Summer Internship Report at Neel Metal Products Limited, Manesar

This is report of Summer Internship at Neel Metal Products Limited, Manesar. This is a major vendor company of Honda Two Wheeler India.

1. ARYA COLLEGE OF ENGINEERING & INFORMATION TECHNOLOGY

Industrial Training Report
at








NEEL METAL PRODUTS LIMITED
MANESAR

Submitted To:- Submit By:-
Prof Arun Kumar Arya Hitesh Pathak
(Head of Mechanical Department) 11EARME044
B. Tech Mechanical
4
th
Year

2. ACKNOWLEDGEMENT

It is indeed a great pleasure and privilege to present this report on training at
NEEL METAL PRODUCTS LIMITED, JBM GROUP, MANESAR.
I am extremely grateful to my Head of Department and training and placement
officer for issuing a Training letter, which made my training possible at NEEL
METAL PRODUCTS LIMITED, JBM GROUP, MANESAR.
First, I thank The HR Head, MR. Gaurav Saraswat for considering my potential
in doing this training and providing this wonderful opportunity.
I would like to express my gratitude to MR. Rakesh Kumar for his invaluable
suggestions, motivation, guidance and support throughout 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- July 2014 Hitesh Pathak

3. 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

4. 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, MANESAR
Head Quarters: DELHI
Established: 1983
Turnover: Rs.4500 Crores(overall)
Employees (No.): AROUND 15,000
Introduction:-
The Neel Metal Products Limited, Manesar is a
major vendor company of Honda 2 Wheelers India
Ltd. Neel Metal Products Ltd. (NMPL) is the fastest
growing Company of JBM Group with high-tech plants at various locations in

6. India. NMPL has earned a leading position in industry with facilities available in
press lines up to 1200 tons, weld lines and ED coating plant- which are not only
limited to auto world but also fitting for white goods industry.
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

7. 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.
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.
Departments in Neel Metal Products Limited, Manesar:-
1) Paint shop
2) Weld shop
3) Press Shop
4) Quality department
5) Engineering department
6) IT department

8. 7) Finance department
8) Purchase department
9) Maintenance department
Operation and Facilities:-
Facilities to design manufacture and do real time testing of welding and
checking fixtures
Rim rolling line, central anode tri chrome nickel plating and complete wheel
assembly set up
Steel Service Centre - The Company has 4 blanking lines capable of producing
blanks of regular and irregular geometrical shapes and sizes
Tube mills to manufacture Electrical Resistance Welding (ERW) tubes
Vehicle Assembly - Capability to produce complete bodies
Product Range:-
Complete Frame Assembly, Welding and Painting
Tubes for Tubular Components.
Underbody Frames and Parts.
Certifications:-
ISO 9001
ISO/TS 16949
ISO 14001
OHSAS 18001

9. Production:-
Production is defined by the Webster online as “to make into a product
suitable to use.”
The action of manufacturing from components or raw material or the process
if being so produced.
Production is a process of combining various material inputs and immaterial
inputs in order to make something for consumption. It is the act of creating
output, a good or service which has value and contributes to the utility of
individuals. Economic well-being is created in a production process, meaning of
all economic activities that aim directly or indirectly to satisfy human needs.
The degree to which the needs are satisfied is often accepted as a measure of
economic well-being.




Types of Production Procedure:-
Casting Process:- This type of procedure required liquid material. This is the
only process which uses liquid material. This is oldest procedure of production
in which the molten metal is poured into refractory mould cavity and allowed
to solidify. The object from the cavity removed after the solidification.
Forming Process:- This solid state production process involving minimum
amount of material wastage. In this process the metal may be heated to a
Suppliers
 Material
 Energy
 Capital
 Service
Company
(Production)
Customers
 Households
 Other
Products

10. temperature, which is slightly below the solidus temperature and then large
force is applied such that material flows and takes the desired shape.
Fabrication Process:- It essentially, involves joining pieces either permanent or
temporarily so that they would perform necessary function. The joining can be
achieved by either or both of heat and pressure or joining through material. It
is secondary manufacturing procedure.
Material Removal Process:- This is also a secondary procedure where the
additional unwanted material is removed in the form of chips from the blank
material by a harder tool so as to obtain the final desired shape.
Production Line:-
A production line is defined as an arrangement in a factory in which a thing
being manufactured is passed through a set linear sequence of mechanical or
manual operations.
A production line is a set of sequential operations established in a factory
whereby materials are put through a refining process to produce an end-
product that is suitable for onward consumption; or components assembled to
make a finished article.
The production line is required to produce products fast. As well the market
demand is getting increase as well we need more products also with more in
quantity. A production of a whole body by a single labour was unable satisfied
this they was also unable fulfil the demand properly then we need some
processes by which we can produce things fast and fulfil the requirement of
market. Due to these the concept of production lines introduced in which
many units work together to produce something. This concept reduces the
production time up to a mark and exponentially increases the profits.

11. Advantages of Production line:-
 One of the biggest advantages of assembly line manufacturing is that it
reduces the skill requirements for line workers. When manufacturing a
doll, a craftsman may have to know how to mould the body, attach hair,
paint the face, and sew the clothing. Assembly manufacturing, however,
isolates one specific task or set of tasks to each worker, meaning that it is
easier to train new workers and mastery of the skill may come faster.
Additionally, automated assembly lines may be easier to create than
craftsman-based versions, because machines may only be able to perform
a limited number of specific tasks.
 A benefit of the task-isolation principle is it makes it easier to understand
where breakdowns in efficiency occur. If products are moving along on
schedule until they reach a certain point in the line, it is easy to see that
the speed-reduction in speed occurs at a specific point. This may make
efficiency issues easier to address, since problems may be immediately
apparent and have specific solutions that can be quickly applied.
 Increased production and better uniformity are two other advantages of
assembly methods. Since the line is optimized for speed and efficiency, and
tasks are limited, most lines can turn out products much faster than
traditional methods of manufacturing. Since every product is put together
in the same order, at the same speed, by the same technicians, variations
in quality are also less likely. With products that need to be manufactured
in large quantities at a rapid rate, assembly lines may be the most efficient
choice of manufacturing structure.
 In terms of wages, there are both advantages and disadvantages to
assembly lines. Since employees on a line are typically less skilled and
educated, their wage range is generally lower than educated craftsmen

12. with multiple skills. On the other hand, the savings created by efficiency,
fast production, and automation can mean the unskilled or semi-skilled
labourers are paid higher than their counterparts at non-assembly based
manufacturing jobs.
 Advantage of an assembly line is the ease of progression from unskilled to
skilled labour. Manufacturing plants may start new workers at jobs that
require the least skills, but as a worker masters his or her particular task,
he or she may get opportunities for more highly-skilled positions that build
directly on basic task abilities. This means that there may be a high chance
for career advancement within an assembly line plant.
 Now in the series of reducing production time we are also using automatic
machines and robots to do the work. These are reducing the time of
production with mark able increment in quality too. Robots are single time
investment and also have low maintenance. They don’t demand wedges
after a regular interval of time and factor of risk also low in these case. The
human harm has been reduced up to a mark by using robots.
Disadvantages of Production line:-
 The invention of assembly line production resulted in many different
advantages, but there are some significant disadvantages in the method as
well. Most of the benefits have to do with a reduction in cost and an
increased uniformity of the finished products. In addition to creating higher
profit margins, this can also result in products that are more affordable and
easier to repair. Disadvantages that are often associated with this method
of mass production include lower build qualities, rigid or inflexible
production facilities, and a substantially higher initial capital investment.

