Chapter-1

INTRODUCTION

Talbros Automotive Components Ltd., the flagship manufacturing company of the Group was
established in the year 1956 to manufacture Automotive & Industrial Gaskets in collaboration
with Coopers Payen of UK.

Today, after 58 successful years, Talbros stands proud and tall as a mother brand of Gaskets &
Heat Shields, Forgings, Suspension Systems & Modules, Anti Vibration components and Hoses.

Talbros Group has strong partnerships formed with global giants. Notable among the joint
venture partners are Nippon Leakless Corporation- Japan, Magneti Marelli- Italy, Marugo
Rubber- Japan and technology partners are Sanwa Packaging Japan and Interface Solutions
USA.

While our symbiotic relationship with our Global partners have kept us abreast with
innovations within the field, our long and fruitful association with them bears witness to the
trust and solidarity that Talbros name is synonymous with.

Our Research & Development Centres showcase our design capabilities including endurance,
static and simulated environment testing. Today, our manufacturing prowess spans over 5
business and 8 facilities.

The largest OEMs like Ashok Leyland, Bajaj Auto, Cummins Group, Eicher India, Escorts Group,
Force Motors, General Motors, Hero Honda, Honda, Hyundai, John Deere, Mahindra &
Mahindra, Maruti Suzuki, Suzuki, TAFE, Tata Motors, Tata Cummins, Simpsons and international
corporates like Carraro, DANA, KMP Brand, Maxi Force, GKN Driveline are our proud customers.
I

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The Group companies are TS 16949, ISO 14001 and OHSAS 18001 certified. Our team takes the
quest for quality very seriously. For every piece that is manufactured, quality standards are
strictly adhered to and industry benchmarks often set.
Our unrelenting quest for perfection extends to the supply chain and to every person
responsible for extending quality service to the customer.
Talbros is where it is today due to the excellence of its product offerings, its commitment to
quality, attention to detail and, primarily, due to its incredible workforce. Our people-friendly
and professional approach towards human resource development is responsible for our
remarkably low attrition rate.
Constant upgradation of skills at training programmes in India and abroad and an exemplary
work culture has made every member of our team geared for new challenges. Both employee
and customer satisfaction are of extreme importance to us.
Talbros Group portfolio also includes Mercedes Benz dealership for passenger cars.
Talbros, where it is today is due to the excellence of its product offerings, commitment to
quality, attention to detail and professional approach.

Fig: 1.1 Company Logo

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1.2 GLOBAL PARTNERSHIPS

The Indian automobile industry is growing leaps and bounds. With new players from across the
globe venturing into the Indian market to tap its immense and future potential, the demand for
cutting-edge automotive components is skyrocketing.
To further consolidate its leadership position in such a scenario, and provide its customers with
world-class components, Talbros Group has entered into partnerships with global giants. Each
of these partnerships brings along new know-how, technology and vast experience, and
empowers the Group to further enhance its product offerings for its esteemed customers.

1. Nippon Leakless (JV partner in Nippon Leakless Talbros Pvt. Ltd.)

Established in 1955 Nippon Leakless is one of the largest global manufacturers of Gaskets for
Automotive, Motorcycle, Power Equipment, Industrial and a major Honda supplier.
Head quarter in SAITAMA Japan With facilities spread over 10 countries; it has annual sales of
US$ 156 million. Its range of in-house developed products like Mats and Rubber Coating.

2. Magneti Marelli (JV partner in Magneti Marelli Talbros Chassis Systems Pvt. Ltd.)
With 8 business lines, 85 manufacturing units, 26 application centre and 12 R&D facilities in
Italy, Germany, France, Brazil and India, Magneti Marelli is a name to reckon with in the
automotive industry the world over. Employing over 38,000 people globaly and having an
annual sale of 6 Billion. Its technological and design prowess, added to its vast experience in
manufacturing is simply unmatched.

3. Marugo Rubber (JV partner in Talbros Marugo Rubber Pvt. Ltd.)

Marugo Rubber is a US $ 300 million company headquartered in Kurashiki, Japan. It is a leading
supplier of anti-vibration products and hoses to OEMs globally. Through subsidiaries or joint
ventures, it has manufacturing facilities in 9 countries outside Japan, which include US, China,
Germany, UK, Thailand, Indonesia, Malaysia, India and Taiwan.
4. Sanwa Packing (Technology Partner in Talbros Automotive Components Limited.)
Sanwa Packing came into existence in 1945 to manufacture automobile gaskets. Since then it
has come a long way and created a diverse set of gaskets products based on metal -forming and
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coating technologies. Today, its gasket and heat shield products especially the Nimbus Heat
shield developed in 1975, is widely used in the automotive industry. With manufacturing base
in China and Thailand, has a diverse customer base including Daihatsu; Toyota; Honda, Suzuki
and Nissan.

