...NATIONAL INSTITUTE OF TECHNOLOGY DURGAPUR A PROJECT REPORT ON “SPOT BURR REDUCTION BY IMPROVING THE WORKABILITY OF SPOT GUN” Submitted in the partial fulfilment of the requirements for the award of the Degree of Bachelor of Technology in Mechanical Engineering Submitted By Mayukh Biswas ( 10/ME/27) Project Work Carried Out at Toyota Kirloskar Motor Private Limited Under the Guidance of Mr. Abhinand S AM Underbody, Weld Shop ( Plant 1 ) Toyota Kirloskar Motor (TKM) NATIONAL INSTITUTE OF TECHNOLOGY DURGAPUR (DEEMED UNIVERSITY) M.G. ROAD, DURGAPUR 713209 CERTIFICATE This is to certify that the Project work entitled “SPOT BURR REDUCTION BY IMPROVING THE WORKABILITY OF SPOT GUN” Carried out by Mayukh Biswas bearing R. No. : 10/ME/27 in partial fulfilment for the award of Bachelor of Technology in Mechanical Engineering of National Institute of Technology, Durgapur. It is certified that all corrections/suggestions indicated for internal assessment have been incorporate in the Report. The project report has been approved as it satisfies the academic requirements in respect of project work prescribed for said Degree. Mr. Abhinand S AM Underbody, Weld Shop (Plant 1) Toyota Kirloskar Motor (TKM) Ms. Mili Mathew HR Learning & Development Toyota Kirloskar Motor (TKM) Acknowledgement It gives me great pleasure to acknowledge the numerous personalities involved in lending their help to make this Project Work titled “ SPOT BURR REDUCTION...
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... JULY INTAKE 2012 RESISTANCE WELDING REPORT NAME | TRAINEE ID | JACK LAI KAR HAO | 323265 | ALLEN LAW CHI SEAN | 323359 | L.F NAME : MOHD. FADZIL BIN MUSA CONTENTS m/s Overview and introduction 3 Variables in welding process 4 How is resistance welding work 5 Types of resistance welding 6 Advantages and disadvantages of resistance welding 10 Application of resistance welding 11 Conclusion 12 Overview of Resistance Welding Introduction In simplest terms, welding is a process by which two or more pieces of metal are joined by applying heat and pressure. Back in the good old days, blacksmiths and other crafty people would heat metals in a furnace and then weld them by hammering the red-hot metals together. By hammering the metals as they cooled, the weld would be made stronger. This heating-and-hammering method is known as forge welding. While forge welding worked quite well for most of the welding done back then, today's welding requirements are a bit more advanced. After...
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...revolution to that of Yield strength, Ultimate strength and Weld quality are obtained. Also, simulations are performed, and the actual values are compared with the predicted values. Finally, multi-objective optimization of mechanical properties fuselage aluminium was undertaken using Genetic Algorithm to improve the performance of the tools industrially. AIMS AND OBJECTIVES Objectives of the dissertation include Understanding the basic principles of operation of Friction Stir Welding (FSW). Gaining experience in modelling and regressive analysis. Gaining expertise in MATLAB programming. Identifying the best strategy to achieve the yield strength, Ultimate Tensile strength and Weld quality of Friction Stir Welding. Performing optimization of mechanical properties of FSW using Genetic Algorithm. I To draw conclusions on prediction of mechanical properties of FSW optimization of aircraft fuselage aluminium. ACHIEVEMENTS The basic principles of friction welding of the welding operations are well studied and understood. The theoretical concepts of modelling techniques are familiarised. Gained expertise in MATLAB programming. The best model that can predict the mechanical properties of friction stir welded aircraft fuselage aluminium has been developed using ANFISRegressive modelling. Performed optimization of mechanical properties friction stir welded...
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...Fabfurnish Following my under graduation, to tap the taste of start ups and ever growing interest in marketing – I started working ……<framing this> The front end marketing analytics, where direct cum indirect interaction with the customers and their reaction pushed us how to increase the conversion rate and engagement with audiences. <need to frame this> Customer Insights – based on that taking further actions Launching the new campaigns on facebook and optimizing them on the key metrics like CTR(Cost to revenue Ratio),CPC(Cost per Click),CPV(Cost per Visit)– lowering the CRR (Cost to Revenue Ratio – inverse of ROI) bought down by 70%. Optimization was done on the basis of reports in which number are stacked up from Google Analytics and FB Power Editor to check the bounce rate and Conversion Rate Good with reports and reports making Engaging in Mobile as this was the time in India (late 2014) where mobile grew as a major player in the advertising industry and various different inventory of FB like MPA (multiple ads) and doing the category wise segmentation & performing the strategic group analysis which help in growth of 40% mobile revenue. - - -> key insight ran ads of those products which have low basket value (<1000 INR) since audience have more interaction for these products on mobile platform and thus increasing the funds in this segment and generating a 14 lac transaction in a single day through optimized reports * To show interest in...