13. This type of production is often associated with monotonous or repetitive
jobs as well, which can lead to motivational problems with the workers.
 Prior to the advent of the assembly line, the alternatives were less efficient
methods such as cottage industries and craft production. These methods
often allowed for the creation of high quality products, but the cost to
produce them was also high. Each product also tended to be somewhat
unique, which could lead to issues if repairs were needed. Since assembly
line production involves creating highly uniform products at a fast pace,
many of these issues were eradicated. One example is in automobile
manufacturing, where the production method drove down the cost of the
vehicles to the point where the working class could afford to purchase
them.
 The disadvantages of the assembly line style of production are the same
qualities described above but looked at from another angle. While several
workers using interchangeable, standardized parts makes for easy repairs
and replacements, it also means each item loses that individualistic flare of
unique craftsmanship. For some products, especially decorative or
luxurious items, it can be very desirable to know that the piece was
uniquely crafted by a single skilled and experienced artisan, who put a lot
of heart and soul into the creation—not just a bunch of disinterested
people on a production line slapping parts together with no personal
investment in the quality of the finished product.
 Other disadvantages of assembly line production are based on the worker’s
point of view. Because little training is generally required, wages may not
be very competitive. The work itself can also be extremely repetitive and
monotonous, offering little in the way of mental stimulation and creative
critical thinking.

14.  They required huge capital amount to get established.
 Problem in any unit of line stops full production.
 Using of robots creating high unemployment in global market.
 Production of less quantity increases the cost of product.
Factor can affect the Production Process:-
1. Supplies:- Many manufacturing depends on raw material supplied from
outside sources. Some of the factors that can delay or hamper a regular
delivery schedule include a glitch at the site of a supply source, problem
with transportation or inclement weather. If supplies are not forthcoming
as needed, the potential for shutdown in the manufacturing process can
result. Alternatively a smooth supply operation and well managed
inventory promote production as scheduled.
2. Equipment:- When a manufacturing process involves complex machines to
complete production, a temporary malfunction or a breakdown in an
intricate piece of equipment can affect the production. Identifying means
of improving efficiency of all working parts of production promotes a
continual and more efficient operation. Positioning of equipment and the
personal required to operate machine can also affect production. In a
paper on production cycle times, Mandar M. Chincholkar of Intel
Corporation and several of his academic and research colleagues explain
the concept of “Process Drift” which they describe as a common
occurrence in production where machine fail to function properly due to
lack of cleaning.
3. Factory overhead:- Production depends on utilities to power machines,
cool equipment and light the workspace in their factories. Even a
temporary shutdown of the power supply or lack of a steady water source

15. can impact production, thus affecting the production process. In addition
management style can have a significant impact on production in both
negative and positive ways.
4. Need of special Parts:- In the textbooks “Operation Management”
professor R Dan Reid of the University of New Hampshire and Nada R.
Sanders of Lehigh University posit “Conformance to specification” as one
definition of quality in production. They cite as an example the situation of
machine parts being built to specs. Here an unforeseen change in made to
order parts can have significant impact on production, especially if the
parts are shipped over long distance from offsite. Disparities in qualities
may require multiple orders for the same inventory, resulting in delays and
temporary slowdowns or shutdowns of the production.
5. People who work at all points:- The workforce especially “touch labour”,
the workers directly involved in the production can affect that process in
many ways. For example: sick days and vacations taken by key personal
must be figured into production to prevent a negative impact on
production. An intangible factor that affects the production process and is
dealt with after the fact is human error. Alternatively, human inside a
production leading to more labour-efficient and cost-effective methods of
production can affect in a positive way.

16. Object:- Joining procedure of the Chain Case of Honda Unicorn KSPG.
Abstract:- The chain case is a most important part of two wheeler. It prevents
chain from the dirt and mud. As the two wheelers have an open type of body
and chain drives in free environment so there a definite chance of rusting and
corrosion occurs. So chain case prevents the chain from above factors. In India,
the Women wear their traditional dresses like Sari, Ghaghara and many other
dresses which consists a huge round of cloth covering their legs. So when they
sit on back side of two wheelers by wearing these dresses it creates definite
chances of tear of cloth by contacting with driven chain. It makes the condition
of accident many times women also get dead in this case. In other cases of
developing countries like India, Pakistan, African Countries traffic rules are not
so effective. On a single two wheeler more than allowed person travel. It also
creates definite chances of accident by contact with driving chain and chain
can also tear their dress or contact of clothes can make them snagged. So the
chain case is highly essential in two wheelers of India. It works like chain case
and dress guard both. It completely encloses chain and protects it from
contamination.
Theory:- Here the work done on the Honda Unicorn KSPG bike chain case. In
the joining of chain case 5 steps are involved. Pre discharge inspection of this
involves 2 steps. The parts of this chain case are jointed with the spot welding.
This spot welding consist two copper electrodes which transfer a higher
voltage through part this generates high heat at transfer spot and this heat
joint part by a spot. Sheet metal is used to make chain case. The chain case
consists 7 parts which make one side case. It is differentiated in two Left and
Right part in this L part is engaged with Dust cover. Due to the high strength
and low in weight Aluminium is used to make Unicorn chain case.

17. Spot Welding:-
Spot welding is one of the oldest welding processes. It is used in a wide range
of industries but notably for the assembly of sheet steel vehicle bodies. This is
a type of resistance welding where the spot welds are made at regular
intervals on overlapping sheets of metal. Spot welding is primarily used for
joining parts that are normally up to 3 mm in thickness. Thickness of the parts
to be welded should be equal or the ratio of thickness should be less than 3:1.
The strength of the joint depends on the number and size of the welds. Spot-
weld diameters range from 3 mm to 12.5 mm.
Working of Spot Welding:-
Spot welding is one form of
resistance welding, which is a
method of welding two or more
metal sheets together without using
any filler material by applying
pressure and heat to the area to be
welded. The process is used for
joining sheet materials and uses
shaped copper alloy electrodes to
apply pressure and convey the electrical current through the work pieces. In all
forms of resistance welding, the parts are locally heated. The material between
the electrodes yields and is squeezed together. It then melts, destroying the
interface between the parts. The current is switched off and the "nugget" of
molten materials solidifies forming the joint.
To create heat, copper electrodes pass an electric current through the work