1.3 Awards and milestones

1. BAJAJ AUTO (Award received from Bajaj Auto)

2. EICHER MOTORS (Best Vendor Award)

3. WELFARE AWARDS

4. HONDA (Performance Award For Achieving Quality And Delivery Targets (2010-11))

5. MAHINDRA & MAHINDRA AWARDS (Superior Performance(2011)

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Chapter-2
COMPANY MANUFACTURED

2.1.1 STEERING & SUSPENSION COMPONENTS-> TRACK CONTROL ARMS

-> SUSPENSION BALL JOINTS
-> INNER AND OUTER BALL JOINT

2.1.2 WISHBONES

SHEET METAL
FORGED AND ALUMINIUM FORGED
TIE ROD
DRAG ROD
STABLIZER LINK
STEERING LINK
TOURQUE ROD
V FRAME
PITMAN ARMS

1. TIE RODS
Aluminium casting/forging is used to produce aluminium tie-rod ends for the steering systems
of automobiles. First, casting experiments were carried out to attain a satisfactory preform for
forging of tie-rod ends. In the casting experiment, the effects of additives, Ti+B, Zr, Sr, and Mg,
on the mechanical properties and the microstructure of a preform cast were investigated. A
finite element analysis was performed to determine an optimal configuration of the cast
preform. Lastly, a forging experiment was carried out to make the final product of an
aluminium tie-rod end by using the cast preform.

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In the casting experiments, when 0.2% Ti+B and 0.25% Zr were simultaneously added into a
molten AlSi alloy, the highest values of tensile strength and elongation of the cast perform
were obtained. When 0.04% Sr was added into the molten aluminium ally, the finest silicon
structure was observed in the cast perform. The highest hardness was obtained when 0.2% Mg
was added. In the forging experiment, it was confirmed that the optimal configuration of the
perform cast could be predicted by FE analysis. The hardness of a cast/forged product using the
designed perform was superior to that of required specifications.

FIG2.1:- TIE RODS

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2. DRAG LINK
A drag link converts rotary motion from a crank arm, to a second bellcrank, usually in an
automotive steering system.
The term is commonly used in automotive technology for the link in steering linkage that
converts rotation of a pitman arm to a steering arm and eventually to tie rod links which pivot
the wheels to be steered. The drag link converts the sweeping arc of the steering arm to linear
motion in the plane of the other steering links .

FIG 2.2:- DRAG LINK

3. BALL JOINTS
A ball joint is used for allowing free movement in two planes at the same time, including
rotating in those planes. Combining two such joints with control arms enables motion in all
three planes, allowing the front end of an automobile to be steered and a spring and shock
(damper) suspension to make the ride comfortable.

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In an automobile, ball joints are spherical bearings that connect the control arms to the steering
knuckles. They are used on virtually every automobile made and work similarly to the ball-andsocket design of the human hip joint.
A ball joint consists of a bearing stud and socket enclosed in a casing; all these parts are made
of steel. The bearing stud is tapered and threaded, and fits into a tapered hole in the steering
knuckle. A protective encasing prevents dirt from getting into the joint assembly. Usually, this is
a rubber-like boot that allows movement and expansion of lubricant. Motion-control ball joints
tend to be retained with an internal spring, which helps to prevent vibration problems in the
linkage.
On modern vehicles, ball joints are the pivot between the wheels and the suspension of an
automobile. They are today almost universally used in the front suspension, having replaced
the kingpin/ linkpin or kingpin/trunnion arrangement, but can also be found in the rear
suspension of a few higher-performance autos. Ball joints play a critical role in the safe
operation of an automobile's steering and suspension.
Many currently manufactured automobiles worldwide use MacPherson strut suspension, which
utilises one ball joint per side, between the lower end of the strut and the control arm, with the
necessary small amount of articulation at the top of the strut being usually provided by an
elastomeric bearing, within which is a ball bearing to allow free rotation about the steering axis.
So, there are commonly only two ball joints in the suspension, however there will be at least
four (track rod ends and rack ends) in the steering linkage.
In non-MacPherson strut automobile suspension, the two ball joints are called the "upper ball
joint" and "lower ball joint". Lower ball joints are sometimes larger and may wear out faster,
because the fore and aft loads, primarily due to braking, are higher at the bottom bal l joint.
(Torque reaction and drag add at the bottom joint, and partly cancel at the top joint.) Also,
lateral cornering loads are higher at the bottom joint. Depending on the suspension design, the
vertical load from the suspension spring may be handled entirely by the top ball joint, or
entirely by the bottom ball joint. The damper load, (which is low in normal conditions, zero
when stationary, but in peak bump or rebound rate may be almost as large as the spring load) is
usually, but not always, taken on the same ball joint as the spring load. The anti-roll bar loading
is often, but not always, taken on the bottom ball joint. It may be taken by the top ball joint, or
directly from the steering knuckle by ball-jointed drop links.

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FIG 2.3 :- BALL PINS

PURPOSES
If one of the ball joints does not carry spring load, it may be fitted with an internal anti -rattle
spring to keep the ball preferentially in contact with one seat. This was the case in the BMC
Mini of 1959 and its many derivatives, where the lower control arm carried no vertical loading,
so the joint needed and anti-rattle spring, while the top joint, comprising identical parts, was
always in compression due to spring (rubber cone) and damper loads, and s o was not fitted
with a spring.
Other vehicles of the 1960s era, including some Vauxhalls, had lower ball joints with
considerable end float, because the joint was always in tension as the spring and damper loads
were applied via the lower control arm and were always non-zero.
Another example is the Ford Focus, which uses MacPherson struts, and the anti-roll bar is
connected directly to the strut, so the lower ball joint is only carrying fore and aft
traction/braking and lateral cornering loads.