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...and two 8-inch pieces of angle iron. The bar will serve as the top crossbar in your frame while the angle irons will join the frame to a wooden base. 3• Stand all three tubes on their ends, with the long tubes 5.5 inches apart. Place the short tube in between them and use an arc welder to weld the steel crossbar at their top ends, and the angle iron pieces on both sides of their bottom ends. This will make a rectangular metal frame with the short pipe in the middle of one short side. • 4 File or grind any rough edges from your frame, then paint it. The paint will dampen down any shavings. Once painted, it can be attached to a wooden base by passing screws through the holes in the angle iron piece. • 5 Make the press canister by welding a circular piece cut from your plate steel onto one end of a wide steel tube. Drill holes through the outside of the canister and file down any rough edges. • 6 Form the press piston by cutting another circle of plate steel just small enough to fit inside the press canister. On one side of the disk, weld a short length of pipe with a diameter big enough to fit snugly over the end of the short pipe in the press's frame. • 7 Chop off the bottom third of a round plastic jug and cut a hole in the center of it big enough for the middle pipe in your frame. This will collect the oil as it drips...
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...preheat holes or in a two-piece tip the cutting tip will overheat and explode. a. True b. False 4. A cutting torch is used for cutting, welding, and heating. a. True b. False 5. Most hand torches can cut metal up to seven inches thick. a. True b. False 6. It is possible to cut steel that is four feet thick. a. True b. False 7. Acetylene should be used in a two-piece cutting tip. a. True b. False 8. Acetylene cutting tips should be one piece with 1 to 6 preheat holes. a. True b. False 9. The chance of a flashback is less with low pressure regulator settings that with high pressure settings. a. True b. False 10. The oxyfuel gas cutting torch works as a result of the metal being rapidly melted. a. True b. False 11. Hard slag is easier than soft slag to remove. a. True b. False 12. Distortion is not a problem if the correct fuel gas is used. a. True b. False 13. By looking at the drag lines in a cut, you can determine whether the cut was made correctly or incorrectly. a. True b. False 14. The two major methods for controlling distortion while make a cut is making two parallel cuts at the same time and speed and making a short cut and skipping a strip to keep the plate from separating. a. True b. False 15. The advantaged of a combination welding and cutting...
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...Molding Methods Molding process is used to create intricate metal components. The mold material used to make these “molds” could be either temporary or permanent. Temporary molds are made up of refractory sands and resins. The temporary mold has to be broken to retrieve the cast. Permanent molds are made of ferrous materials and are normally employed for casting low melting point materials but this process is too costly. Because of this conundrum, most of the foundry industry has its castings produced using temporary mold materials. Compared to permanent molds, the temporary sand molds can cast high melting point materials and larger parts, while permanent molds can produce small castings of better quality and dimensional accuracy. Sand casting uses temporary sand molds to form complex metal components that can be made of almost any alloy. Sand casting has a relatively lower production rate as each time the part solidifies, the mold has to be broken to retrieve the part. The sand casting process makes use of a furnace, metal, pattern, and sand mold. The metal is melted in the furnace, ladled, and then poured into the cavity of the refractory sand molds. The sand mold is separated using “parting sad” and the solidified cast can be removed. Its relatively cheap and can even be used for steel foundry use. Apart from sand, a bonding agent such as clay is generally used. Water or some other moisturising agent is added to this mixture to develop strength and plasticity of the clay...
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...BODY WELDING - CAN IT BE FLEXIBLE? BODY WELDING - CAN IT BE FLEXIBLE? Some 250~300 pressed panels from in-house and vendor facilities are brought to different subassembly stations of Body Weld Shop. Subassemblies of pressed components are carried out mainly by resistance welding and other joining methods in a planned sequence at number of stations. Some subassemblies are done in off-line manufacturing cells and fed in at appropriate locations into the main assembly line. Fig. 6.1 shows a layout of a typical Body Weld Shop. Front end, rear floor, and front floor, are transported to underbody body line, where all these are welded together in sequence to form the floor structure. Underbody is then transferred to main body welding station. Right hand and left hand body side panels are brought from two sides to main body weld station, after completion of all subassembly operations in separate lines. Preframing of body structure is carried out on special fixture. At same or next station, roof is added to form the body shell, Fig. 6.2. Thereafter, rear doors, front fenders, hood and decklid/ tailgate fitments are carried out to complete the body-inWhite. If necessary, a metal finish line may be added for minor repair of Body-in-White before it moves for painting. Fig. 6.3 illustrates the sequences of subassemblies and the main body weld. Typically, Body weld shop activities cover fixturing, welding, and transportation between the work stations, and the related support services....