18. pieces. The heat generated depends on the electrical resistance and thermal
conductivity of the metal, and the time that the current is applied. The heat
generated is expressed by the equation:
E=I
2
*R*t
Where E is the heat energy, I is the current, R is the electrical resistance and t
is the time that the current is applied.
Copper is used for electrodes because it has a low resistance and high thermal
conductivity compared to most metals. This ensures that the heat is generated
in the work pieces instead of the electrodes.
Materials suitable for spot welding:-
Steel has a higher electrical resistivity and
lower thermal conductivity than the copper
electrodes, making welding relatively easy. Low
carbon steel is most suitable for spot welding.
Higher carbon content or alloy steel tends to
form hard welds that are brittle and could crack. Aluminium has an electrical
resistivity and thermal conductivity that is closer to that of copper. However,
aluminium's melting point is much lower than that of copper, making welding
possible. Higher levels of current must be used for welding aluminium because
of its low resistivity.
Galvanized steel (i.e. steel coated with zinc to prevent corrosion) requires a
different welding approach than uncoated steel. The zinc coating must first be
melted off before the steel is joined. Zinc has a low melting point, so a pulse of
current before welding will accomplish this. During the weld, the zinc can

19. combine with the steel and lower its resistivity. Therefore, higher levels of
current are required to weld galvanized steel.
Electrode force:-
The purpose of the electrode
force is to squeeze the metal
sheets to be joined together. This
requires a large electrode force
because else the weld quality will
not be good enough. However,
the force must not be to large as
it might cause other problems.
When the electrode force is
increased the heat energy will
decrease. This means that the
higher electrode force requires a
higher weld current. When weld
current becomes too high spatter will occur between electrodes and sheets.
This will cause the electrodes to get stuck to the sheet.
An adequate target value for the electrode force is 90 N per mm2. One
problem, though, is that the size of the contact surface will increase during
welding. To keep the same conditions during the whole welding process, the
electrode force needs to be gradually increased. As it is rather difficult to
change the electrode force in the same rate as the electrodes are
"mushroomed", usually an average value is chosen.

20. Diameter of the electrode contact surface:-
One general criterion of resistance spot-welding is that the weld shall have a
nugget diameter of 5*t
1/2
, “t” being the thickness of the steel sheet. Thus, a
spot weld made in two sheets, each 1 mm in thickness, would generate a
nugget 5 mm in diameter according to the 5*t
½
-rule. Diameter of the electrode
contact surface should be slightly larger than the nugget diameter. For
example, spot welding two sheets of 1 mm thickness would require an
electrode with a contact diameter of 6 mm. In practice, an electrode with a
contact diameter of 6 mm is standard for sheet thickness of 0.5 to 1.25 mm.
This contact diameter of 6 mm conforms to the ISO standard for new
electrodes.
Squeeze time:-
Squeeze Time is the time interval between the initial application of the
electrode force on the work and the first application of current. Squeeze time
is necessary to delay the weld current until the electrode force has attained
the desired level.
Weld time:-
Weld time is the time during which welding current is applied to the metal
sheets. The weld time is measured and adjusted in cycles of line voltage as are
all timing functions. One cycle is 1/50 of a second in a 50 Hz power system.
(When the weld time is taken from American literature, the number of cycles
has to be reduced due to the higher frequency (60Hz) that is used in the USA.)
As the weld time is, more or less, related to what is required for the weld spot,
it is difficult to give an exact value of the optimum weld time. For instance:
Weld time should be as short as possible.

21. The weld current should give the best weld quality as possible.
The weld parameters should be chosen to give as little wearing of the
electrodes as possible. (Often this means a short weld time.)
The weld time shall cause the nugget diameter to be big when welding thick
sheets.
The weld time might have to be adjusted to fit the welding equipment in case
it does not fulfil the requirements for the weld current and the electrode force.
(This means that a longer weld time may be needed.)
The weld time shall cause the indentation due to the electrode to be as small
as possible. (This is achieved by using a short weld time.) The weld time shall
be adjusted to welding with automatic tip-dressing, where the size of the
electrode contact surface can be kept at a constant value. (This means a
shorter welding time.) When welding sheets with a thickness greater than 2
mm it might be appropriate to divide the weld time into a number of impulses
to avoid the heat energy to increase. This method will give good-looking spot
welds but the strength of the weld might be poor. By multiplying the thickness

22. of the sheet by ten, a good target value for the weld time can be reached.
When welding two sheets with the thickness 1 mm each, an appropriate weld
time is 10 periods (50Hz).
Hold time (cooling-time):-
Hold time is the time, after the welding, when the electrodes are still applied
to the sheet to chill the weld. Considered from a welding technical point of
view, the hold time is the most interesting welding parameter. Hold time is
necessary to allow the weld nugget to solidify before releasing the welded
parts, but it must not be to long as this may cause the heat in the weld spot to
spread to the electrode and heat it. The electrode will then get more exposed
to wear. Further, if the hold time is too long and the carbon content of the
material is high (more than 0.1%), there is a risk the weld will become brittle.
When weld galvanized carbon steel a longer hold time is recommended.
Weld current:-
The weld current is the current in the welding circuit during the making of a
weld. The amount of weld current is controlled by two things; first, the setting
of the transformer tap switch determines the maximum amount of weld
current available; second the percent of current control determines the
percent of the available current to be used for making the weld. Low percent
current settings are not normally recommended as this may impair the quality
of the weld. Adjust the tap switch so that proper welding current can be
obtained with the percent current set between seventy and ninety percent.
The weld current should be kept as low as possible. When determining the
current to be used, the current is gradually increased until weld spatter occurs

23. between the metal sheets. This indicates that the correct weld current has
been reached.
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. Then in the series of making Right side of case first operation is performed
in this step we joint upper R body to Patch A and Patch B.
4. Patch A has two spots points and Patch B has four spot points.
5. One point of Patch A also will be jointed with bolt support to body
6. One corner point of Patch B also will be jointed with bolt support to body.
7. Right Side of Chain case is final now.
8. Then in the series of making Left side of case first operation is performed in
this step we joint upper L body to Plate A, Plate B and Plate C.
9. Plate A has two spot points Plate B has four spot points and Plate C has
four spot points too.
10. Swing arm patch also will be attached with Plate B at Corner.
11. These Plates A, B, C will further used for fitment of case with body.
12. Then we joint Dust Guard on L body. Dust Guard has seven spot points.
13. In last Plate D will attach with both sides and then chain case will go for
PDI.
PDI of Chain Case:-
1. In first step of PDI we measure the holes via gauge and inspect the position
of hole and joints.

24. 2. In second step of PDI we test the strength of joint via performing stretch
test. Scratch and Roundness of edges and corner also perform again here.
3. Then Chain case will send for Painting.
The whole procedure of making Chain Case will take 20 seconds to complete
with PDI. Making process of Right and Left Part has been done parallel. The
annual defects of the pieces are 2% of total.

Precaution to take in Joining:-
1. Do not stop the part at a same place.
2. Do not perform welding without wearing gloves.
3. Do the work at same rate as guided.
4. Always wear an apron before start working.
5. Always follow the rules of workshop.
6. In case of any hazard contact to supervisor and medical officer.

Conclusion of Project:-
Joining procedure of Chain Case of Honda Unicorn has been completed. The
total find error is 5% on my work.