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FAILURES:While there is no exact lifespan that can be put on sealed ball joints, they can fail as early as
80,000 miles (130,000 km) in modern vehicles, and much sooner in older vehicles. Signs of a
failing ball joint may start with a sudden burst sound as a result of ball joint dismantling. Then it
keeps on with clicking, popping or snapping sound when the wheel is turned and eventually
turn into a squeaking sound at the end of a stop, when the gas pedal is used and/or also when
hitting bumps. Another symptom could be 'thud' noises coming from front suspension when
going over bumps. Dry ball joints have dramatically increased friction and can cause the
steering to stick or be more difficult.
If a ball joint fails, the results can be dangerous as the wheel's angle becomes unconstrained,
causing loss of control. Because the tire will be at an unintended angle, the vehicle will come to
an abrupt halt, damaging the tires. Also, during failure, debris can damage other parts of the
vehicle.

FIG 2.4 :- CUTTING SECTION OF BALL PINS

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MAINTAINENCE
Sealed ball joints do not require lubrication as they are "lubed for life". Formerly most ball
joints had grease fitting (sometimes called a grease zerk) and were designed for periodic
addition of a lubricant, however almost all modern cars use sealed ball joints to minimise
maintenance requirements. The lubricant was usually a very high-viscosity lubricant. It is
commonly believed that standard ball joints will outlive sealed ones because eventually the seal
will break, causing the joint to dry out and rust.

4.

CONTROL ARMS:-

In automotive suspension, a control arm, also known as an A-arm, is a hinged suspension link
between the chassis and the suspension upright or hub that carries the wheel.
The inboard (chassis) end of a control arm is attached by a single pivot, usually a rubber
bushing. It can thus control the position of the outboard end in only a single degree of freedom,
maintaining the radial distance from the inboard mount. Although not deliberately free to
move, the single bushing does not control the arm from moving back and forth; this motion is
constrained by a separate link or radius rod.
This is in contrast to the wishbone. Wishbones are triangular and have two widely spaced
inboard bearings. These constrain the outboard end of the wishbone from moving back and
forth, controlling two degrees of freedom, and without requiring additional links.
Control arms are most commonly encountered as part of the MacPherson strut independent
front suspension. The control arms are perpendicular to the axis of the vehicle and are termed
track control arms. A diagonal radius rod constrains the strut from moving forward and back.

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FIG 2.5:- CONTROL ARM

5.

WISHBONES

In automobiles, a double wishbone (or upper and lower A-arm) suspension is an independent
suspension design using two (occasionally parallel) wishbone-shaped arms to locate the wheel.
Each wishbone or arm has two mounting points to the chassis and one joint at the knuckle. The
shock absorber and coil spring mount to the wishbones to control vertical movement. Double
wishbone designs allow the engineer to carefully control the motion of the wheel throughout
suspension travel, controlling such parameters as camber angle, caster angle, toe pattern, roll
center height, scrub radius, scuff and more.

ADVANTAGES AND DISADVANTAGES:Double wishbone suspension provides the engineer more free parameters than some other
types do. It is fairly easy to work out the effect of moving each joint, so the kinematics of the
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suspension can be tuned easily and wheel motion can be optimized. It is also easy to work out
the loads that different parts will be subjected to which allows more optimised lightweight
parts to be designed. They also provide increasing negative camber gain all the way to full
jounce travel, unlike the MacPherson strut, which provides negative camber gain only at the
beginning of jounce travel and then reverses into positive camber gain at high jounce amounts.
Conversely, it may take more space and is slightly more complex than other systems like a
MacPherson strut. Due to the increased number of components within the suspension set up it
takes much longer to service and is heavier than an equivalent MacPherson design. At the other
end of the scale, it offers less design choice than the more costly and complex multi-link
suspension system.

6. PITMAN ARM
The Pitman arm is a steering component in an automobile or truck. As a linkage the steering
box (see recirculating ball) sector shaft, it converts the angular motion of the sector shaft into
the linear motion needed to steer the wheels. The arm is supported by the sector shaft and
supports the drag link or center link with a ball joint. It transmits the motion it receives from
the steering box into the drag (or center) link, causing it to move left or right to turn the wheels
in the appropriate direction. The idler arm is attached between the opposite side of the center
link from the Pitman arm and the vehicle's frame to hold the center or drag link at the proper
height. A worn ball joint can cause play in the steering, and may get worse over time.

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FIG 2.6:- PITMAN ARM

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Chapter -3
MANUFACTURING PROCESS

3.1 MAIN WORKSHOP

THE WORKSHOP FLOOR IS DIVIDED INTO 2 PARTS
1. Machine shop and,
2. Assembly line.

3.1.1 Machine shop

The machine shop is divides in 3 bays
Bay 1
Bay 2
Bay 3

Bay 1 includes magnaflux and drilling machines.

Magnaflux is used to check for internal cracks, which may rise due to several casting and
cooling defects,present in component. The component is exposed to UV rays and the region
where cracks are present appears red. The machine takes 30 minutes to become functIon after
switching on the power supply and once the machine started, the life of the UV bulbs is
reduced by 4 hrs.
Bay 2 includes special purpose machine (SPM) and CNCs. SPMs carry out burnishing process.
Bay 3 includes a mixture, i.e., CNCs, Drilling and Boring Machine.

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3.1.1.1
Computer Numerical control
Computer Numeric Control (CNC) is the automation of machine tools that are operated by
precisely programmed commands encoded on a storage medium as opposed to controlled
manually by hand wheels or levers, or mechanically automated by cams alone. Most NC today
is computer (or computerized) numerical control (CNC), in which computers play an integral
part of the control.