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...Variations of Joint Designs or Energy Directors For the design of plastic parts for assembly with ultrasonic energy, many recommendations exist to save time, energy and tooling modifications. The first step for a designer is to determine the most suitable joining technique. The following variations are possible: Ultrasonic Welding Ultrasonic Swaging, Staking, Spot-Welding Ultrasonic Insertion Ultrasonic Welding The molten material builds at the contact area of the energy director between the to be welded parts. The ultrasonic waves are transferred through the part to the joint area. Common "standard" joint designs include: Basic 90 Degree Energy Director 90 Degree Energy Director Step Joint 90 Degree Energy Director Tongue & Groove Herrmann Ultrasonics Mash Joint Double V-Point Tongue & Groove The recommended process examples listed above can be varied with inserted gaskets or in-molded 2K injection molded gaskets. Ultrasonic Swaging, Staking, Spot-Welding please click for enlargement In addition to conventional types of joint design for bonding injection molded plastic parts, ultrasonic welding can be used in a verity of forms to accomplish a mechanical bond when only one part is of thermoplastic material. Common applications include: Swaging, for deforming or bending an area of a plastic piece to trap the other part (of different plastic or other materials). Through swaging, different kinds of plastic parts...
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...operation. B&L manufactured approximately 40 trailers per year, with about two-thirds produced during the period from November to April. The outrigger bracket, part number T-178, was an accessory that could be used to secure oversized containers. The bracket consisted of four component parts welded together, and each trailer sold by B&L had 20 brackets – 10 per side. The Metal Fabricating Division was presently manufacturing the outrigger bracket. The subassembly parts – T-67, T-75, T-69, and T-77 – were processed on a burn table, which cut the raw material to size. Although the burn table could work with eight stations, this machine had only been operating with one station. The final assembly operation, T-70, was performed at a manual welding station. Manufacturing lead time for the outrigger bracket was two weeks. However, the Metal Fabricating Division had been able to coordinate supply and production with assembly operations. Consequently, finished inventory levels of the outrigger bracket were kept to a minimum. B&L’sinventory holding costs were 20 percent...
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...your First project Welding technology offer's society many beneficial ability's in enginering, construction, architecture, and also creates varied safety Concern's for the individual tradesmen' "tradeswomen"and their environment's. Welding Cover's a temperature range from 1500 F - 3000 ººF (800 ºC - 1635 ºC) and poses certain inevitable inherent risk's. As a skilled worker in this industry, one must proactively plan, prepare for any and all possible problem's, determine solution's and prepare preventative measures to use in case they arrive. Many welders reflecting on thier welding shop experience can admit they have acquired scars, acknowledge the dangers, and admit the necessity of demonstrating a professional respect for proper personal safety equipment and techniques. it has been said “If you play with fire you get burned” There are three main different risk's associated with welding including , heat, inhaling toxic fumes and electrical shock that are the most hazardous to your health, other various danger's include Gas leak, fire's and explosion's. In addition the extreme heat welding creates can burn you in many ways if not properly protected. There is ultraviolet light generated by the welding arc “electrical connection between welder and workpiece” that can cause severe radient heat, sunburns and increase your risk of skin cancer. Sparks can burn right through your gloves, boots and multiple layers of clothing even specialized welding coats! Using personal protection...