25. Object:- Painting Procedure of Chain Case of Honda Unicorn KSPG, Connecting
Rod of Honda Unicorn KSPG and Honda Activa KWPG.
Abstract:- A primer or undercoat is a preparatory coating put on materials
before painting. Priming ensures better adhesion of paint to the surface,
increases paint durability, and provides additional protection for the material
being painted
Primer is a paint product that allows finishing paint to adhere much better
than if it was used alone. For this purpose, primer is designed to adhere to
surfaces and to form a binding layer that is better prepared to receive the
paint. Because primers do not need to be engineered to have durable, finished
surfaces, they can instead be engineered to have improved filling and binding
properties with the material underneath. Sometimes, this is achieved with
specific chemistry, as in the case of aluminium primer, but more often, this is
achieved through controlling the primer's physical properties such as porosity,
tackiness, and hygroscope.
In practice, primer is often used when painting many kinds of porous materials,
such as concrete and especially wood (see detailed description below). Priming
is mandatory if the material is not water resistant and will be exposed to the
elements. Priming gypsum board (drywall) is also standard practice with new
construction because it seals the wall and aids in preventing mould. Primers
can also be used for dirty surfaces that, for some reason, cannot be cleaned, or
before painting light colours over existing dark colours.
Primers can usually be tinted to a close match with the colour of the finishing
paint. If the finishing paint is a deep colour, tinting the primer can reduce the
number of layers of finishing paint that are necessary for good uniformity
across the painted surface.

26. There may be a maximum time frame within which a topcoat should be
applied over the primer after the primer dries, in order to achieve maximum
performance. Depending on the primer, the next coat of paint should be
applied as quickly as 24 hours or you may have as long as 2 weeks. Painting
after the suggested timeframe may cause performance issues depending on
the specific situation. Supposedly, you want to apply the finish coat of paint
before the primer fully cures on a molecular level. Doing this allows maximum
adhesion/bonding of the topcoat to the primer. If top coating after the
suggested timeframe, consider using a "self priming" topcoat. For definitive
answers on recommended repainting timeframe, check the primer
label/website, or contact the manufacturer directly. Recoat timeframe is most
likely a more critical factor in exterior application because of the more extreme
climatic exposure.
A primer designed for metal is still highly recommended if a part is to be
exposed to moisture. Once water seeps through to the bare
metal, oxidation will begin (plain steel will simply rust). Metal primers might
contain additional materials to protect against corrosion, such as sacrificial
zinc.
Metal hydroxides/oxides do not provide a solid surface for the paint to adhere
to, and paint will come off in large flakes. Using a primer will provide extra
insurance against such a scenario. An additional reason for using a primer on
metal could be the poor condition of the surface. A steel part can be rusty, for
example. Of course, the best solution is to thoroughly clean the metal
(blasting), but when this is not a viable option, special kinds of primers can be
used that chemically convert rust to the solid metal salts. And even though

27. such surface is still lacking in comparison to the shiny clean metal, it is yet
much better than weak, porous rust.
Methodology:-
Process Flow Chart (Paint Shop)
Loading
Hot Water Rinse
Knock of Degreasing
Degreasing
Industrial Water Rinse 1
Industrial Water Rinse 2
Surface Activation
Phosphatising
DM Water Rinse 1
DM Water Rinse 2
Water Dry Oven
Tag Rag
Primer Coat
Base Coat
Top Coat
Paint Baking Oven
Unloading

28. Preparations for the Painting Procedure:-
1. For the Hot Water Rinse: Here we take a sump tank for containing of water
than we heat that up to 40 to 60˚C with maintaining of 0.5 to 1.2 Kg/cm
2

pressure. Here we take normal water which is usually available.
2. For Knock of Degreasing: Here we take a cleaning chemical in a tank and
maintain 40 to 60˚C temperature, 0.5 to 1.2 Kg/cm
2
pressure and alkalinity
30 to 35 ml.
3. For Degreasing: Here we again maintain the cleaning chemical condition as
Knock of Degreasing.
4. For Water Rinse 1: Here we take water in a tank and maintain pressure at
0.5 to 1.0 Kg/cm
2
and pH value at 8.0 to 10.0.
5. For Water Rinse 2: Here we again take water in tank and maintain pressure
at 0.5 to 1.0 Kg/cm
2
and pH value at 8.0 to 9.0.
6. For Surface Activation: Here we take a special chemical in tank for that
maintains pressure at 0.5 to 1.0 Kg/cm
2
and pH value at 8.0 to 10.0.
7. For Phosphatising: We take a coat of phosphate for that maintain pressure
at 0.8 to 1.0 Kg/cm
2
, Temperature at 40 to 50˚C, Total Acidity 20 to 24 ml,
Free Acidity 0.6 to 0.8 ml and Tonner Value at 2 to 4 ml.
8. For DM Rinse 1: We take water in tank and maintain pressure at 0.5 to 1.0
Kg/cm
2
and pH value at 5 to 6.
9. For DM Rinse 2: We take water in tank and maintain pressure at 0.5 to 1.0
Kg/cm
2
and pH value at 6.5 to 7.0.
10. For Dry off Oven: Maintain Temperature at 90 to 100˚C.
11. For Coating: A spray paint equipment is required and Water-Grease
Solution to prevent walls from Coat.
12. For Paint Baking Oven: Maintain Temperature at 130 to 140˚C.

29. *Cleaning chemical for KOD and chemical for Surface Activation are patented
products of company. They don’t disclose composition and name of these.
These chemicals are only known by their work.
Process:-
1. In first step chain case, connecting rod loaded on Hangers. This hanger is
attached with the 249 meter long belt. On the whole length of belt 416
hangers are attached.
2. Then these loaded parts went to first chamber which is Hot Water Rinse
chamber. In this chamber hot water rain dropped on the parts which cleans
all the dirt and all other things.
3. Then these loaded parts went to next chamber which is KOD (Knock of
Degreasing) chamber. In this chamber a cleaning chemical dropped on the
parts which remove water from surface, other dirt which cannot be
cleaned by water and extra material.
4. Then these parts went to next chamber degreasing chamber which again
perform KOD action. This is for precautions that if any impurity is left that
will definitely clear here.
5. Then it went to Industrial Water Rinse 1 chamber where distilled water
clears the cleaning chemical.
6. In next chamber industrial Water Rinse 2 again distilled water rain over
parts and clean them.
7. Then they sanded to Surface Activation chamber where a chemical
dropped on parts and this rain activates surface of parts for next step.
8. Then parts went into Phosphatising chamber here rain of phosphate occurs
over parts which creates a layer of phosphate over them. This coat of
phosphate makes paint properly bind with part.