In modern CNC systems, end-to-end component design is highly automated using computeraided design (CAD) and computer-aided manufacturing (CAM) programs. The programs
produce a computer file that is interpreted to extract the commands needed to operate a
particular machine by use of a post processor, and then loaded into the CNC machines for
production. Since any particular component might require the use of a number of different
tools drills, saws, etc. modern machines often combine multiple tools into a single "cell". In
other installations, a number of different machines are used with an external controller and
human or robotic operators that move the component from machine to machine. In either
case, the series of steps needed to produce any part is highly automated and produces a part
that closely matches the original CAD design.

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FIG 3.1 :- CNC MACHINE

Description:Examples of CNC machines

1.

MILLS

CNC mills use computer controls to cut different materials. They are able to
translate programs consisting of specific numbers and letters to move the spindle
(or workpiece) to various locations and depths. Many use G-code, which is a
standardized programming language that many CNC machines understand, while
others use proprietary languages created by their manufacturers. These
proprietary languages, while often simpler than G-code, are not transferable to
other machines. CNC mills have many functions including face milling, shoulder
milling, tapping, drilling and some even offer turning. Standard linear CNC mills

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are limited to 3 axis (X, Y, and Z), but others may also have one or more rotational
axes. Today, CNC mills can have 4 to 6 axes.

2.

LATHES

Lathes are machines that cut workpieces while they are rotated. CNC lathes are able to make
fast, precision cuts, generally using indexable tools and drills. They are particularly effective for
complicated programs designed to make parts that would be infeasible to make on manual
lathes. CNC lathes have similar control specifications to CNC mills and can often read G-code as
well as the manufacturer's proprietary programming language. CNC lathes generally have two
axes (X and Z), but newer models have more axes, allowing for more advanced jobs to be
machined.

FIG 3.2:- BENDING MACHINE

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3.

PLASMA CUTTERS

Plasma cutting involves cutting a material using a plasma torch. It is commonly used to cut steel
and other metals, but can be used on a variety of materials. In this process, gas (such as
compressed air) is blown at high speed out of a nozzle; at the same time an electrical arc is
formed through that gas from the nozzle to the surface being cut, turning some of that gas to
plasma. The plasma is sufficiently hot to melt the material being cut and moves sufficiently fast
to blow molten metal away from the cut.

4.

ELECTRO DISCHARGE MACHINING

Electric discharge machining (EDM), sometimes colloquially also referred to as spark machining,
spark spark eroding, burning, die sinking, or wire erosion, is a manufacturing process in which a
desired shape is obtained using electrical discharges (sparks). Material is removed from the
workpiece by a series of rapidly recurring current discharges between two electrodes,
separated by a dielectric fluid and subject to an electric voltage. One of the electrodes is called
the tool electrode, or simply the "tool" or "electrode," while the other is called the workpiece
electrode, or "workpiece."
When the distance between the two electrodes is reduced, the intensity of the electric field in
the space between the electrodes becomes greater than the strength of the dielectric (at the
nearest point(s)), which electrically break down, allowing current to flow between the two
electrodes. This phenomenon is the same as the breakdown of a capacitor. As a result, material
is removed from both the electrodes. Once the current flow stops (or it is stopped depending
on the type of generator), new liquid dielectric is usually conveyed into the inter-electrode
volume, enabling the solid particles (debris) to be carried away and the insulating properties of
the dielectric to be restored. Adding new liquid dielectric in the inter-electrode volume is
commonly referred to as flushing. Also, after a current flow, a difference of potential between
the two electrodes is restored to what it was before the breakdown, so that a new liquid
dielectric breakdown can occur.

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5.

WIRE EDM

Also known as wire cutting EDM, wire burning EDM, or traveling wire EDM, this process uses
spark erosion to machine or remove material with a traveling wire electrode from any
electrically conductive material. The wire electrode usually consists of brass or zinc -coated
brass material.

6.

WATER JET CUTTERS

A water jet cutter, also known as a waterjet, is a tool capable of slicing into metal or other
materials (such as granite) by using a jet of water at high velocity and pressure, or a mixture of
water and an abrasive substance, such as sand. It is often used during fabrica tion or
manufacture of parts for machinery and other devices. Waterjet is the preferred method when
the materials being cut are sensitive to the high temperatures generated by other methods. It
has found applications in a diverse number of industries from mining to aerospace where it is
used for operations such as cutting, shaping, carving, and reaming.

OTHERS CNC MACHINES:Many other tools have CNC variants, including:

1.

Drills

2.

EDMs

3.

Embroidery machines

4.

Lathes

5.

Milling machines

6.

Canned cycle

7.

Wood routers

8.

Sheet metal works (Turret punch)

9.

Wire bending machines

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10.

Hot-wire foam cutters

11.

Plasma cutters

12.

Water jet cutters

13.

Laser cutting

14.

Oxy-fuel

15.

Surface grinders

16.

Cylindrical grinders

17.

3D Printing

18.

Induction hardening machines

19.

Submerged welding

20.

Knife cutting

21.