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...2003 ECI Conference on Advanced Materials for Construction of Bridges, Buildings, and Other Structures III % FILE: /main/production/doc/data/journals/services.bepress.com/advanced materials/assets/location.inc Switzerland% FILE: (cont) /main/production/doc/data/journals/services.bepress.com/eci/assets/proceedings/pdftitlepage.te Editors: % FILE: /main/production/doc/data/journals/services.bepress.com/advanced materials/assets/editors.incV Mistry, P.E., Office of Bridge Technology, Federal Highway Administration, USA Dr. Atorod Azizinamini, Ph.D., P.E., Civil Engineering Department, University of Nebraska, USA John M. Hooks, P.E., Office of Infrastructure Research & Development, Federal Highway Administration, USA % FILE: /main/production/doc/data/journals/services.bepress.com/eci/assets/proceedings/defines.tmpl (cont) Year Paper High Performance Steel For Highway Bridges Vasant C. Mistry ∗ ∗ Federal Highway Administration High Performance Steel For Highway Bridges Abstract All steels possess a combination of properties that determines how well steel performs. Strength, weldability, toughness, ductility, corrosion resistance, and formability are all important to determine how well steel performs. High-performance steel (HPS) can be defined as having an optimized balance of these properties to give maximum performance in bridge structures while remaining cost-effective. http://services.bepress.com/eci/advanced materials/1 Copyright c 2005 by the...
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...www.inspection for industry.com Inspection and Test Plan for Seel Structure Activity By No. Inspection and Test Plan Reference Document Acceptance Criteria Remark Verifying Document Manuf. 1 Pre Inspection Meeting Spec. Spec. TPI Client MOM H H H Before Manufacturing 2 DWG, Design, Calculation Document AISC AISC DWG, Calculation book H R A 3 WPS&PQR AWS D1.1 AWS D1.1 Welding Book H R A 4 Welder Qualification Certificates AWS D1.1 AWS D1.1 Certificates H R 5 NDT procedures AWS D1.1 AWS D1.1 Procedures H R 6 NDE Personnel Certificates AWS D1.1 AWS D1.1 Certificates H R 7 Painting Procedure SSPC SSPC Procedure H R Materials 8 Visual Inspection of Materials for General Appearance, Corrosion and Dimension ASTM ASTM Original Material Certificates H H 9 Welding Material Control ASME II/AWS ASMEII/AWS Report H W 10 Review of Certificates ASTM ASTM Certificates H H 1 A A www.inspection for industry.com 11 Inspection of Bolt , Nut and Washers (General Appearance, Corrosion and Dimension, Chemical Composion and Mechanical Properties) ASTM ASTM Report H W 12 Material Identification ASTM ASTM Report H H During Fabrication 13 Fit Up Inspection AWS D1.1 AWS D1.1 Report ...
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...Career Plan test. Therefore, the results should be based on my answers, which would be derived from my own personal learning and experiences. Based on this, I would have thought that the Career Plan would have made choices based on my 51 years of life. It did not. I have always enjoyed working with my hands. My father was an electrician. He was also very talented with other trades, such as pipe fitting, plumbing, and just about everything related to manual labor. To say that he taught me a lot is an understatement. I learned how to fill fire extinguishers at the age of 8. I also learned basic electrical wiring and was able to do complex motor control by the time I was 18. By the time I was 21, I was a certified welder in 4 different welding processes. Most recently, I built an electrical contracting business with 15 employees, and over $2 million dollars in yearly sales. My point is that I do very well with “hands-on” work. When my Career Interest Profile stated that I am “Realistic, Enterprising, and Social” I began reading the report with great interest. Imagine my disappointment when I further read that my career matches were a “Barista”, or a “Medical Assembler”. It also suggested that I explore jobs in “Cosmetology, Manicurist, and Make-up Artist”. Therefore, let me state that I will completely ignore my...
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...Tanay, Rizal Cel. No. 09051307787 Email Address: victor.saberdo@yahoo.com Passport No.: XX5643270 POSITION DESIRED WELDER WORKING EXPERIENCE Company : Taisei Address : Doha, Qatar Position : Welder Inclusive Date : May 10, 2010 – May 20, 2012 Job Description: • Preparation of tools, materials and permit needed on daily activities • 360o look around hazard identification • Full welding of I-beam, 10mm thick plate, stiffener of I-beam, 5mm thick plate support stainless I-6, 40x40 frame cladding and frame cp2 panel • And support all welding works in fabrication activities Company : KEPCO Philippines Corporation Address : Malaya Pililla, Rizal Position : Welder Inclusive Date : October 11, 2003 – January 20, 2007 Job Description: • Preparation tools materials and equipment of daily activities • Coordination with safety officer and supervisor for necessary hot work permit, before to proceed to welding work • Full welding, tank column, over head tank, railing, flat form, pipe, trusses, for light post. Company : Engineering & Construction of Asia Address : Makati, City Position : Scaffolder Inclusive Date : 1999 – 2002 Job Description: • Preparation of tools and materials • 360o look around hazard identification • Installing Ø assign every scaffold needed on a site putlog scaffold, birdcage scaffold Company...
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