30. 9. Then in DM Rinse Water 1 chamber these parts again cleans. This cleans
the unwanted phosphate coating and impurity (if left).
10. Then in DM Rinse Water 2 chamber these parts again cleans. This again
cleans impurity (if left).
11. In next step it sanded to air blower chamber which dries water from parts.
12. After air blowing it went to Water Dry Oven chamber here it heats up to 90
to 100˚C which definitely removes water from parts.
13. After these pre treatment processes now Parts come into TAG RAG
chamber. Here workman manually check all parts and put some another
parts (which have some error in painting in previous cycle).
14. Now after manually checking parts sanded to Primer Coat chamber here a
medium viscous paint has been painted manually via spray paint gun. Here
a gel mixture of Water-Grease continuous flow on chamber wall to prevent
walls from Paint.
15. Then parts sanded to Base Coat chamber here a high viscous paint has
been panted manually over Primer Coated part. This creates a second layer
of paint on Parts.
16. Then parts sanded to Top Coat chamber (if required) here a low viscous
paint has been painted manually via spray paint gun on Base Coated Parts.
This process is only necessary for some parts. Usually this is not required.
17. Then at last parts sanded to Paint Bake Oven here they left for the Baking
at temperature of 130 to 140˚C for 20 minutes. This makes paint
permanently bind with part.
18. After the baking process parts unloaded from Hangers for PDI
19. The whole process runs at 1.6m/min speed of belt.

31. Chemical Tests:-
For Knock of Degreasing: Alkalinity Test:
1. Take 10 ml sample in a beaker.
2. Then add 4-6 ml of phenolphthalein (indicator)(red).
3. Then add 16-14 ml H2SO4 in beaker.
4. Now titrate them this titration make red colour invisible this value should
be in given range of 30 to 35 ml.
5. If the value is not in range then change the chemical in tank.
Water Rinse:
Perform pH test via litmus paper and litmus scale.
Phosphatising: Total Acidity:
1. Take 10 ml sample in beaker.
2. Then add 4-6 ml of phenolphthalein this will make sample colourless.
3. Then add NaOH in Sample and on which point this sample show Light Pink
colour will be the last point and this should be in given range of 20 to 24
ml.
4. If the value is not in range then change the chemical in tank.
Free Acidity:
1. Take 10 ml of sample in beaker.
2. Then add chromo phenol blue indicator in sample which make sample
yellow.
3. Then by the help of NaOH titrate this mixture when it show Light Blue
colour that will be the end point of reaction and this should be in given
range of 0.6 to 0.8 ml.
Chemical Tests must be performed after every 4 hours.

32. Viscosity Tests:-
The viscosity of a fluid is a measure of its resistance to gradual deformation
by shear stress or tensile stress. For liquids, it corresponds to the informal
notion of "thickness".
Viscosity is due to the friction between neighbouring particles in a fluid that
are moving at different velocities. When the fluid is forced through a tube, the
fluid generally moves faster near the axis and very slowly near the walls;
therefore, some stress (such as a pressure difference between the two ends of
the tube) is needed to overcome the friction between layers and keep the fluid
moving. For the same velocity pattern, the stress required is proportional to
the fluid's viscosity. A liquid's viscosity depends on the size and shape of its
particles and the attractions between the particles.
A fluid that has no resistance to shear stress is known as an ideal fluid or in
viscid fluid. Zero viscosity is observed only at very low temperatures, in super
fluids. Otherwise all fluids have positive viscosity. If the viscosity is very high,
for instance in pitch, the fluid will appear to be a solid in the short term. A
liquid whose viscosity is less than that of water is sometimes known as
a mobile liquid, while a substance with a viscosity substantially greater than
water is called a viscous liquid
Viscosity is measured with various types of viscometers and rheometers. A
rheometer is used for those fluids that cannot be defined by a single value of
viscosity and therefore require more parameters to be set and measured than
is the case for a viscometer. Close temperature control of the fluid is essential
to acquire accurate measurements, particularly in materials like lubricants,
whose viscosity can double with a change of only 5 °C.

33. For some fluids, viscosity is a constant over a wide range of shear rates
(Newtonian fluids). The fluids without a constant viscosity (non-Newtonian
fluids) cannot be described by a single number. Non-Newtonian fluids exhibit a
variety of different correlations between shear stress and shear rate.
One of the most common instruments for measuring kinematic viscosity is the
glass capillary viscometer.
In coating industries, viscosity may be measured with a cup in which the efflux
time is measured. There are several sorts of cup- e.g. Zahn cup, Ford viscosity
cup- with usage of each type varying mainly according to the industry. The
efflux time can also be converted to kinematic viscosities (centistokes, cSt)
through the conversion equations.
Also used in coatings, a Stormier viscometer uses load-based rotation in order
to determine viscosity. The viscosity is reported in Krebs units (KU), which are
unique to Stormier viscometers.
Vibrating viscometers can also be used to measure viscosity. These models
such as the Dynatron use vibration rather than rotation to measure viscosity.
Extensional viscosity can be measured with various rheometers that
apply extensional stress.
Volume viscosity can be measured with an acoustic rheometer.
Apparent viscosity is a calculation derived from tests performed on drilling
fluid used in oil or gas well development. These calculations and tests help
engineers develop and maintain the properties of the drilling fluid to the
specifications required.

34. Ford Cup:
The Ford viscosity cup is a simple gravity device that permits the timed flow of
a known volume of liquid passing through an orifice located at the bottom.
Under ideal conditions, this rate of flow would be proportional to
the kinematic viscosity (expressed in stokes and centistokes) that is dependent
upon the specific gravity of the
draining liquid. However, the
conditions in a simple flow cup are
seldom ideal for making true
measurements of viscosity. It is
important when using a Ford Cup and
when retesting liquids that the
temperature of the cup and the liquid
is maintained, as ambient temperature
makes a significant difference to
viscosity and thus flow rate.
The original Ford Cup was based on Imperial (US) measurement of the
aperture.
Din Cup 4 mm., standard DIN 53211 (cancelled) ISO Cup 2, 3, 4, 5, 6, 8 mm.
standard ISO 2431 AFNOR Cup 2,5, 4, 6, 8 mm. standard NF T30-014 ASTM Cup
1,2,3,4,5 standard ASTM D1200
Here Paint used for Painting Chain Case, Connecting Rod is Nerolec Paint.
The Ford Viscosity Cup which is used in Company has volume of 100-106 ml.
Viscosity test must repeat after every 4 hours.
Total Time is 30 min. in Painting Procedure of Chain Case & Connecting Rod.

35. Coat Type Ford Viscosity Cup Value
Primer Coat 15-18 sec
Base Coat 17-20 sec
Top Coat 15 sec

Pre Discharge Inspection of Painted Parts:-
This PDI involves two steps of inspection:-
1. First check every side that should be painted uniformly.
2. Check every side carefully no scratch should be there.
3. If any problem occurs then part should be again hanging in TAG RAG.
Precaution to take in Painting:-
1. Hang parts on hanger carefully.
2. All the tests must be performed after regular time interval.
3. Carefully check every part in TAG RAG chamber
4. Every Part should be unloaded carefully
5. Every movement must be like the last movement of spray gun in the
coating chamber.
6. Heating Chambers should be clean by HNO3 after every rest of machine.
Total annual error in painting of Chain Case and Connecting Rod is 0.2%.
Conclusion of Project:-
Painting procedure of the Chain Case of Honda Unicorn and Connecting Rod of
Honda Unicorn and Honda Activa is completed. No error was found in working
procedure.