Glass cutting

FIG 3.3:- BENDING MACHINE

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3.1.2 ASSEMBLY LINE

The assembly line is classified in:

Assembly line 1
Assembly line 2
Assembly line 3
Assembly line 4 (inner ball joints)
Assembly line 5(outer ball joints)
Assembly line YR-9

Assembly line YR-9 houses a sealing machine, which seals the ball pin to the control arm with
specific amount of lubricants with the help of cap, by applying pressure. The machine has 3
rollers, which after the component is kept in place for sealing, come down and apply uniform
pressure, thus sealing the joints. The machine is known as orbital machine.
After the ball pins has fitted , the control arm is then sent in to a furnace, where the mobility of
all pin is increased with the application of heat.
A no. of tests , rubber and metal bush is fixed on to control arm structure .As the components
are fitted, a marketing is provided simultaneously, to indicate that ,that particlepart had been
fitted at the time of assembly. This technique is helpful to elude the situation in which blame is
put on the company for providing incomplete assemblies.
After these many processes, the control arm is then kept in lost boxes and loaded for delivery.

ORDER OF MACHINING OF FEMALE PARTS (HOUSING)

1. Forging
2. Pre Drilling
3. Incoming inspection
4. PPC department
5. Machine shop
6. Body machining
7. OD Turning and Grooving
8. Shank Turning
9. Burnishing
10. Induction Harding
11. Paint shop
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12. Phosphating
13. Thread Rolling
14. Component Inspection
15. Assembly

MALE PART (BALL PIN)

1. FORGING
2. Semi finish
3. Store
4. Incoming inspection
5. PPC Department
6. Machine Shop
7. Profile Turning
8. Split hole drill
9. Ball Burnishing
10. Induction hardening
11. Oil Grooving
12. Ball Grinding
13. Thread rolling
14. Component Inspection
15. Assembly

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Chapter -4
QUALITY CONTROL

4.1 QUALITY CONTROL DEPARTMENT

Quality control, or QC for short, is a process by which entities review the quality of a ll factors
involved in production. ISO 9000 defines quality control as "A part of quality management
focused on fulfilling quality requirements".
Elements such as controls, job management, defined and well managed processes,
performance and integrity criteria, and identification of records
Competence, such as knowledge, skills, experience, and qualifications
Soft elements, such as personnel, integrity, confidence, organizational culture, motivation,
team spirit, and quality relationships.
Controls include product inspection, where every product is examined visually, and often using
a stereo microscope for fine detail before the product is sold into the external market.
Inspectors will be provided with lists and descriptions of unacceptable product defects s uch as
cracks or surface blemishes for example.
The quality of the outputs is at risk if any of these three aspects is deficient in any way.
Quality control emphasizes testing of products to uncover defects and reporting to
management who make the decision to allow or deny product release, whereas quality
assurance attempts to improve and stabilize production (and associated processes) to avoid, or
at least minimize, issues which led to the defect(s) in the first place.[citation needed] For
contract work, particularly work awarded by government agencies, quality control issues are
among the top reasons for not renewing a contract.

4.2 QUALITY POLICY

The company commits itself to manufacture and deliver products that consistenly meet
customer specifications at each stage and operations of manufacturing thus producing reliable
and enduring products.
Quality at each stage by all is the company motto and guiding principle, this shall be attached
by-

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 Continual improvements in systems, technology,& process.

Employee development, involvement and empowerment thereby improving
competence.
Reducing cost and improving performance by eliminating variation and wastes.

4.3 QUALITY OBJECTIVES: Improving in design for product reliability.

Reducing non conformities.
Continual up graduation of system and operations.
Improvements In technology to enhance operational performance and
meet over changing of all global environment.
4.4 SUB-DEPATMENTS: Centralised Sample evaluation Cell
Supplier Quality Control
Receipt Inspection
Standard Room
PROCESS: Receipt inspection- Inspection at the time of receiving the stock from vendor.
Process Inspection- Inspection done time to time at various stages of machining,
painting, assembling for conformation.
Final Inspection- Inspection of the finished products before the dispatch of order to
ensure quality.
Supplier Quality Assurance- Confidence in a suppliers ability to deliver a good or service
that will satisfy the customers needs.

4.5 QUALITY CONTROL TOOLS

1. Check Sheet- A Sample from used to enable data to be collected and interpreted by
making check marks.
2. Pareto Diagram- Diagram which defines VITAL FEW- TRIVAL MANY problems.
3. Histograms- A graphic summary of variation is a set of data which is known as frequency
distribution diagram.
4. Cause & Effect Diagram- A useful method for identifying potential root causes of a
problem.
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5. Graphs & Controls Charts

Graph- A graph for plotting data and showing temporal changes to easily
understand the overall situation.
Control chart- A line graph used to access and maintain the stability of a process for
reducing process variability.
6. Scatter Diagram- A diagram which represents relation between two sets of data.
7. Stratification- A method of regrouping data by common points to understand similarities
and characteristics of data.

