be employed to perform. For
example, a press for metal forging, a press for extrusion, a press for impact extrusion, or a press
for sheet metal working will all have different general requirements. The next very important
factor in machine press selection for a manufacturing operation is the press capacity required.
Required press capacity is likely related to the size of the work stock, and type of process.
Length of stroke over which the press delivers force is another primary factor when choosing a
press machine tool, this also will be related to the basic type of process being employed. These
initial considerations should give an immediate idea of the general type of press required. After
this, all the specific factors of the manufacturing process should be weighed, to determine the
best choice for a press machine tool.
Hydraulic Presses
Hydraulic presses are a powerful class of machine tools, they derive the energy they deliver
through hydraulic pressure. Fluid pressure, in a particular chamber, can be increased or
decreased by the use of pumps, and valves. Sometimes devices and systems may be used to
increase the capacity of the pumps in more powerful presses. These presses can operate over a
long distance and at a constant speed. Hydraulic presses are generally slower relative to other
press machine types. This involves longer contact with the work, therefore the cooling of the
work can be an issue when hot forming a part with hydraulic force. Hydraulic presses are
capable of being the most powerful class of presses. Some may be as large as buildings, and can
deliver awesome pressure. The largest hydraulic presses are capable of applying 75,000 tons,
(150,000,000 lbs), of force. The hydraulic press shown is being used to manufacture a metal
forging. Extrusion is also a very common use for such a press, although extrusion is often
performed horizontally.

21. The basic working principles of the hydraulic press are simple, and rely on differences in fluid
pressure. Fluid is pumped into the cylinder below the piston, this causes the fluid pressure under
the piston to increase. Simultaneously, fluid is pumped out of the top channel, causing the fluid
pressure above the piston to decrease. A higher pressure of the fluid below the piston than the
fluid above it causes the piston to rise. In the next step, fluid is pumped out from below the
piston, causing the pressure under the piston to decrease. Simultaneously, fluid is pumped into
the cylinder from the top, this increases the fluid pressure above the piston. A higher pressure of
the fluid above the piston, than the fluid below it, moves the piston downward.
Mechanical Presses
Mechanical presses belong to a class of machine tools that encompass a wide range of different
machine types. Primarily, the mechanical press transforms the rotational force of a motor into a
translational force vector that performs the pressing action. Therefore, the energy in a
mechanical press comes from the motor. These types of presses are generally faster than
hydraulic or screw presses, (actually the screw press may also be classified as a mechanical
press). Unlike some presses, in a mechanical press, the application of force varies in both speed
and magnitude throughout the distance of the stroke. When performing a manufacturing
operation using a mechanical press, the correct range of the stroke is essential.
Presses are chosen based on the characteristics of the manufacturing process. Mechanical press
machine tools are commonly used in metal forging manufacture, and sheet metal working. The
desired application of force will dictate the type of machine required. Extrusion will often
necessitate a more consistent force over a longer distance. However, a mechanical press may
often be a good choice for impact extrusion, since a fast, quickly repeatable application of force

22. over a limited distance is what is needed for that type of manufacturing process. The most
powerful mechanical presses in modern manufacturing industry will have a press capacity of
about 12,000 tons, (24,000,000 lbs).

23. SHEET METAL WORKING
1. Introduction
Sheet metal is simply metal formed into thin and flat pieces. It is one of the fundamental forms
used in metalworking, and can be cut and bent into a variety of different shapes. Countless
everyday objects are constructed of the material. Thicknesses can vary significantly, although
extremely thin thicknesses are considered foil or leaf, and pieces thicker than 6 mm (0.25 in) are
considered plate.
2. Sheet metal processing
The raw material for sheet metal manufacturing processes is the output of the rolling process.
Typically, sheets of metal are sold as flat, rectangular sheets of standard size. If the sheets are thin and
very long, they may be in the form of rolls. Therefore the first step in any sheet metal process is to cut
the correct shape and sized ‘blank’ from larger sheet.
3. Sheet metal forming processes
Sheet metal processes can be broken down into two major classifications and one minor classification
 Shearing processes -- processes which apply shearing forces to cut, fracture, or separate
the material.
 Forming processes -- processes which cause the metal to undergo desired shape changes
without failure, excessive thinning, or cracking. This includes bending and stretching.
 Finishing processes -- processes which are used to improve the final surface
characteristics.
3.1 Shearing Process
1. Punching: shearing process using a die and punch where the interior portion of the sheared
sheet is to be discarded.
2. Blanking: shearing process using a die and punch where the exterior portion of the shearing
operation is to be discarded.
3. Perforating: punching a number of holes in a sheet
4. Parting: shearing the sheet into two or more pieces
5. Notching: removing pieces from the edges

24. 6. Lancing: leaving a tab without removing any material
Fig.1Shearing Operations: Punching, Blanking and Perforating
3.2 Forming Processes
 Bending: forming process causes the sheet metal to undergo the desired shape change by
bending without failure. Ref fig.2 & 2a
 Stretching: forming process causes the sheet metal to undergo the desired shape change
by stretching without failure. Ref fig.3
 Drawing: forming process causes the sheet metal to undergo the desired shape change by
drawing without failure. Ref fig.4
 Roll forming: Roll forming is a process by which a metal strip is progressively bent as it
passes through a series of forming rolls. Ref fig.5

25. Fig.2 Common Die-Bending Operations
Fig.2a Various Bending Operations
Fig.3 Schematic illustration of a stretch-forming process.

26. Fig.4 Schematic of the Drawing process.
Fig.5 Eight-roll sequence for the roll forming of a box channel
3.3 Finishing processes
Material properties, geometry of the starting material, and the geometry of the desired final
product play important roles in determining the best process

27. 4. Equipments
Basic sheet forming operations involve a press, punch, or ram and a set of dies.
5.1 Marking and measuring tools
 Steel Rule - It is used to set out dimensions.
 Try Square - Try square is used for making and testing angles of 90degree
 Scriber – It used to scribe or mark lines on metal work pieces.
 Divider - This is used for marking circles, arcs, laying out perpendicular lines, bisecting lines, etc.
Fig.9 Marking and measuring tools
Cutting Tools
 Straight snip - They have straight jaws and used for straight line cutting.
 Curved snip - They have curved blades for making circular cuts.
Striking Tools
 Mallet - It is wooden-headed hammer of round or rectangular cross section. The striking
face is made flat to the work. A mallet is used to give light blows to the Sheet metal in
bending and finishing. Ref fig.11

28. Fig.11 Types of Mallets
6. Merits
 High strength
 Good dimensional accuracy and surface finish
 Relatively low cost
7. Demerits
 Wrinkling and tearing are typical limits to drawing operations
 Different techniques can be used to overcome these limitations
o Draw beads
o Vertical projections and matching grooves in the die and blank holder
 Trimming may be used to reach final dimensions
8. Applications
 Roofings
 Ductings
 Vehicles body buildings like 3 wheelers, 4 wheelers, ships, aircrafts etc.
 Furnitures, House hold articles and Railway equipment.

29. CONCLUSION
It’s always a great opportunity to experience the valuable exposure of an industry. There is lot of
difference between the Theories and Practices. This Training enables me to understand the aspects
of professional life. I like the working environment followed at NEEL METAL PRODUCTS
LTD. and come to know how to deal with our colleagues. 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 measures. The company is
constantly focusing on providing better services, quality and reliability to customers, and running
successfully in this era of competition.