36. Object:- Making process of Step Pillion of Honda Activa.
Abstract:- Step Pillion or Foot Rest is provided for the relaxation of back sitter
foot. This is made of Mild Steel and attached with the frame. Honda Activa has
two foot rest Left Side and Right Side. This step pillion is jointed via Mig
Welding Process and it is jointed to frame via Electric Arc Welding.
MIG Welding:-
Metal Inert Gas (MIG) welding, sometimes referred to by Gas metal arc
welding (GMAW) welding or metal active gas (MAG)welding, is a welding
process in which an electric arc forms between a
consumable wire electrode and the work piece metal(s), which heats the work
piece metal(s), causing them to melt, and join. Along with the wire electrode,
a shielding gas feeds through the welding gun, which shields the process from
contaminants in the air. The process can be semi-automatic or automatic. A
constant voltage, direct current power source is most commonly used with
GMAW, but constant current systems, as well as alternating current, can be
used. There are four primary methods of metal transfer in GMAW, called
globular, short-circuiting, spray, and pulsed-spray, each of which has distinct
properties and corresponding advantages and limitations.
Originally developed for welding aluminium and other non-ferrous materials in
the 1940s, GMAW was soon applied to steels because it provided faster
welding time compared to other welding processes. The cost of inert gas
limited its use in steels until several years later, when the use of semi-inert
gases such as carbon dioxide became common. Further developments during
the 1950s and 1960s gave the process more versatility and as a result, it
became a highly used industrial process. Today, GMAW is the most common
industrial welding process, preferred for its versatility, speed and the relative

37. ease of adapting the process to robotic automation. Unlike welding processes
that do not employ a shielding gas, such as shielded metal arc welding, it is
rarely used outdoors or in other areas of air volatility. A related process, flux
cored arc welding, often does not use a shielding gas, but instead employs an
electrode wire that is hollow and filled with flux.
Equipment of MIG:-
To perform gas metal arc welding, the basic necessary equipment is a welding
gun, a wire feed unit, a welding power supply, an electrode wire, and
a shielding gas supply.
Welding Gun:-
The typical GMAW welding gun has a number of key parts—a control switch, a
contact tip, a power cable, a gas nozzle, an electrode conduit and liner, and a
gas hose. The control switch, or trigger, when pressed by the operator, initiates
the wire feed, electric power, and the shielding gas flow, causing an electric arc
to be struck. The contact tip, normally made of copper and sometimes
chemically treated to reduce spatter, is connected to the welding power
source through the power cable and transmits the electrical energy to the
electrode while directing it to the weld area. It must be firmly secured and
properly sized, since it must allow the electrode to pass while maintaining
electrical contact. On the way to the contact tip, the wire is protected and
guided by the electrode conduit and liner, which help prevent buckling and
maintain an uninterrupted wire feed. The gas nozzle directs the shielding gas
evenly into the welding zone. Inconsistent flow may not adequately protect
the weld area. Larger nozzles provide greater shielding gas flow, which is useful
for high current welding operations that develop a larger molten weld pool. A
gas hose from the tanks of shielding gas supplies the gas to the nozzle.

38. Sometimes, a water hose is also built into the welding gun, cooling the gun in
high heat operations.
The wire feed unit supplies the electrode to the work, driving it through the
conduit and on to the contact tip. Most models provide the wire at a constant
feed rate, but more advanced machines can vary the feed rate in response to
the arc length and voltage. Some wire feeders can reach feed rates as high as
30.5 m/min (1200 in/min), but feed rates for semiautomatic GMAW typically
range from 2 to 10 m/min (75–400 in/min)
Tool style:-
The top electrode holder is a semiautomatic air-cooled holder. Compressed air
circulates through it to maintain moderate temperatures. It is used with lower
current levels for welding lap or butt joints. The second most common type of
electrode holder is semiautomatic water-cooled; where the only difference is
that water takes the place of air. It uses higher current levels for welding T or
corner joints. The third typical holder type is a water cooled automatic
electrode holder—which is typically used with automated equipment.
Power Supply:-
Most applications of gas metal arc welding use a constant voltage power
supply. As a result, any change in arc length (which is directly related to
voltage) results in a large change in heat input and current. A shorter arc
length causes a much greater heat input, which makes the wire electrode melt
more quickly and thereby restore the original arc length. This helps operators
keep the arc length consistent even when manually welding with hand-held
welding guns. To achieve a similar effect, sometimes a constant current power
source is used in combination with an arc voltage-controlled wire feed unit. In
this case, a change in arc length makes the wire feed rate adjust to maintain a

39. relatively constant arc length. In rare circumstances, a constant current power
source and a constant wire feed rate unit might be coupled, especially for the
welding of metals with high thermal conductivities, such as aluminium. This
grants the operator additional control over the heat input into the weld, but
requires significant skill to perform successfully.
Alternating current is rarely used with GMAW; instead, direct current is
employed and the electrode is generally positively charged. Since
the anode tends to have a greater heat concentration, this results in faster
melting of the feed wire, which increases weld penetration and welding speed.
The polarity can be reversed only when special emissive-coated electrode
wires are used, but since these are not popular, a negatively charged electrode
is rarely employed.
Electrode:-
Electrode selection is based primarily on the composition of the metal being
welded, the process variation being used, joint design and the material surface
conditions. Electrode selection greatly influences the mechanical properties of
the weld and is a key factor of weld quality. In general the finished weld metal
should have mechanical properties similar to those of the base material with
no defects such as discontinuities, entrained contaminants or porosity within
the weld. To achieve these goals a wide variety of electrodes exist. All
commercially available electrodes contain deoxidizing metals such
as silicon, manganese, titanium and aluminium in small percentages to help
prevent oxygen porosity. Some contain denaturising metals such as titanium
and zirconium to avoid nitrogen porosity. Depending on the process variation
and base material being welded the diameters of the electrodes used in
GMAW typically range from 0.7 to 2.4 mm (0.028–0.095 in) but can be as large

40. as 4 mm (0.16 in). The smallest electrodes, generally up to 1.14 mm
(0.045 in) are associated with the short-circuiting metal transfer process, while
the most common spray-transfer process mode electrodes are usually at least
0.9 mm (0.035 in).
Shielding Gas:-
Shielding gases are necessary for gas metal arc welding to protect the welding
area from atmospheric gases such as nitrogen and oxygen, which can cause
fusion defects, porosity, and weld metal embrittlement if they come in contact
with the electrode, the arc, or the welding metal. This problem is common to
all arc welding processes; for example, in the older Shielded-Metal Arc Welding
process (SMAW), the electrode is coated with a solid flux which evolves a
protective cloud of carbon dioxide when melted by the arc. In GMAW,
however, the electrode wire does not have a flux coating, and a separate
shielding gas is employed to protect the weld. This eliminates slag, the hard
residue from the flux that builds up after welding and must be chipped off to
reveal the completed weld.
The choice of a shielding gas depends on several factors, most importantly the
type of material being welded and the process variation being used. Pure inert
gases such as argon and helium are only used for nonferrous welding; with
steel they do not provide adequate weld penetration (argon) or cause an
erratic arc and encourage spatter (with helium). Pure carbon dioxide, on the
other hand, allows for deep penetration welds but encourages oxide
formation, which adversely affect the mechanical properties of the weld. lts
low cost makes it an attractive choice, but because of the reactivity of the arc
plasma, spatter is unavoidable and welding thin materials is difficult. As a
result, argon and carbon dioxide are frequently mixed in a 75%/25% to