4.6 IN-PROCESS INSPECTION

Inspection done time to time during the process of machining for conformation is in process
inspection.
It includes the following checking parameters: Parts per million calculation=(qty rejected)/(qty produced)*1000000
Process parameter Audit.
Functionality of machine:Tailstock Pressure
Feed
Speed

4.7 PRODUCT AUDIT- Drawing verification/ parts checking with visual of with gauges or
instrument like: Articulation Torque Gauge
Rotational Torque Rig

CSE CELL
Centeralised Sample Evalution (CSE) - This department works for sample evalution which is
coming from varios vendors for manufacturingcomponent in the existing point.
Through every lot no. of pieces are selected and verified. This can be done through 2 verified
methods:1. Physical Verification:- critical dimensions, color, appearance
2. Chemical verification:-Metallurgical verification
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4.8 PPAP (PRODUCTION PART APPROVAL PROCESS)

This documents include following: Part submission warrant- This is the warrant statement given by material control
department to CSE cell along with documentation for verification.
Process control plan- this plan helps us to control the critical dimensions during varios
machining process.
Incoming material Control Plan- this plan includes all the parameters which are
necessary to determined at the preliminary stage.
Report-this report helps us in identifying potential causes of failure to aware
manufacture in future and to device its remedies in due time.
Dimensional Results-this is a verification sheet stating that all the dimensions have been
checked using specific gauges.
Metallurgical test results- this report tells us about the micro structure of the
component.
Process capability Evalution- it forecasts about the manufacturing capability of a plant.
Checking aid list This list gives us a brief idea about the type of instruments gauges
used for measurement which is properly caliberated in accordance with some
standards.
Gauge repeatability and reproducibility Study- This study depicts the precession and
accuracy of gauges to measure different dimensions.
Attribution Gauge Study- this study shows the quality characteristics of a gauges.
Raw material TC- this is a certification which includes composition at the time when
materials heat treated. It includes following important parameters.
1. Heat treatment no.- it helps us to detect component profile at any stage.
2. Hardness test.
3. Inclusion
4. Oil Quenched.

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4.9 MATERIAL RECEIPT REPORT

GATE ENTRY-

When the raw material is brought to company, the first stage is passes by gate. Here, entry is
made in the system giving the necessary details. A unique serial no. is provided, through which
the particle lot of raw material can be traced in the store. This completes MRA or material
receipt advice.
STOREAfter entering the company, the material is placed in the store according to the place
allotted to the material at the time of gate entry.
For the material leaving the company, following 4 bills are attached along:
1.
2.
3.
4.

Original MRR
Photocopy of MRR
Form Vat D3
Tax invoice

FINAL STEP

The materials received are tested dimensionally and visually. The no. of parts to be inspected depends
on the size of goods.

4.10 MARKETING DEPARTMENT

This department may be classified into following: Marketing
Sales
The marketing departments has following field to look after:
Export Segment
OE Segment
Department of after market

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EXPORT SEGMENT- This segment looks after the selling of companys products in the
international market

OE SEGMENT-This segment caters to the need of original equipment manufactured.

DEPARTMENT AFTER MARKET-This is the most important part of marketing part of the
marketing department. The company also has its authorized retail outlets throughtout the
country to cater for servicing needs.

SALES-This departments looks after the transportation needs of the company. Arrangement
for logistics is responsible of segment.

4.11 LABORATORYIn the lab., varios tests are performed to determine the metallurgical structure of material
received. This is also a part of component inspection. A detailed report is prepared giving the
details of internal structure of component.
APPARATUS AVAILABLE: SALT SPRAY TEST
This test determines the corrosion resistance of a component. The red abd white corrosion time
for the component is determined. The component is exposed to 5% NACL sol. For the time
period. If any rust appears on the comp. before the specified time, the entire lot is rejected.
ROCKWELL HARDNESS TESTING MACHINE

This test is used to determine the hardness of a material. The test is conducted and the
specimen with the specified strength is passed while the oters are rejected.
MICROSCOPE

This is used for microstructure analysis. Materials with specified grain size are passed whereas
others are rejected.
SPECIFIC GRAVITY TESTING MACHINE

This machine is used to test the specific gravity of component. Materials are ground and mixed
for testing. The readings are taken and component is put to use only when the component
fulfills the set norms.
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 STROHLEN APPARATUS
This apparatus is used to test the C content of material.

Chapter -5

PHOSPHATING PROCESS
Phosphate coatings are used on steel parts for corrosion resistance, lubricity, or as a foundation
for subsequent coatings or painting .It serves as a conversion coating in which a dilute solution
of phosphoric acid and phosphate salts is applied via spraying or immersion and chemically
reacts with the surface of the part being coated to form a layer of insol uble, crystalline
phosphates. Phosphate conversion coatings can also be used on aluminium , zinc, cadmium,
silver and tin.
The main types of phosphate coatings are manganese, iron and zinc. Manganese phosphates
are used both for corrosion resistance and lubricity and are applied only by immersion. Iron
phosphates are typically used as a base for further coatings or painting and are applied by
immersion or by spraying. Zinc phosphates are used for corrosion resistance (phosphate and
oil), a lubricant base layer, and as a paint/coating base and can also be applied by immersion or
spraying.

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FIG 5.1:- PIECES AFTER PHOSPHATING TREATMENT

5.2 PROCESS
The application of phosphate coatings makes use of phosphoric acid and takes advantage of the
low solubility of phosphates in medium or high pH solutions. Iron, zinc or manganese
phosphate salts are dissolved in a solution of phosphoric acid. When steel or iron parts are
placed in the phosphoric acid, a classic acid and metal reaction takes place which locally
depletes the hydronium (H3O+) ions, raising the pH, and causing the dissolved salt to fall out of
solution and be precipitated on the surface. The acid and metal reaction also creates iron
phosphate locally which may also be deposited. In the case of depositing zinc phosphate or
manganese phosphate the additional iron phosphate is frequently an undesirable addition to
the coating.
The acid and metal reaction also generates hydrogen gas in the form of tiny bubbles that
adhere to the surface of the metal. These prevent the acid from reaching the metal surface and
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slows down the reaction. To overcome this sodium nitrite is frequently added to act as an
oxidizing agent that reacts with the hydrogen to form water. This chemistry is known as a
nitrate accelerated solution. Hydrogen is prevented from forming a passivating layer on the
surface by the oxidant additive.

