Career Episode 11

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c          !   "  # $ !$% %&'((#&$) h  &* From 02nd May 2005 to 23rd May 2005 Duration: 21 Days.

h £ +* c$& * Neelambur, Coimbatore 641 014 Tamilnadu India Phone:+91 422 - 2628567, 2628568, 2627055 Fax: +91 4222 ± 2628569 Website:www.psgfoundry.in h $ * PSG & SONS CHARITIES, Metallurgy & Foundry Division

h * Final year engineering student - Trainee Engineer

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I completed my Bachelor degree from Coimbatore Institute of Technology (CIT), Coimbatore, an autonomous institution affiliated to Anna University, Chennai, India, in Mechanical Engineering, during the academic year 2002-2007. It was a part of my mechanical engineering prospectus to pursue industrial training during my course period. As per the requirement of my curriculum, I prepared a detailed report of my industrial training and submitted it to the faculty of Mechanical Engineering. PSG & SONS CHARITIES Metallurgy & Foundry Division, India is an expertise inPressure Die Cast Components)Plastic injection mould componentsanddesign & manufacture of Various Tools. The main aim of the training is to have a real industrial experience and to learn about the implementation of our engineering knowledge in the industry. During my training, I focussed on designing of the die used to manufacture the components, the casting and moulding of the components, and till the packing process. The company supplies to extensive range of industries including Automobile, auto ancillary, textile machinery, Consumer durables, auto electricals, etc.,  c ''*,0c1/.
£ The objectives of the training taken by me at English Tools & Castings Pvt. Ltd., India were as mention below, h To study the component drawings supplied by the customers. h To make use of my AutoCAD, Proe knowledge in designing of the die as per the drawing requirements of the component. h To study about the manufacturing operations carried out in the process. h To understand the various operating conditions and the parameters needed for moulding and injection process. h To study about the inspection process, packing & delivery of components to the customers.

h Provide training in the use of Coordinate Measuring Machine (CMM). During my training, I was given a schedule by the company concerning my training in various departments like planning, design, manufacturing and marketing. I was allocated to spend more of my time in manufacturing area undergoing training in each and every operation carried out in the machine. As per the company regulation, I provided daily report to my senior official. I was given training 8 hours every day. c '2*. 
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The nature of my particular work area during training was, o My work was to get trained in the design department for design calculations required for die design and also to make drafting of the die using AutoCAD, Proe and Solidworks. o My job was to understand the various operations related to moulding and casting of the components by spending most of my time in manufacturing department. o My job was to get trained in knowing the chemical properties of various ingredients used for injection moulding. o My job was to get trained in quality inspection of the components. o As a part of my training, I designed a die for a component named Bracket using AutoCAD, Proe and Solidworks with the support of the design department.          

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-+ c c14 My training at PSG & SONS CHARITIES, Metallurgy & Foundry Division was my first industrial experience related to mechanical engineering. In the initial days of my training, I started with knowing the company policies, objectives, their product manufacturing range and their customers. I was trained by the design engineers and production engineers about the designing process and the production operations. I used my knowledge obtained during my course when undergoing training in each department. I referred to manuals used by each

department in order to get a clear view of what each department deals with and also to know the structure of the departments.

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 c 2   The first step was that I got trained in designing pressure die casting dies, die parts and Plastic moulds. AutoCAD, ProE and Solid works was used for designing. I had knowledge in using AutoCAD and so I learned using ProE and Solid works with the help of the design engineers. I also gained knowledge in reading complex engineering drawings provided to us by our customers. With the things I learned, I designed a die comprising two parts for a component called Bracket taking into consideration the gate for the die and passage for the moulding metal. c 2 ' After training in the design department, I was schedules to be trained in Pressure die casting operations. In Pressure die casting, molten metal was forced into the cavities of steel moulds. Metals used include zinc and aluminium. This process was used to mould components that Have a very smooth surface. Precise in dimensions Have very thin sections Additional movable slides were used with the die to make undercuts in the components. Various post die casting operations like shot blasting, lacquering, vibro-finishing and fettling is also done. c 2 2 Then I got trained in Plastic moulding process. Here the thermoplastic materials like polypropylene (PP), Acrylonitrile Butadiene Styrene (ABS) were used in injection moulding. The plastic raw material granules were placed in the hopper. The injection unit takes them, heats them until molten, and injects them into the mould. The machine has a barrel that contains an injection screw. The heater bands are outside the barrel, which raises the temperature to the correct level to melt the plastic. When the right amount of molten material for the next shot has been accumulated the screw stops rotating. The screw then acts like a plunger and

moves forward and forces the molten plastic into the mould. After injecting the molten plastic into the mould, pressure is applied to ensure all cavities are filled. This is called dwelling. The result is that the shape is exactly copied. Once the plastic moulding has cooled sufficiently, the mould opens releasing the part. The whole injection moulding process then repeats. c 2 6 + c0c3+£3 c. 

I learned about the various parts in a mould. They are as follows: Guide pins: This was fixed to one half of the mould and it aligns the two halves by entering the holes in the other half. Runner: It is the aisle in the mould connecting the cavities. Gate: Gate is the point where the runner and cavity meet. It is the weak point enabling the moulding to be easily broken or cut from the runner.

Sprue Bush: It is the tapered hole in the centre of the mould into which the molten plastic is first injected. Locating Ring: It positions the mould on the fixed platen so that, the injection nozzle lines up with the sprue bush. Mould Cavity: The space in the mould shaped to produce the finished component. Ejector pins: These pins push the moulding out of the mould. c 2 ; I completed my training in major production areas in 10 days. Then I got trained in special purpose machines used for certain operations performed in the die to get the designed die. One of them was EDM machines. It is used for removing material by electric arching between electrode and the work piece. The particles are washed away by continuously flushing dielectric fluid. The other was wire cut machine. In this a thin metal wire was fed through the work piece. The movement is usually controlled by CNC. Also learned post moulding operations like spray painting and screen printing. c 2 # I also got trained in Quality department about inline inspections. I learned the inspection of components using various quality equipments like CMM, Hardness tester, Projector and Trimos height gauge. The calibration schedule for measuring instruments with traceability was also observed.

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The Manager (Plastic Injection & Moulding Division) allotted me three tasks. The first task was daily submission of a brief summary report concerning about what knowledge I gained that day. My second task was to design a die for Die casting of one of the components named Bracket. I completed the task successfully in the given time frame. The third task was to make a final report containing all that I learned in the training and do a presentation to the employees of the company.

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4 At the end of my training at PSG & SONS CHARITIES, Metallurgy & Foundry Division., I learnt the various steps in the manufacturing industry like design, planning, production, quality, sales and purchase. I learnt the application of AutoCAD, ProE and Solid Works software for drafting the die of the product. The training at English Tools & Castings Pvt. Ltd., provided me the knowledge of manufacturing processes moulding, casting, drilling, tapping, shot blasting, vibro finishing and also the use of special quality equipment like CMM. It was my first industrial training and I learnt the technical applications of my knowledge in the field of mechanical engineering. I was given training certificate from English Tools & Castings Pvt. Ltd., for my work in the company.