41. 90%/10% mixture. Generally, in short circuit GMAW, higher carbon dioxide
content increases the weld heat and energy when all other weld parameters
(volts, current, electrode type and diameter) are held the same. As the carbon
dioxide content increases over 20%, spray transfer GMAW becomes
increasingly problematic, especially with smaller electrode diameters.
Argon is also commonly mixed with other gases, oxygen, helium, hydrogen,
and nitrogen. The addition of up to 5% oxygen (like the higher concentrations
of carbon dioxide mentioned above) can be helpful in welding stainless steel,
however, in most applications carbon dioxide is preferred. Increased oxygen
makes the shielding gas oxidize the electrode, which can lead to porosity in the
deposit if the electrode does not contain sufficient deoxidizers. Excessive
oxygen, especially when used in application for which it is not prescribed, can
lead to brittleness in the heat affected zone. Argon-helium mixtures are
extremely inert, and can be used on nonferrous materials. A helium
concentration of 50%–75% raises the required voltage and increases the heat
in the arc, due to helium's higher ionization temperature. Hydrogen is
sometimes added to argon in small concentrations (up to about 5%) for
welding nickel and thick stainless steel work pieces. In higher concentrations
(up to 25% hydrogen), it may be used for welding conductive materials such as
copper. However, it should not be used on steel, aluminium or magnesium
because it can cause porosity and hydrogen embrittlement.
Operation:-
For most of its applications gas metal arc welding is a fairly simple welding
process to learn requiring no more than a week or two to master basic welding
technique. Even when welding is performed by well-trained operators weld
quality can fluctuate since it depends on a number of external factors. All

42. GMAW is dangerous, though perhaps less so than some other welding
methods, such as shielded metal arc welding. The basic technique for GMAW is
quite simple, since the electrode is fed automatically through the torch (head
of tip). By contrast, in gas tungsten arc welding, the welder must handle a
welding torch in one hand and a separate filler wire in the other, and in
shielded metal arc welding, the operator must frequently chip off slag and
change welding electrodes. GMAW requires only that the operator guide the
welding gun with proper position and orientation along the area being welded.
Keeping a consistent contact tip-to-work distance (the stick out distance) is
important, because a long stick out distance can cause the electrode to
overheat and also wastes shielding gas. Stick out distance varies for different
GMAW weld processes and applications. The orientation of the gun is also
important—it should be held so as to bisect the angle between the work
pieces; that is, at 45 degrees for a fillet weld and 90 degrees for welding a flat
surface. The travel angle, or lead angle, is the angle of the torch with respect to
the direction of travel, and it should generally remain approximately vertical.
However, the desirable angle changes somewhat depending on the type of
shielding gas used—with pure inert gases; the bottom of the torch is often
slightly in front of the upper section, while the opposite is true when the
welding atmosphere is carbon dioxide.
Advantages of MIG welding:-
The ability to join a wide range of metals and thicknesses
All-position welding capability
A good weld bead
A minimum of weld splatter

43. Easy to learn
Disadvantages of MIG welding:-
MIG welding can only be used on thin to medium thick metals
The use of an inert gas makes this type of welding less portable than arc
welding which requires no external source of shielding gas
Produces a somewhat sloppier and less controlled weld as compared to TIG
(Tungsten Inert Gas Welding)
Parts:-
1. Holder
2. Cable Tie
3. R Pipe
4. Straight Pipe
5. Stay
6. Patgn (Thick and Thin)
7. Gusset Stay
8. MIG Welding
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. After this all inspection Gusset Holder will join with R Pipe and Straight
Pipe.
4. In next step Patgn will join with upper made assembly.
5. Further Stay will join with made assembly.

44. 6. Then Cable Tie and Gusset Stay will join with assembly in left side assembly
of pillion whole process is same but cable tie will not be jointed. Then it will
send to PDI.
Pre Discharge Inspection of Step Pillion:-
1. First we check all the part by pillion gauge.
2. Then we check the welding and overlapping of metal at joints.
3. In last all hole consisting part will check.
Total Annual defect is 5% in the production of step pillion of Honda Activa.
Total time for the making of step pillion of Honda Activa is 20 second.
Precaution for production of Step Pillion:-
1. Always use a black glass eye protective film in welding procedure.
2. Always wear gloves in welding procedure.
3. Always wear an apron before start welding.
4. Always wear long boots to prevent skin from spark.
5. Always check gas nozzle before start.
Conclusion of Project:-
Production procedure of Step Pillion of Honda Activa is completed. The total
error find is 10% in my work.

45. Object:- Production procedure of Frame of Honda Activa KWPG.
Abstract:- A frame is the main structure of the chassis of a motor vehicle. All
other components fasten to it; a term for this design is body-on-frame
construction.
The main functions of a frame in motor vehicles are:-
 To support the vehicle's chassis components and body
 To deal with static and dynamic loads, without undue deflection or
distortion.
These include:
 Weight of the body, passengers, and cargo loads.
 Vertical and torsion twisting transmitted by going over uneven surfaces.
 Transverse lateral forces caused by road conditions, side wind, and
steering the vehicle.
 Torque from the engine and transmission.
 Longitudinal tensile forces from starting and acceleration, as well as
compression from braking.
 Sudden impacts from collisions.
A motorcycle frame includes the head tube that holds the front fork and allows
it to pivot. Some motorcycles include the engine as a load-bearing, stressed
member. The rear suspension is an integral component in the design.
Traditionally frames were steel, but titanium, aluminium, magnesium,
and carbon-fibre, along with composites of these materials, are now used.
Because of different motorcycles' varying needs of cost, complexity, weight
distribution, stiffness, power output and speed, there is no single ideal frame
design.