FIG 5.2: - STEPS FOR PHOSPHATING PROCESS

The following is a typical phosphating procedure:

1.
2.
3.
4.
5.
6.
7.

Cleaning the surface

Rinsing
Surface Activation
Phosphating
Rinsing
Neutralizing Rinse
Drying

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1. Degreasing- In the industry of materials transformation, the degreasing is necessary

stage before any other treatment. It is realized with the help of an aqueous sol.
Containing the detergent, which is to emulsify the oil recovering the degreased.
The bath containing the degrease becomes progressively charged with the oil and
degreased must be replaced frequently, otherwise it quickly becomes inefficient.
Mixture used is ASTRA Clean 702
Tank temp. is 53-65 degrees
Density of mixture should be 45-53 points
The component is kept in the tank for about 8-16 min.

2.

Derusting- Mixture used ASTRA derusting 702

1

3.

Temperature of tank 55-65 degrees

Density of mixture is 45-55 points
The components are placed in the tanks for duration of about 10-15 min.

Activation- Mix. Used is ASTRA active 702

-

Tank temp. is same as room temp.

Density of the mix. Is 7-10 points

Component kept for 1 min.

4.

Phosphating- Mix. Used is ASTRA phosphate 702 + Toner.

-

Tank temp. is 45-55 degree

Component kept for 1 min.
Density of mix. Is 14-20 points.

Then the comp. are dried in an electric heater at a temp. of 70-100 degrees.
After Phospahting is done, the component are to proceed to powder coating or spray
painting and is more effective too.
After these treatments, the comp. are then again passed through an electric furnace and then
kept outside in room temp. After this, the comp. are placed in the finished lot and then are
loaded for delivery to specific clients.

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5.3 APPLICATIONS:
The performance of the phosphate coating is significantly dependent on the crystal structure as
well as the weight. For example, a microcrystalline structure is usually optimal for corrosion
resistance or subsequent painting. A coarse grain structure impregnated with oil, however, may
be the most desirable for wear resistance. These factors are controlled by selecting the
appropriate phosphate solution, using various additives, and controlling bath temperature,
concentration, and phosphating time. A widely used additive is to seed the metal surface with
tiny particles of titanium salts by adding these to the rinse bath preceding the phosphating.This
is known as activation.

FIG 5.3 :- WORKPIECE BEFORE AND AFTER PHOSPHATINNG TREATMENT

5.4 USES:Phosphate coatings are often used to provide corrosion resistance, however, phosphate
coatings on their own do not provide this because the coating is porous. Therefore, oil or other
sealers are used to achieve corrosion resistance. Zinc and manganese coatings are used to help
break in components subject to wear and help prevent galling.
Most phosphate coatings serve as a surface preparation for further coating and/or painting, a
function it performs effectively with excellent adhesion and electric isolation. The porosity
allows the additional materials to seep into the phosphate coating and become mechanically
interlocked after drying.

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5.5 PAINTS
As we all known that, painting is used for decoration, looking well. But it also protect the
material from rusting, and all environmental conditions.

So, there are 2 types of painting were held:1. DRY PAINTING

2. WET PAINTING
First one we discuss about the dry painting. So on dry painting, there is a chamber in
which all the workpiece whos are ready for paint get hang by the help of hangers. Then,
little amount of current is passes through the track, where the hangers are hanged.
From all of this, there is a small container in which powder(MATBLACK POWDER) is
charged and leave for some time for proper mixing of powder with air. After charging of
powder, it is passes through medium pressure by the help of nozzle. Powder is sprayed
on the workpiece. This works on the principle of adhesion property. When the
workpieces gets charged, then it is passes through the oven. The temperature of oven is
about 200- 230 degrees. When it come out from the oven, it goes for cooling in
atmospheric air for some time. In this way, our dry painting is working. It is also known
as powder coating machine.

FIG 5.4:- DRY PAINTING

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FIG 5.5:- POWDER COATING

Second one is wet painting. This painting is very simple in working. In this paint is mixed with
kerosene in a container and leave for mixing properly. Then it is passes through a highly
pressurized nozzle, and directly sprayed on the workpiece and our workpiece is gets paint.

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FIG 5.6 :- WET PAINTING

5.6 INDUCTION HARDENING

A widely used process for the surface hardening of steel. The components are heated by means
of an alternating magnetic field to a temperature within or above the transformation range
followed by immediate quenching
Induction hardening is a form of heat treatment in which a metal part is heated by induction
heating and then quenched. The quenched metal undergoes a martensitic transformati on,
increasing the hardness and brittleness of the part. Induction hardening is used to selectively
harden areas of a part or assembly without affecting the properties of the part as a whole .

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FIG 5.7: INDUCTION HARDENING

5.6.1 PROCESS:Induction heating is a non contact heating process which utilises the principle of
electromagnetic induction to produce heat inside the surface layer of a work-piece. By placing a
conductive material into a strong alternating magnetic field, electric current can be made to
flow in the material thereby creating heat due to the I2R losses in the material. In magnetic
materials, further heat is generated below the curie point due to hysteresis losses. The current
generated flows predominantly in the surface layer, the depth of this layer being dictated by
the frequency of the alternating field, the surface power density, the permeability of the
material, the heat time and the diameter of the bar or material thickness. By quenching this
heated layer in water, oil, or a polymer based quench, the surface layer is altered to form a
martensitic structure which is harder than the base metal.

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5.6.2 EQUIPMENTS:-

1.

POWER

Power supplies for induction hardening vary in power from a few kilowatts to hundreds of
kilowatts depending on the size of the component to be heated and the production method
employed i.e. single shot hardening, traverse hardening or submerged hardening.
In order to select the correct power supply it is first necessary to calculate the surface area of
the component to be heated. Once this has been established then a variety of methods can be
used to calculate the power density required, heat time and generator operating frequency.
Traditionally this was done using a series of graphs, complex empirical cal culations and
experience. Modern techniques typically utilise finite element analysis and Computer-aided
manufacturing techniques, however as with all such methods a through working knowledge of
the induction heating process is still required.

2.

FREQUENCY

Induction heating systems for hardening are available in a variety of different operating
frequencies typically from 1 kHz to 400 kHz. Higher and lower frequencies are available but
typically these will be used for specialist applications. The relations hip between operating
frequency and current penetration depth and therefore hardness depth is inversely
proportional. i.e. the lower the frequency the deeper the case.

3. COOLING TOWERS
Two cooling towers are situated near the induction hardening area. Reservoir for these cooling
towers is an IHB tank. The water used for induction hardening process is cooled in these
towers. Separate inlet and outlet are provided for incoming and outgoing water. After
induction hardening process, the water gains temp. after some cycles, it becomes unsuitable
for the hardening process. Therefore, cooling towers are employed for maintaining the temp. of
water at a certain suitable.
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Chemicals are used for treating water:1. Chemical Thinner- 605

2. QD Enamel Deep Dark Grey

5.6.3 ADVANTAGES:1.

Fast process, no holding time is required, hence more production rate.

2.

No scaling or decarburizing.

3.

More case depth up to 8 mm.

4.

Selective hardening.

5.

High wear and fatigue resistance .

5.6.4 APPLICATIONS:1.

The process is applicable for electrically conductive materials such as steels and cast

iron.
2.

Long work pieces such as axles can be processed.

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Chapter -6
TOOL ROOM
Tool room is divided into 2 parts. One part houses:
1.
2.
3.
4.
5.

2 Lathe machine
2 Milling machine
1 bench drill
1 Power drill
1 power hacksaw

As the products manufactured by the company are in bulk, it becomes essential to use jigs and
fixtures for certain operations. Fixtures for testing the angle and dimension of certain comp. are
also manufactured within the company itself.

6.2 TESTING AREA

The second part of tool room houses is the testing equipments:

Rigidity Testing machine

Universal testing machine
Dustcover testing machine
Endurance testing machine
Ball joint test bed
Ozone chamber
Computerised Smoothness Tester
Leakage Testing machine
Fatigue Testing machine
Impact Test Rig

6.3 MAINTENCE DEPARTMENT

This department caters to maintenance needs of company. Fixing of the defects in the machine
is the responsibility of this department. The department also has the responsibility of this
department. The department also has the responsibility of servicing the mac. In due time and
keeping them fit for efficient and accurate production.

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6.4 CMM(COORDINATE MEASURING MACHINE)

This machine is used to exactly mark and locate the position where a particular machining
operation has to be perfomed. The machine can do the following operations:

Location and Dimensions

True position Dimensions
Distance
Angle
Concentricity
Coaxiality
Cylindricity
Circularity
Straightness
Flatness Dimensions
Perpendicular Dimensions
Profile, arc, angularity and symmetricity.

A reference point is selected in the beginning and all the marking are then made with reference
to that reference point.

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CHAPTER 7
7.1 Conclusion
Maximum of their work was done manually. While in production division, the whole processing
is automatic. But now days they are trying to set up new NOVA CNC machines. It will reduce
the human effort or will increase productivity up to a large extent. This setting up of new nova
machines will place the TALBROS at a position to compete with other worldwide steering &
suspension mfg. companies.

I LEARN :

How an Industry works.

Learning of practical aspects of various dept. (Heat treatment, Grinding) in ball pins &
housings.

Got a brief idea about various heat treatment processes along-with their industrial use.

Working of conventional machining process (grinding).

Industrial applications of all types of grinding and finishing processes.

Use of various quality gauges along-with applications of dial indicators in gauges.

How all the maintenance and inspections is done on in line processing or after processing.

Various techniques of inspection methods.

Got small knowledge of cncs machines.

Got a idea of various processes of welding.

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7.2 REFERANCES
Workshop Technology I Book, S. K. Hazara

Choudhary, Chapter Fundamentals of

metals & alloys.

Workshop Technology I Book, S. K. Hazara Choudhary, Chapter testings of materials.

Workshop Technology I Book, S. K. Hazara Choudhary, Chapter Heat Treatment Of
metals and Alloys.

Workshop Technology I Book, S. K. Hazara Choudhary, Chapter Measurement &

Inspection.

Workshop Technology II Book, S. K. Hazara Choudhary, Chapter The Lathe.

Automobile Book.
Talbros Company Site.

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