46. Material used for Frame:-
 Steel
 Aluminium
 Carbon Fibre
 Titanium
 Magnesium
 Composite
Type of Two Wheeler Frame:-
 Spine or Backbone
 Single Cradle
 Half-Duplex Cradle
 Full Duplex Cradle
 Perimeter
 Beam
 Pressed
 Monocoque
 Trellis
 Underbone
The frame is welded via electric arc welding.
Electric Arc Welding:-
Arc welding is a type of welding that uses a welding power supply to create
an electric arc between an electrode and the base material to melt the metals
at the welding point. They can use either direct (DC) or alternating (AC)
current, and consumable or non-consumable electrodes. The welding region is
usually protected by some type of shielding gas, vapor, or slag. Arc welding

47. processes may be manual, semi-automatic, or fully automated. First developed
in the late part of the 19th century, arc welding became commercially
important in shipbuilding during the Second World War. Today it remains an
important process for the fabrication of steel structures and vehicles.
Power Supply:-
To supply the electrical energy necessary for arc welding processes, a number
of different power supplies can be used. The most common classification is
constant current power supplies and constant voltage power supplies. In arc
welding, the voltage is directly related to the length of the arc, and the current
is related to the amount of heat input. Constant current power supplies are
most often used for manual welding processes such as gas tungsten arc
welding and shielded metal arc welding, because they maintain a relatively
constant current even as the voltage varies. This is important because in
manual welding, it can be difficult to hold the electrode perfectly steady, and
as a result, the arc length and thus voltage tend to fluctuate. Constant voltage
power supplies hold the voltage constant and vary the current, and as a result,
are most often used for automated welding processes such as gas metal arc
welding, flux cored arc welding, and submerged arc welding. In these
processes, arc length is kept constant, since any fluctuation in the distance
between the wire and the base material is quickly rectified by a large change in
current. For example, if the wire and the base material get too close, the
current will rapidly increase, which in turn causes the heat to increase and the
tip of the wire to melt, returning it to its original separation distance.
The direction of current used in arc welding also plays an important role in
welding. Consumable electrode processes such as shielded metal arc welding
and gas metal arc welding generally use direct current, but the electrode can

48. be charged either positively or negatively. In welding, the positively
charged anode will have a greater heat concentration and, as a result,
changing the polarity of the electrode has an impact on weld properties. If the
electrode is positively charged, it will melt more quickly, increasing weld
penetration and welding speed. Alternatively, a negatively charged electrode
results in more shallow welds. Non-consumable electrode processes, such as
gas tungsten arc welding, can use either type of direct current (DC), as well as
alternating current (AC). With direct current however, because the electrode
only creates the arc and does not provide filler material, a positively charged
electrode causes shallow welds, while a negatively charged electrode makes
deeper welds. Alternating current rapidly moves between these two, resulting
in medium-penetration welds. One disadvantage of AC, the fact that the arc
must be re-ignited after every zero crossing, has been addressed with the
invention of special power units that produce a square wave pattern instead of
the normal sine wave, eliminating low-voltage time after the zero crossings
and minimizing the effects of the problem.
Duty cycle is a welding equipment specification which defines the number of
minutes, within a 10 minute period, during which a given arc welder can safely
be used. For example, an 80 A welder with a 60% duty cycle must be "rested"
for at least 4 minutes after 6 minutes of continuous welding. Failure to observe
duty cycle limitations could damage the welder. Commercial- or professional-
grade welders typically have a 100% duty cycle.
The pros of ARC welding are:-
 The equipment that is used for welding purposes is not very expensive and
can be afforded by all. It is also easy to use. This makes it very convenient
for people who want to weld using ARC welding.

49.  You will generally think of welding equipment as being unwieldy and
heavy. The equipment used in ARC welding is portable making it very easy
for use in all places. It can be taken to any place and can also be inside a
confined place.
 It is not necessary to have auxiliary gas shielding.
 The reason that it is most used is that it is suitable for welding most metals
and alloys. So, you need not go in for different types of welding and can do
with ARC welding.
The cons of Arc welding are:-
 There is need to replace the weld electrode in ARC welding frequently. So,
care should be taken to do it whenever necessary.
 The rate of deposition is lower than continuous electrode process.
 It is necessary to remove the slag from the weld.
 When welding, very bright is produced. The welding operator should be
very careful and wear protective glasses. The welder should also wear
protective gear, so that he is protected from electric shock, burns and
other problems that might arise while welding due to the high intensity of
heat.
 Welding is an essential process for joining two metals and arc welding is
most commonly used because of the minimum equipment used and a
person with minimum training. So, you should consider the pros and cons
before starting to arc weld. Since the cons can all be taken care of and arc
welding is a very useful and simple process for welding, people should use
it for welding purposes.

50. Methodology:-
ERW Steel 2 is used to make frame which has
Thickness = 2.60 mm, 1.60 mm
Diameter = 38.10 mm
Length = 929 mm
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 pipe,
grade of the metal pipe and the visual defects of the metal pipe.
3. In after inspection step pipe is bended via Bending Machine which is made
by YLM Taiwan. It is a computer operated system. This machine used
Hydraulic energy for Clamping, Holding and Pressing. The pressure is used
to bend this pipe is 110 Kg/cm
2
with maximum tolerance of 1 mm. Here
pipe is bended to a pre defined shape. Honda Avtiva has underbone type of
frame.
4. After bending the pipe sanded to Milling Section. In this section milling
section Drill holes in it during the drill operation water is used as coolant.
5. Than operation performed pipe sanded for Grinding Operation. In this
section Grinder wheel is used to finish surface and remove extra material
from pipe.
6. In next step of assembly a Rod opener and centre cross welding has to be
done.
7. Then this prepared pipe sanded for the assembly. In first step of assembly
pipe is pivoted and under covered.

51. 8. In next step L shape bended pipe welded with Seat Lock, Duet Pipe and join
with 3 rubber clips.
9. Then a robot do Round welding of duet pipe. Rear frame is prepared by
going through these steps.
10. In the assembly of front frame first bended pipe join with Lower Cross via
Patch Welding
11. Then main pipe joint with Lower Cross via welding.
12. Then at next assembly main pipe head pipe, gusset pipe, step bar join via
welding and a wise harshness has clipped with it.
13. Then to make these permanent joint an open final welding has to be done.
14. Then an open final welding and round welding joint both side of frames.
15. Then main pipe gusset is jointed with round welding.
16. Then guide cable, RR break cable, guide throsed cable jointed and sand for
quality check.
Quality Check of Honda Activa Frame:-
 In first step of quality check the completed frame grinded and reworked.
 The fine boring operation has to be done where required.
 Then tapping operation performed and Frame sand to PDI.
Pre Discharge Inspection of Frame:-
1. In first step of PDI a hand jig gauge is used to inspect.
2. Then final gauge is used to inspect
3. Then all welded joints and curves has inspected.
The total process of assembling of both frames is completed in 30 seconds.
The total annual defects are 0.20% of total production.
Problems occur with production of Honda Activa Frame:-

52. Problems with bending operation:
1. Due to the uneven grains many times wrinkle occur during bending. This
problem cannot be solved. This makes pipe waste.
2. Due to uneven force many times bending variation occurs. This is also a
insolvable problem and makes pipe waste.
Problem with milling operations:
1. Due to uneven grains notching problem occurs and this is also insolvable
problem and makes pipe waste.
2. Due to wear of drill jig many times holes drilling get uneven. This problem
can be solved via drilling with new jig.
Problem with grinding operation:
1. Due to problem in pipe shape and grinding wheel more chip get removed
from pipe. This may make pipe waste.
2. Surface Finish
Conclusion of Project:
The production procedure of Honda Activa Frame completed. This procedure
makes me able to work in hard environment. The error in my work of
production procedure is 10%.

53. 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.